Numerical simulation of friction welding processes: An arbitrary Lagrangian-Eulerian approach

Hamed, Maien Mohamed Osman

Numerical simulation of friction welding processes: An arbitrary Lagrangian-Eulerian approach

Doctoral Thesis

2022

Abstract

The development and implementation of a finite strain thermo-viscoplasticity solver with thermomechanical friction contact for numerical simulation of friction welding processes are described. A finite strain associative coupled thermoplasticity model is used, which is suited for the large deformations characteristic of friction welding processes, and which resolves the viscoplastic deformations in the thermomechanically affected zone as well as the elastic stresses in the parent material. To prevent the large deformations from causing large distortions and degrading the simulation accuracy, an arbitrary Lagrangian Eulerian (ALE) formulation for coupled finite strain thermoplasticity is developed and incorporated into the solver, in which the motion of the reference configuration is represented incrementally in terms of a reference velocity field. Thus, the deformation from the material configuration is required neither explicitly in terms of a deformation field, nor implicitly in terms of the deformation gradient. The solver is implemented using the deal. II library and programmed for distributed memory parallel computing architectures, which reduces simulation run times and enables simulations with larger meshes than would fit on a single computer. The interprocess communications required in such a distributed memory parallel implementation of the ALE formulation and the thermomechanical friction contact are described and implemented. The axisymmetric solver implementation is validated with benchmark problems and used to simulate a direct drive friction welding process.

Keywords

Mechanical Engineering

Reference:

Collections

PhD / Doctoral

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