Numerical Simulation of the Friction Stir Welding Process Using Coupled Eulerian Lagrangian Method

The Taguchi method was employed to find the optimum values of friction stir welding parameters including welding speed, rotating speed, and tilt angle for joining AA6061-T6 aluminum alloys. The combined influences of these parameters were entirely analyzed. Statistical outcomes were investigated by the study of variances and signal-to-noise ratios. A Coupled Eulerian and Lagrangian technique is implemented to simulate and verify the optimal parameters during the friction stir welding. To verify results, a comparison between the welding process under optimized parameters with experimental and non-optimized parameters was simulated for the friction stir welding process. The material flow, strain rate, thermal behaviors, and mechanical properties of samples fabricated with optimal welding parameters are higher than those produced from the non-optimal parameters. It was also concluded that the grain size of the stir zone under optimal welding parameters (6–8 µm) is finer than that of non-optimal welding parameters (11–13 µm). Low uniform distribution of material element and coarse microstructure were some of the results of welding with non-optimized parameters. Based on residual stress analysis, the application of optimal joining conditions can decrease the peak tensile residual stress by about 38.3%. The much desirable results obtained in terms of microstructure and mechanical properties could be of great significance to the welding industry.

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“…Coupled Eulerian–Lagrangian fabrication: (a) Lagrangian part; (b) Eulerian part; and (c) coupled Eulerian–Lagrangian part. 29 …”

Section: Methodsmentioning

confidence: 99%

On the role of input welding parameters on the microstructure and mechanical properties of Al6061-T6 alloy during the friction stir welding: Experimental and numerical investigation

Bagheri

Sharifi

Abbasi

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part L:

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“…For simulation, the frictional contact between rotating tool and Eulerian domain is "general contact" given by Coulomb friction law as given in equation [25].…”

Section: Interaction and Boundary Conditionsmentioning

confidence: 99%

Temperature Analysis of Friction Stir Welding (AA6061-T6) with Coupled Eulerian-Lagrangian Approach.

Chalurkar

Shukla

2022

IOP Conf. Ser.: Mater. Sci. Eng.

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For Friction Stir Welding (FSW), several simplified FEM models have been developed to explain key parts of thermal-mechanical phenomena. In this study, to simulate the FSW process of the AA6061-T6 aluminum alloy, a thermo-mechanical 3-D finite element model based on the Coupled Eulerian-Lagrangian (CEL) approach is used. The CEL method combines the benefits of both the Lagrangian and Eulerian approaches, allowing it to solve large-scale deformation issues. The Abaqus/CAE software is used to simulate the stages of the FSW process using the Johnson–Cook material law and the Johnson-Cook failure model. The CEL approach is used to estimate process parameters based on the model's boundary conditions of the 3-D rigid tool. Thermocouples were installed in the appropriate positions on the AA6061-T6 plate, and temperature is correlated with the simulation results. The temperature generated during the plunging, dwelling, and welding stages of the FSW of AA6061-T6 is 80% to 90% of the melting temperature being evaluated. The experimental data was obtained from the HMT made CNC (Siemens) operated VMC and the same is compared with the results obtained from the overall FEM simulation.

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“…The classical Coulomb's friction model is used to describe the contact behavior between the pin and the workpiece. In the present model, the friction coefficient µ is set to be 0.3 according to M. Iordache et al 3 .…”

Section: Thermal Responsementioning

confidence: 99%

“…Weld tool has two main parts including shoulder and pin. Dimension of them is referred to M. Iordache's paper 3 , which is showed in picture below (Figure 2). This study will investigate threaded cylindrical with three flats in pin tool.…”

Section: Toolmentioning

confidence: 99%

“…The Welding Institute (TWI) in the United Kingdom invented friction stir welding (FSW) in 1991 2 . It has been used to join non-ferrous metals and aluminum alloys of different thicknesses, physical, chemical and mechanical qualities 3 . FSW differs from other traditional welding procedures in that it does not melt the materials being connected.…”

Section: Introductionmentioning

confidence: 99%

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A Analysis the influence of threaded pin profiles in friction stir welding by numerical simulation

Nhu

Vu²

2021

Sci.Tech.Dev.J.-Eng.Tech.

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Currently, the welding industry has made significant contributions in most production fields to meet the needs of people's lives. However, traditional welding methods have disadvantages such as: a large amount of energy consumption, production of many toxic gases that are harmful to the environment and the health of workers. Therefore, the friction stir welding method was introduced from the research of scientists to overcome the above disadvantages. Besides that, it is suitable for welding aluminum alloys and non-ferrous metals with low melting point. This green welding technology has been continuously researched to improve weld quality through two main research models: experiment models and numerical simulation models. Experimental results provide provides the basic mechanical properties of the materials at the weld and the process optimization parameters. It will be the basis to establish a numerical simulation model closest to reality, based on mathematical models and working principles, thereby helping to predict weld quality through prediction of formation defects, temperature distribution with changes in welding process parameters such as time, velocity, material or welding pin profile. In this study, the influence of threaded pin profiles on weld quality of alloy aluminum 7075 -T6 during friction stir welding was investigated by numerical simulation model through ABAQUS software to recommend a new pin profile bringing an efficient welding process. To increase the reliability of this research approach, the numerical simulation results of the temperature distribution are compared with the experimental results obtained from a foreign scientific paper with an average error of 14%. Threaded pin profiles are designed in combination with three cross-sections having different opening angles named TF0, TF30, TF60 and TF90. Coupled Eulerian-Lagrangian formulation is applied for this model where the welding tool is Lagrangian domain and workpiece is Eulerian domain. Because material deformation in friction stir welding process is large and related to temperature, the elastic-plastic Johnson-Cook model is used for workpiece. Results of this research shows a new pin profile named TF60 which it gives the best weld quality of the four configurations of the pin tool examined in this study through evaluating temperature distribution and predicting weld defect formation.

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Numerical Simulation of the Friction Stir Welding Process Using Coupled Eulerian Lagrangian Method

Cited by 10 publications

References 4 publications

On the role of input welding parameters on the microstructure and mechanical properties of Al6061-T6 alloy during the friction stir welding: Experimental and numerical investigation

On the role of input welding parameters on the microstructure and mechanical properties of Al6061-T6 alloy during the friction stir welding: Experimental and numerical investigation

Temperature Analysis of Friction Stir Welding (AA6061-T6) with Coupled Eulerian-Lagrangian Approach.

A Analysis the influence of threaded pin profiles in friction stir welding by numerical simulation

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