A contribution to a critical review of friction stir welding numerical simulation

Abstract

Various modelling approaches using commercial numerical software have been proposed in the friction stir welding literature. We initiate a comparative analysis of such modellings, involving aspects such as the constitutive laws, the representation of the continuum medium and the contact between medium and tool, and the definition of the heat sources. Numerical problems are also considered: contact definition, mass scaling, and the use of the arbitrary Lagrangian Eulerian in ABAQUS/Explicit. Finally, we propose numerical tests to explore the ability of a Lagrangian code with an ALE option to simulate the process.

A new algorithm based on Moving Least Square method to simulate material mixing in friction stir welding

“…Lagrangian formulation is well adapted for history dependence in solids and for simulation of material flow with free surfaces but mesh distortions require special procedure as remeshing. The ALE formulation has been proposed to benefit from both advantages of Eulerian and Lagrangian formulations [6]. In this technique, one has to describe the motion of the mesh and material particles separately with respect to a reference domain.…”

“…ALE has been applied successfully in many fields and particularly in metal forming processes. Despite the intensive development of these techniques, material mixing in FSW process remains very difficult to achieve numerically and especially when using finite element method [6,7].…”

An Implicit Algorithm Based on Continuous Moving Least Square to Simulate Material Mixing in Friction Stir Welding Process

“…It has been investigated by several authors considering thermal or thermomechanical framework [2][3][4][5][6][7][8]. The difficulty in modeling this welding type resides to large deformations generated by the material mixing.…”

“…Lagrangian formulation is well adapted for history dependence in solids and for simulation of material flow with free surfaces but mesh distortions require special procedure as remeshing. The ALE formulation has been proposed to benefit from both advantages of Eulerian and Lagrangian formulations [3]. In this technique, one has to describe the motion of the mesh and material particles separately with respect to a reference domain.…”

“…ALE has been applied successfully in many fields and particularly in metal forming processes. Despite the intensive development of these techniques, material mixing in FSW process remains very difficult to achieve numerically and especially when using finite element method [2,3].…”