An adaptive remeshing model was coupled with the Archard equation to calculate
the tool wear in friction stir welding (FSW). The Monte Carlo method was used to
simulate recrystallization in FSW with worn tools. In addition, experiments were
used to validate the predicted temperatures and microstructures. As indicated by the
results, appropriate tool wear can lead to self-optimization of the tool in
FSW. This wear mechanism is controlled by the change in the average strain
rate during the FSW process. The average strain rate first increases and
then decreases with tool wear, which is the key factor when determining the
final grains. An appropriate amount of tool wear can lead to smaller grains
in the stirring zone of FSW whereas excess tool wear can lead to larger
grains.
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