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<p>This study employs computational fluid dynamics (CFD) simulations, incorporating an advanced shear stress boundary condition at the tool-workpiece interface, to investigate the influence of tool rotation speed on the interface friction regime, material flow, and heat generation. Experimental measurements of the temperature cycle curve, the shape of plastic deformation zone, and the deposition position of marking material validate the simulation accuracy. The simulation results indicate a transition in the friction mechanism from sliding to sticking as the tool rotation speed increases. At higher tool rotation speeds, the total heat generation depends on the strength of the material itself. Therefore, tool rotation speeds in a certain range will not significantly affect the heat generation. Regardless of the tool rotation speed, the material flow from the front of the metal through the pin’s influence zone consistently follows a straight-through pattern. However, at higher tool rotation speeds, some materials flowing through the shoulder’s influence zone from the front of the metal rotate around the tool multiple times, exhibiting a multi-turn flow pattern. The deposition position of marking materials also changes from a symmetric to an asymmetric distribution when the friction regime transitions from sliding to sticking.</p>

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Influence of rotation tool-induced friction regime transformation on heat generation and material flow during friction stir welding: a computational fluid dynamics study

  • 期刊论文

  • 发表日期：

    2025年6月16日

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  • Junnan Qiao,
  • Qingyu Shi,
  • Shujun Chen,
  • Chengle Yang,
  • Yang Han,
  • Gaoqiang Chen

摘要

This study employs computational fluid dynamics (CFD) simulations, incorporating an advanced shear stress boundary condition at the tool-workpiece interface, to investigate the influence of tool rotation speed on the interface friction regime, material flow, and heat generation. Experimental measurements of the temperature cycle curve, the shape of plastic deformation zone, and the deposition position of marking material validate the simulation accuracy. The simulation results indicate a transition in the friction mechanism from sliding to sticking as the tool rotation speed increases. At higher tool rotation speeds, the total heat generation depends on the strength of the material itself. Therefore, tool rotation speeds in a certain range will not significantly affect the heat generation. Regardless of the tool rotation speed, the material flow from the front of the metal through the pin’s influence zone consistently follows a straight-through pattern. However, at higher tool rotation speeds, some materials flowing through the shoulder’s influence zone from the front of the metal rotate around the tool multiple times, exhibiting a multi-turn flow pattern. The deposition position of marking materials also changes from a symmetric to an asymmetric distribution when the friction regime transitions from sliding to sticking.