Effect of Coefficient of Friction in Finite Element Modeling of Friction Stir Welding and its Importance in Manufacturing Process Modeling Applications

Friction Stir Welding (FSW) is a relatively new joining process which is gaining significance in many joining applications. The development in Finite element (FE) modeling is also aiding in widening the applicability of FSW by simulating the process for better understanding. The success of modeling of FSW depends on selection of suitable techniques and models/laws irrespective of FE package used for simulation. The principal equations that govern modeling of FSW are the material model and the friction model. This paper aims at discussing the effect of variation in Coefficient of Friction (COF) on simulation outputs. It also highlights the modification required in friction model to get the realistic results from FSW simulations using ABAQUS.