Investigating the Effects of Tool Pin Profile on Strain and Temperature During Friction Stir Welding Process Using CEL Method

The pin profile in Friction Stir Welding (FSW) has a significant influence on the temperature and strain distribution during the welding process. The shape and geometry of the pin can affect the material flow and heat generation, which in turn impacts the temperature within the weld zone. In this research, the effect of different square, triangular, and cylindrical pin profiles on strain and temperature during FSW was investigated numerically. The coupled Eulerian-Lagrangian (CEL) method was utilized to model the FSW process and further analyze strain and temperature. In this approach, the workpiece is represented using an Eulerian formulation, while the tool is described through a Lagrangian formulation. Results showed that the cylindrical tool generates higher temperatures due to its larger surface area, while the triangular tool keeps the sample cooler with a smaller pin surface area. Despite the triangular tool's longer revolving arm causing greater strain, it results in less pulsation, limiting the strain's impact to a smaller area. The maximum strain generated by the circular tool was approximately 16, whereas the triangular tool produced a maximum strain of 45.