HAL Id: hal-01712005
https://hal-mines-paristech.archives-ouvertes.fr/hal-01712005
Submitted on 19 Feb 2018
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Linear Friction Welding of Aeronautical alloys Modeling and Numerical Simulation
Antoine Potet, Katia Mocellin, Lionel Fourment
To cite this version:
Antoine Potet, Katia Mocellin, Lionel Fourment. Linear Friction Welding of Aeronautical alloys Modeling and Numerical Simulation. 4th International Linear Friction Welding Symposium, Mar 2017, Cambridge, United Kingdom. �hal-01712005�
full 3D, entire process simulation Forge® solver
(metal forming framework)
• Implicit formulation
• Updated lagrangian
• (v-p) based formulation
• Remeshing
Modeling challenge
• Friction model is critical but unknown
Proposed solution : inverse analysis from
recorded real-process data
Results presented here are based on a Coulomb model
𝜏 = −𝜇𝜎𝑛 ∆𝑣𝑡
|∆𝑣𝑡|
Considered material
Ti6242, TA6V, Ti17, Inconel718
Experimental conditions • Temperature : 20 − 1200°𝐶 • Strain : 0 − 50 • Strain rate : 0 − 500 𝑠−1 JMatPro ® -based elasto-viscoplastic material 0 200 400 600 800 1000 1200 1400 1600 1800 0 1 2 3 4 • friction/contact model • Sensitivity to contact algorithm
• New surface smoothing algorithm 2 bodies model 0.0E+0 2.0E-6 4.0E-6 6.0E-6 8.0E-6 1.0E-5 0 250 500 750 1000 1250 1500 Dif fusiv ity (m² /s) Temperature (°C) -3 -2.5 -2 -1.5 -1 -0.5 0 0.5 0 0.5 1 1.5 2 2.5 coulomb 0.7 coulomb 0.4 coulomb 1 experiment 0 1 2 3 4 5 6 7 8 9 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 H e at p o we r (k W) Time (s)
Averaged thermal sources simulated
friction power
plastic deformation power
0 20 40 60 80 100 120 0 1 2 3 4 25°C 700°C 1200°C Strain rate (𝑠−1) Flo w str ess (Mpa ) Flow strain 0 200 400 600 800 1000 1200 0 1 2 3 4
Symmetric bodies model
• friction/contact model • Simplified to friction against rigid body • Assumption of a perfect perfect weld
• Can simulate the end of the process
• No friction / perfect contact
• Requires initial
temperature distribution
Distance from friction plane (mm)
In iti al Temp . ( °C) -0.5 -0.45 -0.4 -0.35 -0.3 -0.25 -0.2 -0.15 -0.1 -0.05 0 0 0.2 0.4 0.6 0.8 1 2500 nodes mesh 10 000 nodes mesh 50 000 nodes mesh
Friction Coulomb coefficient influence On shortening H alf -up set (mm) Time (s)
Mesh size influence on shortening
H alf -up set (mm) Time (s) Numerical challenge
• Surface phenomena are dominant
• Locally refined mesh must be used to ensure accuracy
Proposed solution : Mesh adaptation Process insights
• Purely surfacic to volumic heat generation transition
• Relative irrelevance of heat exchange model with air and clamps
Perfect weld model
Machine builtin upset and global friction force monitoring
K-type thermocouple measurements
Linear Friction Welding of Aeronautical alloys
Modeling and Numerical Simulation
A. Potet*, K. Mocellin, L. Fourment
*antoine.potet@mines-paristech.fr
MINES ParisTech, PSL Research University, CEMEF, CNRS UMR 7635
Providing an efficient LFW thermomechanical simulation tool Challenges
• Predictive simulation (friction force, shortening, temperature)
• Complex geometries (L and T shapes)
• Welding of dissimilar materials
Intended usages of simulation tool
• Process design
• Microstructure prediction from thermomechanical history
Purpose
Project partners
LFW machine designer Material Science Research Laboratory Material Science Research Laboratory Aircraft Manufacturer
Thermo-mechanical
coupled process
Material model
Friction model
LFW simulation
Experimental Measurements
1. P. Wanjara, and M. Jahazi, , Metallurgical and materials transactions, 36A,8, 2159-2164 (2005) 2. MTU Aero Engines, Munchen; 'Military Engines', Public Relations, March 1999.
3. A. R. McAndrew, P. A. Colegrove, A. C. Addison, B. C. D. Flipo, M. J. Russell, and L. A. Lee. MATERIALS & DESIGN, 87, 1087-1099 (2015).
4. R. Turner, J. C. Gebelin, R. M. Ward, and R. C. Reed. Acta Materialia, 59,10,:3792-3803(2011). 5. A Vairis and M Frost. Wear, 217,1, 117-131(1998).
6. Garcia, A. M. M. (2011). “Blisk fabrication by linear friction welding advances in gas turbine technology” in Advances in Gas
Turbine Technology edited by Dr. Ernesto Benini (InTech, 2011). pp. 411-434.
7. Guo,Z.,Turner,R.,DaSilva,A.D.,Sauders,N.,Schroeder,F.,Cetlin,P.R.,and Schille,J.-P. Physical and numerical simulation of materials, 762, 266-276(2013).
8. A Vairis and M Frost. Materials science and engineering, 292,1, 8-17(2000). 9. P. Zhao, L. Fu, and D. Zhong. Computational materials, 92, 325-333(2014).
Bibliography
LFW process measures* dedicated to
• friction model calibration • model validation Temperature (°C) 1200 800 400 Temperature (°C) 1200 800 400 U pse t (mm) Frictio n force( kN )
Authors would like to thank OPTIMUM project partners : ACB, Airbus Group, UTC and CDM for their implication and support.
Aknowledgements
Numerical defectBurr formation
Locally refined mesh
*Processes were realized with ACB machine and expertise
