Abstract:The present work is aimed to simulate the Friction Stir Welding process as a three-dimensional thermally coupled viscoplastic flow. A Finite Element technique is employed, within the context of a general purpose FEM framework, to provide the temperature distributions and the patterns of plastic flow for the material involved in the welded joints. The computational tool presented here may be of great relevance for technologist seeking to set the process control variables, as they are intended to obtain suitable… Show more
“…The heat generated during the welding process is equivalent to the power input introduced into the weld by the tool minus some losses due to microstructural effects [21]. The peripheral speed of the shoulder and probe is much higher than the translational speed (the tool rotates at high speeds).…”
Section: Heat Generationmentioning
confidence: 99%
“…Simar et al introduce a parameter ( γ ) that exposes the relative importance of both contributions [32]: (21) where V Q is the volume heat contribution and S Q is the total tool surface heat contribution. For thermal computational models which take into account the material fluid flow, Simar et al…”
Section: Surface and Volume Heat Contributionsmentioning
confidence: 99%
“…The power spent in the translation movement, which is approximately 1% of the total value, is typically neglected in the total heat input estimative [11,30]. Therefore, the power introduced by the tool (input power P ) can be obtained experimentally from the weld moment and angular rotation speed [21,32]: η QP (23) where η is the fraction of power generated by the tool that is directly converted into heat in the weld material. Nandan et al refer to this as the power efficiency factor [33].…”
Section: Heat Input Estimation Using the Torquementioning
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.
“…The heat generated during the welding process is equivalent to the power input introduced into the weld by the tool minus some losses due to microstructural effects [21]. The peripheral speed of the shoulder and probe is much higher than the translational speed (the tool rotates at high speeds).…”
Section: Heat Generationmentioning
confidence: 99%
“…Simar et al introduce a parameter ( γ ) that exposes the relative importance of both contributions [32]: (21) where V Q is the volume heat contribution and S Q is the total tool surface heat contribution. For thermal computational models which take into account the material fluid flow, Simar et al…”
Section: Surface and Volume Heat Contributionsmentioning
confidence: 99%
“…The power spent in the translation movement, which is approximately 1% of the total value, is typically neglected in the total heat input estimative [11,30]. Therefore, the power introduced by the tool (input power P ) can be obtained experimentally from the weld moment and angular rotation speed [21,32]: η QP (23) where η is the fraction of power generated by the tool that is directly converted into heat in the weld material. Nandan et al refer to this as the power efficiency factor [33].…”
Section: Heat Input Estimation Using the Torquementioning
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.
“…These analyses are based on a heat source model, not considering the thermo-mechanical coupling generated by plastic flow. It is worth mentioning that due to the characteristics of this problem, by using fully coupled thermal-mechanical viscoplastic flow models [11][12][13], good results can be expected where plastic deformations commonly occur. Besides, due to its geometric and kinematic characteristics, the problem is mainly threedimensional, which together with the presence of high strain rate gradients around the probe imposes a high computational demand.…”
“…Estos análisis se basan en un modelo de fuente de calor, sin contemplar el acoplamiento termomecánico provocado por el flujo plástico. Es de destacar que por las características del problema, donde las deformaciones plásticas son dominantes, pueden lograrse buenos resultados empleando modelos de flujo viscoplástico termomecánicamente acoplados (Ulysse [5]; Santiago et al [6,7]; Colegrove et al [8]). …”
En el presente trabajo se modela el proceso de Soldadura por Fricción-Agitación (SFA) en aceros inoxidables mediante la utilización de un programa de elementos finitos de propósito general, reproduciendo el mapa térmico y la distribución del flujo del material. En el proceso de SFA el equipo de soldadura consta de una herramienta que gira y se desplaza sobre la unión de dos chapas restringidas. La unión se produce por el calentamiento por fricción inducido por la herramienta, que promueve un comportamiento pastoso/viscoso del material y su correspondiente flujo entre las chapas a unir. Este trabajo simula el proceso para una unión de aceros inoxidables austeníticos considerando acoplamiento termomecánico. Para la resolución del problema mecánico se utiliza un modelo viscoplástico con una ley constitutiva representativa de estos aceros en el rango de las temperaturas del proceso. Por otro lado, el problema térmico se modela teniendo en cuenta los fenómenos advectivos debidos al movimiento de la herramienta. En esta primera etapa, los resultados obtenidos han sido contrastados con datos reportados en la bibliografía, obteniéndose una buena correlación entre los mismos.
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