Multi‐physics simulation of friction stir welding process

Abstract

Article information:To cite this document: Robert Hamilton, Donald MacKenzie, Hongjun Li, (2010),"Multi-physics simulation of friction stir welding process", Engineering Computations, Vol. 27 Iss: 8 pp. 967 -985 Permanent link to this document: http://dx.Access to this document was granted through an Emerald subscription provided by University of Calgary For Authors:If you would like to write for this, or any other Emerald publication, then please use our Emerald for Authors service. Information about how to choose which publication to write for and submission guidelines are available for all. Please visit www.emeraldinsight.com/authors for more information. About Emerald www.emeraldinsight.comWith over forty years' experience, Emerald Group Publishing is a leading independent publisher of global research with impact in business, society, public policy and education. In total, Emerald publishes over 275 journals and more than 130 book series, as well as an extensive range of online products and services. Emerald is both COUNTER 3 and TRANSFER compliant. The organization is a partner of the Committee on Publication Ethics (COPE) and also works with Portico and the LOCKSS initiative for digital archive preservation. AbstractPurpose -The friction stir welding (FSW) process comprises several highly coupled (and non-linear) physical phenomena: large plastic deformation, material flow transportation, mechanical stirring of the tool, tool-workpiece surface interaction, dynamic structural evolution, heat generation from friction and plastic deformation. This paper aims to present an advanced finite element (FE) model encapsulating this complex behaviour and various aspects associated with the FE model such as contact modelling, material model and meshing techniques are to be discussed in detail. Design/methodology/approach -The numerical model is continuum solid mechanics-based, fully thermo-mechanically coupled and has successfully simulated the FSW process including plunging, dwelling and welding stages. Findings -The development of several field variables are quantified by the model: temperature, stress, strain. Material movement is visualized by defining tracer particles at the locations of interest. The numerically computed material flow patterns are in very good agreement with the general findings from experiments. Originality/value -The model is, to the best of the authors' knowledge, the most advanced simulation of FSW published in the literature.

The Influence of Friction Stir Welding Process Idealization on Residual Stress and Distortion Predictions for Future Airframe Assembly Simulations

“…For the purpose of obtaining good order of magnitude predictions of the residual stress levels occurring in FSW, conventional sequentially coupled thermomechanical models have demonstrated considerable efficiency. In order to reliably predict the extent of small asymmetrical variations in the residual stress pattems, significantly more computationally expensive finite element simulations may well be required [10].…”

“…Two methods are potentially capable of modeling the required physics: (a) Material flow simulation to predict heat generation and transfer, plus a coupled mechanical analysis to predict stresses and deformations and (b) inverse thermal analysis to generate temperature data, plus a coupled mechanical analysis, again to predict stresses and deformations. Focusing first on method (a) and examining the literature, it is clear that modeling the material flow to predict the process generated temperature data implies exceptionally high computational costs [10]. Thus with our ultimate goal to model assembly processes for large structures, the focus herein will be on method (b) which demonstrates orders of magnitude lower computational cost.…”

Synthesis of Fibrous Complex Structures: Designing Microstructure to Deliver Targeted Macroscale Response

“…Among the most used "labels" for today's research in applied mechanics we indeed find: advanced materials [26][27][28][29], architectured materials [30][31][32][33][34][35][36], optimized materials [37][38][39], metamaterials [40][41][42][43][44], smart materials [45][46][47][48][49], multiscale materials [50][51][52][53], multiphysics materials [54][55][56][57][58][59][60][61][62][63][64][65][66][67][68], materials with negative mechanical constitutive coefficients (stiffness, modulus, Poisson ratio, etc.) [69][70][71][72][73], composite materials …”

Verification of Johnson-Cook Material Model Constants of Aa2024-T3 for Use in Finite Element Simulation of Friction Stir Welding and Its Utilization in Severe Plastic Deformation Process Modelling

“…In the literature various values of constants for the Johnson-Cook were considered for an AA2024-T3 [17][18][19][20][21][22]. The simulations were performed for the values shown in Table-2 Here, for all the cases considered the melting temperature of material and room temperature are 502°C and 25°C respectively.…”