Detailed thermal and material flow analyses of friction stir forming using a three-dimensional particle based model

Fagan, T.; Lemiale, Vincent; Nairn, John A.; Ahuja, Yogita; Ibrahim, Raafat N; Estrin, Yuri

doi:10.1016/j.jmatprotec.2016.01.009

Cited by 24 publications

(8 citation statements)

References 26 publications

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“…The thermal contact between SPH particles and solid elements needs further elaboration and is discussed in Sect. 4.1 Note that although many studies showed satisfactory results with the Coulomb-Tresca friction law for both FSE and FSW [42,54,57,58], the friction coefficient μ f is purely empirical or hypothetical, and its value may affect the accuracy of the simulation result. The Coulomb-Tresca friction law is used in the current SPH model because it is a natural option when the Lagrangian framework is used.…”

Section: Contact Condition and Heat Generationmentioning

confidence: 99%

Meshfree simulation and experimental validation of extreme thermomechanical conditions in friction stir extrusion

Gupta

Xiao

et al. 2021

Comp. Part. Mech.

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Friction stir extrusion (FSE) is a novel solid-phase processing technique that consolidates and extrudes metal powders, flakes, chips, or billets into high-performance parts by plastic deformation, which has the potential to save substantial processing time and energy. Currently, most studies on FSE are experimental and only a few numerical models have been developed to explain and predict the complex physics of the process. In this work, a meshfree simulation framework based on smoothed particle hydrodynamics (SPH) was developed for FSE. Unlike traditional grid-based methods, SPH is a Lagrangian particle-based method that can handle severe material deformations, capture moving interfaces and surfaces, and monitor the field variable histories explicitly without complicated tracking schemes. These aspects of SPH make it attractive for the FSE process, where in situ evolution of field variables is difficult to observe experimentally. To this end, a 3-D, fully thermomechanically coupled SPH model was developed to simulate the FSE of aluminum wires. The developed model was thoroughly validated by comparing the numerically predicted material flow, strain, temperature history, and extrusion force with experimental results for a certain set of process parameters. The validated SPH model can serve as an effective tool to predict and better understand the extreme thermomechanical conditions during the FSE process.

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Section: Contact Condition and Heat Generationmentioning

confidence: 99%

Meshfree simulation and experimental validation of extreme thermomechanical conditions in friction stir extrusion

Gupta

Xiao

et al. 2021

Comp. Part. Mech.

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“…In their method, the effects of the temperature field and deformation field on each other are considered simultaneously. Fagan et al (2016) developed a fully coupled thermomechanical model using the MPM. It included the heat-transfer process due to plastic dissipation and frictional heat generation.…”

Section: Introductionmentioning

confidence: 99%

Simulation of heat and fluid flow in porous medium and fractures by material point method

Wang

Sun

Wang

et al. 2022

HFF

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Purpose The material point method (MPM)is a particle-based numerical method suitable for solid–liquid simulation and large deformation problems. However, MPM is generally used in solid deformation at present, to develop a multi-physics coupling MPM; the purpose of this study is to extend the MPM to simulate the heat and fluid flow and address the thermal-hydrological (TH) coupling problems. Design/methodology/approach The porous medium was discretized into two sets of Lagrangian points, and the motion of fluid points follows the Darcy’s law. Two sets of heat transport equations were established for the heat conduction and heat exchange in the pore fluid and solid skeleton. Fractures were considered by adding the porosity gradient term in the governing equations; also a transition function was introduced to smoothen the fracture boundary. Findings Four cases of heat and fluid flow in porous medium and fractures were presented to verify the feasibility of the proposed method. And the effects of fractures on heat and fluid flow were investigated. Additionally, a case of geothermal extraction was solved and the importance of the interstitial convective heat transfer coefficient was analyzed. Originality/value The proposed method extends the conventional MPM, using two sets of material points and two sets of heat transport equations to simulate the heat and fluid flow and address the TH coupling problems, which can be applied in both porous medium and fractures.

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“…In recent years, several authors have studied the temperature profile during the FSW process using a range of different numerical methods, which clearly indicates the importance of this research topic. Fagan et al [8] presented a model for friction stir forming based on the material point method as a framework considering both plastic dissipation and frictional heating. They concluded this method could be used to predict the temperature profile and material flow with reasonable accuracy.…”

Section: Introductionmentioning

confidence: 99%

A Semi-Analytical Solution for Temperature Distribution in Friction Stir Welding

Darvazi¹

2021

Preprint

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In this paper, a semi-analytical thermal model of friction stir welding processes is developed in which the heat-generating regions are divided into many elements as point heat sources. The heat generation in each element involves the friction and plastic deformation, and the temperature rise caused by each element is calculated by solving the heat conduction equation of a moving heat source in a solid body. The heat loss through the top and bottom surfaces are considered in the model as heat sinks. The asymmetric distribution of the temperature is calculated through the whole process and over the whole volume of the workpiece by integrating the effects of all heat sources and sinks. The temperature-dependent material properties are updated by a numerical routine. The comparison between the calculated results and the experimental data clearly approved the validity of the proposed method for some aluminum and steel alloys.

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Detailed thermal and material flow analyses of friction stir forming using a three-dimensional particle based model

Cited by 24 publications

References 26 publications

Meshfree simulation and experimental validation of extreme thermomechanical conditions in friction stir extrusion

Meshfree simulation and experimental validation of extreme thermomechanical conditions in friction stir extrusion

Simulation of heat and fluid flow in porous medium and fractures by material point method

A Semi-Analytical Solution for Temperature Distribution in Friction Stir Welding

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