high speed stir model.pptVIP

HIGH SPEED FSW MODELING Vanderbilt University: Welding and Automation Laboratory: Nashville, TN Dr. Reginald Crawford Thomas S. Bloodworth III Paul A. Fleming David H. Lammlein Tracie Prater Dr. George E. Cook Dr. Alvin M. Strauss Dr. D. Mitch Wilkes Los Alamos National Laboratory: Los Alamos, NM. Dr. Daniel A. Hartman OVERVIEW Introduction Experimental Method/Setup Mechanical Models Simulation Results Conclusions Current and Future Work INTRODUCTION Current uses of FSW: Aerospace (Spirit, Boeing, Airbus) Railway (Hitachi Rail) Shipbuilding/marine (Naval vessels) Construction industries and others (Audi) Moving to lighter materials (e.g. Aluminum) Conflict: 3-D contours difficult with heavy duty machine tool type equipment INTRODUCTION Ideally see widely applicable industrial robots equipped for FSW Benefits: lower costs energy efficient 3-D contours etc. Problem: High axial forces required to FSW (1-12+ kN or 225-2700+ lbs), difficult to maintain even using robust robots especially at large distances from the base unit Possible solution: Utilize increased rotational speed/decreased axial force relationship to aid in developing a larger operational envelope for high speed FSW EXPERIMENTAL METHOD Purpose: Examine axial forces during high speed friction stir welding with respect to mechanistic defect development due to process parameter variation Two Mechanical Models Smooth Tool Pin (Preliminary) Threaded Tool Pin (More Comprehensive) Parameters (Variables) Rotational Speed (RS) Travel Speed (TS) EXPERIMENTAL METHOD Model solved with CFD package FLUENT for steady state solutions Force simulated for the three spatial dimensions as well as torque Experimental force and torque data recorded using a Kistler dynamometer (RCD) Type 9124 B EXPERIMENTAL SETUP VU FSW Test Bed: Milwaukee #2K Universal Milling Machine utilizing a Kearney and Treker Heavy Duty Vertical Head Attachment modified to accommodate high spindle speeds. Samples- AA 6061-T6: 76.2 x 457.2 x