Numerical simulation of the friction stir welding process

Abstract : This work presents the development of a numerical tool. An Arbitrary Lagrangian Eulerian (ALE) formulation is implemented in the 3D FORGE3® F.E. software to simulate the different stages of the Friction Stir Welding (FSW) process. A splitting method is utilized:a) the material velocity/pressure and temperature fields are calculated, b) the mesh velocity is derived from the domain boundary evolution and an adaptive refinement criterion provided by error estimation, c) nodal and P0 variables are remapped. Different velocity computations and remap techniques are investigated, providing significant advantages with respect to more standard approaches. Improvement is also brought to the contact algorithm through a tool smoothing procedure. These proposed enhancements have been tested and applied on industrial cases.Steady state welding, but also transient welding phases are simulated, exhibiting good robustness and accuracy of the developed ALE formulation. On the first hand, friction parameters are identified using Eulerian steady welding state simulations by comparison with experimental results. On the second hand, one major interest of the ALE model being the possibility to simulate void formation at the tool/workpiece interface, the transient plunge and welding phases are modeled. Their simulations can thus help to better understand the mechanisms of the deposition process that occurs at the trailing edge of the probe in order to obtain sound and defect-free welds. Finally, the flexibility and robustness of the model allows the investigation of new tooling designs influence in the deposition process.
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Submitted on : Tuesday, April 8, 2008 - 3:34:04 PM
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  • HAL Id : tel-00271234, version 1

Citation

Simon Guerdoux. Numerical simulation of the friction stir welding process. Mechanics [physics.med-ph]. École Nationale Supérieure des Mines de Paris, 2007. English. ⟨NNT : 2007ENMP1518⟩. ⟨tel-00271234⟩

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