This paper presents a new thermomechanical model of friction stir welding which is capable of simulating the three major steps of friction stir welding （FSW） process, i.e., plunge, dwell, and travel stages. A rate-d...This paper presents a new thermomechanical model of friction stir welding which is capable of simulating the three major steps of friction stir welding （FSW） process, i.e., plunge, dwell, and travel stages. A rate-dependent Johnson- Cook constitutive model is chosen to capture elasto-plastic work deformations during FSW. Two different weld schedules （i.e., plunge rate, rotational speed, and weld speed） are validated by comparing simulated temperature profiles with experimental results. Based on this model, the influences of various welding parameters on temperatures and energy generation during the welding process are investigated. Numerical results show that maximum temperature in FSW process increases with the decrease in plunge rate, and the frictional energy increases almost linearly with respect to time for different rotational speeds. Furthermore, low rotational speeds cause inadequate temperature distribution due to low frictional and plastic dissipation energy which eventually results in weld defects. When both the weld speed and rotational speed are increased, the contribution of plastic dissipation energy increases significantly and improved weld quality can be expected.展开更多
Friction stir welding （FSW） is a solid-state joining process, where joint properties largely depend on the amount of heat generation during the welding process. The objective of this paper was to develop a numerical...Friction stir welding （FSW） is a solid-state joining process, where joint properties largely depend on the amount of heat generation during the welding process. The objective of this paper was to develop a numerical thermomechanical model for FSW of aluminum--copper alloy AA2219 and analyze heat generation during the welding process. The thermomechanical model has been developed utilizing ANSYS APDL. The model was verified by comparing simulated temperature profile of three different weld schedules （i.e., different combinations of weld parameters in real weld situations） from simulation with experimental results. Furthermore, the verified model was used to analyze the effect of different weld parameters on heat generation. Among all the weld parameters, the effect of rotational speed on heat generation is the highest.展开更多
基金financial support provided by Louisiana Economic Development Assistantship (EDA) programpartially supported by NASA through the NASA-SLS Grant # NNM13AA02G
文摘This paper presents a new thermomechanical model of friction stir welding which is capable of simulating the three major steps of friction stir welding （FSW） process, i.e., plunge, dwell, and travel stages. A rate-dependent Johnson- Cook constitutive model is chosen to capture elasto-plastic work deformations during FSW. Two different weld schedules （i.e., plunge rate, rotational speed, and weld speed） are validated by comparing simulated temperature profiles with experimental results. Based on this model, the influences of various welding parameters on temperatures and energy generation during the welding process are investigated. Numerical results show that maximum temperature in FSW process increases with the decrease in plunge rate, and the frictional energy increases almost linearly with respect to time for different rotational speeds. Furthermore, low rotational speeds cause inadequate temperature distribution due to low frictional and plastic dissipation energy which eventually results in weld defects. When both the weld speed and rotational speed are increased, the contribution of plastic dissipation energy increases significantly and improved weld quality can be expected.
基金financial support received from the Louisiana Economic Development Assistantship (EDA) program
文摘Friction stir welding （FSW） is a solid-state joining process, where joint properties largely depend on the amount of heat generation during the welding process. The objective of this paper was to develop a numerical thermomechanical model for FSW of aluminum--copper alloy AA2219 and analyze heat generation during the welding process. The thermomechanical model has been developed utilizing ANSYS APDL. The model was verified by comparing simulated temperature profile of three different weld schedules （i.e., different combinations of weld parameters in real weld situations） from simulation with experimental results. Furthermore, the verified model was used to analyze the effect of different weld parameters on heat generation. Among all the weld parameters, the effect of rotational speed on heat generation is the highest.
