Effect of process parameters on material strength (AA6061-T6) during Friction Stir Processing: Simulation and Experimental validation

In this work, an ABAQUS 6.13-1 finite element model of the friction stir process using arbitrary lagrangian-eulerian (ALE) equations is developed. The deformable plate and rigid tool are modeled in dynamic/explicit. Properties of AA6061-T6 are applied to the plate. Coulomb's frictional contact model is used to define the tool-plate interaction. The process parameters such as traverse feed, tool rotational speed, and penetration depth are varied to obtain the optimum parameters for maximum strength. The stress-strain graphs are obtained from the developed model and the strength values are calculated. In the simulation, the maximum yield strength of 149 MPa and ultimate tensile strength of 310 MPa were obtained for the optimum parameters; tool rotational speed of 1400 rpm, traverse feed of 22 mm/min, and penetration depth of 0.15 mm. By setting the optimum parameters, experiments were performed and found to be +/- 8% of simulations.(c) 2022 Elsevier Ltd. All rights reserved.Selection and peer-review under responsibility of the scientific committee of the Second International Conference on Engineering Materials, Metallurgy and Manufacturing.