Simulation of rotary friction welding using a viscoelastic Maxwell model

Abstract

A 3-D finite element model of rotary friction welding was developed using a viscoelastic Maxwell model. The thermal softening of the material was accounted for in the viscous part of the material model as well as in an additional friction model. The thermal and mechanical material data were adapted from existing data of tempering steel AISI 4140. The final model was used to predict rotary friction welding of shafts using three different parameter settings. The simulation results showed that the melt temperature was never exceeded at the faying surfaces, which is seen as a main characteristic of friction welding. Subsequent validation also demonstrated that the shortening of the specimen as well as the resulting flash geometry could be predicted successfully.

Thermal–Mechanical and Microstructural Simulation of Rotary Friction Welding Processes by Using Finite Element Method

“…In the RFW process, the accurate measurement of the temperature during experimental tests can be challenging. To overcome this, numerical simulation of the RFW process has been introduced as the most effective method for studying the temperature evolution [47,49]. It is known that 90% of heat generation in this process is attributed to the friction between two surfaces [20].…”

“…It is generally required to validate the variables of thermomechanical simulations with experimental test results. To ensure the accuracy of a simulation, one effective strategy is to juxtapose the deformed area observed in a practical process with its counterpart in the simulation [11,14,15,44,47]. This comparison allows researchers to scrutinize the similarities and discrepancies between the two.…”

Quasi-equal strength and toughness matching rail steel joint obtained via friction welding below Ac1 temperature

“…11 CDFW is highly efficient, energy-saving, and capable of preserving the original properties of the being joined base metal (BM) within the welded joint to a large extent. 12 In addition, careful control of process parameters such as low spindle speed and adopting appropriate axial pressure in the frictional stage of CDFW could minimise welding heat input, effectively reducing the risk of harmful microstructures and defects generation within the welded joint. 13 For steel materials, maintaining the peak temperature of the weld interface below A c1 could preserve the strength and toughness of BM within welded joint.…”