Numerical Simulation of Friction Stir Welding (FSW) Process Based on ABAQUS Environment

Abstract:

. Simulation of the FSW process is a complex issue, as it implies interactions between thermal and mechanical phenomena and the quality of the welding depends on many factors. In order to reduce the time of the experimental tests, which can be long and expensive, numerical simulation of the FSW process has been tried during the last ten years. However, there still remain aspects that cannot be completely simulated. In this paper the authors present the steps of the numerical simulation using the finite elements method, in order to evaluate the boundary conditions of the model and the geometry of the tools by using the Arbitrary Lagrangian Eulerian (ALE) adaptive mesh controls.

• Periodical: Solid State Phenomena (Volume 254)
• Pages: 272-277
• DOI: https://doi.org/10.4028/www.scientific.net/SSP.254.272
• Online since: August 2016
• Authors: Daniela Monica Iordache*, Claudiu Bădulescu, Eduard Laurentiu Nitu, Doina Iacomi
• Keywords: ABAQUS, Aluminum Alloys, CAE, Friction Stir Welding (FSW), Numerical Simulation

References

[1] X. He, F. Gu, A. Ball, A review of numerical analysis of friction stir welding, Progress in Materials Science 65 (2014) 1-66.

DOI: 10.1016/j.pmatsci.2014.03.003

[2] M. Nourani, A. S. Milani, S. Yannacopoulos, On the effect of different material constitutive equations in modeling friction stir welding, International Journal of Advances in Engineering & Technology 7 (2014) 1-20.

[3] M. Awang, Simulation of Friction Stir Spot Welding (FSSW) Process: Study of Friction Phenomena, Dissertation, College of Engineering and Mineral Resources at West Virginia University, (2007).

[4] V. Soundararajan, S. Zekovic, R. Kovacevic Thermomechanical model with adaptive boundary conditions for friction stir welding of Al 6061. International Journal of Machine Tools & Manufacture 45 (2005) 1577–1587.

DOI: 10.1016/j.ijmachtools.2005.02.008

[5] G.R. Johnson, W.H. Cook, A constitutive model and data for metals subjected to large strains, high strain rates and high temperatures, 7th International Symposium on Ballistics, Netherlands, (1983) 541–547.

[6] F. Al-Badour, M. Nesar, S. Abdelrahman, A. Bazoune, Thermo-mechanical finite element model of friction stir welding of dissimilar alloys, International Journal of Advanced Manufacturing Technology 72 (2014) 607-617.

DOI: 10.1007/s00170-014-5680-3

[7] M. Assidi, L. Fourment, S. Guerdoux, T. Nelson, Friction model for friction stir welding process simulation: Calibrations from welding experiments, International Journal of Machine Tools & Manufacture 50 (2010) 143-155.

DOI: 10.1016/j.ijmachtools.2009.11.008

[8] Z. Zhang, J.T. Chen, The simulation of material behaviors in friction stir welding process by using rate-dependent constitutive model, Journal of Materials Science 43 (2008) 222-232.

DOI: 10.1007/s10853-007-2129-1

[9] M. Riahi, H. Nazari, Analysis of transient temperature and residual thermal stresses in friction stir welding of aluminum alloy, International Journal of Advanced Manufacturing Technology 55 (2011) 143-152.

DOI: 10.1007/s00170-010-3038-z

[10] ABAQUS analysis user's manual, version 6. 7, ABAQUS Incorporation (2007).