Optimisation of process parameters in friction stir welding based on residual stress analysis: a feasibility study

Cem Celal Tutum, Jesper Henri Hattel

Research output: Contribution to journalJournal articleResearchpeer-review

Abstract

The present paper considers the optimisation of process parameters in friction stir welding (FSW). More specifically, the choices of rotational speed and traverse welding speed have been investigated using genetic algorithms. The welding process is simulated in a transient, two-dimensional sequentially coupled thermomechanical model in ANSYS. This model is then used in an optimisation case where the two objectives are the minimisation of the peak residual stresses and the maximisation of the welding speed. The results indicate that the objectives for the considered case are conflicting, and this is presented as a Pareto optimal front. Moreover, a higher welding speed for a fixed rotational speed results, in general, in slightly higher stress levels in the tension zone, whereas a higher rotational speed for a fixed welding speed yields somewhat lower peak residual stress, however, a wider tension zone, leading to a substantially higher residual tensile force.
Original languageEnglish
JournalScience and Technology of Welding and Joining (Online Edition)
Volume15
Issue number5
Pages (from-to)369-377
ISSN1743-2936
DOIs
Publication statusPublished - 2010

Keywords

  • Friction stir welding
  • Thermal pseudo mechanical model
  • Constrained multi-objective optimisation
  • Residual stress
  • Non-dominated sorting genetic algorithm

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