Numerical Simulation of Friction Welding Processes Based on ABAQUS Environment

Abstract

Friction welding (FW) is a collection of a series of friction-based solid state joining processes which can produce high quality welds of different components with either similar or dissimilar materials and has been attracting increasing attention. Due to the extreme condition encountered during FW and the highly thermomechanical coupled nature of FW, finite element methods have been widely developed to study the FW process. In the light of reasonable simplification, we developed several effective methods based on the ABAQUS environment. Initially 2D models were developed to investigate the complete FW process, where an implicit method with remeshing and map solution techniques and an explicit method with the Arbitrary Lagrangian Eulerian (ALE) adaptive mesh controls were proposed to effectively overcome the excessive element distortion by using the ABAQUS Standard and Explicit packages, respectively. In addition, a 3D model was also developed to obtain better simulation results with the help of the ALE adaptive mesh controls in the ABAQUS/Explicit package and the map solution technique in the ABAQUS/Standard package combined with the HYPERWORKS software. The experiments validate the feasibility and accuracy of the developed models.

High - resolution scheme based on the undetermined coefficient method and its application

“…But the accuracy is not quite high, especially in shock capturing [5,6,7,8]. The truncation error is so large that its using area is confined.…”

Experimentally validated structural vibration frequencies’ prediction from frictional temperature signatures using numerical simulation: A case of laced cantilever beam-like structures

“…This leads to non-linear structural material properties over the entire period, and for the case of numerical simulation, it usually results in higher computational cost. 20,21 Accordingly, higher loading of the FEM at the expense of greater computational efforts leads to more frictional heat generation. However, since this study entailed an investigation, for this reason, it considered small loads to shorten the computation time.…”

“…It takes into account the initial ambient temperature and the relative interaction properties for calculating the transient temperature distribution. Li et al 21 carried out a numerical modelling and simulation of friction welding processes based on ABAQUS using coupled temperature-displacement transient. The temperature results were in good agreement with experimentally measured using thermocouples.…”

“…The contact frictional heat, however, is strongly dependent on relative motion. 17,21 The ABAQUS/CAE 13 solver uses coupled temperaturedisplacement analysis of simulations involving thermomechanical analysis. It takes into account the initial ambient temperature and the relative interaction properties for calculating the transient temperature distribution.…”

Rotary Friction Welding of Dissimilar Joints between SSM356 and SSM6061 Aluminium Alloys Produced by GISS

“…These usually occur when welding workpiece at low melting point because the heat input from the welding place is not sufficient and the upset pressure while welding is not high enough. Over the past several years, non-ferrous materials such as titanium alloy [4], magnesium alloy [5][6][7] and aluminum alloy [8][9][10][11][12] turn popular to this RFW method because it is widely used, especially aluminum alloy in automotive industry, marine industry and the aircraft industry [13]. Aluminum-Silicon was used in this industry because of its high strength, lightweight and corrosion resistance.…”