Abstract-This paper presents a methodology for modeling the transient thermal and mechanical responses without computing the heat generated by friction or plastic deformation. The externally applied heat source accounts for the heat generated from tool movement. The novel heat source model includes two parts: surface heat flux at the shoulder-workpiece interface and nodal heat generation in the material that should have been displaced by the tool. The heat source algorithm is described through equations and flow charts. This thermal model was shown to predict a temperature history in good agreement with experimentally measured results. The mechanical interaction between the contacting surfaces was modelled with contact elements. However the analysis failed to converge with the contact pairs active. For the analysis without contact pairs, the predicted longitudinal direction stresses matched well with experiment but the transverse direction stresses were significantly different.Index Terms-Finite element analysis, friction stir welding, thermo-mechanical modeling, sequential method.
An advanced CFD cede for turbine blade design and analysis has been developed. The non-skewed shifted periodic grids are used in the code. With this high quality grids, the accuracy of the solutions, particularly in loss predictions, are greatly improved. Extensive studies have been conducted for code verification and calibrations. Results show that the solutions are accurate and consistent. Numerical results are presented and compared with experimental data for different blade sections. Good agreements are observed between numerical prediction and test data for the cases compared.
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