A finite element model for surface and volumetric defects in the FSW process using a coupled Eulerian–Lagrangian approach

Das, Debtanay; Bag, Swarup; Pal, Surjya K.

doi:10.1080/13621718.2021.1931760

Cited by 29 publications

(5 citation statements)

References 32 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…One of the problems raised in the field of FSP simulation with CEL method is the penetration of the Eulerian material into the Lagrangian domain [22]. To solve this problem, the size of the Lagrangian element is usually considered small enough [23]. Reducing the elements increases the analysis time.…”

Section: -1 Governing Equationsmentioning

confidence: 99%

A new method for localization the residual stress distribution and enhancement wear resistance through underwater friction stir processing with stationary shoulder

arezoudar,

hosseini

2023

Preprint

View full text Add to dashboard Cite

A new method to achieve friction stir processed parts with higher wear resistance and lower residual stress values was presented. The underwater stationary shoulder FSP process (USSFSP) was investigated using experimental and numerical methods. Also, the presented process was compared with the conventional underwater FSP method (UCFSP). An improved CEL simulation method was used to prevent errors in the contact boundary between Eulerian and Lagrangian domains. Heat input was reduced significantly and resulted in a fine microstructure with higher microhardness and lower residual stresses. Temperature field was concentrated around the pin and caused a symmetrical residual stress distribution. The distribution area of Von-Mises and longitudinal stresses during the USSFSP was significantly narrower than the UCFSP process. The stress distribution around the UCFSP tool was compressive and tensile stress was produced at further distances. However, the longitudinal stress distribution in the USSFSP was completely opposite. Tensile stress was generated in the lower part of the thickness and compressive stress in the upper part and in locations away from the centerline. This method caused the formation of a compressive residual stress region and considerably reduced the width of the tensile residual stress zone. By increasing the hardness and decreasing the residual stress level, the USSFSP proved to be instrumental in improving the material's wear resistance. The wear rate in the stir zone undergoes a substantial reduction, decreasing from 5.6x10-3 mm3/m in UCFSP to 1.4x10-3 mm3/ m in USSFSP.

show abstract

Section: -1 Governing Equationsmentioning

confidence: 99%

A new method for localization the residual stress distribution and enhancement wear resistance through underwater friction stir processing with stationary shoulder

arezoudar,

hosseini

2023

Preprint

View full text Add to dashboard Cite

show abstract

“…We modeled FSW following the CEL technique using commercially available FEMbased software ABAQUS 2017. The conventional thermal validation of the model is provided elsewhere [15]. The current model focused on material flow, material mixing, and the evolution of defects in dissimilar FSW.…”

Section: The Theoretical Modelmentioning

confidence: 99%

“…where, D is the damage parameter, ε is the effective plastic strain, ε f is the plastic strain in failure, d 1 − d 5 is material dependent constants, p and σ are the pressure and von-mises stress. The application of the JC damage in the developed numerical model is described previously by the authors elsewhere [15]. The JC model material constants are provided in Tables 4 and 5.…”

Section: The Theoretical Modelmentioning

confidence: 99%

“…The need to clearly and accurately predict thermomechanical responses has increased the scope of the applications of numerical models to investigate the FSW process in depth. For instance, the surface and sub-surface defects in FSW of similar materials have been numerically modeled [15]. Ajri et al [16] predicted the formation of cavities and tunnel defects.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Material Defects in Friction Stir Welding through Thermo–Mechanical Simulation: Dissimilar Materials with Tool Wear Consideration

et al. 2022

Self Cite

View full text Add to dashboard Cite

Despite the remarkable capabilities of friction stir welding (FSW) in joining dissimilar materials, the numerical simulation of FSW is predominantly limited to the joining of similar materials. The material mixing and defects’ prediction in FSW of dissimilar materials through numerical simulation have not been thoroughly studied. The role of progressive tool wear is another aspect of practical importance that has not received due consideration in numerical simulation. As such, we contribute to the body of knowledge with a numerical study of FSW of dissimilar materials in the context of defect prediction and tool wear. We numerically simulated material mixing and defects (surface and subsurface tunnel, exit hole, and flash formation) using a coupled Eulerian–Lagrangian approach. The model predictions are validated with the experimental results on FSW of the candidate pair AA6061 and AZ31B. The influence of tool wear on tool dimensions is experimentally investigated for several sets of tool rotations and traverse speeds and incorporated in the numerical simulation to predict the weld defects. The developed model successfully predicted subsurface tunnel defects, surface tunnels, excessive flash formations, and exit holes with a maximum deviation of 1.2 mm. The simulation revealed the substantial impact of the plate position, on either the advancing or retreating side, on the defect formation; for instance, when AZ31B was placed on the AS, the surface tunnel reached about 50% of the workpiece thickness. The numerical model successfully captured defect formation due to the wear-induced changes in tool dimensions, e.g., the pin length decreased up to 30% after welding at higher tool rotations and traverse speeds, leading to surface tunnel defects.

show abstract

“…These modeling tools revealed the critical parameters in each case, leading to useful conclusions for the improvement of the results of these processes. In FSW, arithmetical modeling tools, such as Finite Element Analysis (FEA), have been applied [31], with research also focusing on the simulation and the investigation of volumetric defects during the FSW process [32]. Various computational or statistical models have also been introduced for the study of process performance.…”

Section: Introductionmentioning

confidence: 99%

Friction Stir Welding Optimization of 3D-Printed Acrylonitrile Butadiene Styrene in Hybrid Additive Manufacturing

et al. 2022

View full text Add to dashboard Cite

The feasibility of joining material extrusion (MEX) 3D-printed acrylonitrile butadiene styrene (ABS) plates with the friction stir welding (FSW) process was investigated herein as a promising topic of hybrid additive manufacturing (HAM). The influence of three process parameters on the mechanical strength of the joints was thoroughly examined and analyzed with a full factorial experimental design and statistical modeling. Hereto, the welding tool pin geometry, travel speed, and rotational speed were investigated. The joint’s efficiency and quality are evaluated through tensile tests and morphological characterization. More specifically, specimens’ areas of particular interest were investigated with stereoscopic, optical, and scanning electron microscopy. Throughout the FSW experimental course, the welding temperature was monitored to evaluate the state of the ABS material during the process. The majority of the welded specimens exhibited increased mechanical strength compared with the respective ones of non-welded 3D printed specimens of the same geometry. Statistical modeling proved that all processing parameters were significant. The feasibility of the FSW process in 3D printed ABS workpieces was confirmed, making the FSW a cost-effective process for joining 3D printing parts, further expanding the industrial merit of the approach.

show abstract

A finite element model for surface and volumetric defects in the FSW process using a coupled Eulerian–Lagrangian approach

Cited by 29 publications

References 32 publications

A new method for localization the residual stress distribution and enhancement wear resistance through underwater friction stir processing with stationary shoulder

A new method for localization the residual stress distribution and enhancement wear resistance through underwater friction stir processing with stationary shoulder

Material Defects in Friction Stir Welding through Thermo–Mechanical Simulation: Dissimilar Materials with Tool Wear Consideration

Friction Stir Welding Optimization of 3D-Printed Acrylonitrile Butadiene Styrene in Hybrid Additive Manufacturing

Contact Info

Product

Resources

About