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MpCCI在焊接模拟中的应用

Application of MpCCI in welding simulations

Tom de Vuyst, Vinay Madhavan – Cenaero, Tom van Eekelen – Samtech S.A.

at MpCCI UF 2009

Currently most numerical models for the calculation of residual stresses or metallurgy in FSW rely on the measurement of the heat source to be imposed as input data into the numerical model. This means that these models are not predictive. This report discusses a numerical model which does not require a calibrated heat source for the calculation of residual stresses after FSW. Instead a local-global modelling approach is used. The calibrated heat source is replaced by the amount of generated heat predicted using a thermo-fluid simulation.

This predicted amount of heat is then transferred to the thermo-mechanical model, to calculate the residual stresses. The local thermo-fluid model has been developed in the Morfeo finite element code. The model uses the assumption of a steady-state Stokes flow with a Norton-Hoff constitutive law. Furthermore, it is also assumed that a sticking contact between the tool and workpiece material exists. The heat loss into the tool and backing plate are accounted for by explicitly modelling these components. The global thermo-mechanical model has been created in the SAMCEF finite element code. The exchange of data between the two codes was performed using the MpCCI library. The thermo-mechanical model takes into account workpiece, tool and backplate. A temperature dependent elasto-plastic law was used, and the contact workpiece-backplate and tool workpiece was taken into account.

The modelling approach was tested for by modelling FSW of 1.6mm thick AA2024-T3 and AA 2198 T8 sheets. Instrumented welds were performed using an ESAB FSW machine in order to measure thermal cycles, residual stresses and to evaluate the distortion of the sheets. The experimental data gained from these tests were compared to the modelling results. This work was carried out in the framework of the European Specific Targeted Research Project DEEPWELD.




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