Numerical analysis of high-speed water jet spot welding using the arbitrary Lagrangian-Eulerian (ALE) method
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ORIGINAL ARTICLE
Numerical analysis of high-speed water jet spot welding using the arbitrary Lagrangian-Eulerian (ALE) method Mohammad Ali Ansari 1 & Reza Abdi Behnagh 2
&
Alberto Salvadori 3
Received: 7 July 2020 / Accepted: 4 November 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract The high-speed water jet is used for different manufacturing processes such as cutting, shot peening, cleaning, machining, and spot welding. As water jet spot welding is a concise time welding process, numerical analysis can optimize it and examine the effect of input parameters on plastic deformation and stress distribution that would be difficult to measure experimentally. In this study, the entire water jet spot welding process of aluminum HS30 is modeled through ABAQUS/EXPLICIT based on an arbitrary Lagrangian-Eulerian (ALE) formulation which helps to alleviate many of the traditional Lagrangian-based implementation drawbacks. Three-dimensional (3D) models are used to evaluate the effect of water jet velocity, flyer stand-off distance (SD), and flyer thicknesses during the process. The weld’s quality in terms of failure or success is also investigated by using stress and strain measures. Numerical analysis of influence factors can be a promising avenue to avoid high-cost post-production inspection, which is intended for mass production. Keywords Spot welding . Water jet . Aluminum alloy . Finite element simulation . Arbitrary Lagrangian-Eulerian
1 Introduction Water jet technology takes advantage of the high-speed jet system as a potential manufacturing technique, applied in different processes. Water jet applications have expanded in the aerospace, automotive industries, mining, construction industries, or even food processing. In the automotive and aerospace industries, the water jet is applied for spot welding, punching, cutting, peening, cleaning, deburring, and even tubes and sheet rapid forming of various materials [1–5]. In all applications, the converging nozzle is a popular way to produce high-speed water jet up to 4000 m/s. For all the water jet processes, generally, three stages can be identified. In the beginning, the energy is induced by raising the liquid pressure,
* Reza Abdi Behnagh [email protected] 1
Department of Mechanical Engineering, University of Wisconsin-Madison, Madison, USA
2
Faculty of Mechanical Engineering, Urmia University of Technology, The 2nd kilometer of Band Road, Urmia, Iran
3
Dipartimento di Ingegneria Meccanica e Industriale (DIMI), Universita` di Brescia, Brescia, Italy
while the high-speed liquid jet is generated through the orifice afterward. Eventually, the interaction of the high-speed water jet and target surface releases the kinematic energy of the water jet [6, 7]. The high-speed impact of the liquid against the solid may damage the structure surface and induce highstress fields in the solid bulk. Therefore, understanding the mechanism of the high-speed water jet impact as well as modeling the effects of liquid transient pressure on the soli
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