Influence of Mesh Density on Repeatability of FSW Process Simulation Based on DEFORM

Abstract

To solve the problem of the relative error caused by mesh density is difficult to quantitatively evaluate, a process simulation model of FSW (friction stir welding) 2219 aluminum alloy is built based on DEFORM. Process simulation models with different mesh densities are solved, the influence of mesh density on simulation repeatability and time-consuming is analyzed, and the mesh density suitable for the process simulation model is determined. The evaluation method proposed offers a theoretical reference for the determination of local optimal mesh density of the FSW process simulation model based on DEFORM. This study provides a basis for high precision prediction and characterization of the temperature distribution of FSW on heavy-lift launch vehicle fuel tank.