Welding Simulations Using ABAQUS – A Practical Guide for Engineers

Welding Simulations Using ABAQUS – A Practical Guide for Engineers
Bahman Meyghani, Mokhtar Awang
Contents
1 Introduction to Friction Stir Welding (FSW) , 1
References . 2
2 Thermomechanical Analysis . 5
References . 6
3 Finite Element Modeling of FSW 7
3.1 Different Modelling Methods , . 8
3.1.1 CSM Method , . 8
3.1.2 CFD Method , . 9
3.1.3 Comparison of Governing Equations for CSM
and CFD Methods , 10
3.1.4 Computational Approaches , . 10
References . 11
4 Arbitrary Lagrangian–Eulerian (ALE) Method , . 13
4.1 Geometry and Preprocessor . 13
4.2 Material Property , 17
4.3 Assembly of the Model . 24
4.4 Step Creation . 27
4.5 Interactions , . 31
4.6 Loads and the Boundary Conditions , 43
4.7 Meshing . 46
References . 60
5 Post Processor and Visualization of the Results 63
5.1 Post Processer 63
6 Thermomechanical Simulation of FSW Using User Defined
Subroutine Modeling Technique . 69
6.1 Preparation of the Model , . 69
6.2 Material Property , 69
6.3 Assembly of the Model . 70
xixii Contents
6.4 Simulation Step Creation , . 75
6.5 Interaction Definitions . 79
6.6 Mesh Module . 82
6.7 Loads and Boundary Conditions . 87
6.8 Postprocessor (Thermal Model) . 98
6.9 Mechanical Step , 101
6.10 Loads and Boundary Conditions . 105
6.11 Mesh Module . 107
6.12 Returning to the Step Module in Order to Request the Results 109
6.13 Postprocessor . 109
References .
List of Figures
Fig. 1.1 Schematic view of the FSW process [18] , 2
Fig. 4.1 Comparison between the main domain and the ALE . 14
Fig. 4.2 Creating a new part 14
Fig. 4.3 Creating a rectangle , . 15
Fig. 4.4 Defining rectangle points , . 15
Fig. 4.5 Selecting material thickness . 15
Fig. 4.6 Creating part . 16
Fig. 4.7 Tool dimensions , 17
Fig. 4.8 Revolving the tool . 17
Fig. 4.9 Selecting the tool as a rigid reference . 18
Fig. 4.10 Creating shell 18
Fig. 4.11 Selecting the tool , 18
Fig. 4.12 Approving the selected body 18
Fig. 4.13 Creating the material , . 19
Fig. 4.14 Defining thermal conductivity , . 19
Fig. 4.15 Applying the density , . 20
Fig. 4.16 Defining the elastic behaviour , . 20
Fig. 4.17 Defining the expansion . 21
Fig. 4.18 Selecting the inelastic heat fraction , . 21
Fig. 4.19 Defining the latent heat . 21
Fig. 4.20 Defining the plasticity , 21
Fig. 4.21 Defining the rate dependent . 22
Fig. 4.22 Defining the specific heat , . 23
Fig. 4.23 Creating the solid homogenous section 23
Fig. 4.24 Assigning the section , 23
Fig. 4.25 Selecting the region 24
Fig. 4.26 Editing the assignment . 24
Fig. 4.27 Creating the assembly , 25
Fig. 4.28 Rotating the position , . 25
Fig. 4.29 Setting the position 26
Fig. 4.30 Corrected position of the workpiece , 26
xiiixiv List of Figures
Fig. 4.31 Changing the position of the tool . 27
Fig. 4.32 Setting the tool position 27
Fig. 4.33 Correction position for the tool and the workpiece , . 28
Fig. 4.34 Partitioning the workpiece , 28
Fig. 4.35 Selecting the line and creating the rectangle 28
Fig. 4.36 Drawing the rectangle for the partitioning . 29
Fig. 4.37 Create partitions , 29
Fig. 4.38 Selecting the edge . 29
Fig. 4.39 Selecting the edges and extrude it along the direction 30
Fig. 4.40 Selecting the line , 30
Fig. 4.41 Creating the partition , 30
Fig. 4.42 Partitining the face 31
Fig. 4.43 Selecting the vertical line , . 31
Fig. 4.44 Selecting the rectangle . 31
Fig. 4.45 Rectangle in another position 32
Fig. 4.46 Selecting extrude/sweep edges , . 32
Fig. 4.47 Selecting the cells . 32
Fig. 4.48 Selecting the rectangle . 32
Fig. 4.49 Approving the selected region , . 33
Fig. 4.50 Showing the preview of the partitioned region , 33
Fig. 4.51 Creating the partition , 33
Fig. 4.52 Partitioned workpiece , 34
Fig. 4.53 Creating the step , 34
Fig. 4.54 Select the step time 35
Fig. 4.55 Applying the mass scaling , 35
Fig. 4.56 Applying the ALE adaptive mesh 36
Fig. 4.57 Selecting ALE region , 36
Fig. 4.58 Approving the region , 36
Fig. 4.59 Confirming the region , 37
Fig. 4.60 Approving the rigid body , . 37
Fig. 4.61 Selecting the tool , 38
Fig. 4.62 Confirming the region , 38
Fig. 4.63 Selecting the tool set , . 38
Fig. 4.64 Confirming the rigid body , 39
Fig. 4.65 Applying the friction coefficient . 39
Fig. 4.66 Applying the heat generation 40
Fig. 4.67 Contact surface , . 40
Fig. 4.68 Approving the selected region , . 41
Fig. 4.69 Selected region in the workpiece . 41
Fig. 4.70 Approving the region , 41
Fig. 4.71 Confirming the interaction part , 42
Fig. 4.72 Creating the boundary condition . 43
Fig. 4.73 Selecting the region 43
Fig. 4.74 Approving the region , 44
Fig. 4.75 Applying the boundary condition 44List of Figures xv
Fig. 4.76 Creating the boundary condition . 45
Fig. 4.77 Confirming the boundary condition , . 45
Fig. 4.78 Selecting the limitations of the boundary conditions . 45
Fig. 4.79 Applying the boundary condition 46
Fig. 4.80 Velocity boundary condition 46
Fig. 4.81 Create boundary condition , 47
Fig. 4.82 Selecting the region 47
Fig. 4.83 Applying the boundary condition 47
Fig. 4.84 Applying the amplitude 48
Fig. 4.85 Creating the predefined field 49
Fig. 4.86 Selecting the set , 49
Fig. 4.87 Selecting the set , 50
Fig. 4.88 Applying the value of 25 , . 50
Fig. 4.89 Creating the predefined field 51
Fig. 4.90 Selecting the set , 51
Fig. 4.91 Selecting the set , 51
Fig. 4.92 Applying the value of 25 , . 52
Fig. 4.93 Selecting the part , 52
Fig. 4.94 Applying the part instances . 52
Fig. 4.95 Global seeds selection , 53
Fig. 4.96 Selecting the part instances . 53
Fig. 4.97 Applying the seed edges 53
Fig. 4.98 Selecting the assigned region 53
Fig. 4.99 Selecting the local seeds 54
Fig. 4.100 Assigning the region , . 54
Fig. 4.101 Selecting the region 54
Fig. 4.102 Applying the part instances . 55
Fig. 4.103 Assigning the element type for the workpiece , 55
Fig. 4.104 Selecting the region 55
Fig. 4.105 Selecting the element type , 56
Fig. 4.106 Applying the region , . 56
Fig. 4.107 Seed part instances 56
Fig. 4.108 Approving the region , 57
Fig. 4.109 Selecting the size of the mesh , . 57
Fig. 4.110 Selecting the part instances . 57
Fig. 4.111 Mesh part instances 57
Fig. 4.112 Approving the region , 58
Fig. 4.113 Assigning the element type for the tool 58
Fig. 4.114 Selecting the set , 58
Fig. 4.115 Selecting the set between sets , . 58
Fig. 4.116 Applying the explicit element type , . 59
Fig. 4.117 Selecting the set , 59
Fig. 4.118 Confirming the region , 59
Fig. 5.1 Creating the job , . 64
Fig. 5.2 Editing the job manager 64xvi List of Figures
Fig. 5.3 Running the job , . 65
Fig. 5.4 Completed job 65
Fig. 5.5 Stress across the plate , 66
Fig. 5.6 Nodal temperature . 66
Fig. 5.7 Equivalent plastic strain 67
Fig. 6.1 Creating the new model 70
Fig. 6.2 Creating the part , 70
Fig. 6.3 Creating the rectangle , 71
Fig. 6.4 Rectangle dimentions , 71
Fig. 6.5 Extrusion values , 71
Fig. 6.6 Final part 72
Fig. 6.7 Creating the material property , . 72
Fig. 6.8 Material property definition . 73
Fig. 6.9 Creating the solid homogenous section 74
Fig. 6.10 Assigning the section , 74
Fig. 6.11 Confirming the region , 74
Fig. 6.12 Editing the section assignment , . 75
Fig. 6.13 Creating the instance part , . 75
Fig. 6.14 The created part , . 76
Fig. 6.15 Selection the rotation point , 76
Fig. 6.16 The rotation angle . 76
Fig. 6.17 Confirming the rotation 76
Fig. 6.18 Positioning , . 77
Fig. 6.19 Creating the instance , . 77
Fig. 6.20 Selecting the point . 78
Fig. 6.21 Selecting the point for the coordinate system , . 78
Fig. 6.22 Confirming the position of the instance 78
Fig. 6.23 Creating the step , 79
Fig. 6.24 Creating the second step 80
Fig. 6.25 Requesting the filed output , 81
Fig. 6.26 Requesting the filed output , 81
Fig. 6.27 Requesting the restart , 82
Fig. 6.28 Defining the interaction 82
Fig. 6.29 Defining the surface film condition , . 83
Fig. 6.30 Selecting the surface , . 83
Fig. 6.31 Editing the interaction , 84
Fig. 6.32 Creating the interaction 84
Fig. 6.33 Selecting the surface , . 85
Fig. 6.34 Editing the interaction , 85
Fig. 6.35 Creating the interaction 86
Fig. 6.36 Selecting the surface , . 86
Fig. 6.37 Editing the interaction , 87
Fig. 6.38 Selecting the seed edge . 88
Fig. 6.39 Selecting the seed edge . 89
Fig. 6.40 Selecting the surface , . 90List of Figures xvii
Fig. 6.41 Selecting the heat transfer element , . 91
Fig. 6.42 Creating the mesh . 92
Fig. 6.43 Creating the predefined field 92
Fig. 6.44 Defining the initial temperature , 93
Fig. 6.45 Selecting of the workpiece , 93
Fig. 6.46 Approving the selected workpiece 94
Fig. 6.47 Selecting the temperature , . 94
Fig. 6.48 Applying the subroutine 95
Fig. 6.49 Applying the load . 96
Fig. 6.50 Deactivation of the step 97
Fig. 6.51 Creating the job , . 98
Fig. 6.52 Creating the thermal model . 99
Fig. 6.53 Defining the subroutine for the simulation . 99
Fig. 6.54 Managing the job . 100
Fig. 6.55 Job manager part , 100
Fig. 6.56 Requesting to continue the job , . 100
Fig. 6.57 Completed job 101
Fig. 6.58 Heat flux results , 101
Fig. 6.59 Element temperature results . 102
Fig. 6.60 Nodal temperature results , . 102
Fig. 6.61 Copying the model 103
Fig. 6.62 Creating the mechanical model , 103
Fig. 6.63 Checking the model , . 103
Fig. 6.64 Creating the step , 103
Fig. 6.65 Deleting the step , 104
Fig. 6.66 Creating the mechanical step 104
Fig. 6.67 Replacing the step . 105
Fig. 6.68 Modifying the step 106
Fig. 6.69 Modifying the step 106
Fig. 6.70 Creating the boundary condition . 107
Fig. 6.71 Creating the boundary condition . 107
Fig. 6.72 Selecting the side of the workpiece , . 108
Fig. 6.73 Confirming the set . 108
Fig. 6.74 Selecting the boundary condition . 108
Fig. 6.75 Selecting the workpiece 109
Fig. 6.76 Creating the boundary condition . 109
Fig. 6.77 Slecting the boundary condition , 110
Fig. 6.78 Selecting the workpiece 110
Fig. 6.79 Confirming the set . 110
Fig. 6.80 Selecting the boundary condition . 111
Fig. 6.81 Selecting the boundary condition in the workpiece , 111
Fig. 6.82 Creating the predefined field 112
Fig. 6.83 Selecting the temperature , . 112
Fig. 6.84 Selecting the workpiece 113
Fig. 6.85 Confirming the set . 113xviii List of Figures
Fig. 6.86 Editing the predefined field . 114
Fig. 6.87 Assigning the element type . 114
Fig. 6.88 Selecting the element type , 115
Fig. 6.89 Selecting the field output manager 115
Fig. 6.90 Editing the field output . 115
Fig. 6.91 Editing the field output . 116
Fig. 6.92 Creating the job , . 117
Fig. 6.93 Selecting the model 117
Fig. 6.94 Job creation , 118
Fig. 6.95 Selecting the job manager , 118
Fig. 6.96 Submiting the job . 119
Fig. 6.97 Completed job 119
Fig. 6.98 Selecting the ODB display option 120
Fig. 6.99 Selecting the mirror tab 121
Fig. 6.100 Nodal temperature results , . 121
Fig. 6.101 Nodal temperature at the cross section 122
Fig. 6.102 Stress results . 122

كلمة سر فك الضغط : books-world.net
The Unzip Password : books-world.net