Research on the Influence of Welding Parameters of FSW on Stirring Tool Wear

Studying how to reduce the wear of stirring tools in friction stir welding (FSW) is of great significance for its development. By finding the optimal welding parameters, the service life of stirring tools can be improved or extended. Based on the determination of the material flow stress equation, the shear friction model between the stirring tool and the weldment material, and the relationship between the surface temperature of the stirring tool and its hardness, a multi-physical field coupled finite element model for FSW was established. By varying the rotational speed ω and travel speed ν of the stirring tool, multiple simulation calculations and analyses were conducted to obtain 20 sets of data on the relationship between ω, ν, and tool wear W. Based on these data, the relationship between (ω, ν) and W was analyzed, and a surface function between (ω, ν) and W was established through surface fitting. A set of relatively optimal parameters corresponding to the minimum tool wear was found within the range of (720, 60) to (960, 180), with ω being 840 rpm and ν being 180 mm/min. At this time, the wear amount of the stirring tool during the travel stage is 0.006 × 10^−3 mm, which is 97.9% less than the wear amount of 0.292 × 10^−3 mm during the travel stage when (ω, ν) is (720, 60). During the actual processing, (ω, ν) should avoid the three points (2250, 180),(2250, 360), and (2700, 180) and their surrounding areas within the range of (900, 60) to (2700, 360), to prevent excessive wear of the stirring tool. This research has practical significance and value for reducing the wear of stirring tools and promoting FSW technology.