Calibration of 3D ALE finite element model from experiments on friction stir welding of lap joints

Fourment, Lionel; Gastebois, Sabrina; Dubourg, L.

doi:10.1063/1.4963500

Cited by 7 publications

(2 citation statements)

References 12 publications

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“…Three different numerical methods have been suggested by researchers to investigate the behavior of the process at local and global scales, Lagrangian, Eulerian and Arbitrary Lagrangian-Eulerian (ALE) [54,73]. The differences between these approaches are shown in Figure 3.…”

Section: Different Welding Zones and Different Modelling Scalesmentioning

confidence: 99%

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

Meyghani

Awang

Emamian

et al. 2017

Metals

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Friction Stir Welding (FSW) is a novel kind of welding for joining metals that are impossible or difficult to weld by conventional methods. Three-dimensional nature of FSW makes the experimental investigation more complex. Moreover, experimental observations are often costly and time consuming, and usually there is an inaccuracy in measuring the data during experimental tests. Thus, Finite Element Methods (FEMs) has been employed to overcome the complexity, to increase the accuracy and also to reduce costs. It should be noted that, due to the presence of large deformations of the material during FSW, strong distortions of mesh might be happened in the numerical simulation. Therefore, one of the most significant considerations during the process simulation is the selection of the best numerical approach. It must be mentioned that; the numerical approach selection determines the relationship between the finite grid (mesh) and deforming continuum of computing zones. Also, numerical approach determines the ability of the model to overcome large distortions of mesh and provides an accurate resolution of boundaries and interfaces. There are different descriptions for the algorithms of continuum mechanics include Lagrangian and Eulerian. Moreover, by combining the above-mentioned methods, an Arbitrary Lagrangian-Eulerian (ALE) approach is proposed. In this paper, a comparison between different numerical approaches for thermal analysis of FSW at both local and global scales is reviewed and the applications of each method in the FSW process is discussed in detail. Observations showed that, Lagrangian method is usually used for modelling thermal behavior in the whole structure area, while Eulerian approach is seldom employed for modelling of the thermal behavior, and it is usually employed for modelling the material flow. Additionally, for modelling of the heat affected zone, ALE approach is found to be as an appropriate approach. Finally, several significant challenges and subjects remain to be addressed about FSW thermal analysis and opportunities for the future work are proposed.

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Section: Different Welding Zones and Different Modelling Scalesmentioning

confidence: 99%

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

Meyghani

Awang

Emamian

et al. 2017

Metals

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“…They show the strong dependence of the heat generation on the tool rotating and advancing speed. In reference [34], they use a parallel ALE formulation developed in Forge® finite element code to model the defects such as flashes and worm holes. The friction at the tool/workpiece interface is modeled using Norton's friction law.…”

Section: Introductionmentioning

confidence: 99%

Enhanced friction model for Friction Stir Welding (FSW) analysis: Simulation and experimental validation

Dialami

Chiumenti

Cervera

et al. 2017

International Journal of Mechanical Sciences

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Friction is one of the main heat generation mechanisms in Friction Stir Welding (FSW). This phenomenon occurs between the pin and the workpiece as the rotating tool moves along the weld line. An accurate friction model is essential for obtaining realistic results in a FSW simulation in particular temperature, forces and torque. In this work, a modified Norton's friction law is developed. The suggested enhanced friction model aims at providing not only the realistic temperature field but also the forces and torque. This model does not exclusively relate the frictional shear stress to the sliding velocity; conversely it takes into account the effect of non-uniform pressure distribution under the shoulder, as this latter has an important role in the process of heat generation. Longitudinal, transversal and vertical forces and torque are numerically calculated. The effect of the enhanced friction model is reflected in these forces. In particular, it leads to a more realistic estimation of the transversal and longitudinal forces in comparison with the results obtained using former models. The friction model is successfully validated by the experimental measurements provided by the industrial partner (Sapa). The experimental analysis is performed for the material characterization, the calibration of the friction model and, more generally, the assessment of the overall numerical strategy proposed for the FSW simulation.

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Influence of PU foam reinforcement of I-beam on buckling resistance

Lacki

Derlatka

2018

Composite Structures

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Calibration of 3D ALE finite element model from experiments on friction stir welding of lap joints

Cited by 7 publications

References 12 publications

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

Enhanced friction model for Friction Stir Welding (FSW) analysis: Simulation and experimental validation

Influence of PU foam reinforcement of I-beam on buckling resistance

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