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Fully Coupled Thermo Mechanical Modelling Of A Friction Stir Welding Process Using Finite Elements Analysis
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Book Synopsis Fully Coupled Thermo-mechanical Modelling of a Friction Stir Welding Process Using Finite Elements Analysis by : Ferran Roura Port
Download or read book Fully Coupled Thermo-mechanical Modelling of a Friction Stir Welding Process Using Finite Elements Analysis written by Ferran Roura Port and published by . This book was released on 2010 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt:
Book Synopsis Fully Coupled Thermo-mechanical Modelling of a Friction Stir Welding Process Using Finite Elements Analysis by :
Download or read book Fully Coupled Thermo-mechanical Modelling of a Friction Stir Welding Process Using Finite Elements Analysis written by and published by . This book was released on 2010 with total page 52 pages. Available in PDF, EPUB and Kindle. Book excerpt:
Book Synopsis Thermo-mechanical analysis of welding processes by : Narges Dialami
Download or read book Thermo-mechanical analysis of welding processes written by Narges Dialami and published by . This book was released on 2014 with total page 155 pages. Available in PDF, EPUB and Kindle. Book excerpt: This thesis deals with the numerical simulation of welding processes. The analysis is focused either at global level, considering the full component to be jointed, or locally, studying more in detail the heat affected zone (HAZ). Even if most of the considerations are quite general, two specific welding technologies are studied in depth: multi-pass arc welding and its extension to Shaped Metal Deposition (SMD) processes (global level analysis) and Friction Stir Welding (FSW) technology (local framework). The analysis at global (structural component) level is performed defining the problem in the Lagrangian setting while, at local level, both Eulerian and Arbitrary Lagrangian Eulerian (ALE) frameworks are used. More specially, to model the FSW process, an apropos kinematic framework which makes use of an efficient combination of Lagrangian (pin), Eulerian (metal sheet) and ALE (stirring zone) descriptions for the different computational sub-domains is introduced for the numerical modeling. As a result, the analysis can deal with complex (non-cylindrical) pin-shapes and the extremely large deformation of the material at the HAZ without requiring any remeshing or remapping tools. A fully coupled thermo-mechanical framework is proposed for the computational modeling of the welding processes proposed both at local and global level. A staggered algorithm based on an isothermal fractional step method is introduced. To account for the isochoric behavior of the material when the temperature range is close to the melting point or due to the predominant deviatoric deformations induced by the visco-plastic response, a mixed finite element technology is introduced. The Variational Multi Scale (VMS) method is used to circumvent the LBB stability condition allowing the use of linear/linear P1/P1 interpolations for displacement (or velocity, ALE/Eulerian formulation) and pressure fields, respectively. The same stabilization strategy is adopted to tackle the instabilities of the temperature field, inherent characteristic of convective dominated problems (thermal analysis in ALE/Eulerian kinematic framework). At global level, the material behavior is characterized by a thermo-elasto-viscoplastic constitutive model. The analysis at local level is characterized by a rigid thermo-visco-plastic constitutive model. Different thermally coupled (non-Newtonian) fluid-like models as Norton-Ho¿ or Sheppard-Wright, among others are tested. The balance of energy equation is solved in its enthalpy format for a treatment of the phase-change phenomena. An accurate definition of the heat source (laser, arc, electron beam, etc), as well as the heat generation induced by the visco-plastic dissipation or the frictional contact (Coulomb and Norton model) are described. An ad-hoc technique to account for the use of a filler material in the shape metal deposition (SMD) process is developed. The element activation methodology proposed allows for an accurate layer-by-layer deposition of the material without introducing spurious stress/strain fields. To better understand the material flow pattern in the stirring zone, a (Lagrangian based) particle tracing is carried out while post-processing FSW results. The final numerical tool developed to study the FSW process is able to give detailed information concerning the characteristics of the weld and their relationship with the welding process parameters (e.g. advancing and rotation velocities). The simulation tool presented in this work is validated with analytical results and calibrated with experimental data. This thesis is a collection of research articles supplemented with some introductory chapters summarizing the state-of-the-art, the motivations and objectives of the work as well as the main contributions and some suggested lines for future work. It comprises 7 already-published (or accepted for publication) peer-review journal articles which are integral part of this work.
Book Synopsis Theory of Thermomechanical Processes in Welding by : Andrzej Sluzalec
Download or read book Theory of Thermomechanical Processes in Welding written by Andrzej Sluzalec and published by Springer Science & Business Media. This book was released on 2005-12-05 with total page 173 pages. Available in PDF, EPUB and Kindle. Book excerpt: The main purpose of this book is to provide a unified and systematic continuum approach to engineers and applied physicists working on models of deformable welding material. The key concept is to consider the welding material as an thennodynamic system. Significant achievements include thermodynamics, plasticity, fluid flow and numerical methods. Having chosen point of view, this work does not intend to reunite all the information on the welding thermomechanics. The attention is focused on the deformation of welding material and its coupling with thermal effects. Welding is the process where the interrelation of temperature and deformation appears throughout the influence of thermal field on material properties and modification of the extent of plastic zones. Thermal effects can be studied with coupled or uncoupled theories of thermomechanical response. A majority of welding problems can be satisfactorily studied within an uncoupled theory. In such an approach the temperature enters the stress-strain relation through the thennal dilatation and influences the material constants. The heat conduction equation and the relations governing the stress field are considered separately. In welding a material is either in solid or in solid and liquid states. The flow of metal and solidification phenomena make the welding process very complex. The automobile, aircraft, nuclear and ship industries are experiencing a rapidly-growing need for tools to handle welding problems. The effective solutions of complex problems in welding became possible in the last two decades, because of the vigorous development of numerical methods for thermal and mechanical analysis.
Book Synopsis Simulations for Design and Manufacturing by : Uday S. Dixit
Download or read book Simulations for Design and Manufacturing written by Uday S. Dixit and published by Springer. This book was released on 2018-04-19 with total page 308 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book focuses on numerical simulations of manufacturing processes, discussing the use of numerical simulation techniques for design and analysis of the components and the manufacturing systems. Experimental studies on manufacturing processes are costly, time consuming and limited to the facilities available. Numerical simulations can help study the process at a faster rate and for a wide range of process conditions. They also provide good prediction accuracy and deeper insights into the process. The simulation models do not require any pre-simulation, experimental or analytical results, making them highly suitable and widely used for the reliable prediction of process outcomes. The book is based on selected proceedings of AIMTDR 2016. The chapters discuss topics relating to various simulation techniques, such as computational fluid dynamics, heat flow, thermo-mechanical analysis, molecular dynamics, multibody dynamic analysis, and operational modal analysis. These simulation techniques are used to: 1) design the components, 2) to investigate the effect of critical process parameters on the process outcome, 3) to explore the physics of the process, 4) to analyse the feasibility of the process or design, and 5) to optimize the process. A wide range of advanced manufacturing processes are covered, including friction stir welding, electro-discharge machining, electro-chemical machining, magnetic pulse welding, milling with MQL (minimum quantity lubrication), electromagnetic cladding, abrasive flow machining, incremental sheet forming, ultrasonic assisted turning, TIG welding, and laser sintering. This book will be useful to researchers and professional engineers alike.
Book Synopsis Residual Stresses in Friction Stir Welding by : Nilesh Kulkarni
Download or read book Residual Stresses in Friction Stir Welding written by Nilesh Kulkarni and published by Butterworth-Heinemann. This book was released on 2013-11-20 with total page 59 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book describes the fundamentals of residual stresses in friction stir welding and reviews the data reported for various materials. Residual stresses produced during manufacturing processes lead to distortion of structures. It is critical to understand and mitigate residual stresses. From the onset of friction stir welding, claims have been made about the lower magnitude of residual stresses. The lower residual stresses are partly due to lower peak temperature and shorter time at temperature during friction stir welding. A review of residual stresses that result from the friction stir process and strategies to mitigate it have been presented. Friction stir welding can be combined with additional in-situ and ex-situ manufacturing steps to lower the final residual stresses. Modeling of residual stresses highlights the relationship between clamping constraint and development of distortion. For many applications, management of residual stresses can be critical for qualification of component/structure. - Reviews magnitude of residual stresses in various metals and alloys - Discusses mitigation strategies for residual stresses during friction stir welding - Covers fundamental origin of residual stresses and distortion
Book Synopsis 2nd International Conference on Mechanical, Manufacturing and Process Plant Engineering by : Mokhtar Awang
Download or read book 2nd International Conference on Mechanical, Manufacturing and Process Plant Engineering written by Mokhtar Awang and published by Springer. This book was released on 2017-04-28 with total page 128 pages. Available in PDF, EPUB and Kindle. Book excerpt: This volume presents selected papers from the 2nd International Conference on Mechanical, Manufacturing and Process Plant Engineering (ICMMPE 2016) which was held from 23rd to 24th November, 2016 in Kuala Lumpur, Malaysia. The proceedings discuss genuine problems of joining technologies that are heart of manufacturing sectors. It discusses the findings of experimental and numerical works from soldering, arc welding to solid state joining technology that faced by current industry.
Book Synopsis Welding Simulations Using ABAQUS by : Bahman Meyghani
Download or read book Welding Simulations Using ABAQUS written by Bahman Meyghani and published by Springer Nature. This book was released on 2022-03-21 with total page 135 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book presents the use of ABAQUS software in a simplified manner, for use in welding-related issues. Increasing human needs leads to the creation of complicated scientific problems. In the majority of these problems, it is necessary to join different parts and geometries together. Classical methods such as elasticity theory of stress distribution and governing equations of temperature distribution are not appropriate for solving these complicated problems. To overcome these challenges, finite element methods are proposed in order to solve different processes using differential equation. ABAQUS is a user-friendly commercial finite element software for modeling different processes in mechanical, civil, aerospace and other engineering fields. This book contains unified and detailed tutorials for professionals and students who are interested in simulating different welding processes using the ABAQUS finite element software.
Book Synopsis Numerical Simulation of the Plunging Phase of a Modified Refill Friction Stir Spot Welding Process Using a Thermo-mechanical FEM Model by : Sindhura Kalagara
Download or read book Numerical Simulation of the Plunging Phase of a Modified Refill Friction Stir Spot Welding Process Using a Thermo-mechanical FEM Model written by Sindhura Kalagara and published by . This book was released on 2008 with total page 328 pages. Available in PDF, EPUB and Kindle. Book excerpt: The primary objective of this research is to use the commercially available finite element software ABAQUS/Explicit to develop a three-dimensional, fully coupled thermo-mechanical model of the plunge phase of a modified refill Friction Stir Spot Welding (FSSW) process. In the numerical model, the plates being joined are modeled as a single deformable body while the pin and clamp are assumed as rigid bodies. The dimensions of the tool were provided by Advanced Material Processing and Joining (AMP) Laboratory of SDSM & T. Temperature-dependent material properties of Aluminum 7075-T6 representing an elastic-perfectly plastic constitutive relation were used in the model. An Arbitrary Lagrangian-Eulerian (ALE) formulation together with an adaptive meshing strategy was used for the analysis. In addition, a contact algorithm with a modified Coulomb friction law was employed to take into account the interaction between the tool and the plate material. The model was used to predict temperature distribution, stresses, and deformations in the plates being spot welded. An experimental study was conducted to validate the temperatures predicted by the model at selected locations close to the path of the motion of the tool. In addition, the material flow predicted by the model was compared against experimental results published in the literature. The simulation results were in good agreement with the temperatures measured in the experiment. Also, the model was able to predict in a reasonable fashion the mechanical response of the plate material. Improvements are required in the model to remove some of the assumptions made and to refine the value of key parameters that control the numerical results. In addition to the FEM model and validation experiment mentioned above, preliminary flow visualization experiments were also conducted by inserting markers into the bottom plate in order to visualize the material flow in the vicinity of the pin during the plunge phase of the process. Three different marker materials were chosen for the experiments and the flow patterns observed were compared to select the appropriate marker material for a more comprehensive experimental study. Based on the results, inferences were made regarding the path of motion of the plate material during the process.
Book Synopsis Advanced Joining Processes by : Lucas F. M. da Silva
Download or read book Advanced Joining Processes written by Lucas F. M. da Silva and published by Springer Nature. This book was released on 2020-03-31 with total page 178 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book presents recent material science-based and mechanical analysis-based advances in joining processes. It includes all related processes, e.g. friction stir welding, joining by plastic deformation, laser welding, clinch joining, and adhesive bonding, as well as hybrid joints. It gathers selected full-length papers from the 1st Conference on Advanced Joining Processes.
Book Synopsis Thermal and Thermo-mechanical Analysis of High-speed Friction Stir Welding by : Harsha Raikoty
Download or read book Thermal and Thermo-mechanical Analysis of High-speed Friction Stir Welding written by Harsha Raikoty and published by . This book was released on 2005 with total page 134 pages. Available in PDF, EPUB and Kindle. Book excerpt: [Author's abstract] Friction Stir Welding (FSW) is a solid state joining technology in which butted plates are heated, plasticized, and joined together by the application of frictional heat generated between the tool shoulder and the top surface of the workpiece. In this thesis a three dimensional Finite Element Analysis (FEA) of High Speed Friction Stir Welding (HS FSW) is presented to calculate the temperature and residual stress distribution of the workpiece The analysis adopted a thermal model to predict the temperature distribution within the workpiece and a thermo mechanical analysis to determine the residual stress. The thermal model with a moving heat source was used to find the temperature distribution. During the process, results from the thermal model are applied to the mechanical model to find the residual stresses of the workpiece A butt welded A1 6061T6 was used and temperature results were validated experimentally with an infrared camera and thermocouple measurements. By comparing actual welds performed on Aluminum 6061 T6 and with the FE predictions, it was observed that the appropriate range for the (maximum) temperature for a sound weld is between 570° C and 530° C, and that these temperatures were achieved between spindle translation velocities of 125 mm/min and 250 mm/min, respectively. Tool rotational speed was kept constant at 15,000 rpm for all FEA simulations and experiments.
Book Synopsis State of the Art Review by : A. Yaghi
Download or read book State of the Art Review written by A. Yaghi and published by . This book was released on 2005 with total page 34 pages. Available in PDF, EPUB and Kindle. Book excerpt:
Book Synopsis Friction Stir Welding and Processing by : Rajiv S. Mishra
Download or read book Friction Stir Welding and Processing written by Rajiv S. Mishra and published by ASM International. This book was released on 2007-01-01 with total page 360 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book covers the rapidly growing area of friction stir welding. It also addresses the use of the technology for other types of materials processing, including superplastic forming, casting modification, and surface treatments. The book has been prepared to serve as the first general reference on friction stir technology,. Information is provided on tools, machines, process modeling, material flow, microstructural development and properties. Materials addressed include aluminum alloys, titanium alloys, steels, nickel-base alloys, and copper alloys. The chapters have been written by the leading experts in this field, representing leading industrial companies and university and government research insititutions.
Book Synopsis Thermomechanical Modeling of Friction Stir Welding by Finite Element Method by : Changming Chen
Download or read book Thermomechanical Modeling of Friction Stir Welding by Finite Element Method written by Changming Chen and published by . This book was released on 2004 with total page 244 pages. Available in PDF, EPUB and Kindle. Book excerpt:
Book Synopsis Advances in Friction-Stir Welding and Processing by : M.-K. Besharati-Givi
Download or read book Advances in Friction-Stir Welding and Processing written by M.-K. Besharati-Givi and published by Elsevier. This book was released on 2014-12-08 with total page 827 pages. Available in PDF, EPUB and Kindle. Book excerpt: Friction-stir welding (FSW) is a solid-state joining process primarily used on aluminum, and is also widely used for joining dissimilar metals such as aluminum, magnesium, copper and ferrous alloys. Recently, a friction-stir processing (FSP) technique based on FSW has been used for microstructural modifications, the homogenized and refined microstructure along with the reduced porosity resulting in improved mechanical properties. Advances in friction-stir welding and processing deals with the processes involved in different metals and polymers, including their microstructural and mechanical properties, wear and corrosion behavior, heat flow, and simulation. The book is structured into ten chapters, covering applications of the technology; tool and welding design; material and heat flow; microstructural evolution; mechanical properties; corrosion behavior and wear properties. Later chapters cover mechanical alloying and FSP as a welding and casting repair technique; optimization and simulation of artificial neural networks; and FSW and FSP of polymers. - Provides studies of the microstructural, mechanical, corrosion and wear properties of friction-stir welded and processed materials - Considers heat generation, heat flow and material flow - Covers simulation of FSW/FSP and use of artificial neural network in FSW/FSP
Book Synopsis Thermomechanical Industrial Processes by : Jean-Michel Bergheau
Download or read book Thermomechanical Industrial Processes written by Jean-Michel Bergheau and published by John Wiley & Sons. This book was released on 2014-02-19 with total page 364 pages. Available in PDF, EPUB and Kindle. Book excerpt: The numerical simulation of manufacturing processes and of their mechanical consequences is of growing interest in industry. However, such simulations need the modeling of couplings between several physical phenomena such as heat transfer, material transformations and solid or fluid mechanics, as well as to be adapted to numerical methodologies. This book gathers a state of the art on how to simulate industrial processes, what data are needed and what numerical simulation can bring. Assembling processes such as welding and friction stir welding, material removal processes, elaboration processes of composite structures, sintering processes, surface-finishing techniques, and thermo-chemical treatments are investigated. This book is the work of a group of researchers who have been working together in this field for more than 12 years. It should prove useful for both those working in industry and those studying the numerical methods applied to multiphysics problems encountered in manufacturing processes.
Book Synopsis Thermo-mechanical Modeling of Welding Process by Finite Element Method by : Ruiwen Zhao
Download or read book Thermo-mechanical Modeling of Welding Process by Finite Element Method written by Ruiwen Zhao and published by . This book was released on 1995 with total page 322 pages. Available in PDF, EPUB and Kindle. Book excerpt:
