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Calibration of 3D ALE finite element model from experiments on friction stir welding of lap joints

Abstract : In order to support the design of such a complex process like Friction Stir Welding (FSW) for the aeronautic industry, numerical simulation software requires (1) developing an efficient and accurate Finite Element (F.E.) formulation that allows predicting welding defects, (2) properly modeling the thermo-mechanical complexity of the FSW process and (3) calibrating the F.E. model from accurate measurements from FSW experiments. This work uses a parallel ALE formulation developed in the Forge® F.E. code to model the different possible defects (flashes and worm holes), while pin and shoulder threads are modeled by a new friction law at the tool / material interface. FSW experiments require using a complex tool with scroll on shoulder, which is instrumented for providing sensitive thermal data close to the joint. Calibration of unknown material thermal coefficients, constitutive equations parameters and friction model from measured forces, torques and temperatures is carried out using two F.E. models, Eulerian and ALE, to reach a satisfactory agreement assessed by the proper sensitivity of the simulation to process parameters.
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https://hal-mines-paristech.archives-ouvertes.fr/hal-01414675
Contributor : Magalie Prudon <>
Submitted on : Monday, December 12, 2016 - 2:50:28 PM
Last modification on : Thursday, September 24, 2020 - 5:22:56 PM

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Lionel Fourment, Sabrina Gastebois, Laurent Dubourg. Calibration of 3D ALE finite element model from experiments on friction stir welding of lap joints . ESAFORM 2016, Apr 2016, Nantes, France. pp.100006, ⟨10.1063/1.4963500⟩. ⟨hal-01414675⟩

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