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

Abstract

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.

Nonlinear Finite Element Simulation of Friction Stir Welding of AA7075 T651 Aluminium Alloy

“…A 3 D modelling is developed for analyzing thermal history during friction stir welding by the help of ANSYS APDL and similar results were found as previous [10]. Figure 6 shows temperature distribution during welding.…”

“…If contact shear stress is less than the value of 0.577 σ y behaves as sticking condition. In this model temperature dependent friction coefficient is used which vary 0.3 to 0.01 [10]. Figure 3 shows the modified coulomb's law.…”

Validation of Maximum Temperature during Friction Stir Welding of Butt Joint of Aluminium Alloy by using HyperWorks

“…They showed that temperature distribution in the friction stir welding process is symmetrical along the weld line. Hongjun Li and Di Liu [3] worked on simplified thermo-mechanical modeling of friction stir welding with a sequential FE method. They presented a methodology for modeling the transient thermal and mechanical responses without computing the heat generated by friction or plastic deformation.…”