Friction Stir Welding With Synchronous Rolling for Deformation Control

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Solution Overview

Problem

Existing methods fail to effectively reduce welding deformation in friction stir welding, particularly for large-size thin-walled or special-shaped weldments, and there is a lack of simulation modeling and process optimization for synchronous rolling during friction stir welding.

Innovation Solution

A method and device for optimizing process parameters of friction stir welding with synchronous rolling using a system finite element model, incorporating heat source, contact, and mechanical action relationships, and performing thermal-mechanical simulation to determine optimal parameters that reduce welding deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If synchronous rolling control during welding is used to reduce welding deformation, then welding deformation is reduced, but it is very time-consuming and costly to obtain the optimal process parameters through experiments

Engineering Contradiction:

Improvewelding deformation reductionVSAvoidparameter optimization time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent creates a finite element model that copies and simulates the actual welding and synchronous rolling process. This virtual model allows for parameter optimization through simulation rather than expensive and time-consuming physical experiments, significantly reducing development time and cost.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces physical experimentation with computer simulation. The finite element model substitutes for actual welding experiments, allowing virtual testing and optimization of synchronous rolling parameters without requiring repeated physical trials.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If synchronous rolling control during welding is used to perform welding accompanied by straightening control, then welding deformation is reduced, but there is no existing simulation modeling and process optimization method for friction stir welding

Engineering Contradiction:

Improvewelding accompanied by straightening controlVSAvoidsimulation modeling complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent divides the welding system into distinct finite element models: the weldment model, the stirring tool model, and the synchronous rolling device model. This segmentation allows for independent modeling and analysis of each component while capturing their interactions during the welding process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent develops a universal finite element model that can simulate both the friction stir welding process and the synchronous rolling process simultaneously. This multi-functional model integrates thermal, mechanical, and deformation fields to comprehensively analyze the welding accompanied by straightening control.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method and device enable accurate prediction and optimization of process parameters for friction stir welding, effectively reducing welding deformation and improving welding quality.

Implementation Method 1

the heat source model is a model equivalent to friction heat generation of a real stirring tool

Methodology Applied

Scientific EffectFriction heat generation: Friction

Implementation Method 2

performing a heat transfer simulation on a welding process and a cooling process of friction stir welding

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 3

performing a thermal-mechanical simulation on the welding process, the cooling process and a clamp release process

Methodology Applied

Scientific EffectThermal-mechanical coupling: Thermomechanical Effect

Implementation Method 4

the contact relationship between the roller finite element model and the weldment finite element model is a frictional surface-to-surface contact relationship

Methodology Applied

Scientific EffectFrictional contact: Friction

Data Source

PatentUS20260027645A1Method for optimizing process parameters of friction stir welding with synchronous rolling and related device

Publication Date: 2026.01.29 NANCHANG HANGKONG UNIVERSITY

AI summary

A method for optimizing process parameters of friction stir welding with synchronous rolling and a related device are provided. A heat source model is applied to a system finite element model, and heat transfer simulation is performed on the welding and cooling processes of friction stir welding. Furthermore, contact relationships and mechanical action relationships between a stirring tool finite element model and a weldment finite element model and between a roller finite element model and the weldment finite element model are applied in the system finite element model. Thermal-mechanical simulation is performed on the welding process, the cooling process and a clamp release process of friction stir welding with synchronous rolling with a temperature field result obtained from heat transfer simulation as an input. Based on the welding stress and welding deformation results obtained from thermal-mechanical simulation, process parameters are adjusted and re-simulated until optimal parameters are obtained.