Numerical Analysis Of Tool Rotational Speed And Welding Speed Effects On Temperature Distribution And Residual Stress In Friction Stir Welding AA6061-T6 Plate

Tarigan, Raphael Riammi (2024) Numerical Analysis Of Tool Rotational Speed And Welding Speed Effects On Temperature Distribution And Residual Stress In Friction Stir Welding AA6061-T6 Plate. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Friction stir welding (FSW) is known for producing
high-quality welds with minimal distortion, making it an attractive
solid-state joining technology for aluminium alloys that are
difficult to joined with conventional fusion welding, particularly
AA6061-T6. This study employs numerical analysis to explore the
impact of tool rotational speed and transversal speed on
temperature distribution and residual stress during the FSW
process of AA6061-T6 plate, useful to offer an insight into optimal
operating conditions to minimize induced defects from the heat and
residual stresses. A finite element model is developed to replicate
the complex thermomechanical interactions in FSW. The study
systematically varies transversal speed and rotational speeds to
examine their effects on the mechanical response and thermal
history of the welded material. ANSYS Workbench software is used
to simulate welding parameters and conditions across nine heat
input variations, with rotational speeds of 500, 800, and 1000 RPM
and transversal speed of 80, 140, and 200 mm/min. The coupled
field transient approach combines thermal and structural analysis
to evaluate temperature distribution and residual stress. The
findings indicate that higher rotational speeds and lower traverse
speeds elevate temperatures, whereas higher rotational speeds
combined with higher traverse speeds escalate residual stress levels.
Maximum temperatures peak at 499.68°C at 1000 RPM and 80
mm/min, with maximum residual stress reaching 234,67 MPa at
1000 RPM and 200 mm/min. The optimal results, in terms of
temperature and residual stress, were achieved using a rotational
speed of 800 RPM and a welding speed of 80 mm/min.
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Friction stir welding (FSW) dikenal menghasilkan sambungan berkualitas tinggi dengan
distorsi minimal, menjadikannya teknologi penyambungan keadaan padat yang menarik untuk
paduan aluminium yang sulit disambung dengan pengelasan fusi konvensional, terutama
AA6061-T6. Studi ini menggunakan analisis numerik untuk mengeksplorasi dampak kecepatan
rotasi alat dan kecepatan transversal pada distribusi suhu dan tegangan sisa selama proses FSW
pada pelat AA6061-T6, memberikan wawasan tentang kondisi operasi optimal untuk
meminimalkan cacat yang disebabkan oleh panas dan tegangan sisa. Model elemen hingga
dikembangkan untuk mereplikasi interaksi termomekanik yang kompleks dalam FSW. Studi
ini secara sistematis memvariasikan kecepatan transversal dan kecepatan rotasi untuk
memeriksa efeknya pada respons mekanik dan sejarah termal material yang dilas. Perangkat
lunak ANSYS Workbench digunakan untuk mensimulasikan parameter dan kondisi pengelasan
dalam sembilan variasi input panas, dengan kecepatan rotasi 500, 800, dan 1000 RPM dan
kecepatan transversal 80, 140, dan 200 mm/menit. Pendekatan coupled field transient yang
mengombinasikan analisis termal dan struktural untuk mengevaluasi distribusi suhu dan
tegangan sisa. Temuan menunjukkan bahwa kecepatan rotasi yang lebih tinggi dan kecepatan
transversal yang lebih rendah meningkatkan suhu, sedangkan kecepatan rotasi yang lebih tinggi
dikombinasikan dengan kecepatan transversal yang lebih tinggi meningkatkan tingkat tegangan
sisa. Suhu maksimum mencapai puncaknya pada 499,68°C pada 1000 RPM dan 80 mm/menit,
dengan tegangan sisa maksimum mencapai 234,67 MPa pada 1000 RPM dan 200 mm/menit.
Hasil optimal, dalam hal suhu dan tegangan sisa, dicapai menggunakan kecepatan rotasi 800
RPM dan kecepatan pengelasan 80 mm/menit/min.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Distribusi Temperature, Finite Element Method, Friction Stir Welding, Kecepatan Rotasi, Kecepatan Pengelasan, Metode Elemen Hingga, Residual stress, Rotational speed, Tegangan Sisa , Temperature Distribution, Welding Speed
Subjects:	T Technology > TA Engineering (General). Civil engineering (General) > TA169.5 Failure analysis T Technology > TA Engineering (General). Civil engineering (General) > TA347 Finite Element Method T Technology > TN Mining engineering. Metallurgy > TN879.6 Welding
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Material & Metallurgical Engineering > 28201-(S1) Undergraduate Thesis
Depositing User:	Raphael Riammi Tarigan
Date Deposited:	01 Aug 2024 08:48
Last Modified:	01 Aug 2024 08:48
URI:	http://repository.its.ac.id/id/eprint/110993

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