Numerical analysis of cooling and joining speed effects on friction stir welding by smoothed particle hydrodynamics (SPH
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O R I G I NA L
Behrouz Bagheri · Mahmoud Abbasi · Amin Abdolahzadeh · Amir Hossein Kokabi
Numerical analysis of cooling and joining speed effects on friction stir welding by smoothed particle hydrodynamics (SPH) Received: 26 February 2020 / Accepted: 7 June 2020 © Springer-Verlag GmbH Germany, part of Springer Nature 2020
Abstract This current work considers the utilization of the completely Lagrangian technique, smoothed particle hydrodynamics to improve the 3D finite element model for numerical analysis of the friction stir welding (FSW) in the air and underwater conditions. This technique was primarily applied to simulate fluid motion because of various advantages compared to conventionally grid-based methods. Newly, its usage has been developed to analyze the metal-forming analysis. The temperature history, strain and stress distributions during the FSW process in the air, as well as underwater, were considered. Besides the cooling influence, the effect of traveling speed, friction coefficient, mesh size and the mass scaling technique to find the converged model and decrease the CPU time were studied. The improved model is confirmed by comparing the numerical welding temperature with experimental outcomes. There was close compatibility between finite element analysis and experimental results. The conclusions indicated that the lower peak temperature was achieved due to higher cooling effect in underwater welding in comparison with conventional welding. Moreover, the peak temperature and strain rate decreased as traveling speed increased for both welding conditions, while stress values increased. Keywords Friction stir welding · Underwater · FEM · Mass scaling · Mesh size · Temperature distribution
1 Introduction The friction stir welding (FSW) method is widely enhancing the welding process of option for aluminum alloys. The solid-state method can produce high-fidelity joints at the highest throughput rates. Quite a few researchers [1–6] have studied on analyzing optimization process parameters. They have concentrated on B. Bagheri (B) Department of Mining and Metallurgy, Amirkabir University of Technology, Tehran, Iran E-mail: [email protected]; [email protected] M. Abbasi Faculty of Engineering, University of Kashan, Kashan, Iran A. Abdolahzadeh · A. H. Kokabi Department of Materials Science and Engineering, Sharif University of Technology, Tehran, Iran A. Abdolahzadeh National Elites Foundation of Iran, Tehran, Iran A. Abdolahzadeh Institute of Materials Engineering and Advanced Processes, Department of Mining and Metallurgy, Amirkabir University of Technology, Tehran, Iran
B. Bagheri et al.
optimizing weld strength through experimental results. The common result from these studies has been shown that the rotational and traveling speeds are of great significance to play in the final joint quality. During the FSW, spinning and consequently, a substantial connection will occur between the sheets to joint [7]. The low input heat in friction stir welding does not cause the melting of the parent
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