Modeling heat transfer during friction stir welding using a meshless particle method

Xiao, Yihua, Zhan, Haifei, Gu, YuanTong, & Liu, Qinghua (2017) Modeling heat transfer during friction stir welding using a meshless particle method. International Journal of Heat and Mass Transfer, 104, pp. 288-300.

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Abstract

Modeling heat transfer during friction stir welding (FSW) process is crucial for understanding welding mechanism and optimizing process parameters. Since heat transfer is usually accompanied with the material flow in FSW, the meshless method, which can easily treat large deformation in a Lagrangian framework, is promising for FSW modeling. In this paper, we develop a meshless particle method for the analysis of transient heat transfer during FSW process. In the developed method, a heat source model based on sticking friction is implemented to describe the heat generation of FSW. A particle approximation with first-order consistency is employed to discretize the governing equation of heat transfer. A penalty method is proposed to impose different thermal boundary conditions, and a smoothing algorithm is introduced to enhance numerical stability. Two examples are firstly given to verify the accuracy and parametric effect of the meshless particle method. The method is then used to simulate heat transfer during FSW of 12.7 mm-thick Al6061-T6 plates. The calculated temperature distributions are presented and compared with those computed by FEM. The obtained thermal cycles are found to be in good agreement with those obtained from experiments. The validated model of FSW of Al6061-T6 plates is then employed to predict the maximum temperature, heat generation rate and torque for various welding parameters and tool dimensions.

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ID Code: 99965
Item Type: Journal Article
Refereed: Yes
Additional URLs:
Keywords: Heat transfer, Friction stir welding, Meshless particle method
DOI: 10.1016/j.ijheatmasstransfer.2016.08.047
ISSN: 0017-9310
Subjects: Australian and New Zealand Standard Research Classification > ENGINEERING (090000) > MECHANICAL ENGINEERING (091300)
Australian and New Zealand Standard Research Classification > ENGINEERING (090000) > MECHANICAL ENGINEERING (091300) > Numerical Modelling and Mechanical Characterisation (091307)
Divisions: Current > Schools > School of Chemistry, Physics & Mechanical Engineering
Current > QUT Faculties and Divisions > Science & Engineering Faculty
Copyright Owner: Copyright 2016 Elsevier
Deposited On: 13 Oct 2016 23:37
Last Modified: 23 Oct 2016 04:45

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