Abstract
Friction Stir Spot Welding (FSSW) is a highly complex joining process, coupling multiple physical phenomena. The thermo-mechanisms taking place during welding are very complex and still not thoroughly elucidated. The investigation of the mechanisms, involved in the weld zone, by experimental means is a very difficult task. Therefore the use of numerical simulation methods is highly required. Since 1996, various Finite Element modeling techniques have been developed for simulating friction stir welding (FSW). It is now well known that one of the most challenging issues in the FE-modeling is the large strains that take place during the process, inducing excessive mesh distortions and hindering convergent solutions. Arbitrary Lagrangian-Eulerian (ALE) and Coupled Eulerian-Lagrangian (CEL) methods are being implemented in FE codes to handle the difficulties in simulating the extremely large deformations. However, each one of these approaches has pros and cons. This paper aims to compare the accuracy and the efficiency of the aforementioned methods in the three dimensional numerical simulation of the FSSW of an AA6082-T6 aluminum alloy using ABAQUS®/Explicit. The computational cost of each model and the temperature distribution results were discussed. Based on these results, some useful guidelines for selecting the most suitable FSSW simulation technique were presented.
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Hannachi, N., Khalfallah, A., Leitão, C., Rodrigues, D.M. (2022). Comparison Between ALE and CEL Finite Element Formulations to Simulate Friction Stir Spot Welding. In: Bouraoui, T., et al. Advances in Mechanical Engineering and Mechanics II. CoTuMe 2021. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-030-86446-0_36
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