An analytical model integrating tool kinematics and material flow for the spindle torque prediction in additive friction stir deposition

Jiajie Wu; Mason Ma; Jaydeep Karandikar; Christopher Tyler; Tony Shi; Tony Schmitz

doi:10.1016/j.mfglet.2025.06.137

An analytical model integrating tool kinematics and material flow for the spindle torque prediction in additive friction stir deposition

Jiajie Wu
, Mason Ma
, Jaydeep Karandikar
, Christopher Tyler
, Tony Shi
, Tony Schmitz

Advanced Machining and Machine Tools Res

Research output: Contribution to journal › Article › peer-review

1 Scopus citations

Abstract

Understanding the relationship between spindle torque, tool kinematics, and material flow is important for the emerging solid-state additive friction stir deposition (AFSD) process. This study presents the first analytical modeling effort to integrate tool kinematics and material flow for the spindle torque prediction in AFSD. In the proposed model, material flow is first inferred by tool kinematics with consideration of slippage. The derived strain rate is then used to calculate flow stress based on the Johnson-Cook constitutive models for different materials. Spindle torque is estimated by integrating the effects of plastic deformation and sliding friction across tool-deposition surface. Experiments of wall deposition using aluminium 7075 feedstock at different spindle speeds are performed. In addition to aluminium 7075, the experimental data of stainless steel 316 in the literature is also applied for model validation. Experimental validation results show that the proposed analytical model can achieve good performance of spindle torque prediction for different deposition materials in AFSD.

Original language	English
Pages (from-to)	1177-1186
Number of pages	10
Journal	Manufacturing Letters
Volume	44
DOIs	https://doi.org/10.1016/j.mfglet.2025.06.137
State	Published - Aug 2025

Funding

The authors acknowledge support from the NSF Engineering Research Center for Hybrid Autonomous Manufacturing Moving from Evolution to Revolution (ERC-HAMMER) under Award Number EEC-2133630. This work was partially supported by the DOE Office of Energy Efficiency and Renewable Energy (EERE), under contract DE-AC05 00OR22725. The U.S. government retains and the publisher, by accepting the article for publication, acknowledges that the U.S. government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for U.S. government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan. The authors also gratefully acknowledge the Southeastern Advanced Machine Tools Network (SEAMTN) for partially supporting this research.

Keywords

Additive friction stir deposition
Analytical model
Material flow
Spindle torque
Tool kinematics

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10.1016/j.mfglet.2025.06.137

Cite this

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title = "An analytical model integrating tool kinematics and material flow for the spindle torque prediction in additive friction stir deposition",

abstract = "Understanding the relationship between spindle torque, tool kinematics, and material flow is important for the emerging solid-state additive friction stir deposition (AFSD) process. This study presents the first analytical modeling effort to integrate tool kinematics and material flow for the spindle torque prediction in AFSD. In the proposed model, material flow is first inferred by tool kinematics with consideration of slippage. The derived strain rate is then used to calculate flow stress based on the Johnson-Cook constitutive models for different materials. Spindle torque is estimated by integrating the effects of plastic deformation and sliding friction across tool-deposition surface. Experiments of wall deposition using aluminium 7075 feedstock at different spindle speeds are performed. In addition to aluminium 7075, the experimental data of stainless steel 316 in the literature is also applied for model validation. Experimental validation results show that the proposed analytical model can achieve good performance of spindle torque prediction for different deposition materials in AFSD.",

keywords = "Additive friction stir deposition, Analytical model, Material flow, Spindle torque, Tool kinematics",

author = "Jiajie Wu and Mason Ma and Jaydeep Karandikar and Christopher Tyler and Tony Shi and Tony Schmitz",

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doi = "10.1016/j.mfglet.2025.06.137",

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AU - Wu, Jiajie

AU - Ma, Mason

AU - Karandikar, Jaydeep

AU - Tyler, Christopher

AU - Shi, Tony

AU - Schmitz, Tony

PY - 2025/8

Y1 - 2025/8

N2 - Understanding the relationship between spindle torque, tool kinematics, and material flow is important for the emerging solid-state additive friction stir deposition (AFSD) process. This study presents the first analytical modeling effort to integrate tool kinematics and material flow for the spindle torque prediction in AFSD. In the proposed model, material flow is first inferred by tool kinematics with consideration of slippage. The derived strain rate is then used to calculate flow stress based on the Johnson-Cook constitutive models for different materials. Spindle torque is estimated by integrating the effects of plastic deformation and sliding friction across tool-deposition surface. Experiments of wall deposition using aluminium 7075 feedstock at different spindle speeds are performed. In addition to aluminium 7075, the experimental data of stainless steel 316 in the literature is also applied for model validation. Experimental validation results show that the proposed analytical model can achieve good performance of spindle torque prediction for different deposition materials in AFSD.

AB - Understanding the relationship between spindle torque, tool kinematics, and material flow is important for the emerging solid-state additive friction stir deposition (AFSD) process. This study presents the first analytical modeling effort to integrate tool kinematics and material flow for the spindle torque prediction in AFSD. In the proposed model, material flow is first inferred by tool kinematics with consideration of slippage. The derived strain rate is then used to calculate flow stress based on the Johnson-Cook constitutive models for different materials. Spindle torque is estimated by integrating the effects of plastic deformation and sliding friction across tool-deposition surface. Experiments of wall deposition using aluminium 7075 feedstock at different spindle speeds are performed. In addition to aluminium 7075, the experimental data of stainless steel 316 in the literature is also applied for model validation. Experimental validation results show that the proposed analytical model can achieve good performance of spindle torque prediction for different deposition materials in AFSD.

KW - Additive friction stir deposition

KW - Analytical model

KW - Material flow

KW - Spindle torque

KW - Tool kinematics

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An analytical model integrating tool kinematics and material flow for the spindle torque prediction in additive friction stir deposition

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Keywords

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