HW#4, due 9-22-2010

1 - New) In a process known as friction welding, two identical, metal rods are fused by placing
them end-to-end and rotating them in opposite directions around their common axis. Friction at
the interphase generates heat at a not necessarily constant rate of Q Energy/time/area. The heat
generated by the friction eventually cause the metal at the interphase to melt such that the rods
fuse.
a) Derive the transient energy balance for a rod, assuming cylinder symmetry and constant
physical properties.
b) What boundary condition(s) on temperature hold at the metal-metal interphase?
c) Once the metal melts, the gap between the rods will be filled with liquid metal in laminar flow.
Simplify the Navier-Stokes equation as much as possible for this flow. You can assume constant
physical properties and steady flow.
d) Assuming that the two rods rotate with angular velocities (in opposite directions) and that
the fluid containing gap has width 2, find the fluid velocities in the gap. You can neglect the
effect of gravity.
e) Consider now friction welding of a rod to a plate as shown in fig ??. The depth of the indentation
in the plate is such that the axis of rotation is in the same plane as the plate surface. Derive the
transient energy balance for the rod assuming constant physical properties.

Figure 1: Friction welding of a rod to a plate. The indentation in the plate is of just size that the axis of
rotation is in the same plane as the surface of the plate.

f) If the = 0-direction is defined as being in the plane of the plate surface and pointing to the
right in the figure and with increasing in the same direction as the direction of rotation, what
is the boundary condition at the metal-metal surface?
Also #22, 24, 27

a) The problem has rotational symmetry and temperature will therefore only depend on the
axial and radial coordinate. Define the axial coordinate z as equal to zero at the interface between
the rods and pointing away from this interface. The CV is an annular ring of length and thickness
dz and dr. Transport is by conduction or Fouriers law. Technically speaking, there is also
convection due to the rotation of the solid, but as there is no dependence on temperature, the
net flux due to this rotation is zero. Alternatively, you can use a cylindrical coordinate system
that rotates with the solid. In this coordinate system there is no movement of the solid and
therefore no convective terms. The energy balance is









Cp T
T
T
T
T
2rdr + k
2rdr
2rdz  + k
2rdz 
2rdrdz
k
=
z
z
r
r
t
z
z+dz
r
r+dr
k

1
2T
+
2
z
r r

T
r
r



= Cp

T
t

b) At the metal-metal interface, half of the energy produced by friction is conducted away by
each rod, thus
Q
T
= k
2
z
c) Since the orientation of the process is not described in the problem, we can/will assume
that gravity is not important and ignore the gravitational terms in the Navier-Stokes equation.
The problem has rotational symmetry and the fluid will rotate with an angular velocity that
depends on radius and axial coordinates. The only velocity component is therefore v (r, z). The
Navier-Stokes equation simplifies as follows. Continuity equation
z=0

0=0
r-component

v2
p
=
r
r

-component

0=
r

1 rv
r r

2 v
z 2

z-component
0=0
d) The boundary conditions in the z-direction are
z = v = r , z = v = r
Using a symmetry argument (reflection in the center plane does not change the problem) one
can also see that a possible boundary condition is v = 0 at z = 0. The solution can easily be
found by guessing that the velocity must be proportional to z, i.e.
2

v = C(r)z
Substituting this into the -component of the Navier-Stokes equation gives


d 1 drC
r 2 C2
= 0 C(r) = C1 +
dr r dr
2
r
The velocity must be finite so C2 = 0 giving
v = C3 rz
Applying the boundary conditions in z finally gives
v = rz/
e) The temperature will now depend on r and so the CV is a wedge between r and r + rd
and between and + d, The energy balance is








Cp T
1 T
1
T
T
T
k
k
=
dzdr + k
dzdr
rddz  + k
rddz 
rddrdz
r
r
r
r
t

+d
r
r+dr
k

1
1 2T
+
2
2
r
r r

T
r
r



= Cp

T
t

f) At the metal-metal surface, the heat evolving from the friction is conducted into both the
rod and the plate. Without a model of the temperature in the plate, we cant know what amount
of this heat is conducted into the plate and what amount into the rod, so we will just assume that
the flux into the rod is Q. This flux must equal the conduction flux into the rod, i.e.
r = R and 0 < < Q = k

T
r