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In the present work, a numerical model, based on the smoothed particle hydrodynamics method (SPH), is developed to simulate Friction Stir Welding process (FSW). This model considers a non Newtonian fluid near the tool region using a thermo-mechanical constitutive law. We limit ourselves to bi-dimensional problems. A comparison with an industrial CF...
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... order to validate the numerical results of the SPH approach, we propose to perform the same computation by using Fluent software. This code is based on an Eulerian formulation and a finite volume discretization. Thus, two equivalent configurations between the Lagrangian and Eulerian formulations have been considered (see figures 1 and 4). The SPH calculation is performed until the tool reaches the plate center. This tool position corresponds to the time t = 9s. In the Eulerian formulation, unsteady calculation with the same time t is also performed. The two calculations use the same constitutive law (equation 17). Figures 7 and 8 show the comparison between SPH and Fluent for the temperature evolutions along the horizontal and vertical cut views (see figure 6). It can be observed that a relative error of at least 5% is obtained confirming the relevance of the proposed ...
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Citations
... This is owing to large material deformations that occur during the FSW process and which are not easy to model using grid-based techniques. Hence non-grid based meshless techniques have been proposed [11,9,12]. Smoothed particle hydrodynamics (SPH) is most popular among the meshless techniques. SPH was initially proposed for astrophyical problems but was soon adapted to handle problems in projectile impact, fluid flow etc in processes involving large and rapid material deformation [13]. ...
... Heat generation model. Following literature [10,11], the heat generation is modeled as arising from viscous dissipation: ...
... m j is the mass of the j th node and l i ; l j are material viscosities at the i th and j th nodes resp. The fuller details of the source term and the temperature evolution may be obtained from Eqs. 15 and 16 of [11]. However, our heat generation model is certainly an oversimplification of the actual heat generation in FSW where three tool-workpiece interfaces, viz at the tool shoulder, the lateral surface of the pin and the bottom face of the pin need to be considered [20]. ...
... The authors looked at the stress field but focused little attention on the thermal heat production and softening events throughout the process. Timesli et al. [25] later modelled a 2D SPH for the FSW process, although they did not empirically test their model. To ascertain how the FSP process factors influenced peak temperatures, Meyghani et al. [26] examined the SPH and ALE together. ...
A thermo-mechanical model of friction stir processing (FSP) using the Altair based on meshless Smoothed-Particle Hydrodynamics (SPH) was developed and verified experimentally. Process parameters adopted for both experimentation and simulation during the FSP of AZ91 were 1000 rpm tool stirring speed, 40 mm/min tool advancing speed, and 0° tool tilt angle. The numerical analysis predicted the temperature distribution and material movement in the three phases: plunging , dwelling, and traversing. Simulated temperatures during the traversal phase were found to be greater than experimental temperatures using the Ti32 thermal camera as the heat was only transported by friction and plastic deformation. Peak temperatures for all three phases were observed to be in the range of 47% to 87% of the material's melting point and are in accordance with the findings of the experiments. The SPH mesh-free model was proven to be capable of predicting the in-process thermal-mechanical state variables during and after the process by extracting morphology. The material movement around the tool has been predicted using SPH node tracking, which further anticipates that there was no complete flow of SPH nodes from RS to AS, leaving a gap that must be filled. Post-processed morphology shows inadequacy in the material flow due to lower compressive force. It formed the wormhole at the advancing side's trailing and was verified experimentally.
... Although the stress field was investigated in this study, heat generation and thermal softening of the process was not considered. The two-dimensional SPH model to simulate the FSW process was implemented by Timesli et al. [15]. Although they did not validate their model experimentally, they have presented their output results with the equivalent CFD model in terms of stress and strain rate. ...
... La méthode SPH a également été appliquée pour quelques procédés industriels faisant L cernant un procédé industriel [147,148], depuis plusieurs études sont venues enrichir ce sujet [149][150][151][152]. 55 L observer le remplissage de la cavité par le métal en fusion ainsi que sa solidification. Plus récemment, des recherches ont été également menées sur le forgeage des métaux [150,153] ainsi que sur le procédé de soudage par friction et malaxage (FSW) [154,155]. ...
Reactive rotational molding is a process to manufacture hollow plastic parts where synthesis occurs during the shaping. This method has several advantages compared to traditional rotomolding using thermoplastic powders: shorter cycle time, possible use of high performance materials, and decrease of energy consumption and raw materials costs. However reactive rotational molding is more complex to implement mainly because of the important and quick change of viscosity occurring during polymerization. One of the solutions to optimize this process is to simulate the reactive system flow during processing.In this work we used thermoset polyurethane as reactive system. Thanks to thermal and rheological analysis, gelation and vitrification phenomena were studied and Time-Temperature-Transformation diagram was established. Material chemiorheological behavior was also modeled.The process has been simulated using a solver based on Smoothed Particle Hydrodynamics (SPH) method. This solver was developed in our research team and several improvements have been added during this study. To be able to simulate realistic flows with a high number of particles, the first improvement was to accelerate the resolution of calculations. Then the change of viscosity has been taken into account using a chemiorheological model and a new boundary condition was developed to simulate adhesion of polymer on the mold wall. To be able to simulate 3D flows, the needed modifications have been also added to the SPH solver.
