A simple Eulerian thermomechanical modeling of friction stir welding

Jacquin, Dimitri; Betzenbroeck, Bruno de Meester de; Simar, Aude; Deloison, Dominique; Montheillet, F.; Desrayaud, C.

doi:10.1016/j.jmatprotec.2010.08.016

Cited by 79 publications

(59 citation statements)

References 17 publications

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“…This is because the heat affected region in FSW is very small compared to the whole length of the workpiece [3,[12][13][14]. The tool and the plate were considered in the fully sticking condition.…”

Section: The Geometry Used To Model the Tooling And Workpiecementioning

confidence: 99%

Modelling of friction stir welding of DH36 steel

Al-moussawi

Smith

Young

et al. 2017

Int J Adv Manuf Technol

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A 3-D computational fluid dynamics (CFD) model was developed to simulate the friction stir welding of 6-mm plates of DH36 steel in an Eulerian steady-state framework. The viscosity of steel plate was represented as a nonNewtonian fluid using a flow stress function. The PCBN-WRe hybrid tool was modelled in a fully sticking condition with the cooling system effectively represented as a negative heat flux. The model predicted the temperature distribution in the stirred zone (SZ) for six welding speeds including low, intermediate and high welding speeds. The results showed higher asymmetry in temperature for high welding speeds. Thermocouple data for the high welding speed sample showed good agreement with the CFD model result. The CFD model results were also validated and compared against previous work carried out on the same steel grade. The CFD model also predicted defects such as wormholes and voids which occurred mainly on the advancing side and are originated due to the local pressure distribution between the advancing and retreating sides. These defects were found to be mainly coming from the lack in material flow which resulted from a stagnant zone formation especially at high traverse speeds. Shear stress on the tool surface was found to increase with increasing tool traverse speed. To produce a "sound" weld, the model showed that the welding speed should remain between 100 and 350 mm/min. Moreover, to prevent local melting, the maximum tool's rotational speed should not exceed 550 RPM.

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Section: The Geometry Used To Model the Tooling And Workpiecementioning

confidence: 99%

Modelling of friction stir welding of DH36 steel

Al-moussawi

Smith

Young

et al. 2017

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

“…Another interesting study shows a 3-D thermomechanical model FSW based on CFD analysis [6]. This model describes the material flow around the tool during the welding operation.…”

Section: Heat Generation Modelmentioning

confidence: 99%

Numerical Simulation of Temperature Distribution and Material Flow During Friction Stir Welding 2017A Aluminum Alloys

et al. 2016

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Abstract.This study describes the use of fluid dynamic code, FLUENT to model the flow of metal in the AA2017A case around the welding tool pin (FSW). A standard threaded tool profile is used for the analysis of phenomena during welding such as heat generation and flow of the material are included. The main objective is to gain a better understanding of the flow of material around a tool. The model showed a large number of phenomena similar to those of the real process. The model has also generated a sufficient amount of heat, which leads to a good estimate of the junction temperature. These results were obtained using a viscosity which is near the solidus softening.

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“…However, the high gradient values of the state variables near to the probe and the thermomechanical coupling imply a large number of degrees of freedom in FSW modeling, which is costly in terms of CPU time [14]. Recent research demonstrated that the computational time can be reduced by recurring to high performance computing (HPC) techniques [15].…”

Section: Numerical Modelingmentioning

confidence: 99%

“…Van der Stelt et al use an ALE formulation to simulate the material flow around the pin during FSW process [16]. These models of the process can predict the role played by the tool plunge depth on the formation of flashes, voids or tunnel defects, and the influence of threads on the material flow, temperature field and welding forces [14]. Lagrangian, Eulerian and ALE approaches have been used to numerically simulate the FSW process, using software such as FORGE3 and THERCAST [18], ABAQUS [10], DiekA [16], WELDSIM [19] and SAMCEF [20].…”

Section: Numerical Modelingmentioning

confidence: 99%

Numerical modeling of friction stir welding process: a literature review

Neto

2012

Int J Adv Manuf Technol

164

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Abstract:This survey presents a literature review on friction stir welding (FSW) modeling with a special focus on the heat generation due to the contact conditions between the FSW tool and the workpiece. The physical process is described and the main process parameters that are relevant to its modeling are highlighted. The contact conditions (sliding/sticking) are presented as well as an analytical model that allows estimating the associated heat generation. The modeling of the FSW process requires the knowledge of the heat loss mechanisms, which are discussed mainly considering the more commonly adopted formulations. Different approaches that have been used to investigate the material flow are presented and their advantages/drawbacks are discussed.A reliable FSW process modeling depends on the fine tuning of some process and material parameters.Usually, these parameters are achieved with base on experimental data. The numerical modeling of the FSW process can help to achieve such parameters with less effort and with economic advantages.

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A simple Eulerian thermomechanical modeling of friction stir welding

Cited by 79 publications

References 17 publications

Modelling of friction stir welding of DH36 steel

Modelling of friction stir welding of DH36 steel

Numerical Simulation of Temperature Distribution and Material Flow During Friction Stir Welding 2017A Aluminum Alloys

Numerical modeling of friction stir welding process: a literature review

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