CFD Modelling of Temperature Distribution and Material Flow Investigation During FSW of DH36 Shipbuilding Grade Steel
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ORIGINAL ARTICLE
CFD Modelling of Temperature Distribution and Material Flow Investigation During FSW of DH36 Shipbuilding Grade Steel Avinish Tiwari1
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Pardeep Pankaj1 • Saurav Suman1 • Pankaj Biswas1
Received: 26 March 2020 / Accepted: 21 June 2020 The Indian Institute of Metals - IIM 2020
Abstract A modified heat transfer and material transfer model was investigated for friction stir welding of DH36 steel by considering the Eulerian framework in steady state. During this analysis, temperature-dependent properties of the workpiece and the tool material were used. The material viscosity was modelled as a non-Newtonian viscoplastic fluid depending on the temperature and flow stress. The heat generation at the tool workpiece interface incorporated the partial sticking and partial sliding condition. An asymmetric and skewed temperature distribution at the advancing trailing side was observed. Asymmetry of temperature distribution was increased with an increase in the tool traverse speed. It was observed that the temperature was maximum at the interface between the shoulder and tool, and the peak temperatures decreased non-uniformly along the thickness direction. The results of material flow analysis indicated that the hot plasticized material flew ahead the tool along the retreating side in counterclockwise direction, passed the tool and got released behind the tool during the welding stage. There existed a swirl region on the advancing side which was highly prone to defect formation. The temperature field and plastic flow
& Avinish Tiwari [email protected] Pardeep Pankaj [email protected] Saurav Suman [email protected] Pankaj Biswas [email protected] 1
Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Guwahati, Assam 781039, India
field of the computational model matched satisfactorily with the experiment results. Keywords CFD DH36 steel WC tool Thermal history Material flow Mechanical properties
1 Introduction The friction stir welding (FSW) process is highly complex in nature due to its nonlinear coupled behavior of the physics involved. Complex physical interaction occurs simultaneously during FSW process, including the thermal, mechanical and coupled interactions. Heat flow and material flow during FSW process depend on the thermophysical properties of the workpiece material, the tool material, tool workpiece contact condition and the welding condition. The interactions between the materials, affect the weld thermal (heating and cooling) cycles, flow analysis, and the quality characteristics of the friction stir welded joints. From the beginning, the FSW technique has been extensively investigated by numerical techniques and the experimental characterization to optimize the process window and weld quality [1–5]. Numerical simulations can ease the more in-depth understanding of the complex physics involved during the FSW process. Several attempts were made previously to establish numerical models based on the coupled nature of the process [6–9].
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