Thermo-Mechanical-Fluid Fully Coupled Simulation of Friction Stir Welding Process:Comparison of Simulation Results with Different Constitutive Models

LIU Xin; SHI Qingyu; LU Baokun; MIN Aiwu; QIAO Junnan; YANG Chengle; CHEN Gaoqiang

doi:10.7512/j.issn.1001-2303.2024.08.03

Welding Virtual Simulation | Views : 0 下载量: 3 CSCD: 0

PDF
Export
Share
Collection
Album

Thermo-Mechanical-Fluid Fully Coupled Simulation of Friction Stir Welding Process:Comparison of Simulation Results with Different Constitutive Models
Vol. 54, Issue 8, Pages: 20-28(2024)
Published： 25 August 2024 ，
DOI： 10.7512/j.issn.1001-2303.2024.08.03
稿件说明：

扫描看全文

刘新，史清宇，路宝坤，等.搅拌摩擦焊过程热-力-流全耦合仿真：不同本构方程的仿真效果对比［J］.电焊机，2024，54（8）：20-28.

LIU Xin, SHI Qingyu, LU Baokun, et al.Thermo-Mechanical-Fluid Fully Coupled Simulation of Friction Stir Welding Process:Comparison of Simulation Results with Different Constitutive Models[J].Electric Welding Machine, 2024, 54(8): 20-28.
刘新，史清宇，路宝坤，等.搅拌摩擦焊过程热-力-流全耦合仿真：不同本构方程的仿真效果对比［J］.电焊机，2024，54（8）：20-28. DOI： 10.7512/j.issn.1001-2303.2024.08.03.

LIU Xin, SHI Qingyu, LU Baokun, et al.Thermo-Mechanical-Fluid Fully Coupled Simulation of Friction Stir Welding Process:Comparison of Simulation Results with Different Constitutive Models[J].Electric Welding Machine, 2024, 54(8): 20-28. DOI： 10.7512/j.issn.1001-2303.2024.08.03.

摘要

本构方程是搅拌摩擦焊过程热-力-流全耦合仿真模型的重要部分。针对6 mm铝合金6061-T6板材FSW过程开展热-力-流全耦合仿真分析。为分析本构方程的形式对仿真效果的影响，在模型中分别采用Chen-Liu本构模型、Sellars-Tegart模型和Johnson-Cook模型，并对仿真结果进行对比分析。仿真结果表明，Chen-Liu模型计算得到的FSW温度场及流动场与实验结果的吻合程度均高于Sellars-Tegart模型和Johnson-Cook模型。究其原因，在搅拌头-工件界面附近的温度条件下，Sellars-Tegart模型和Johnson-Cook模型预测的流变应力较高，使得材料流动困难，搅拌头与工件之间的界面状态主要为滑动摩擦。相比之下，Chen-Liu模型能够体现材料在温度升高时的迅速软化现象，在搅拌头-工件界面附近的温度条件下，材料的剪切流变应力低于搅拌头/工件界面的摩擦应力，因而在摩擦作用下工件发生塑性流动，这降低了搅拌头/工件之间的滑动摩擦速度，从而使得滑动摩擦产热减少，且其减少量大于工件发生塑性流动产生的额外热量，从而使得采用Chen-Liu模型预测得到的焊接温度更低。综合来看，FSW过程温度场与材料流动速度场受材料本构模型影响归因于FSW的热-力-流全耦合效应。

Abstract

The constitutive equation is a crucial component of the fully coupled thermal-mechanical-flow simulation model for the friction stir welding (FSW) process. This paper conducts a fully coupled thermal-mechanical-flow simulation analysis of the FSW process for 6mm thick aluminum alloy 6061-T6 plates. To analyze the impact of the form of the constitutive equation on the simulation results

the Chen-Liu constitutive model

the Sellars-Tegart model

and the Johnson-Cook model were used in the simulation

and their results were compared. The simulation results show that the FSW temperature field and flow field calculated by the Chen-Liu model aligned more closely with experimental results than those calculated by the Sellars-Tegart model and the Johnson-Cook model. The reason was that under the temperature conditions near the tool-workpiece interface

the Sellars-Tegart model and the Johnson-Cook model predicted higher flow stresses

making material flow difficult. As a result

the interface state between the tool and the workpiece was primarily sliding friction. In contrast

the Chen-Liu model accurately reflected the rapid softening of the material as the temperature increases. Under the temperature conditions near the tool-workpiece interface

the shear flow stress of the material was lower than the friction stress at the tool/workpiece interface. Consequently

the workpiece undergoes plastic flow due to friction

reducing the sliding friction speed between the tool and the workpiece. This reduction in sliding friction heat generation was greater than the additional heat generated by the plastic flow of the workpiece

resulting in a lower predicted welding temperature using the Chen-Liu model. Overall

the influence of the material constitutive model on the FSW process's temperature field and material flow velocity field is due to the fully coupled thermal-mechanical-flow effects of FSW.

关键词

搅拌摩擦焊数值仿真本构模型温度场材料流动

Keywords

Friction stir weldingNumerical SimulationConstitutive ModelsTemperature FieldMaterial Flow

references

Geng P，Qin G，Zhou J，et al. Hot deformation behavior and constitutive model of GH4169 superalloy for linear friction welding process［J］. J. Manuf. Process.，2018，32：469-481.

Jin F，Li J，Du Y，et al. Numerical simulation based upon friction coefficient model on thermo-mechanical coupling in rotary friction welding corresponding with corona-bond evolution［J］. J. Manuf. Process.，2019， 45：595-602.

Sonne M R，Hattel J H. Thermomechanical Modelling of Direct-Drive Friction Welding Applying a Thermal Pseudo Mechanical Model for the Generation of Heat. Key Eng［J］. Key Eng. Mater.，2018，767：343-350.

Yang X，Li W，Ma J，et al. Thermo-physical simulation of the compression testing for constitutive modeling of GH4169 superalloy during linear friction welding［J］. J. Alloys Compd.，2016， 656：395-407.

Wu H Y，Yang J C，Zhu F J，et al.Hot compressive flow stress modeling of homogenized AZ61 Mg alloy using strain-dependent constitutive equations［J］. Materials Science and Engineering： A，2013，574：17-24.

Lin Y C，Chen X M，Wen D X，et al.A physically-based constitutive model for a typical nickel-based superalloy［J］. Computational Materials Science，2014，83：282-289.

Han Y，Qiao G，Sun J，et al. A comparative study on constitutive relationship of as-cast 904L austenitic stainless steel during hot deformation based on Arrhenius-type and artificial neural network models［J］. Computational Materials Science，2013，67：93-103.

Sellars C，McTegart W. On the mechanism of hot deformation［J］. Acta Metall.，1966，14：1136-1138.

Johnson G R，Cook W K. A Constitutive Model and Data for Metals Subjected to Large Strains， High Strain Rates and High Temperature［C］// In Proceedings of the 7th International Symposium on Ballistics， Hague， the Netherlands，1983：19-21.

Geng P，Ma Y，Ma N，et al. Effects of rotation tool-induced heat and material flow behaviour on friction stir lapped Al/steel joint formation and resultant microstructure［J］. International Journal of Machine Tools & Manufacture，2022，174：103858.

Zhai M，Wu C，Shi L. Numerical simulation of friction stir lap welding of Al-to-Mg alloys under different lap conFig.urations and pin lengths［J］. Journal of Materials Research and Technology，2022，20：2889-2904.

Shi L，Chen J，Yang C，et al.Thermal-fluid-structure coupling analysis of void defect in friction stir welding［J］.International Journal of Mechanical Sciences，2023， 241：107969.

Chen G，Shi Q，Li Y，et al. Computational fluid dynamics studies on heat generation during friction stir welding of aluminum alloy［J］. Computational Materials Science，2013，79：540-546.

Yang C，Chen G，Qiao J，et al. Material flow during dissimilar friction stir welding of Al/Mg alloys［J］. International Journal of Mechanical Sciences，2024，272：109173.

Qiao J，Shi Q，Chen S，et al. Visualization of vertical transfer of material through high-velocity rotating flow zone during friction stir welding［J］. Materials Letters，2024，367：139566.

Qiao J，Shi Q，Wu C，et al. Elucidation of solid-state metal flow behaviors during friction stir welding： Numerical and experimental investigation［J］. Physics of Fluids，2023，35（12）：123105.

MILLS K C. Recommended values of thermophysical properties for selected commercial alloys［M］. Woodhead Publishing，2002.

Chen G，Feng Z，Zhu Y，et al. An alternative frictional boundary condition for computational fluid dynamics simulation of friction stir welding［J］. Journal of Materials Engineering and Performance，2016，25（9）：4016-4023.

Chen G，Liu X，Qiao J，et al.Improved Analytical Model for Thermal Softening in Aluminum Alloys Form Room Temperature to Solidus［J］. Materials， 2023， 16（23）：7358.

Alert me when the article has been cited

提交

Overview of application status of flow field simulation in friction stir welding

Heat Transfer and Material Flow in Friciton Stir Lap Welding of Al Alloy/ Steel

Numerical Analysis of Coaxial One-Side Resistance Spot Welding between Al5052 and CFRP

Material Flow and Its Induced Joint Formation of FSLW Process by X-shaped Reverse-threaded Pin