Sayed Ali
Laser forming simulation tutorial in Abaqus
The laser forming process is performed by applying thermal stresses to the workpiece surface by heating the surface with a laser beam. These internal stresses induce plastic strains in the part resulting in local elastic-plastic deformation (Laser-induced plastic deformation). In this laser forming simulation tutorial the DFLUX subroutine is used to apply heat flux (Gaussian heat distribution) dependent on location and time in finite element simulation. For example, the linear heating processes of laser forming and welding (with a slight simplification) can be simulated by this subroutine. In the linear heating process, by applying heat flux to the surface of a sheet, a thermal gradient is created in its thickness. This thermal gradient causes permanent deformation of the sheet. To simulate the laser forming process, it is necessary to apply a time and location-dependent heat flux to the sheet. In this type of loading, a heat flux is applied on the plate, which is defined using the DFLUX subroutine, including the laser power, movement speed, beam diameter, absorption coefficient, and laser movement path according to the designed experiments (Laser forming process parameters). To verify this Abaqus laser forming simulation, the simulation results and experimental results of sheet deformation (U) are compared. The displacement of the sheet in the simulation is in good agreement with the experimental results.
Friction Stir Welding simulation Tutorial | FSW Advanced level
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.
