An efficient coupled Eulerian-Lagrangian finite element model for friction stir processing
An efficient coupled Eulerian-Lagrangian finite element model for friction stir processing
复制标题
DOI：
10.1007/s00170-018-3000-z
复制
发表时间：
2019-04-01
影响因子：
3.4
通讯作者：
Ding, Hongtao
中科院分区：
文献类型：
--
作者：
Ansari, Mohammad Ali;Samanta, Avik;Ding, Hongtao
搅拌摩擦加工(FSP)是一种以搅拌摩擦为基础的材料加工方法，目的是改善材料的微观组织和表面性能。由于FSP是一个多物理问题，加上严重的塑性变形、材料流动、热流和组织演变，FSP过程的建模可能非常复杂和具有挑战性。关于FSP材料改性的建模和仿真研究报道较少。在本研究中，基于耦合欧拉-拉格朗日(CEL)公式，利用ABAQUS/EXPLICIT开发了一个计算效率高的过程模型来模拟5083铝合金的FSP过程。三维(3D)有限元模型模拟了FSP的整个过程，包括刀具的下沉、驻留和搅拌阶段。对FSP加工过程中刀具转速和刀销轮廓的影响进行了仿真研究。并与现有的搅拌摩擦焊接模型进行了比较，评价了该模型的计算效率。为验证模型，进行了FSP实验，测量了过程作用力和温度。研究表明，CEL模型是模拟复杂过程力学和优化FSP工艺参数的强有力的数值工具，可用于工业应用。
Friction stir processing (FSP) is a friction stir-based material processing method for enhancement of material microstructural and surface properties. As FSP is a multi-physics problem coupled with severe plastic deformation, material flow, heat flow, and microstructure evolution, modeling of the FSP process can be very complicated and challenging. Few research work has been reported on modeling and simulations of FSP for material modification. In this study, a computation-efficient process model is developed using ABAQUS/Explicit based on coupled Eulerian-Lagrangian (CEL) formulation to simulate FSP of aluminum alloy 5083. The three-dimensional (3D) finite element model simulates the entire process of FSP including tool plunging, dwelling, and stirring phases. Simulations are performed to evaluate the effects of tool-rotational speed and tool pin profile during the FSP process. The computational efficiency of the developed model is also evaluated in comparison with other existing models for friction stir-welding processes. FSP experiment is performed with measurements of process force and temperature for model validation. This study shows that the CEL model can be a powerful numerical tool to simulate the complex process mechanics and optimize the FSP process parameters for industrial applications.