Development of mathematical model for Thermo-Mechanical behavior of Friction Stir Welding and Induction Soldering by using FEM/BEM
- Issued Date
- 2007
- Abstract
- This work has been focused on characterization of the Friction Stir Welding (FSW) and Induction Soldering joints, and modeling of the process by mathematical model. Friction stir welding is being attracted and developed as an efficient joining method in the manufacturing field of Automobile, Aerospace and Ship building industries. As the FSW develops, more scientific research work investigations in this field have also been increased. Recent studies in FSW have revealed that both heat and metal flow characteristics have a non-symmetric complex nature about the tool axis. But until now there is no efficient 3D- heat flow model to be comparable with the experimentally measured values. The body of the work covered FSW of Al6061-T6 and its thermal distribution, Residual stress analysis and Metal flow analysis. A nonsymmetrical Mathematical model for the heat input zone in the matrix of Al plates due to the effect of combined translation and rotational motion of the tool pin and shoulder has been developed. This mathematical model has been used for 3D finite element heat transfer and residual stress analysis. The numerically simulated temperature field and residual stress values agreed well with independently determined experimental values. So the boundary of the stir zone defined by the mathematical model is found agreeable and could be used for the further metal flow analysis using FEM/BEM.
Also a mathematical model of coupled heat transfer and electromagnetic phenomena in induction heating of Sn-3.5Ag solder ball has been described. The model takes into account the nonlinearity of all coefficients, the characteristics of the supply source and the thermal influence on the solder ball surfaces based on its variation with respect to time.
The hybrid Finite Element / Boundary Element method represents an optimal approach for modeling metal flow patterns in FSW and large scale electromagnetic-thermal material processing systems. In both the FSW and Induction Soldering the volume ratio of the sample over the entire computational domain is small. Overall the modeling approach in both the cases is shown to produce useful results when compared with the experimental values.
- Alternative Title
- FEM/BEM을 이용한 마찰교반용접과 유도가열 솔더링의 열변형 거동의 수학적 모델 개발.
- Affiliation
- 조선대학교 대학원
- Department
- 일반대학원 첨단해상운송시스템설계및생산관리학과
- Awarded Date
- 2007-02
- Table Of Contents
- CONTENTS = i
ABSTRACT = v
List of Figures = vi
List of Tables = ix
Chapter 1 INTRODUCTION = 1
1.1 Background to the Research = 1
1.2 Literature Review = 2
1.2.1 Characteristics of Friction Stir Welding = 2
1.2.2 Characteristics of Induction Heating Soldering = 3
1.2.3 Characteristics of Al6061-T6 = 6
1.2.4 Characteristics of Sn3.5Ag, Au, Cu, Ni = 7
1.2.5 Thermal ＆ Metal flow modeling of Friction Stir Welding = 10
1.2.6 Thermal ＆ Metal flow modeling Induction Heating Soldering = 11
1.3 Definitions = 12
1.3.1 Friction Stir Welding = 12
1.3.2 Induction Heating Soldering = 12
1.4 Research Hypothesis = 13
1.5 Research Objectives = 13
1.6 Methodology = 14
1.7 Outline of the report = 15
Chapter 2 MATHEMATICAL MODELS FOR ANALYSIS = 16
2.1 Introduction = 16
2.2 Mathematical model for Friction Stir Welding = 17
2.2.1 Specification and identification of the model = 25
2.2.1.1 Model developed by William = 25
2.2.1.2 New Mathematical model = 26
2.3 Mathematical model for Induction Heating of solder ball = 28
2.3.1 Specification and identification of the model = 31
2.3.1.1 Exciting model of induction heating = 31
2.3.1.2 New model = 31
2.4 Conclusions = 32
Chapter 3 HEAT INPUT EQUATIONS = 33
3.1 Introduction = 33
3.2 Heat input equations for FSW = 33
3.2.1 Heat Generated by Viscous Dissipation = 33
3.2.2 Heat Generated by Plastic Deformation = 34
3.2.3 Heat Generated by Friction = 34
3.3 Heat input equations for Induction Soldering = 35
3.3.1 Heat Generated by Induction = 35
3.4 Conclusions = 36
Chapter 4 HEAT TRANSFER AND RESIDUAL STRESS ANALYSIS = 37
4.1 Introduction = 37
4.2 Assumption of the analysis = 37
4.3 Heat Transfer analysis = 37
4.4 Residual Stress analysis = 40
4.5 Finite Element Model Details = 43
4.5.1 Friction Stir Welding = 43
4.3.2 Induction Soldering = 43
4.6 Conclusions = 44
Chapter 5 COUPLED FEM/BEM ANALYSIS = 45
5.1 Introduction = 45
5.2 Coupling theory in FSW = 45
5.2.1 Finite element formulation = 46
5.2.2 Boundary element Formulation = 48
5.3 Coupling theory in Induction Soldering = 48
5.3.1 Finite element formulation = 48
5.3.2 Boundary element Formulation = 49
5.3.3 Coupling of boundary and finite element = 50
5.4 Conclusions = 50
Chapter 6 EXPERIMENTAL RESULTS AND DISCUSSION = 51
6.1 General details and nominal dimensions = 51
6.1.1 Friction Stir Welding = 51
6.1.2 Induction Soldering = 52
6.2 Results = 54
6.2.1. Friction Stir Welding = 54
6.2.1.1. Surface appearance = 54
6.2.1.2. Cross Sectional variations = 55
6.2.1.3. Micro structural variations = 56
6.2.1.4. Metal flow observations = 57
6.2.1.5. Temperature measurements = 58
6.2.1.6. Residual stress Measurements = 60
6.2.2. Induction Soldering = 61
6.2.2.1 Surface appearance = 61
6.2.2.2 Cross Sectional variations based on heating time = 62
6.2.2.3 SEM of the Solder joint = 63
6.2.2.4 Metal flow observations = 64
6.2.2.5 Temperature measurements = 64
6.3 Comparison and discussions = 66
6.3.1 Friction Stir Welding = 66
6.3.2 Induction Soldering = 71
6.4 Conclusion = 73
Chapter 7 CONCLUSION AND FUTURE WORKS = 74
7.1 Conclusion = 74
7.1.1 Friction Stir Welding = 74
7.1.2 Induction Soldering = 75
7.2Suggestions for further studies = 75
7.2.1 Friction Stir Welding = 75
7.2.2 Induction Soldering = 75
Chapter 8 REFERENCES = 76
Appendix-Ⅰ ： Extrusion zone width calculation = 81
ACKNOWLEDGEMENT = 0
- Degree
- Doctor
- Publisher
- 조선대학교
- Citation
- Rajesh S.R. (2007). Development of mathematical model for Thermo-Mechanical behavior of Friction Stir Welding and Induction Soldering by using FEM/BEM.
- Type
- Dissertation
- URI
- https://oak.chosun.ac.kr/handle/2020.oak/6794
http://chosun.dcollection.net/common/orgView/200000231594
- Appears in Collections:
- General Graduate School > 4. Theses(Ph.D)
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