Thermal-Mechanical Numerical Modeling of the Friction Element Welding Process

2018 ◽  
Author(s):  
Ankit Varma ◽  
Saheem Absar ◽  
Xin Zhao ◽  
Hongseok Choi ◽  
Tim Abke ◽  
...  
Keyword(s):  
Automobile Industry ◽  
Weight Ratio ◽  
Welding Process ◽  
Dissimilar Materials ◽  
High Strength ◽  
Element Model ◽  
Friction Element ◽  
Physical Mechanisms ◽  
Friction Element Welding ◽  
Good Agreement

To improve the fuel economy, the automobile industry is vigorously shifting towards using a mix of lightweight materials which offers high strength-to-weight ratio. Dissimilar material joining is of critical importance in this area. Friction element welding (FEW) has been proposed for dissimilar materials, with the capability of joining high strength materials of varying thickness in minimal time with low input energy. A coupled thermal-mechanical finite element model is developed in this work to better understand the physical mechanisms involved in the process and predict the evolution of parameters such as temperature, stress, material flow, and weld quality. The Coupled Eulerian-Lagrangian (CEL) approach is adopted to capture the severe plastic deformation of both the tool and the workpiece. The material deformation and temperature evolution are analyzed at different steps, and good agreement are shown between the simulation results and the experimental data.

Investigation of the Cleaning and Welding Steps From the Friction Element Welding Process

2017 ◽  
Author(s):  
Jamie D. Skovron ◽  
Brandt J. Ruszkiewicz ◽  
Laine Mears ◽  
Tim Abke ◽  
Ankit Varma ◽  
...  
Keyword(s):  
Weld Zone ◽  
Welding Process ◽  
High Strength Steels ◽  
High Strength ◽  
Process Time ◽  
Friction Element ◽  
Joint Quality ◽  
Head Height ◽  
Friction Element Welding ◽  
Step Parameters

The requirement of increased fuel economy standards has forced automakers to incorporate multi-materials into their current steel dominant vehicles in order to lightweight their fleets. Technologies such as Self Piercing Rivets and Flow Drill Screws are currently implemented for joining aluminum to high-strength steels but only one-technology is viable for joining aluminum to ultra-high-strength steels without pre-holes, namely Friction Element Welding. This study is aimed at investigating how variations in the cleaning and welding steps of the Friction Element Welding process influence joint quality. A design of experiment was conducted to understand the influence of key process parameters (endload, spindle RPM, and relative distance) during these steps on the pre-defined joint quality metrics of head height, weld zone diameter, under-head fill area, temperature, and microhardness. It is found that cleaning step parameters have the greatest influence on process time and energy consumption, while welding step parameters greatly influence maximum torque on the element, head height, and underhead fill, with both cleaning force and weld force influencing weld diameter, all parameters influence temperature.

Modeling the interrelationship between the parameters for improving weld strength in plastic hot plate welding: A DEMATEL approach

2019 ◽  
Vol 52 (2) ◽  
pp. 117-141
Author(s):  
K Mathiyazhagan ◽  
Krishna Kumar Singh ◽  
V Sivabharathi
Keyword(s):  
Product Design ◽  
Manufacturing Process ◽  
Weight Ratio ◽  
Welding Process ◽  
High Strength ◽  
Weld Strength ◽  
Melting Time ◽  
Hot Plate ◽  
Plate Temperature ◽  
Hot Plate Welding

Application of plastics is increasing day by day since plastics offer many distinct advantages as compared to metals. Plastics has mainly good thermal and electrical insulation properties, corrosion resistance, chemical inertness, and high strength to weight ratio. Additionally, these are cheaper in cost as compared to conventional materials. Plastics are additionally easy to process. Nowadays, product requirements are getting critical and thus product design is getting more complex in shape. To manufacture intricate complex shape creates complexity in manufacturing process which is sometimes very difficult or almost not feasible to produce with single manufacturing process. To manufacture such critical products, welding is a complimentary process. Type of weld joint and welding process can be selected based on the product design and load application on the product. Hot plate welding is very simple welding process as compared to other plastic welding process and most commonly used. Good quality weld is the prime objective of welding process. Weld strength is dependent on several parameters which may be process parameters as well as product parameters. The objective of this study is to identify the key parameters in hot plate welding process of the plastics using Decision Making Trial and Evaluation Laboratory which is one of the prioritization techniques. Results of the study focus on understanding the key parameters affecting the weld strength. Study shows that hot plate temperature, welding time, and melting time are the key parameters affecting the weld strength.

Investigation of Residual Stresses Distribution in Titanium Weldments

2014 ◽  
Vol 777 ◽  
pp. 171-175 ◽  
Author(s):  
Shao Pin Song ◽  
Anna M. Paradowska ◽  
Ping Sha Dong
Keyword(s):  
Residual Stresses ◽  
High Performance ◽  
Weight Ratio ◽  
Welding Process ◽  
High Strength ◽  
Naval Research ◽  
Office Of Naval Research ◽  
And Performance ◽  
Superior Corrosion Resistance ◽  
The University

Titanium and its alloys have increasingly become a material of choice for applications in high-performance structures due to their superior corrosion resistance and high strength-to-weight ratio. However, in contrast to conventional steel alloys, there exist little design and manufacturing experience in the heavy fabrication industry with large welded structures made of titanium materials. In addressing the above concern, the University of New Orleans funded by Office of Naval Research (ONR) initiated program on investigation of manufacturability and performance of a titanium mid-ship section. The uniqueness of this program is its focus upon a representative full-size mid-ship section upon which relevant scientific and technological challenges are simulated and experimentally validated. This paper reports the measurements of residual stresses using neutron diffraction in titanium T-joints. The residual stresses were measured using Engin-X at ISIS (UK) and the Kowari Strain Scanner at ANSTO (Australia). This experimental research was used to validate our in house predictions and significantly improved the knowledge and understanding of the welding process of titanium alloys.

Real-Time Monitoring of the Weld Penetration State in Laser Welding of High-Strength Steels by Airborne Acoustic Signal

2009 ◽  
Author(s):  
Wei Huang ◽  
Shanglu Yang ◽  
Dechao Lin ◽  
Radovan Kovacevic
Keyword(s):  
Laser Welding ◽  
Real Time ◽  
Optical Sensors ◽  
Weight Ratio ◽  
Welding Process ◽  
High Strength Steels ◽  
High Strength ◽  
Acoustic Signals ◽  
Real Time Monitoring ◽  
Laser Welding Process

Nowadays high-strength steels have great applications in different industries due to their good combination of formability, weldability, and high strength-to-weight ratio. To guarantee a high quality without the presence of defects such as partial penetration (PP) in the laser welding of high-strength steels, it is very important to on-line monitor the whole welding process. While optical sensors are widely applied to monitor the laser welding process, we are proposing to use a microphone to acquire the airborne acoustic signals produced during laser welding of high-strength steel DP980. In order to extract valuable information from a very noisy signal acquired in a harsh environment such as industrial welding, spectral subtraction (SS), a noise reduction method is used to process the acquired airborne sound signals. Furthermore, by applying the power spectrum density (PSD) estimation method, the frequency characteristics of the acoustic signals are analyzed as well. The results indicate that the welds in full penetration (FP) and PP produce different signatures of acoustic signals that are characterized with different sound pressure levels and frequency distributions ranging from 500 Hz to 1500 Hz. Based on these differences, two algorithms are developed to distinguish the FP from PP during the laser welding process. A real-time monitoring system is implemented by a LabVIEW-based graphic program developed in this research. A feedback control system that could guarantee the FP will be developed in the near future.

scholarly journals Pull-out Behaviour of Extended Hollobolts for Hollow Beam-Column Connections

2018 ◽  
Author(s):  
Mohd Fazaulnizam Bin Shamsudin ◽  
Walid Tizani
Keyword(s):  
Concrete Strength ◽  
Weight Ratio ◽  
High Strength ◽  
Element Model ◽  
Embedment Depth ◽  
Gusset Plates ◽  
Hollow Section ◽  
Hollow Beam ◽  
Pull Out ◽  
Joint Behaviour

The use of structural hollow sections (SHS) as columns in single-storey and multi-storey results in better compression strength, low surface area, architectural attractiveness and high strength to weight ratio. One major constraint when connecting to hollow sections is in accessing and tightening the bolt from the inside of the hollow section. To resolve this issue, full welding is usually applied. But this may suffer from high labour cost, and the potential of low quality welding due to workmanship and varied environmental conditions. Connecting using additional components, such as gusset plates and brackets, helps to ease this problem but lowers aesthetic appeal. To avoid the need to access to the inner face of the column section, new type of fasteners known as blind bolts were introduced. In this paper, experimental and numerical studies were conducted using a new anchored blind bolt known as the Extended HolloBolt (EHB), with the objective of using the component method for predicting joint behaviour within the tensile region. The behaviour of EHB in a group with different connection topologies and configurations was investigated using a total of 36 tests with one row of M16 Grade 8.8 and 10.9 bolts subjected to pull-out loading in tension. The experimental work covers a range of parameters such as bolt gauge, concrete strength, concrete type, bolt embedment depth and bolt class. A finite element model was implemented with good agreement between experimental and simulated load-deflection results, which have a maximum difference of 2.5%, shows that the model is suitable to be used for parametric studies or analytical work in further research on the EHB.

scholarly journals Modelling and Analysis of Composite Leaf Spring under the Static Load Condition by using FEA

2011 ◽  
pp. 1-4
Author(s):  
M. M. Patunkar ◽  
D. R. Dolas
Keyword(s):  
Automobile Industry ◽  
Weight Ratio ◽  
Load Condition ◽  
High Strength ◽  
Leaf Spring ◽  
Modeling And Analysis ◽  
Wild Fire ◽  
Leaf Springs ◽  
Generalized Force ◽  
Reaction Forces

Leaf springs are one of the oldest suspension components they are still frequently used, especially in commercial vehicles. The past literature survey shows that leaf springs are designed as generalized force elements where the position, velocity and orientation of the axle mounting gives the reaction forces in the chassis attachment positions. Another part has to be focused, is the automobile industry has shown increased interest in the replacement of steel spring with composite leaf spring due to high strength to weight ratio. Therefore, analysis of the composite material becomes equally important to study the behavior of Composite Leaf Spring. The objective of this paper is to present modeling and analysis of composite mono leaf spring (GFRP) and compare its results. Modelling is done using Pro-E (Wild Fire) 5.0 and Analysis is carried out by using ANSYS 10.0 software for better understanding.

scholarly journals Weld Strength of Laser Welded SS316 and SS321

2020 ◽  
Vol 9 (7) ◽  
pp. 1319-1322
Keyword(s):  
Stainless Steel ◽  
Galvanic Corrosion ◽  
Weight Ratio ◽  
Dissimilar Materials ◽  
High Strength ◽  
Optical Microscope ◽  
Metal Corrosion ◽  
Weld Strength ◽  
Potential Candidate ◽  
Dissimilar Welds

Nowadays, due to economic considerations, stainless steel is frequently used in dissimilar welds configurations– alloyed steel, carbon steel, copper, titanium. Current research in laser welding aims at joining a large category of structurally dissimilar materials, like copper, stainless steel or aluminum components. The weld quality of 10mm thick stainless steel grades of 316 and 321 laser welded in butt configuration is studied. SS321 is well known for its corrosion resistance property especially dissimilar metal corrosion ie., galvanic corrosion. SS316 provides high strength to weight ratio even at high temperature which makes its as a potential candidate for aerospace application. The joint quality is characterized in terms of hardness, microstructure and inspected using NDT. Scanning Electron Microscope and Optical Microscope were used to study the microstructure of welded specimen. The microhardness test is conducted on the weld joints to quantify the effect of weld parameters in mechanical strength of the joints. Radiography test was conducted to identify the defects in the specimen.

Validation of Macroscopic Forming Simulations of a Unidirectional Pre-Impregnated Material through Optical Measurements

2013 ◽  
Vol 554-557 ◽  
pp. 465-471 ◽  
Author(s):  
Alexane Margossian ◽  
François Dumont ◽  
Uwe Beier
Keyword(s):  
Finite Element ◽  
Carbon Fibre ◽  
Weight Ratio ◽  
High Strength ◽  
Element Model ◽  
Optical Measurements ◽  
Woven Fabric ◽  
Measuring System ◽  
Finite Element Software ◽  
Carbon Fibre Reinforced Plastic

Presenting interesting aspects such as a high strength-to-weight ratio, Carbon Fibre Reinforced Plastic components are frequently used in the aerospace industry. The forming step, which conforms the reinforcement to a specific geometry, is a sensitive phase of the manufacturing process. In order to detect the occurrence of defects prior to any trial, forming methods are often simulated via finite element software. The presented work will detail the simulation validation of a double curved helicopter frame forming out of a unidirectional carbon fibre pre-impregnated material (M21E, Hexcel®). The finite element model was based on an explicit approach at a macroscopic level and developed via the commercially available software Visual-Crash PAM (ESI®) [1]. The validation was carried out on six different preforms. Measurements of the top layers were performed by an enhanced version of a 4D measuring system, originally developed for non-woven fabric [2], able to make reproducible photographic and height measurements (Fig. 1). Experimental results were then compared to simulated ones. Due to material specificities, the photo quality reached for non-crimp fabrics could not be achieved [2]. After hardware and software modifications, measurements and analyses were eventually successfully completed. The validation of the simulation reached an accuracy of 1° to 3° depending on the geometrical features of the preform (Fig. 2).

MIG-Welding of Dissimilar Advanced High Strength Steel Sheets

2017 ◽  
Vol 885 ◽  
pp. 80-85 ◽  
Author(s):  
Eszter Kalácska ◽  
Kornél Májlinger ◽  
Enikő Réka Fábián ◽  
Pasquale Russo Spena
Keyword(s):  
Automobile Industry ◽  
Welding Process ◽  
High Strength Steels ◽  
High Strength ◽  
Tensile Specimen ◽  
Dissimilar Welding ◽  
Welding Parameters ◽  
Mig Welding ◽  
Advanced High Strength Steels ◽  
Steel Sheets

The need for steel materials with increasing strength is constantly growing. The main application of such advanced high strength steels (AHSS) is the automobile industry, therefore the welding process of different types of AHSSs in dissimilar welding joint was investigated. To simulate the mass production of thin steel sheet constructions (such as car bodies) automated metal inert gas (MIG) welding process was used to weld the TWIP (twinning induced plasticity) and TRIP (transformation induced plasticity) steel sheets together. The welding parameters were successfully optimized for butt welded joints. The joints were investigated by visual examination, tensile testing, quantitative metallography and hardness measurements. The TRIP steel side of the joints showed increased microhardness up to (450-500 HV0.1) through increased fraction of bainite and martensite. Macroscopically the tensile specimen showed ductile behaviour, they broke in the austenitic weld material.

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