Material flow study during friction stir welding process using computational fluid dynamics simulation

2011 ◽  
Author(s):  
Nurul Syahida binti Sataruddin ◽  
Mokhtar Awang ◽  
Ku Zilati Ku Shaari
Keyword(s):  
Fluid Dynamics ◽  
Computational Fluid Dynamics ◽  
Friction Stir Welding ◽  
Material Flow ◽  
Welding Process ◽  
Dynamics Simulation ◽  
Computational Fluid Dynamics Simulation ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Flow Study

scholarly journals Multiphysics Coupling Method to Simulate the Friction Stir Welding Process

2020 ◽  
Vol 25 (1) ◽  
pp. 92-96
Author(s):  
Willman Antonio Orozco Lozano ◽  
Jonathan Fábregas Villegas ◽  
Rafael Ramírez Restrepo ◽  
Javier Andrés Carpintero Durango ◽  
Jimy Unfried Silgado
Keyword(s):  
Fluid Dynamics ◽  
Friction Stir Welding ◽  
Welding Process ◽  
Maximum Temperature ◽  
Ansys Software ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Multiphysics Coupling ◽  
Study Process ◽  
Transient Structure

In In this work the methods are developed to perform simulations of the friction stir welding process using the ANSYS software working scheme, developing multiphysics couplings between computational fluid dynamics tools to Model the viscoplastic effect of the fluidity of the material when it is stirred by means of a solid tool modeled in the Transient Structure application that allows calculating the thermo-mechanical effects of the study process. The results show the validations corresponding to the modeled and experimentally performed analysis showing a lot of reliability in the proposed method. The torque reached in the process is maintained in the ranges of 14 Nm, the maximum temperature reached in the process was 540°C, this being 78.3% of the melting temperature of the material studied, having an adequate range for these studies.

Material Flow Behavior Modelling and Strain Distribution Prediction During Self-Reacting Friction Stir Welding Process Based on Computational Fluid Dynamics Method

2020 ◽  
Author(s):  
Chenyu Zhao ◽  
Xun Liu ◽  
Wei Zhang ◽  
Weiyu Cao
Keyword(s):  
Fluid Dynamics ◽  
Computational Fluid Dynamics ◽  
Friction Stir Welding ◽  
Strain Distribution ◽  
Process Model ◽  
Flow Behavior ◽  
Experimental Studies ◽  
Welding Process ◽  
Friction Stir ◽  
Stress Boundary

Abstract Self-reacting friction stir welding (SRFSW) is an advanced variant of friction stir welding (FSW) and shows several superiorities with the double-sided tool configuration. Despite the considerable amount of experimental studies in this field, most of the tool development efforts are still empirical and resort to trial-and-error solutions. To reveal effects of tool features on process physics and guide tool designs, in this study, a multi-physics SRFSW process model is developed within the framework of computational fluid dynamics (CFD). A shear stress boundary condition is applied at the tool-workpiece contact interface. First, the velocity distribution at weld cross section are calculated and the results show that the threads on the pin contribute to the enhancement of stirring effect. Second, the temperature evolutions at advancing side (AS) and retreating side (RS) are compared, and position in RS has higher temperature than position in AS accordingly. Finally, the plastic strain distribution behind pin tool is calculated by integrating effective stain rate along pathlines. The result shows that AS has a more definable strain boundary than RS, which corresponds to the general macroscopic observations in SRFSW. The results may provide a reference on SRFSW tool design.

Finite Element Modelling of Temperature Distribution in Friction Stir Welding Process and Its Influence on Distortion of Copper Canisters

2004 ◽  
Vol 824 ◽  
Author(s):  
Therese Källgren ◽  
Lai-Zhe Jin ◽  
Rolf Sandström
Keyword(s):  
Finite Element ◽  
Friction Stir Welding ◽  
Temperature Distribution ◽  
Welding Speed ◽  
Material Flow ◽  
Finite Element Modelling ◽  
Welding Process ◽  
Element Modelling ◽  
Friction Stir ◽  
Friction Stir Welding Process

AbstractIn an effort to enhance safety for long time disposal of waste nuclear fuel, friction stir welding has been developed as one alternative to seal copper canisters. To avoid the formation of voids and cracks during the welding process, an understanding of the heat and material flow andthereby the evolution of the microstructure, is of great importance. Finite element modelling has been used to simulate the heat and material flow as well as thermal expansion during the friction stir welding process. A model involving heat transfer, material flow, and continuum mechanics has been developed. The steady state solutions have been compared with experimental temperature observations as well as analytical solutions, showing good agreement. Temperature distribution is affected by the welding speed. For a given reference pointperpendicular to the welding direction, a lower welding speed corresponds to a higher peak temperature. The plunging position of welding tool influences the temperature distribution and therefore the displacement distribution of the weldment.

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