Research Methodology Thesis 2022

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RESEARCH METHODOLOGY THESIS
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Thermal analysis of friction welding Using Abaqus CAE Simulation
Summary
Friction welding refers to the welding methods which are based on the green technology,
since it uses non- consumable tools to generate coalescence between the workpiece by
making application of heat generated due to the friction and plastic deformation at the
interface of the work piece affecting the formation of the welding joint material in solid
state. Friction welding is a solid-state joining process which produces heat through
mechanical friction between the parts to be joined. In this process axial forces are applied
which assist in deforming the material and the heated parts are fixed together. The process
of friction welding is a much faster method which does not make application of the
consumables and at the same time allows the material to maintain its original properties. This
thesis will focus on discussing the process of friction welding through the use of Abaqus
CAE simulation.
Introduction
There little difference between the convectional welding and the friction welding considering
that both of them are welding process. Friction n welding process comprises of provision of a
continuous rubbing action between surfaces of a rotary work component and a stationary
work piece whereby because of the continuous frictional rubbing between the piece’s
friction heat is generated at the interface leading to (Bergheau & Fortunier, 2012)the
creation of weld at the joint at the interface (Johns, 2013). The friction welding offers a very
efficient and simple way of joining work pieces together as compared to the traditional fusion
welding process. This technique has a wide application which range from joining members,
such as studs to repairing of cracks. Another aspect of friction welding in involves causing a

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harder material probe to be entered into a softer material work component. In contrast to
standard welding, this so-called "freeze welding method" offers a very easy and effective way
to join parts of weld together. It can be implemented from cracks to joining members like
stuffs and covers to other parts of job. The technique can be repaired. The addition of a
harder material probe to a softer job element for material is an element of the friction welding
method (Awang, 2011)
Background information
The process of friction welding was first discovered in the late 1920s, however during that
time there was very little data which was recorded about its use. A detailed discussion about
friction welding was recorded in the USSR in the early 1960s, but that time it was described
as ‘very doubtful, as a production technique due to the challenges in generating reciprocating
linear motion (Altenbach, 2013). The fist well-structured industrial research into friction
welding took place in the 1980s at TWI, UK, while the first ever research academic to be to
be recorded took place at Ohio State University, and the University of Bristol, UK.In the
recent past, simulation of inertial friction has played a very crucial role in analyzing the
mechanics of inertial friction welding process and this has permitted to see the process of
welding from different perspectives.
Hypothesis
The friction welding technique works on the basic principle of friction. In the process of
welding, friction is used to create heat at the interfaces surfaces (Anderson, 2016). The heat
is used to join the two work pieces through the application of the external pressure at the
work pieces’ surfaces. In friction welding, the friction is applied until the plastic forming
temperature is reached which is usually900-1300oc for steel.