3d fsw numerical model of aa2024: experimental

ICOMP’2014
Philippe Bussetta et al
3D FSW NUMERICAL MODEL OF AA2024:
EXPERIMENTAL VALIDATION
Philippe Bussetta a
∗
Nicolas Legrand b Romain Boman a
Jean-Philippe Ponthot a
Frederik Hendrickx b
University of Liege, Department of Aerospace &
Mechanical Engineering, Non Linear Computational
Mechanics, Building B52/3, Chemin des Chevreuils,
1; B-4000 Liege — Belgium
b
CEWAC, Rue bois St-jean, 8, Liège Science Park;
B-4102 Ougrée — Belgium
∗
corresponding author
a
Keywords: Friction Stir Welding (FSW), Finite Element Method, Arbitrary Lagrangian Eulerian (ALE) formalism, experimental validation, AA2024
Friction Stir Welding (FSW) process is a relatively recent welding process. It was
invented at The Welding Institute (UK) in 1991 [8]. FSW is a solid-state joining process during which materials are not melted. Thus, the heat-affected zone (HAZ)
is smaller and the quality of the welding is better with respect to more classical
welding processes. In spite of the important number of applications of the FSW,
the phenomena happening during the welding are still not well understood. Consequently, the investigations on this process are very active at both the numerical
level [3] as well as the experimental one [7, 6]. A rotating non-consumable tool is
inserted between the two work-pieces to be joined and displaced along the welding
direction (see figure 1).
advancing
side
retreating
side
shoulder
pin
welded
zone
Figure 1: Scheme of the FSW process. The pin is both rotating and advancing which
results in intermixing of the two parts to be joined.
COmputational methods in Manufacturing Processes 2014 - Saint-Étienne, France
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Philippe Bussetta et al
ICOMP’2014
As the material in the neighbourhood of the tool is submitted to extremely high
strains resulting from the mechanical intermixing of the two materials by the tool,
advanced numerical simulation techniques have to be extended and developed in
order to track the actual material deformation. One of these possible extended techniques is the Arbitrary Lagrangian Eulerian (ALE) formulation. This formulation is
used to control the mesh displacement regardless of the real material displacement
[2, 5].
Temperature (in K)
293.0
418.0
544.0
669.0
795.0
Figure 2: Temperature field computed with the solid approach (at 1.5 seconds, after
one revolution of the tool) with a zoom on the neighbourhood of the tool (left)
This paper presents a 3D numerical model of the FSW process. The results obtained with this model have been verified thanks to comparison with another very
different numerical approach [4]. In the present paper, an experimental validation of
this model is shown. The numerical results coming from the 3D model are compared
to the experimental data obtained thanks to the welding machine of the CEWAC
[1]. Figure 2 shows the value of the temperature field computed with the numerical
model. It is shown that these experimental tests allow us to validate the numerical
model as far as the temperature prediction during welding are concerned.
2
COmputational methods in Manufacturing Processes 2014 - Saint-Étienne, France
ICOMP’2014
Philippe Bussetta et al
Acknowledgements
The authors wish to acknowledge the Walloon Region for its financial support to the
FSW-PME project (convention number 1217826) in the context of which this work
was performed.
References
[1] CEWAC - Centre d’Étude wallon de l’Assemblage et du Contrôle des Matériaux
: www.cewac.be.
[2] Official website of Metafor : http://metafor.ltas.ulg.ac.be/dokuwiki.
[3] M. Assidi, L. Fourment, S. Guerdoux, and T. Nelson. Friction model for friction stir welding process simulation: Calibrations from welding experiments.
International Journal of Machine Tools and Manufacture, 50(2):143–155, 2010.
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M. Cervera, and J.-P. Ponthot. 3D numerical models using a fluid or a solid formulation of FSW processes with non-cylindrical pins. In 1st International conference on COmputational methods in Manufacturing Processes, Saint-Etienne, France,
September 2014.
[5] J. Donea, A. Huerta, J.-P. Ponthot, and A. Rodríguez-Ferran. Encyclopedia of Computational Mechanics, chapter Arbitrary Lagrangian-Eulerian Methods. John Wiley & Sons, Ltd, 2004.
[6] D. Jacquin, B. De Meester, A.Simar, D. Deloison, F. Montheillet, and
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welding. Journal of Materials Processing Technology, 211:57–65, 2011.
[7] A. Simar, C. Jonckheere, K. Deplus, T. Pardoen, and B. de Meester. Comparing similar and dissimilar friction stir welds of 2017-6005A aluminium alloys.
Science and Technology of Welding and Joining, 15(3):254–259, 2010.
[8] W.M. Thomas, E.D. Nicholas, J.C. Needham, M.G. Murch, P. Temple-Smith, and
C.J. Dawes. Friction stir butt welding. GB Patent No. 9125978.8, International
Patent No. PCT/GB92/02203, 1991.
COmputational methods in Manufacturing Processes 2014 - Saint-Étienne, France
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