FE Modeling of the Inertia Friction Welding with a Modified Friction Law

2015 ◽  
Vol 740 ◽  
pp. 55-58
Author(s):  
Quan Zhong Zhang ◽  
Li Fen Hu ◽  
Wu Bin Li ◽  
Jiu Chun Gu
Keyword(s):  
Friction Welding ◽  
Welding Process ◽  
Friction Model ◽  
Friction Torque ◽  
Work Piece ◽  
Fe Model ◽  
Inertia Friction Welding ◽  
Friction Law ◽  
The Subject ◽  
Coulomb Friction Model

The subject of this paper was the presentation of a holistic, fully-temperature-coupled FE model of inertia friction welding based on the modified friction law, which divided the friction welding process into beginning friction stage and steady equilibrium friction stage. At each of the stage Coulomb friction model and shear friction model were adopted respectively. The present FE model predicted the temperature of the welding joint as well as variation of friction torque and relative rotating velocity of the work-piece during the welding process. The evolution of friction torque and rotating velocity were compared with the experimental measurement. They showed a good agreement between them.

The Coupled Thermal Mechanical Modeling of the Inertia Friction Welding Process for Inconel718

2011 ◽  
Vol 704-705 ◽  
pp. 710-716 ◽  
Author(s):  
Wen De Bu ◽  
Jin He Liu
Keyword(s):  
Friction Welding ◽  
Welding Process ◽  
Mechanical Analysis ◽  
Friction Torque ◽  
Interface Temperature ◽  
Deformation Pattern ◽  
Fe Model ◽  
Inertia Friction Welding ◽  
Conservation Of Energy ◽  
True Shape

In this paper, numerical modeling of inertia friction welding (IFW) for Inconel718 was performed using ABAQUS/Explicit with a 3D finite-element (FE) model and the coupled thermo-mechanical analysis. A new thermal input model has been deduced according to the characteristics of IFW and law of conservation of energy. The evolution of temperature field as well as the deformation pattern of the inertia welded joint has been predicted. It is shown that the interface temperature firstly increases rapidly to about 1100 °C within 3 s and then increases slowly. The energy input rate at the interface during the IFW process is closely related to the rotational speed and friction torque of flywheels. The temperature distribution at the interface is very inhomogeneous especially at the initial stage and finally tends to become uniform with the increase of time. Consequently, the flash start to appear as the interface temperature becomes homogeneous relatively and the plastic flow of metal at the interface happens. The verifying trial was carried out and the predicted temperature was compared with the experimental data measured by means of thermocouples. The shape of flash in simulation result was contrasted with the true shape of specimen under the same welding conditions. It is noted that the simulation results agrees well with the experimental results.

Finite Element Simulation of Microstructural Evolution during Inertia Friction Welding Process of Superalloy GH4169

2011 ◽  
Vol 675-677 ◽  
pp. 975-978
Author(s):  
Wei Xu ◽  
Li Wen Zhang ◽  
Chong Xiang Yue
Keyword(s):  
Grain Size ◽  
Finite Element ◽  
Microstructural Evolution ◽  
Friction Welding ◽  
Weld Line ◽  
Welding Process ◽  
Equivalent Strain ◽  
Fe Model ◽  
Inertia Friction Welding ◽  
Element Simulation

During the inertia friction welding (IFW) process of superalloy GH4169, the main mechanism for microstructural evolution is dynamic recrystallization (DRX). In order to investigate the microstructural evolution during the process, a finite element (FE) model coupled with the DRX model of the alloy was developed on the platform of MSC.Marc. Equivalent strain was introduced into the DRX model to improve the computational precision. As a result, the IFW process with microstructural evolution was simulated. Simulated results reveal that DRX region is very small. Fully recrystallized region and fine grains appear near the weld line. Dynamically recrystallized fraction (DRXF) decreases and grain size increases with the increase of the distance from the weld line. Predicted results of microstructural distribution agree well with experimental ones.

Efficiency of the Inertia Friction Welding Process and Its Dependence on Process Parameters

2017 ◽  
Vol 48 (7) ◽  
pp. 3328-3342 ◽  
Author(s):  
O. N. Senkov ◽  
D. W. Mahaffey ◽  
D. J. Tung ◽  
W. Zhang ◽  
S. L. Semiatin
Keyword(s):  
Process Parameters ◽  
Friction Welding ◽  
Welding Process ◽  
Inertia Friction Welding

Application of Optimal Control Algorithm to Inertia Friction Welding Process

2013 ◽  
Vol 21 (3) ◽  
pp. 891-898 ◽  
Author(s):  
Johannes Lohe ◽  
Marc Lotz ◽  
Mark Cannon ◽  
Basil Kouvaritakis
Keyword(s):  
Optimal Control ◽  
Friction Welding ◽  
Control Algorithm ◽  
Welding Process ◽  
Inertia Friction Welding

226 Thermo-mechanical simulation of inertia friction welding process

2015 ◽  
Vol 2015.28 (0) ◽  
pp. _226-1_-_226-2_
Author(s):  
Yuta KITAMURA ◽  
Mitsuyoshi TSUNORI ◽  
Shinji MAEKAWA
Keyword(s):  
Friction Welding ◽  
Welding Process ◽  
Inertia Friction Welding ◽  
Mechanical Simulation

Sequential Transient Numerical Simulation of Inertia Friction Welding Process

2008 ◽  
Author(s):  
Medhat Awad El-Hadek ◽  
Mohammad S. Davoud
Keyword(s):  
Temperature Distribution ◽  
Residual Stresses ◽  
Friction Welding ◽  
Welding Process ◽  
Transient Temperature ◽  
Inertia Friction Welding ◽  
Residual Stress Field ◽  
Element Analysis ◽  
Full Field ◽  
Welding Processes

Inertia friction welding processes often generate substantial residual stresses due to the heterogeneous temperature distribution during the welding process. The residual stresses which are the results of incompatible elastic and plastic deformations in weldment will alter the performance of welded structures. In this study, three-dimensional (3D) finite element analysis has been performed to analyze the coupled thermo-mechanical problem of inertia friction welding of a hollow cylinder. The analyses include the effect of conduction and convection heat transfer in conjunction with the angular velocity and the thrust pressure. The results include joint deformation and a full-field view of the residual stress field and the transient temperature distribution field in the weldment. The shape of deformation matches the experimental results reported in the literature. The residual stresses in the heat-affected zone have a high magnitude but comparatively are smaller than the yield strength of the material.

scholarly journals Friction welding of Aluminium Alloy 6063 with copper

2020 ◽  
Vol 170 ◽  
pp. 02004
Author(s):  
Yashwant Chapke ◽  
Dinesh Kamble ◽  
Saoud Md. Salim Shaikh
Keyword(s):  
Aluminum Alloy ◽  
Process Parameters ◽  
Weld Joint ◽  
Friction Welding ◽  
Joint Strength ◽  
Welded Joint ◽  
Welding Process ◽  
Dissimilar Material ◽  
Work Piece ◽  
Electrical Conductors

Friction welding process is a forging welding process in which work piece are joined due to heat produced by friction between two joining surfaces and upset pressure is applied by non-rotating work piece. Joining of aluminum alloy with dissimilar material is important research area to focus on as maximum aircraft structures havexx Aluminum alloy frame and aerospace designers familiar with Aluminum alloy and its design considerations. After comparison of mechanical properties and application of light weight alloys aluminum alloys, tungsten, stainless steel and copper, copper selected as dissimilar material to join with Aluminum alloy AA6063. AA 6063 also known as architectural alloy selected based upon its properties. This dissimilar joint of AA6063 and Copper has application in electrical conductors as copper is good electrical conductivity and used in maximum electrical conductors. In this research work AA6063 joined with Copper successfully using Rotary Friction Welding process. Through process study effective process parameters like Friction Pressure, Upset Pressure, Spindle Speed, and Friction Time identified and their effect on weld joint strength were studied.Testing for measuring UTS of friction welded joint conducted. Using DOE tool optimized set process parameters for friction welding identified and their effect on weld joint strength studied experimentally. Maximum UTS of 222.787 MPa for Friction welded joint achieved, bend test also performed on friction welded samples.

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