Finite Element Analysis (FEA) on Friction Stir Welding of Aluminium Alloy, AA5083 Using Coupled Eulerian-Lagrangian Model with Time-Scaling (original) (raw)

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Application of Coupled Eulerian Lagrangian Approach in Finite Element Simulation of Friction Stir Welding

— Finite Element Simulation of Friction Stir Welding (FSW) is a problem involving large deformations and is often difficult to solve using the classical Finite Element Method (FEM). Large mesh distortions and contact problems can occur due to the large deformations such that a convergent solution cannot be achieved. Since in ABAQUS, a Coupled Eulerian Lagrangian (CEL) approach has been developed to overcome the difficulties with regard to FEM and large deformation analyses. In this article, this method is investigated regarding its capabilities in simulating FSW process. FSW is a mechanical process whereby solid-state welding is performed using heat generated from the friction of a rotating tool and plastic deformation of weld material. FSW is a modification of the traditional Friction Welding, which was invented at the Welding Institute in Cambridge, England in 1991. Since then, it is gaining significance in many joining applications, by overcoming the limitations of other fusion welding processes. For successful incorporation of its potential during industrial applications, mechanism of joining needs to be properly comprehended. Various experimenting and study techniques are used in widening of its applicability in joining process. FE Simulation is one such technique which would help in getting an insight of the process phenomena during the process and the overall result could be used to observe the effect of process parameters on weld quality. Here, an attempt is made to develop a FE model using ABAQUS/Explicit with help of CEL formulation, Johnson-Cook material law and Coulomb's Law of friction. The model has been found to be capable of obtaining certain insight on right processing conditions prior to performing welding process, by predicting the effect of process parameters on outputs like temperature, force on tool and formation of defects. Finally the FE Simulation results are used to obtain the optimized process parameters.

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