Numerical Simulation of Linear Friction Welding Based on ABAQUS Environment: Challenges and Perspectives

Modelling the influence of the process inputs on the removal of surface contaminants from Ti–6Al–4V linear friction welds

“…(9), the burn-off, B o , had no effect on any of the responses. This is in good agreement with other authors who have shown that once Ti-6Al-4V is in the steady-state phase (phase 3) the plastic deformations [1,4,34] and thermal profiles [1,9,15] are independent of the burn-off.…”

“…Computational models offer a pragmatic method to understand what is happening during the rapidly evolving process. Various authors have developed two [1,[6][7][8][9][10][11][12][13][14][15][16] and three [15,[17][18][19][20][21][22][23][24][25] dimensional (2D/3D) computational models. These models have been used to predict various weld responses, such as: residual stress formation [11,13], strain rates [1], flash morphology [1,12], flash formation rates [1,8,9,12,19], thermal fields [1,6,[8][9][10][11][12]14,17,[19][20][21]25] and microstructural evolution [23].…”

“…Although the 2D models do not model the material expulsion perpendicular to the direction of oscillation they do provide a good insight into the process without requiring the heavy computational times of the 3D models. According to the reviewed literature, there are three main approaches that may be taken when finite element modelling the LFW process [1,[6][7][8][9][10][11][12][13][14][15][16][17][18][19][20][21][22][23][24][25], which are illustrated in Fig. 2.…”

“…Also, models of this type show that the two workpieces never truly merge -as happens in reality for many materials [2,26,27] -meaning that the mechanical mixing of the separate workpieces is not considered. The second approach [7,9,10,[14][15][16]18,22,25] is to model only one workpiece, which is oscillated against a non-deformable surface, as shown in Fig. 2(b).…”

On the visualization of joint form ation during linear friction welding

“…Despite the apparent simplicity of this welding process the actual physical processes occurring during its cycle are quite complex, with the most difficult being the speed of its development. There are many papers with results of modeling LFW using finite elements, but the majority of them describes the process before [3][4][5] or after the joining has completed [6][7][8][9]. There are very few works on the simulation of the process of joining welded parts.…”