Numerical simulation of plastic deformation in direct-drive friction welding of AISI 4140 and ASTM A106 steel tubes
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ORIGINAL ARTICLE
Numerical simulation of plastic deformation in direct‑drive friction welding of AISI 4140 and ASTM A106 steel tubes J. Hashemi Khosrowshahi1 · M. H. Sadeghi1 · A. Rasti1 Received: 8 April 2020 / Revised: 10 August 2020 / Accepted: 31 August 2020 © Wroclaw University of Science and Technology 2020
Abstract Direct-drive friction welding of ASTM A106 and AISI 4140 steel tubes has been investigated both experimentally and numerically. A remeshing technique was implemented to accurately simulate highly distorted flashes during the FE simulation. The results revealed that the circumferential thermal expansion led to a higher contact pressure at the inner diameter of the interface and consequently, inner flashes were formed up to 18% larger than the outer ones. The maximum temperature was also located at the outer diameter of the interface in the first moments of the process, then it moved towards the center of the section where there was a balance between the higher slipping rate at the outer section and greater pressure at the inner section of the joint. Validation tests showed the capability of the FE model in terms of temperature, flash cross-section, and axial shortening with the maximum difference of 18.6%. Graphic abstract
Keywords Rotary friction welding · Dissimilar joint · Finite element · Banded structure · Plastic deformation
1 Introduction * M. H. Sadeghi [email protected]; [email protected] 1
Department of Mechanical Engineering, Tarbiat Modares University, Tehran, Iran
Rotary friction welding is a solid-state welding process in which the required heat for welding is obtained by converting the mechanical energy into heat at the interface due to
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rubbing surfaces. Rising in temperature in conjunction with an applied axial load consolidates the joint between materials. Applying the axial pressure causes some material to flow out of the welding interface leading to the formation of flashes. During the friction welding, since the components do not experience melting, the conventional fusion welding defects like porosity, lack of penetration, slag inclusions, etc. do not appear. In addition, due to the lower temperature gradients, narrower heat-affected zone (HAZ) is formed and lower distortion is achieved. Another advantage of the process has to do with the small number of welding parameters, which makes it both repeatable and easy-to-use. These advantages make the rotary friction welding an attractive method for fabricating axisymmetric components and dissimilar materials such as axles of vehicles, bi-material poppet valves, shafts of turbochargers and drilling rods, to name but a few. The rotary friction welding categorized into two methods, namely the inertia friction welding and direct-drive friction welding. In inertia friction welding, the initial speed of the spindle is obtained from a rotating flywheel. First, a drive unit accelerates the flywheel to a specified rotational speed. Once the flywheel is disengage
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