Coupled Eulerian Lagrangian finite element modeling of friction stir welding processes

Al-Badour, Fadi; Merah, Nesar; Shuaib, A. N.; Bazoune, Abdelaziz

doi:10.1016/j.jmatprotec.2013.02.014

Cited by 187 publications

(65 citation statements)

References 12 publications

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“…They have used point tracking method to predict material flow and found out that major material flow takes place from the advancing side of the weld, which lead to higher strain on the advancing side as compared to the retreating side. The researchers [16] have used coupled Eulerian-Lagrangian method to simulate FSW process. They have used Johnson-Cook material model to define flow stress.…”

Section: Introductionmentioning

confidence: 99%

Finite Element Simulation of Temperature and Strain Distribution during Friction Stir Welding of AA2024 Aluminum Alloy

Jain

Pal

Singh

2016

J. Inst. Eng. India Ser. C

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Friction Stir Welding (FSW) is a solid state joining process and is handy for welding aluminum alloys. Finite Element Method (FEM) is an important tool to predict state variables of the process but numerical simulation of FSW is highly complex due to non-linear contact interactions between tool and work piece and interdependency of displacement and temperature. In the present work, a three dimensional coupled thermo-mechanical method based on Lagrangian implicit method is proposed to study the thermal history, strain distribution and thermomechanical process in butt welding of Aluminum alloy 2024 using DEFORM-3D software. Workpiece is defined as rigid-visco plastic material and sticking condition between tool and work piece is defined. Adaptive remeshing is used to tackle high mesh distortion. Effect of tool rotational and welding speed on plastic strain is studied and insight is given on asymmetric nature of FSW process. Temperature distribution on the workpiece and tool is predicted and maximum temperature is found in workpiece top surface.

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Section: Introductionmentioning

confidence: 99%

Finite Element Simulation of Temperature and Strain Distribution during Friction Stir Welding of AA2024 Aluminum Alloy

Jain

Pal

Singh

2016

J. Inst. Eng. India Ser. C

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“…Numerical simulation of FSW has been performed using finite element method (FE) models, computational fluid dynamics (CFD) models, smoothed particle hydrodynamics (SPH) models, or finite volume method (FV) models. For example, over the last years, Al-Badour et al [7] built a 3D localized FE model in which the workpiece and the tool are modeled using Eulerian and Lagrangian formulation, respectively, to predict likely conditions that result in defect generation during FSW process. Albakri et al [8] developed a CFD-based fully coupled 3D thermomechanical model to better understand the effect of process parameters on temperature, material flow, and strain rate during the FSP.…”

Section: Introductionmentioning

confidence: 99%

Thermal modeling of friction stir welding of stainless steel 304L

Darvazi

Iranmanesh

2014

Int J Adv Manuf Technol

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This paper presents a numerical model, based on the displacement of one point of the material flow relative to a fixed reference point, in order to formulate the heat generation during friction stir process and thereby calculate the temperature difference between advancing and retreating sides. This model considers frictional heating dependent on both the temperature and the velocity of the tool, as well as heat generation due to plastic deformation dependent on temperature, and assumes that friction heat at high temperature was replaced by heat generation due to plastic deformation. The heat generated by plastic strain energy dissipation in thermomechanically affected zone is calculated by a new technique, and the convection heat transfer coefficient and the sticking state parameter are considered as a function of temperature. Finally, the thermal equations are solved using a nonlinear finite element code ABAQUS. The numerical results correctly showed the asymmetric nature of temperature distributed at different sides of the weld line which have good agreement with experimental data that are presented in the literature.

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“…e contact conditions between the shoulder and workpiece in the shoulderplunging stage at different steps are exhibited in Figure 8. e surface heat flux from the shoulder q s can be described by equation (9)…”

Section: Advances In Materials Science and Engineeringmentioning

confidence: 99%

“…e CFD models can describe the thermomechanical interaction between the tool and workpiece, and the most important consideration in the frictional boundary condition is the determination of the contact state [8]. In many CFD models, the contact conditions at the tool/workpiece interface are considered as full sticking, which usually leads to an overestimation of peak temperature [8][9][10]. Atharifar et al [11] assumed a sliding contact state during FSW, in which the velocity of material at the tool/workpiece interface was artificially defined as 60% of the tool velocity to investigate the loads carried by the tool.…”

Section: Introductionmentioning

confidence: 99%

A Modified Analytical Heat Source Model for Numerical Simulation of Temperature Field in Friction Stir Welding

Liu

Yang

et al. 2020

Advances in Materials Science and Engineering

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In the conventional analytical model used for heat generation in friction stir welding (FSW), the heat generated at the pin/ workpiece interface is assumed to distribute uniformly in the pin volume, and the heat flux is applied as volume heat. Besides, the tilt angle of the tool is assumed to be zero for simplicity. ese assumptions bring about simulating deviation to some extent. To better understand the physical nature of heat generation, a modified analytical model, in which the nonuniform volumetric heat flux and the tilt angle of the tool were considered, was developed. Two analytical models are then implemented in the FEM software to analyze the temperature fields in the plunge and traverse stage during FSW of AA6005A-T6 aluminum hollow extrusions. e temperature distributions including the maximum temperature and heating rate between the two models are different. e thermal cycles in different zones further revealed that the peak temperature and temperature gradient are very different in the high-temperature region. Comparison shows that the modified analytical model is accurate enough for predicting the thermal cycles and peak temperatures, and the corresponding simulating precision is higher than that of the conventional analytical model.

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Coupled Eulerian Lagrangian finite element modeling of friction stir welding processes

Cited by 187 publications

References 12 publications

Finite Element Simulation of Temperature and Strain Distribution during Friction Stir Welding of AA2024 Aluminum Alloy

Finite Element Simulation of Temperature and Strain Distribution during Friction Stir Welding of AA2024 Aluminum Alloy

Thermal modeling of friction stir welding of stainless steel 304L

A Modified Analytical Heat Source Model for Numerical Simulation of Temperature Field in Friction Stir Welding

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