An efficient coupled Eulerian-Lagrangian finite element model for friction stir processing

被引:71
作者
Ansari, Mohammad Ali [1 ]
Samanta, Avik [2 ]
Behnagh, Reza Abdi [3 ]
Ding, Hongtao [2 ]
机构
[1] Univ Wisconsin, Dept Mech Engn, Madison, WI 53706 USA
[2] Univ Iowa, Dept Mech & Ind Engn, Iowa City, IA 52242 USA
[3] Urmia Univ Technol, Fac Mech Engn, Orumiyeh, Iran
基金
美国国家科学基金会;
关键词
Friction stir processing; Coupled Eulerian-Lagrangian; Finite element model; Aluminum alloy; CORROSION-RESISTANCE; NUMERICAL-SIMULATION; WELDING PROCESS; MICROSTRUCTURE EVOLUTION; GRAIN-REFINEMENT; MAGNESIUM ALLOY; MATERIAL FLOW; RECRYSTALLIZATION; DEFECTS;
D O I
10.1007/s00170-018-3000-z
中图分类号
TP [自动化技术、计算机技术];
学科分类号
0812 ;
摘要
Friction stir processing (FSP) is a friction stir-based material processing method for enhancement of material microstructural and surface properties. As FSP is a multi-physics problem coupled with severe plastic deformation, material flow, heat flow, and microstructure evolution, modeling of the FSP process can be very complicated and challenging. Few research work has been reported on modeling and simulations of FSP for material modification. In this study, a computation-efficient process model is developed using ABAQUS/Explicit based on coupled Eulerian-Lagrangian (CEL) formulation to simulate FSP of aluminum alloy 5083. The three-dimensional (3D) finite element model simulates the entire process of FSP including tool plunging, dwelling, and stirring phases. Simulations are performed to evaluate the effects of tool-rotational speed and tool pin profile during the FSP process. The computational efficiency of the developed model is also evaluated in comparison with other existing models for friction stir-welding processes. FSP experiment is performed with measurements of process force and temperature for model validation. This study shows that the CEL model can be a powerful numerical tool to simulate the complex process mechanics and optimize the FSP process parameters for industrial applications.
引用
收藏
页码:1495 / 1508
页数:14
相关论文
共 78 条
[1]   Computational Modeling and Sub-Grid Scale Stabilization of Incompressibility and Convection in the Numerical Simulation of Friction Stir Welding Processes [J].
Agelet de Saracibar, C. ;
Chiumenti, M. ;
Cervera, M. ;
Dialami, N. ;
Seret, A. .
ARCHIVES OF COMPUTATIONAL METHODS IN ENGINEERING, 2014, 21 (01) :3-37
[2]   Investigation on the Effects of Process Parameters on Defect Formation in Friction Stir Welded Samples Via Predictive Numerical Modeling and Experiments [J].
Ajri, Abhishek ;
Shin, Yung C. .
JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME, 2017, 139 (11)
[3]   Thermo-mechanical finite element model of friction stir welding of dissimilar alloys [J].
Al-Badour, Fadi ;
Merah, Nesar ;
Shuaib, Abdelrahman ;
Bazoune, Abdelaziz .
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY, 2014, 72 (5-8) :607-617
[4]   Coupled Eulerian Lagrangian finite element modeling of friction stir welding processes [J].
Al-Badour, Fadi ;
Merah, Nesar ;
Shuaib, Abdelrahman ;
Bazoune, Abdelaziz .
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY, 2013, 213 (08) :1433-1439
[5]  
[Anonymous], 2007, SIMULATION FRICTION
[6]  
[Anonymous], 1983, CONSTITUTIVE MODEL D
[7]   ACCURATE 3D FRICTION STIR WELDING SIMULATION TOOL BASED ON FRICTION MODEL CALIBRATION [J].
Assidi, Mohamed ;
Fourment, Lionel .
INTERNATIONAL JOURNAL OF MATERIAL FORMING, 2009, 2 :327-330
[8]   Friction model for friction stir welding process simulation: Calibrations from welding experiments [J].
Assidi, Mohamed ;
Fourment, Lionel ;
Guerdoux, Simon ;
Nelson, Tracy .
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE, 2010, 50 (02) :143-155
[9]   Evolution of microstructures and mechanical properties in similar and dissimilar friction stir welding of AA5086 and AA6061 [J].
Aval, H. Jamshidi ;
Serajzadeh, S. ;
Kokabi, A. H. .
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING, 2011, 528 (28) :8071-8083
[10]   Experimental Analysis and Microstructure Modeling of Friction Stir Extrusion of Magnesium Chips [J].
Behnagh, Reza Abdi ;
Shen, Ninggang ;
Ansari, Mohammad Ali ;
Narvan, Morteza ;
Kazem, Mohammad ;
Givi, Besharati ;
Ding, Hongtao .
JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME, 2016, 138 (04)