Numerical analysis of material flow in the probeless friction stir spot welding based on Coupled Eulerian-Lagrangian approach

Chu, Q.; Yang, Xiawei; Li, W.Y.; Vairis, Achilles; Wang, W.B.

doi:10.1016/j.jmapro.2018.10.013

Cited by 54 publications

(20 citation statements)

References 39 publications

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“…The solving software ABAQUS-based finite element method model was applied to simulate the RFSSW process. The CEL methodology was adopted to avoid the issue of mesh distortion because of severe plastic deformation [15]. Especially, the material flowing through the static mesh within the Eulerian domain could be traced by computing corresponding Eulerian volume fraction (EVF) of each element.…”

Section: Solid Model and Mesh Generationmentioning

confidence: 99%

“…Several types of aluminium alloys have been RFSSWed, and the numerical modelling investigations for approximating the actual process were carried out to illuminate severe plastic deformation mechanisms during RFSSW. As reported by most investigators, the finite element models were developed according to coupled Eulerian–Lagrangian (CEL) formulations [14–17]. The two sheets were modelled with shell elements and the joints were modelled with 3D-solid elements [14–22].…”

Section: Introductionmentioning

confidence: 99%

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Prediction and validation of temperature distribution and material flow during refill friction stir spot welding of AZ91D magnesium alloy

Zhang

Zhou

et al. 2020

Science and Technology of Welding and Joining

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Temperature distribution and material flow behaviours during refill friction stir spot welding (RFSSW) of AZ91D magnesium alloy were studied by a combination of numerical modelling and experimentation. The coupled Eulerian-Lagrangian (CEL) formulation was adopted to analyse processing thermal history and plastic deformation mechanisms of the RFSSW joint more accurately. Welding thermal cycles of varying positions in joint were measured by thermocouples so as to validate accuracy of this simulation process. The FEA (Finite Element Analysis) simulation to cover mechanical results was found to be consistent with the experimental values. Moreover, simulation analysis presented that material flow caused the clear hook defects and bonding ligament, and such material flow behaviours were experimentally verified via the macrostructure and microstructure of the RFSSW joint.

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Section: Solid Model and Mesh Generationmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Prediction and validation of temperature distribution and material flow during refill friction stir spot welding of AZ91D magnesium alloy

Zhang

Zhou

et al. 2020

Science and Technology of Welding and Joining

View full text Add to dashboard Cite

show abstract

“…However, in addition to geometrical problem, can be solved and thermic, stresses, quality's problem [19][20][21][22][23][24]. For solve this problem used simulation for friction stir welding in various representation [8,9,13,25].…”

Section: Overview Of Friction Stir Welding Equipmentmentioning

confidence: 99%

Mathematical Simulating of the Process of Friction Stir Welding for the Manufacture of Tank Bottoms in Aerospace Construction

2020

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In modern aerospace technology, one of the perspective ways of assembly parts of thin metal plates is friction stir welding. The advantage of this method is the higher strength of the welds of aluminum alloy joints, compared with the traditional MIG welding for the assembly of rockets and space constructions. However, the lack of friction stir welding is a necessity of formation of the system “machine –tool - part” significantly more effort, which is caused by the need to stir the material in the weld zone in a plastic state. Friction stir welding is used to connect the individual elements of tanks and bodies, in particular, panels, elements of the bottoms with each other. In this paper, is consider the typical design for rocket and space technology bottoms of large tanks. For industrial robot equipped with a special head for friction welding with mixing, a mathematical model of obtaining a spherical bottom from individual segments is proposed. The paper presents a mathematical model describing the geometry of a spherical bottom with a flap articulation and a working zone of an industrial robot, which allows defining constraints on process operation continuous seam welding for standard designs of bottoms and hulls of rocket and space technology. The dependences allowing determining the initial position of the robot relative to the bottom for performing friction stir welding of the continuous seam are proposed.

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“…Recently, CEL method has been used to simulate severe plastic deformation (SPD) during the FSW process. 16,17 In this method, excessive mesh distortion can be avoided during the simulation, because the workpiece domain is modeled by Eulerian formulation. Moreover, in the CEL method, the multi-material configurations can be handled in the Eulerian parts and the material flow can be easily modeled by calculating the Eulerian volume fraction (EVF) within each element, showing an advantage over the ALE model.…”

Section: Introductionmentioning

confidence: 99%

Dissimilar friction stir lap welding of aluminum to brass: Modeling of material mixing using coupled Eulerian–Lagrangian method with experimental verifications

Akbari

Asadi

2020

Proceedings of the Institution of Mechanical Engineers, Part L:

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The intermetallic compounds formation and inter-material mixing have a critical impact on achieving a sound joint with fine mechanical properties in the case of dissimilar metal friction stir welding. In this investigation formation of intermetallic compounds as well as material flow that results in inter-material mixing during friction stir lap welding of aluminum and brass are studied. First, the 2.5-mm-thick aluminum sheet was laid on the same-thickness brass sheet and then, friction stir lap welding was applied using a tool with 4-mm pin length and 6-mm pin diameter. Next, experimental investigations were performed using scanning electron microscopy, energy-dispersive X-ray spectroscopy, X-ray diffraction, microhardness, and tensile shear test to probe the chemical compositions and intermetallic formation in the stir zone. Moreover, the coupled Eulerian–Lagrangian method is employed to simulate the stir zone formation during the process to further study inter-material mixing. In this method, the workpiece is modeled using Eulerian formulation, while Lagrangian formulation is utilized to model the tool. The model successfully predicts the stir zone formation and inter-material mixing in the aluminum–brass interface. Results shows that by increasing tool rotational speed from 500 to 2000 r/min the amount of inter material mixing significantly increases. Therefore, to achieve a joint with the highest strength in friction stir lap welding of aluminum–brass, the rotational speed should be lowered as much as it can produce defect-free joint.

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Numerical analysis of material flow in the probeless friction stir spot welding based on Coupled Eulerian-Lagrangian approach

Cited by 54 publications

References 39 publications

Prediction and validation of temperature distribution and material flow during refill friction stir spot welding of AZ91D magnesium alloy

Prediction and validation of temperature distribution and material flow during refill friction stir spot welding of AZ91D magnesium alloy

Mathematical Simulating of the Process of Friction Stir Welding for the Manufacture of Tank Bottoms in Aerospace Construction

Dissimilar friction stir lap welding of aluminum to brass: Modeling of material mixing using coupled Eulerian–Lagrangian method with experimental verifications

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