Multiphysics models for friction stir welding simulation

Research output: Contribution to journalArticle

Abstract

Purpose: The Friction Stir Welding (FSW) process comprises of several highly coupled (and non-linear) physical phenomena: large plastic deformation, material flow transportation, mechanical stirring of the tool, tool-workpiece surface interaction, dynamic structural evolution, heat generation from friction and plastic deformation, etc. In this paper, an advanced Finite Element (FE) model encapsulating this complex behavior is presented and various aspects
associated with the FE model such as contact modeling, material model and meshing techniques are discussed in detail.
Methodology: The numerical model is continuum solid mechanics-based, fully thermomechanically coupled and has successfully simulated the friction stir welding process including plunging, dwelling and welding stages.
Findings: The development of several field variables are quantified by the model: temperature, stress, strain, etc. Material movement is visualized by defining tracer particles at the locations of interest. The numerically computed material flow patterns are in very good agreement with the general findings from experiments.
Value: The model is, to the best of the authors’ knowledge, the most advanced simulation of FSW published in the literature.
LanguageEnglish
Pages19-30
JournalInternational Journal of CFD Case Studies
Volume10
Publication statusPublished - Mar 2013

Fingerprint

Friction Stir Welding
Friction stir welding
Multiphysics
Plastic Deformation
Finite Element Model
Simulation
Solid Mechanics
Structural Dynamics
Continuum Mechanics
Plastic deformation
Meshing
Flow Pattern
Large Deformation
Welding
Model
Friction
Heat
Structural dynamics
Heat generation
Contact

Keywords

  • multiphysics
  • modelling and simulation
  • friction stir welding

Cite this

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title = "Multiphysics models for friction stir welding simulation",
abstract = "Purpose: The Friction Stir Welding (FSW) process comprises of several highly coupled (and non-linear) physical phenomena: large plastic deformation, material flow transportation, mechanical stirring of the tool, tool-workpiece surface interaction, dynamic structural evolution, heat generation from friction and plastic deformation, etc. In this paper, an advanced Finite Element (FE) model encapsulating this complex behavior is presented and various aspectsassociated with the FE model such as contact modeling, material model and meshing techniques are discussed in detail.Methodology: The numerical model is continuum solid mechanics-based, fully thermomechanically coupled and has successfully simulated the friction stir welding process including plunging, dwelling and welding stages.Findings: The development of several field variables are quantified by the model: temperature, stress, strain, etc. Material movement is visualized by defining tracer particles at the locations of interest. The numerically computed material flow patterns are in very good agreement with the general findings from experiments.Value: The model is, to the best of the authors’ knowledge, the most advanced simulation of FSW published in the literature.",
keywords = "multiphysics, modelling and simulation, friction stir welding",
author = "Donald Mackenzie and Hongjun Li and Robert Hamilton",
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language = "English",
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journal = "International Journal of CFD Case Studies",
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}

Multiphysics models for friction stir welding simulation. / Mackenzie, Donald; Li, Hongjun; Hamilton, Robert.

In: International Journal of CFD Case Studies, Vol. 10, 03.2013, p. 19-30.

Research output: Contribution to journalArticle

TY - JOUR

T1 - Multiphysics models for friction stir welding simulation

AU - Mackenzie, Donald

AU - Li, Hongjun

AU - Hamilton, Robert

PY - 2013/3

Y1 - 2013/3

N2 - Purpose: The Friction Stir Welding (FSW) process comprises of several highly coupled (and non-linear) physical phenomena: large plastic deformation, material flow transportation, mechanical stirring of the tool, tool-workpiece surface interaction, dynamic structural evolution, heat generation from friction and plastic deformation, etc. In this paper, an advanced Finite Element (FE) model encapsulating this complex behavior is presented and various aspectsassociated with the FE model such as contact modeling, material model and meshing techniques are discussed in detail.Methodology: The numerical model is continuum solid mechanics-based, fully thermomechanically coupled and has successfully simulated the friction stir welding process including plunging, dwelling and welding stages.Findings: The development of several field variables are quantified by the model: temperature, stress, strain, etc. Material movement is visualized by defining tracer particles at the locations of interest. The numerically computed material flow patterns are in very good agreement with the general findings from experiments.Value: The model is, to the best of the authors’ knowledge, the most advanced simulation of FSW published in the literature.

AB - Purpose: The Friction Stir Welding (FSW) process comprises of several highly coupled (and non-linear) physical phenomena: large plastic deformation, material flow transportation, mechanical stirring of the tool, tool-workpiece surface interaction, dynamic structural evolution, heat generation from friction and plastic deformation, etc. In this paper, an advanced Finite Element (FE) model encapsulating this complex behavior is presented and various aspectsassociated with the FE model such as contact modeling, material model and meshing techniques are discussed in detail.Methodology: The numerical model is continuum solid mechanics-based, fully thermomechanically coupled and has successfully simulated the friction stir welding process including plunging, dwelling and welding stages.Findings: The development of several field variables are quantified by the model: temperature, stress, strain, etc. Material movement is visualized by defining tracer particles at the locations of interest. The numerically computed material flow patterns are in very good agreement with the general findings from experiments.Value: The model is, to the best of the authors’ knowledge, the most advanced simulation of FSW published in the literature.

KW - multiphysics

KW - modelling and simulation

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JO - International Journal of CFD Case Studies

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SN - 1642-236X

ER -