Thermo-mechanical modelling of the Friction Stir Spot Welding process: Effect of the friction models on the heat generation mechanisms

Friction Stir Spot Welding involves complex physical phenomena, which are very difficult to probe experimentally. In this regard, the numerical simulation may play a key role to gain insight into this complex thermo-mechanical process. It is often used to mimic specific experimental conditions to forecast outputs that may be substantial to analyse and elucidate the mechanisms behind the Friction Stir Spot Welding process. This welding technique uses frictional heat generated by a rotating tool to join materials. The heat generation mechanisms are governed by a combination of sliding and sticking contact conditions. In the numerical simulation, these contact conditions are thoroughly dependent on the used friction model. Hence, a successful prediction of the process relies on the appropriate selection of the contact model and parameters. This work aims to identify the pros and cons of different friction models in modelling combined sliding-sticking conditions. A three-dimensional coupled thermo-mechanical FE model, based on a Coupled Eulerian-Lagrangian formulation, was developed. Different friction models are adopted to simulate the Friction Stir Spot Welding of the AA6082-T6 aluminium alloy. For these friction models, the temperature evolution, the heat generation, and the plastic deformation were analysed and compared with experimental results. It was realized that numerical analysis of Friction Stir Spot Welding can be effective and reliable as long as the interfacial friction characteristics are properly modelled. This approach may be used to guide the contact modelling strategy for the simulation of the Friction Stir Spot Welding process and its derivatives.

A New Approach to Mixed/Boundary Friction Prediction Using the Logistics Curve

There is a strong focus on improving the energy efficiency of machines. Over the last 20-30 years, one way to improve energy efficiency has been to reduce lubricant viscosity. This also has the effect of leading to thinner oil films between the machine’s moving surfaces and is likely to lead to increased mixed/boundary friction. Accurately predicting friction in the mixed/boundary friction regime is therefore becoming of great importance. The work reported here suggests that commonly used asperity friction models significantly underestimate friction in the mixed/boundary friction, and a new model, based on a logistic curve fit, gives a better estimate of mixed/boundary friction, provides good agreement with experimental friction data (from Mini Traction Machine experiments), and is much more straightforward for engineers and tribologists to apply for the estimation of mixed/boundary friction losses.

An Industry First - A Successful Managed Pressure Horizontal Open Hole Gravel Pack Project: Its Preparation, Integration, Modeling, Procedures, and Execution Results

This paper presents how a Controlled Mud Level (CML) Managed Pressure Drilling (MPD) system was used to place Horizontal Open Hole Gravel Packs (HzOHGP) in low Pore Pressure Frac Gradient (PPFG) margin reservoirs. This industry-first accomplishment took extensive preparation and precise on-site coordination between CML and gravel pack operations. In the target reservoirs, the margin between the pore and fracture pressures is too small to place gravel packs using conventional methods. CML was identified as an opportunity to resolve this problem. A primary design phase goal was to develop a deep understanding of the flow paths and fluid properties at every stage of the gravel pack operation. This information is critical to evaluating the frictional pressure drops effecting the pressure in the open hole. The team developed procedures that incorporated step rate tests and real-time downhole measurements to calibrate the friction models, which were then used to precisely control the CML during the pumping jobs. CML was able to limit the downhole treating pressures to stay within the low PPFG limits. The post-job analyses showed that total screen coverage was achieved for all the jobs in the campaign, demonstrating the project team's high level of coordination, cooperation, and cross-discipline understanding. While the industry had adopted CML and HzOHGP systems separately prior to this project, this operation marks the first time they have been combined.

Research on low-speed characteristics of differential double-drive feed system

It is difficult to achieve high-precision control due to frictional nonlinearity by traditional linear control methodology for the classical drive feed system at low speed. Here, the double-drive differential feed system is proposed to reduce the influence of the nonlinear friction at the ball screw pair of a linear feed system operating at low speed. The dynamic models and the LuGre friction models of the classical drive feed system and the double-drive differential feed system are established, respectively. Based on these, the simulation models of the classical drive feed system and the double-drive differential feed system are established in MATLAB to study the critical creeping velocity of the table. Compared with the classical drive feed system, a lower stable velocity can be obtained for the table with the double-drive differential feed system, because the speed of both motors in the double-drive differential feed system is higher than the critical creeping speed of the classical drive feed system screw motor, thereby overcoming the influence of the Stribeck effect and avoiding the frictional nonlinearity at low speed.

Vibration Transmission Characteristics of Periodic Composite Pipeline Considering Friction Coupling Effect

In this paper, transmission characteristic of periodic composite pipeline is investigated for axial vibration, focusing on friction coupling effect. A novel transfer matrix method is developed to calculate band gap structures (BGs) with the consideration of different forms of viscous friction. Frequency response function for finite periods is obtained and shows good consistency with BGs for infinite periods. The energy dissipation caused by viscous friction exists in the entire frequency range, as friction coupling is always distributed along the pipe element. Meanwhile, the attenuation intensity is relatively small compared with that induced by Bragg scattering mechanism. Therefore, viscous friction is not affecting the overall trend of BGs, only exhibiting certain attenuation in pass band frequency range. The effect of kinematic viscous coefficients on axial BGs are systematically examined in different friction models. Attenuation intensity goes up with increasing kinematic viscous coefficients, in addition, energy dissipation caused by frequency dependent friction model is generally higher than that of steady state friction condition. Moreover, frictional dissipation shows more sensitivity to high frequency. The research in this paper enriches fluid structure interaction theory of pipe element, which is also expected to be helpful in controlling the dynamical behaviors of pipeline system conveying fluid.

Assessment of Steady and Unsteady Friction Models in the Draining Processes of Hydraulic Installations

The study of draining processes without admitting air has been conducted using only steady friction formulations in the implementation of governing equations. However, this hydraulic event involves transitions from laminar to turbulent flow, and vice versa, because of the changes in water velocity. In this sense, this research improves the current mathematical model considering unsteady friction models. An experimental facility composed by a 4.36 m long methacrylate pipe was configured, and measurements of air pocket pressure oscillations were recorded. The mathematical model was performed using steady and unsteady friction models. Comparisons between measured and computed air pocket pressure patterns indicated that unsteady friction models slightly improve the results compared to steady friction models.