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Multi-physics simulation of friction stir welding process

Mackenzie, D. and Li, Hongjun and Hamilton, R. (2009) Multi-physics simulation of friction stir welding process. In: NAFEMS World Congress and Exhibition, 2009-06-16 - 2009-06-19, Crete, Greece.

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    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.

    Item type: Conference or Workshop Item (Paper)
    ID code: 15958
    Keywords: multiphysics, stir welding simulation, mechanical engineering, Mechanical engineering and machinery, Mechanical Engineering, Mechanics of Materials, Computational Mechanics, Metals and Alloys, Modelling and Simulation
    Subjects: Technology > Mechanical engineering and machinery
    Department: Faculty of Engineering > Mechanical and Aerospace Engineering
    Related URLs:
    Depositing user: Ms Katrina May
    Date Deposited: 03 Feb 2010 10:28
    Last modified: 07 Sep 2014 14:14
    URI: http://strathprints.strath.ac.uk/id/eprint/15958

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