Determination of heat partition between tool and workpiece during FSW of SS304 using 3D CFD modeling

The temperature distribution in the tool was calculated by solving the energy equations for the tool and the workpiece in a conjugate manner. The three-dimensional computational fluid dynamics code, FLUENT, was used to model the heat and material flow during FSW of SS304 using the polycrystalline cubic boron nitride pin. The calculated temperature profiles in the workpiece were validated against published experimental data. Heat partitioned to the tool was found to be significantly less than what would be expected from the equation based on thermophysical properties. The model correctly predicted the material flow characteristics of FSW. The stagnant regions which have very low material velocity in the workpiece were mapped.