Accurate 3D friction stir welding simulation tool based on friction model calibration

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HAL Id: hal-00509265

https://hal-mines-paristech.archives-ouvertes.fr/hal-00509265

Submitted on 11 Aug 2010

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Accurate 3D friction stir welding simulation tool based on friction model calibration

Mohamed Assidi, Lionel Fourment

To cite this version:

Mohamed Assidi, Lionel Fourment. Accurate 3D friction stir welding simulation tool based on friction model calibration. 12th ESAFORM Conference on Material Forming, Apr 2009, Enschede, Nether- lands. pp.Pages 327-330, �10.1007/s12289-009-0541-6�. �hal-00509265�

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t (s)

F (kN)

Comparison of forces

Case 1: α=0.3 p=0.125, Case 2: α=0.4 p=0.10, Case 3: α=0.4 p=0.125 0

10 20 30 40 50

0 10 20 30 40 50 60

FX 1 FZ 1 FX 2 FZ 2 FX 3 FZ 3 FX exp FZ exp

t (s)

F (kN)

Comparison of forces

Case 1: α=0.3 p=0.125, Case 2: α=0.4 p=0.10, Case 3: α=0.4 p=0.125 0

10 20 30 40 50

0 10 20 30 40 50 60

FX 1 FZ 1 FX 2 FZ 2 FX 3 FZ 3 FX exp FZ exp

Root Shoulder

Pin

Shoulder Root Pin Tip

Temperature (°C)

450 470 490 510 530 550 570

590 Experiment

Norton (case 1) Norton (case 2) Norton (case 3)

Pin

Temperature (°C)

450 470 490 510 530 550 570

590 Experiment

Norton (case 1) Norton (case 2) Norton (case 3)

Figure 1: Global view of the finite element model.

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Figure 2: Comparison of simulated forces for three different couples of friction parameters with experimental measures, versus time

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Figure 3: Comparison of calculated and measured temperatures at pin, root, and shoulder locations in the FSW tool with a Norton friction, using an Eulerian formulation

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450 470 490 510 530 550 570

590 Experiment Coulomb (mu=0.2) Coulomb (mu=0.25) Coulomb (mu=0.3) Coulomb (mu=0.4)

Pin

Thermocouple location

Temperature (°C)

450 470 490 510 530 550 570

590 Experiment Coulomb (mu=0.2) Coulomb (mu=0.25) Coulomb (mu=0.3) Coulomb (mu=0.4)

Pin

Temperature (°C)

Error on force

Error on temperature ФF

ФT

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

0 0.02 0.04 0.06 0.08 0.1

Coulomb

Norton α=0.4, p=0.125

α=0.4, p=0.125

=0.2

=0.25

=0.4

=0.3

Error on force

Error on temperature ФF

ФT

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

0 0.02 0.04 0.06 0.08 0.1

Coulomb

Norton α=0.4, p=0.125

α=0.4, p=0.125

=0.2

=0.25

=0.4

=0.3

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τ 1A2

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Table 2: Calculated and measured tool forces (with error bounds F^<

)

H1C-2 <1C-2

< A &(±^A& ^%&((± ^&'

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6 IG &A/ A/& &%

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6 IG & '& %&''

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Figure 4: Calculated and measured temperatures at pin, root and shoulder locations in the FSW tool with Coulomb friction using an Eulerian formulation

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root root

pin pin

T T T T

T T T

T

T_pin _root _shou

φT 1 2

Figure 5: Pareto plot, comparisons of Norton and Coulomb relative errors on forces and temperatures

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Table3: Comparisons of calculated and measured forces at steady welding states with the ALE formulation

H1C-2 <1C-2

< A &(±A& %&((± &'

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6 IG &% A%±A %&(± &/

6 IG & '&/±A A&(± &/

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450 470 490 510 530 550 570 590

Experiment Coulomb (mu=0.25) Coulomb (mu=0.3) Coulomb (mu=0.4) Coulomb (mu=0.5)

Pin

Temperature (°C)

450 470 490 510 530 550 570 590

Experiment Coulomb (mu=0.25) Coulomb (mu=0.3) Coulomb (mu=0.4) Coulomb (mu=0.5)

Pin

Temperature (°C)

Error on temperature

Error on force

0 0.05 0.1 0.15 0.2 0.25 0.3

0 0.01 0.02 0.03 0.04 0.05

4ipm

8ipm

12 ipm

0.25 0.25 0.3

0.3 0.25

0.3

Error on temperature

Error on force

0 0.05 0.1 0.15 0.2 0.25 0.3

0 0.01 0.02 0.03 0.04 0.05

4ipm

8ipm

12 ipm

0.25 0.25 0.3

0.3 0.25

0.3 ФF

ФT

" " 6 & # 6 8

6 + " 6 8 IG &A/

IG &%& D 8 3 IG &A/ 3

+ " 5 " 6 1 2&

Figure 6: Comparisons of calculated and measured temperatures at pin, root, and shoulder locations in the FSW tool with Coulomb friction and the ALE formulation.

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IG &%2 5 3 6 " + +

3 & # 6 H 6

1+ " 2 + 3 +

" 1 2 ( 1 3 +

3 2 A &

Table3: Comparisons of measured and calculated forces and temperature obtained with the ALE formulation at various travel speeds.

H 1C-2 < 1C-2

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I G &A/ A &A /% /

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6 3 5 8 ( 8

+ " + &

' 8 , 6 "

3 3 & " 8 ++

+ " " ++ " " < & #

3 + " 13 " < 2 ""

3 1 H < 2

'&

Figure 7: Pareto plot, error on forces according error on temperatures with the ALE calculation at various travel speeds.

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