Finite element modeling of friction stir welding—thermal and thermomechanical analysis

Chen, C.M.; Kovacevic, Radovan

doi:10.1016/s0890-6955(03)00158-5

Cited by 390 publications

(180 citation statements)

References 6 publications

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“…Therefore, due to the influence of the heat in producing acceptable welding quality, the study of the welding thermal history is significant [32][33][34]. Through only experiments, investigating the process in depth and predicting the thermal behavior of the weld is not attainable [35], because temperature measurements during experiments is done frequently by using thermocouples [36,37] and the measurement of the temperature inside the welding nugget zone by using thermocouples is challenging. Thus, as mentioned earlier, the Finite Element Methods (FEMs) are proposed as an efficient and suitable method to study the thermal behavior [38].…”

Section: Thermal Analysis Of Fsw (Friction Stir Welding)mentioning

confidence: 99%

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

Meyghani

Awang

Emamian

et al. 2017

Metals

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Friction Stir Welding (FSW) is a novel kind of welding for joining metals that are impossible or difficult to weld by conventional methods. Three-dimensional nature of FSW makes the experimental investigation more complex. Moreover, experimental observations are often costly and time consuming, and usually there is an inaccuracy in measuring the data during experimental tests. Thus, Finite Element Methods (FEMs) has been employed to overcome the complexity, to increase the accuracy and also to reduce costs. It should be noted that, due to the presence of large deformations of the material during FSW, strong distortions of mesh might be happened in the numerical simulation. Therefore, one of the most significant considerations during the process simulation is the selection of the best numerical approach. It must be mentioned that; the numerical approach selection determines the relationship between the finite grid (mesh) and deforming continuum of computing zones. Also, numerical approach determines the ability of the model to overcome large distortions of mesh and provides an accurate resolution of boundaries and interfaces. There are different descriptions for the algorithms of continuum mechanics include Lagrangian and Eulerian. Moreover, by combining the above-mentioned methods, an Arbitrary Lagrangian-Eulerian (ALE) approach is proposed. In this paper, a comparison between different numerical approaches for thermal analysis of FSW at both local and global scales is reviewed and the applications of each method in the FSW process is discussed in detail. Observations showed that, Lagrangian method is usually used for modelling thermal behavior in the whole structure area, while Eulerian approach is seldom employed for modelling of the thermal behavior, and it is usually employed for modelling the material flow. Additionally, for modelling of the heat affected zone, ALE approach is found to be as an appropriate approach. Finally, several significant challenges and subjects remain to be addressed about FSW thermal analysis and opportunities for the future work are proposed.

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Section: Thermal Analysis Of Fsw (Friction Stir Welding)mentioning

confidence: 99%

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

Meyghani

Awang

Emamian

et al. 2017

Metals

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“…The welding configurations in the experimental work [8] are used here with the aim of verifying the computed residual stresses. Each plate to be butt welded has a length of 24 cm, a width of 5 cm and a thickness of 6mm.…”

Section: Welding Configurationsmentioning

confidence: 99%

“…The height of the pin was not given in the paper; a value of 6 mm was used. Chen et al, [8] did not provide any information on the plunge and dwell stages. The present model assumes a plunge speed of 0.2 mm/s, usually used for aluminium alloys.…”

Section: Welding Configurationsmentioning

confidence: 99%

“…Chen and Kovacevic [8], [9] proposed a three-dimensional FE model to study the thermo-mechanical process in the butt-welding of aluminium alloy 6061-T6. The heat generation caused by the friction was calculated using experimentally measured contact pressure and a constant value of the friction coefficient.…”

Section: Introductionmentioning

confidence: 99%

“…Soundararajan et al, [10] refined the FE models in [8], [9] by applying an adaptive contact conductance at the interface of shoulder-workpiece. At the beginning of the FE thermo-mechanical analysis, a uniform contact conductance was used to predict the stress at the interface.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Simplified Thermo-Mechanical Modeling of Friction Stir Welding with a Sequential FE Method

Li¹,

Liu²

2014

IJMO

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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.

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Modeling the Effects of Tool Geometries on the Temperature Distributions and Material Flow of Friction Stir Aluminum Welds

Mohanty

Mahapatra

Kumar

et al. 2012

CFD Modeling and Simulation in Materials Processing

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Finite element modeling of friction stir welding—thermal and thermomechanical analysis

Cited by 390 publications

References 6 publications

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

Simplified Thermo-Mechanical Modeling of Friction Stir Welding with a Sequential FE Method

Modeling the Effects of Tool Geometries on the Temperature Distributions and Material Flow of Friction Stir Aluminum Welds

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