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Problem Description
The model used in this example is a simplified version of the thermo-mechanical model and the tool pin is ignored.
The simulation is performed in three load steps, each representing a respective phase (plunge, dwell, and traverse) of the FSW process.
1.
2.
3.
Traverse (or Traveling) -- The rotating tool moves along the weld line.
193 GPa
Poissons ratio
0.3
18.7 m/m C
290 MPa
Tangent modulus
2.8 GPa
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200
400
600
800
1000
Thermal Conductivity
16
(W/m C)
19
21
24
29
30
540
560
590
600
610
Density (Kg/m3)
7744
7631
7518
7406
7406
7894
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680 GPa
Poissons ratio
0.22
750 J/Kg C
Density
4280 Kg/m3
Modeling
Two rectangular shaped plates 76.2 x 31.75 x 3.18 mm are used. The tool shoulder diameter is 15.24 mm. Both the workpiece (steel plates) and the tool are modeled using
coupled-field element SOLID226 with the structural-thermal option (KEYOPT(1) = 11).
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Boundary Conditions
For thermal Boundary Conditions, all external surfaces except the bottom surface, the value of the convection coefficient is 30 W/m2C for workpiece and tool. A high overall
heat-transfer coefficient (about 10 times the convective coefficient) of 300 W/m2 C is assumed for the conductive heat loss through the bottom surface of the workpiece.
An initial temperature of 25 C is applied on the model.
pic
For mechanical Boundary Conditions, the workpiece is fixed by clamping each plate
pic
Loading
As indicated previously, there are 3 steps in loading condition.
Load Step
1
plunge
2
Dwell
3
Travelling
Boundary Condition
UZ = -7.95E-07 m
5.5
ROTZ = 60 RPM
22.5
ROTZ = 60 RPM
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UY = 60.96E-03 m
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The tool plunges into the workpiece at a very shallow depth, then rotates to generate heat. The depth and rotating speeds are the critical parameters for the weld
temperatures. The tool travels from one end of the welding line to the other at a speed of 2.7 mm/s.
Analysis
A transient analysis is done with large deformation effect and ramped boundary condition. According to the time period and the problem nonlinearity, the maximum time step
is restricted to 0.2.
Results
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Training
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