Review on modelling of friction stir welding using finite element approach and significance of formulations in simulation

Abstract

Friction stir welding (FSW) is a solid-state joining process, which is gaining significance in many joining applications, by overcoming the limitations of other fusion welding processes. For successful incorporation of its potential during industrial applications, mechanism of joining needs to be properly comprehended. The solution lies in developing effective and reliable finite element (FE) model of the FSW process, which would help in getting an insight of the process phenomena (like material flow, heat generation, etc.) during the process. The overall result could be used to observe the effect of process parameters on weld quality. Several attempts have been made to develop an FE model for FSW using different techniques. However, building an efficient model that emulates reality is still to be realised. Here, a review is made to know the current state of various FE modelling techniques and identifying better techniques for simulating FSW and its variants. This review also highlights shortcomings (for ex: mesh distortion, simulation time, the capability of defect prediction) of previous models and discusses on grey areas which are still to be addressed in the broader perspective of FSW and its allied processes using FE approach.

An overview on joining/welding as post-processing technique to circumvent the build volume limitation of an FDM-3D printer

“…Increased productivity with better quality, ease of automation, leeway to produce continuous linear welds and the ability to weld almost any thermoplastics are considered as the advantages of this process (Malik et al , 2020; Vijendra and Sharma, 2015). Compared to conventional welding, FSW offers great advantages, as there is no melting involved, fewer defects with a better weld quality, low energy requirement and no consumables (Kumar et al , 2019; Malik et al , 2014; Quintana and Silveira, 2017).…”

Numerical and Experimental Study on the Grinding Performance of Ti-Based Super-Alloy

“…It permits the mesh and the matter displacing together, facilitating for monitoring surfaces and using boundary conditions. The Lagrangian formulation can simulate matter stream which consists of frictional heat and matter deformation although it requires complicated remeshing [13]. The meshing of the Ti-64 specimen is divided into 7750 bilinear four-node plane strain thermally coupled quadrilateral elements with reduced integration and enhanced hourglass control (CPE4RT).…”

“…Based on FEM, this work also predicts the grinding forces and cutting temperature in the single-grain grinding of Ti-64 alloy using ABAQUS/Explicit software. The explicit approach is used as it can solve dynamic balance problems of solid mechanics, in other words, it is founded on energy balance [13]. The simulation results can be employed to understand the material removal process and to select the cutting and lubricating conditions in the grinding of Ti-64 alloy.…”

A review on in-situ aluminum metal matrix composites manufactured via friction stir processing: meeting on-ground industrial applications

“…During the fabrication of in-situ AMMC using FSP as a primary process, matrix and reinforcement materials are thermo-mechanically treated with a specially designed nonconsumable tool. Interaction of the tool with the matrix produces frictional heat, softens the material and makes it flow along the processed region (Malik et al, 2020b;Kailas, 2018, 2020). The encountered temperature helps in the coalescence of atoms, forms a strong metallic bond and refines the microstructure.…”