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Direct Drive Friction Welding: A Comprehensive Mathematical Model
Direct Drive Friction Welding: A Comprehensive Mathematical Model
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Figure 1. Diagram of welding speed and forces during the Direct Drive Friction Welding process
• the strength of the joint is comparable with that one of the other two approaches produced the experimental analysis of
adjacent joining materials reducing the problems of fragility; several particular cases of coupling different pairs of
• Welding fragility zones are avoided; materials, investigating the conditions to obtain the best
possible technological result. They present a good analysis of
• The presence of oxides of metals is avoided because of individual cases, but often lack of generality.
great weld flash generated;
Adolf and Andrei Sluzalec [7, 8, 9, 10, 11, 12] analyzed of
The process, nevertheless, presents also some intrinsic the thermal problems connected to friction welding, presented
problems: finite elements model describing temperature distribution.
• a complex setup due to difficulties in the prediction of Tsang [13-14] define two process controlling parameters the
welding conditions without an experimental activity; friction welding process can be controlled, or both rotation
and force are maintained for a specific period determined by
• the formation of an important weld flash which could
two different parameters: time and burn-off. Trepte [15-16]
require a machine tooling for increasing the quality of
studied the influences of other technological parameters on
surfaces.
burn-off volume (length) and the applied torque in friction
welding.
Recent literature presents an increasing number of studies
about friction welding process, due to increasing economic
Other authors [17, 18, 19, 20, 21] are interested into a single
and industrial benefits produced by this technology. Studies
material coupling and a particular rod dimensions. They do
are oriented in three different directions:
not try to define a general model of the problem. Their
1. physical analysis and modelling concerning heat experimental analysis produces good results, but sometimes
generation and diffusion models, which investigates heat looses of generality.
generation and thermal diffusion and helps to realize
provisional models of the welding process, to reduce the FRICTION MODEL
setup time and to facilitate the process control;
The general law of friction can be expressed in three different
2. physical analysis and modelling concerning friction forms [1, 2]:
models which concerns tribologic behavior of materials and
investigates methods to facilitate the heating and adhesive 1. Friction is independent of apparent contact area
process;
2. Limiting friction is proportional to the normal load
3. experimental analysis realized on different materials
analyzing the effect of time and upset on the final welding 3. Limiting friction is independent of sliding speed
results, which concerns individual industrial applications and
helps to increase the quality of junctions. Limiting, or breakout, friction is the friction force on the
reciprocally sliding surfaces.
The first approach can produce theoretical models using
general laws, but lacks of attention to individual cases. The
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The simple adhesive theory of friction is expressed as: The product, p v, influences the temperature rise at the sliding
contact, because it is reasonable to assume that:
• presence of low shear strength surface layers (lubricants); It is possible to analyze more in depth the nature of friction in
• difference in terms of surface hardness of the facing the welding process.
materials.
The first part of the process (till the beginning of the
Wear by sliding (either adhesive or abrasive) is usually shortening) is characterized by dry sliding friction
characterized by specific wear rate, ws, which assumes the phenomena, described by equation (7). Sliding friction
following expression: coefficient and sliding stress are represented using the
subscript s.
(3)
(7)
Wear can be classified in two different categories: The second part of the friction phenomena are governed by
viscous sliding model. It can be expressed by a friction
• mild wear: ws ≤ 10−16; coefficient which is proportional to Von Mises stress. It can
be calculated by the viscous stress, τs:
• severe wear: ws > 10−14.
Most material wear rates lie within the range 10−17 and
10−12.
(8)
Calculating V, dividing both sides by the apparent area of where m is a constant and σVM is the Von Mises stress.
contact A, and defining the height of abrasion (ΔH=V/A) and
Dividing and multiplying the second term of equation (8) for
the average contact pressure ( ), it is possible to nominal pressure p it is possible to define the viscous friction
get: coefficient:
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(9)
(10)
(12)
(13)
HYPOTHESIS ON TEMPERATURE
EVOLUTION AND BURN-OFF
VOLUME
It is considered a finite rod of length L free from thermal
insulation and having thermal contact with the surrounding
medium (atmospheric air).
Figure 2. 3D schema of the considered friction welding The following hypotheses have been formulated:
process 1. Removal of material (burn off formation) proceeds with
velocity u starting from the heated end. There are no heat
fluxes at the free end.
By considering the geometry of rotating cylinder it is possible
to define a general mathematical model of the contact. 2. The temperature at the heated end of a welding increases
to reach the temperature of plasticization tp. Then it remains
constant in accord to [7].
can be described as a heated rod on one of its flat sides. The HEAT EXCHANGE MODEL
simplest model would be phenomenon could be modelled as
a rod protruding from a hot base-plate (Fig. 1) and HYPOTHESIS
surrounded by some fluid which has a temperature T∞ far The heat exchange model in the rod can be evaluated
from the rod heated face. adopting the following set of assumptions:
The various heat exchange terms in equation (31) are 1. Heating phase: till the sliding surface reaches
plasticization temperature;
(21)
(24)
The obtained ODE is:
In case of a singular-source regular problem in temperature
the boundary conditions are:
(22)
(30)
(23)
(35)
(32) (36)
becomes: where
(33)
(37)
where .
Assuming , the solution becomes:
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It is known the following relation: The rod length reduction it can be considered by assuming a
higher end temperature than Tp, for example the temperature
of fusion Tf.
It can be created a virtual rod longer than the welded one that
presents T(xv,t0) = Tp.
(40)
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(45)
where 0 ≤ x ≤ Hp.
CALCULATION RESULTS
It can be evaluated at different values of t, producing the Operative temperature is assumed to be plasticization
thermal map of the object in every moment, and the thermal temperature. G20 steel has a plasticization temperature Tp
evolution of the object as a function of time. equal to 1050°C about. Average pressure considered is
40÷100 N/mm2.
VALIDATION OF RESULTS
The same geometry tested by Sluzalec has been used. The rod
PROPERTIES OF THE MATERIAL has a diameter 0.020 m (20 mm). Temperature is evaluated in
The model is validated by results published by Sluzalec [9]. different positions along rod axis (step 5 mm).
These results are referred to G20 steel. Main properties of the
G20 steel are reported below. A section of the rod has area A = 314,16 mm2. The total force
results N = 12566.4÷31416 N.
Using values from this table it is possible to define functions
which approximate the properties of G20 steel. Two welding conditions are assumed: pa = 40 N/mm2 and pb
= 60 N/ mm2. Applied forces are Na = 12566.4 N and Nb =
Thermal conductivity can be approximated by the following 18849.6 N.
first order function:
Friction coefficient is not known and it depends on
temperature. It is assumed by experimental values [11]. By
calculating average value in the temperature range it can be
Average value in the considered interval of data is 20,2 W/(m assumed µ = 1.
K).
In accord to Sluzalec angular speed is assumed to be 1460
Specific heat can be approximated by a third order rpm.
polynomial:
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Figure 6. Graph of temperature obtained by G20 steel data at 5 mm depth compared with Sluzalec data fitting at the same depth.
It can be evaluated the time tp, which results about 4 seconds. CONCLUSIONS
Lp results about 2.5 mm.
This paper presents a general model of the process, which
could be helpful to calculate temperature distribution and
Assuming a length of the rod of 1m (enough to consider the
burn-off volume as a function of directly controllable
problem that the rod is infinite on one side) it results a
technological parameters: axial force, spin velocity, torque
calculation length 1002.5. The graph of temperature obtained
and time.
is similar to the one produced by Sluzalec. In the produced
graph x is assumed, but x is moved on the t axis about 1s.
This model aims to be an advancement of the studies of
Sluzalec, Tsang and Trepte, which describe the process as
The graph appears in line with experimental and theoretical
function of independent variables. This approach could
results obtained by A. Sluzalec [9] at the same depth. By this
present an apparent contrast with Tsang description. It is only
interesting result it can be assumed that the proposed model,
apparent, because it does not exclude the importance of burn-
based on analytical solutions of the heat equation can be
off volume, but assumes that it is a dependent variable of the
useful in order to produce affordable results to the technical
process, instead of an independent one, calculated as a
prediction of thermal behaviour of friction welding.
function of independent variables.
The presented model needs some numerical improvement in
A case of the experimental temperature distribution obtained
order to be more usable. Some improvements are under
by Sluzalec [9-10] is used to verify and validate the model
study. Different and more comprehensive validation are
presented. The last phase of static drawing is not considered,
under development, but it is not easy to obtain experimental
because it is less influenced by thermal heating. It can be
data. An experimental campaign has began but need long
implemented in future developments.
times in order to be completed.
The model has been verified by comparing results to Sluzalec
Figure 12 shows also that in about 20 s the burn-off is about 3
study on G20 steel.
mm in accord with calculation by equation (44), and Sluzalec
experimental data.
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A future development will consist in the burn-off modeling 7. Kleiber, M. and Sluzalec, A., Finite element analysis of
by verifying the direct applicability of the Reye hypothesis: heat flow in friction welding. Eng Trans. 32, 107 (1984).
proportionality between the volume of burn-off volume and
8. Sluzalec, A. Jr, A new finite element approach to heat
the work of the forces of friction.
flow analysis in 3D developable structures, Journal of
thermal analysis ISSN 0368-4466, vol. 30, no5, pp.
Other future developments will regard the experimental
1063-1069 (1985)
validation of the model for different materials. A code
implementing a large database of material data to predict 9. Sluzalec, A. Jr, Thermal effect in friction welding, Int, J.
many rotary friction welding cases could be produced. The Mech. Sci. Vol. 32, No. 6, pp. 467 478, (1990)
problem connected with this activity is related to the
10. Sluzalec, A. and Sluzalec, A. Jr, Solutions of thermal
definition of effective and valuable functions describing
problems in friction welding : comparative study, Int. J. of
material properties, such as density, interface conductivity,
Heat and Mass Transfer, vol. 36, No.6, pp. 1583-1587 (1993).
thermal conductivity, which are function of temperature.
11. Sluzalec, A. Jr, Theory of Metal Forming Plasticity
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W work [J]
Q heat [J]
F force [N]
M couple [Nm]
t time [s]
h convection coefficient
k conduction coefficient
ρ density [kg/m3]
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doi:10.4271/2010-01-1869