Finite element analysis on wear of stirring tool considering temperature effect

According to temperature-depending characteristics of thermo-physical parameters of the welded material during friction stir welding (FSW) process, the modified heat source model of 6061 aluminum alloy sheet was established based on the work done by Coulomb friction, a modified Archard wear model of H13 die steel tool employed in the welding of 6061 aluminum alloy was proposed considering temperature effect. The above two models were embedded into the finite element model. The wear behavior and morphology of H13 die steel tool during plunging into the welded joint and traversing along the welded joint was simulated and analyzed with and without considering the temperature effect. The results showed that the wear behavior and morphology of H13 die steel tool was nearly consistent under the two kinds of conditions. The interaction between stirring tool and base material was intensified under temperature-depending effect, and the wear coefficient of the stirring tool in the welding process was more sensitive to the temperature effect than the change of the material hardness. Thus, it was concluded that the wear model of stirring tool considering the temperature effect had higher accuracy of stirring tool wear prediction.