Evaluation of welding characteristics using three-dimensional finite element simulation and experimentation for FSW of aluminum 6061

Aim of this study is to introduce numerical 3D finite element method (FEM) simulation to study characteristics of friction
stir welding. A coupled experimental and numerical simulation study was carried out to study the effect of process
parameters on welding characteristics for friction stir welding of aluminium 6061. As per Box–Behnken design, 15
experiments have been conducted on aluminium 6061 plates at three levels of spindle speed, tilt angle and tool pin
diameter. Experimental results of tool vibration, force in X, Y and Z directions and ultimate tensile strength were collected
and analyzed. Shearing of metal and metal flow patterns during the welding were analyzed and the responses were
predicted using FEM simulation. Size of the shear zone around the tool pin was studied for different combinations of the
parameters. The experimental results and the FEM-simulated values were found to be in good agreement. Interaction effect
of the process parameters on the responses was analyzed using response surface methodology