Abstract




 
   

IJE TRANSACTIONS B: Applications Vol. 32, No. 2 (February 2019) 313-321    Article in Press

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  A COUPLED RIGID-VISCOPLASTIC NUMERICAL MODELING FOR EFFECTS OF SHOULDER GEOMETRY ON PROCESS PARAMETERS AND THERMAL HISTORY OF FRICTION STIR WELDING IN ALUMINUM ALLOYS
 
J. Fabregas Villegas, A. Martínez Guarín and J. Unfried-Silgado
 
( Received: August 24, 2018 – Accepted in Revised Form: January 03, 2019 )
 
 

Abstract    Shoulder geometry of tool plays an important role in friction-stir welding because it controls thermal interactions and heat generation. This work is proposed and developed a coupled rigid-viscoplastic numerical modeling based on computational fluid dynamics and finite element calculations aiming to understand these interactions. Model solves mass conservation, momentum, and energy equations in three dimensions, using appropriate boundary conditions, considering mass flow as a non-Newtonian, incompressible, viscoplastic material. Boundary conditions of heat transfer and material flow were determined using a sticking/sliding contact condition at tool / workpiece interface. Thermal history, as well as shear stress and rotational speed fields, forces and torque values for three shoulder geometry conditions were calculated. Numerical results of thermal history, torque and forces during welding showed good correlation with experimentally measured data.

 

Keywords    Friction stir welding, finite element model, aluminum alloy, heat generation, plasticity

 

چکیده   

هندسه شانه‌ای از ابزار نقش مهمی در جوشکاری اصطکاک ایفا می‌کند، زیرا کنترل اثر متقابل حرارتی و تولید گرما را کنترل می‌نماید. در این کار، یک مدل‌سازی عددی مشخص و ویسکوپلاستیک با استفاده از دینامیک سیالات محاسباتی و محاسبات عناصر محدود با هدف درک این تعاملات ارائه شده است. مدل حل معادلات حفاظتی جرم، حرکتی و انرژی را در سه بعد، با استفاده از شرایط مرزی مناسب، با توجه به جریان جرم به عنوان مواد غیرنیوتنی، ناپایدار، ویزوپلاستی. شرایط مرزی انتقال حرارت و جریان مواد با استفاده از یک وضعیت تماس کششی/کششی در رابط ابزار/قطعه کار اندازه‌گیری شد. تاریخچه حرارتی، همچنین تنش برشی و میدان‌های سرعت چرخشی، نیروها و مقادیر گشتاور برای سه حالت هندسی شانه محاسبه شده است. نتایج عددی تاریخ حرارتی، گشتاور و نیروها در طی جوشکاری همبستگی خوب با داده‌های آزمایش شده را نشان می‌دهد.

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