Mechanical Engineering

Friction stir welding (FSW) involves complex material flow and plastic deformation. Welding parameters, tool geometry, etc., have important effects on the material flow pattern, heat distribution, and eventually on the structural evolution of the material. In an Abaqus friction stir welding example, the rotational movement of the tool and its friction in contact with the workpiece causes heat generation, loss of strength, and an increase in material ductility around the tool. The feeding movement of the tool causes the material to transfer from the front of the tool to the back of it, and eventually leads to a join. Therefore, heat plays an important role in this process, and parameters such as rotational speed, tool feeding speed, tool geometry, and others, all somehow have a significant impact on controlling the amount of incoming heat, the disturbance and flow pattern of the material, the evolution of the microstructure, and the quality of the resulted weld. This friction stir welding example simulation tutorial shows you how to simulate the Abaqus FSW simulation process in such a way that you can accurately predict the effect of all relevant parameters on the process. In most of the implemented projects, welding mud, and welding defects (welding overfills and overlaps, weld gaps) are not visible and predictable; however, in this simulation, these cases are visible. This project is designed to enhance participants' understanding of how to accurately simulate the FSW process to see the weld's general appearance.