Simulation numérique du soudage par frottement-malaxage.

Accueil || Parcours || Recherche || S'enregistrer || Mon Compte || Contacts || Aide || Langues

Guerdoux, Simon (2007) Simulation numérique du soudage par frottement-malaxage. Doctorat Mécanique Numérique, CEMEF- Centre de mise en forme des matériaux, ENSMP p.224.

Plein texte disponible en tant que : - thèse_S-Guerdoux.pdf ( 11684 Kb )

Licence: Copyright

Autres Localisations: http://tel.archives-ouvertes.fr/tel-00271234/fr/

Résumé

Ce travail présente le développement d’un outil numérique. Une formulation arbitrairement lagrangienne-eulérienne (ALE) est implémentée dans le logiciel 3D éléments finis FORGE3® pour simuler les différentes étapes du procédé de soudage par frottement malaxage (FSW). Une méthode découplée est utilisée : a) les champs de vitesses, pressions et températures du matériau sont calculés, b) la vitesse de maillage est calculée à partir de l’évolution des frontières du domaine et d’un critère de raffinement adaptatif procuré via une estimation d’erreur, c) les variables nodales et P0 sont transportées. Différentes techniques de calcul de la vitesse de maillage et de transport des variables sont étudiées, apportant des avantages significatifs par rapport à des approches plus standard. L’algorithme de contact a également été enrichi par une procédure de lissage d’outil. Ces améliorations ont été testées et appliquées sur des cas industriels.L’état stationnaire de soudage, tout comme les phases transitoires, sont simulés, montrant une bonne robustesse et une bonne précision de la formulation ALE développée. Dans un premier temps, la simulation de la phase de soudage stationnaire permet d’identifier, par comparaison avec des résultats expérimentaux, les paramètres de frottement. Dans un second temps, un des intérêts majeurs du modèle ALE étant la possibilité de simuler la formation de vide à l’interface outil/matière, la phase de plongée et des phases transitoires sont modélisées. Leurs simulations peuvent ainsi aider à mieux appréhender les mécanismes du phénomène complexe de déposition de matière qui doit avoir lieu à l’arrière du pion de façon à obtenir un joint sans défaut.

Références Bibliographiques

1. McClure, J.C., et al., A thermal model of friction stir welding. 5th International Conference: Trends in Welding Research, Pine Mountain,GA,USA, 1-5 June 1998, 1999. 590-595.

2. Russell, M.J., H.R. Shercliff, and P.L. Threadgill, Development and application of an analytical process model for friction stir welding. TMS 2001 Annual Meeting Aluminum Automotive and Joining Symposia, New Orleans,LA,USA, 12-14 Feb. 2001, 2001. 225-234.

3. Feng, Z., J.E. Gould, and T.J. Lienert, A heat flow model for friction stir welding of aluminum alloys. Second Symposium on Hot Deformation of Aluminum Alloys II, Rosemont,IL,USA, 11-15 Oct. 1998, 1998. 149-158.

4. Gould, J.E. and Z.L. Feng, Heat flow model for friction stir welding of aluminum alloys. Journal of Materials Processing & Manufacturing Science, 1999. 7(2): p. 185-194.

5. Schmidt, H., J. Hattel, and J. Wert, An analytical model for the heat generation in friction stir welding. Modelling Simul. Mater. Sci. Eng., 2004. 12: p. 143-157.

6. Khandkar, M.Z.H., J.A. Khan, and A.P. Reynolds, Input torque based thermal model of friction stir welding of Al-6061. 6th International Conference: Trends in Welding Research, Pine Mountain,GA,USA, 15-19 Apr. 2002, 2003. 218-223.

7. Chen, C.M. and R. Kovacevic, Finite element modeling of friction stir welding-thermal and thermomechanical analysis. International Journal of Machine Tools & Manufacture (UK), 2003. 43(13): p. 1319-1326.

8. Lawrjaniec, D., et al., Numerical simulation of friction stir welding. THERMEC 2003: International Conference on Processing & Manufacturing of Advanced Materials, Madrid,Spain, 7-11 Jul 2003, 2003. 426-432(Part 4): p. 2993-2998.

9. Seidel, T.U. and A.P. Reynolds, Two-dimensional friction stir welding process model based on fluid mechanics. Science and Technology of Welding and Joining (UK), 2003. 8(3): p. 175-183.

10. Chao, Y.J., X. Qi, and W. Tang, Heat transfer in friction stir welding: Experimental and numerical studies. Journal of manufacturing science and engineering, 2003. 125 (1): p. 138-145.

11. Ulysse, P., Three-dimensional modeling of the friction stir-welding process. International Journal of Machine Tools and Manufacture, 2002. 42(14): p. 1549-1557.

12. Long, T., et al., A friction stir welding model using computational fluid dynamics. Third Symposium on Hot Deformation of Aluminum Alloys III as held at the 2003 TMS Annual Meeting, San Diego,CA,USA, 2-6 Mar. 2003, 2003. 299-312.

13. Colegrove, P.A. and H.R. Shercliff, Experimental and numerical analysis of aluminium alloy 7075-T7351 friction stir welds. Science and Technology of Welding and Joining, 2003. 8(5): p. 360-368.

14. Colegrove, P.A., H.R. Shercliff, and P.L. Threadgill. Modelling and development of the Trivex Friction Stir Welding Tool (4th International Symposium on Friction Stir Welding). 2003.

15. Xu, S., et al., Finite element simulation of material flow in friction stir welding. Science and Technology of Welding and Joining, 2001. 6(3): p. 191-193.

16. Schmidt, H. and J. Hattel, A local model for the thermomechanical conditions in friction stir welding. Modelling and Simulation in Materials Science and Engineering, 2005. 13(1): p. 77-93.

17. Coupez, T., N. Soyris, and J.-L. Chenot, 3-D finite element modelling of the forging process with automatic remeshing. Journal of Materials Processing Technology, 1991. 27(1-3): p. 119-133.

18. Stoker, H.C., Developments of the Arbitrary Lagrangian-Eulerian Method in non-linear Solid Mechanics, ed. Anonymous. 1999: Enschede, The Netherlands. 152.

19. Perchat, E., MINI-élément et factorisation incomplètes pour la parallelisation d'un solveur de Stokes 2D: application au forgeage, 2000, ENSMP: Centre de Mise en Forme des Matriaux (Sophia-Antipolis).

20. Zlà¡mal, M., Finite element method in physical and technical applications. Computer Physics Communications, 1980. 20(1): p. 37-42.

21. Boussetta, R., T. Coupez, and L. Fourment, Adaptive remeshing based on a posteriori error estimation for forging simulation. Computational Metal Forming, 2006. 195(48-49): p. 6626-6645.

22. Gruau, C. and T. Coupez, 3D tetrahedral, unstructured and anisotropic mesh generation with adaptation to natural and multidomain metric. Unstructured Mesh Generation, 2005. 194(48-49): p. 4951-4976.

23. Chenot, J.L., L. Fourment, and K. Mocellin, Numerical treatment of contact and friction in FE simulation of forming processes. Journal of Materials Processing Technology, 2002. 125-126: p. 45-52.

24. Chamoret, D., et al., New smoothing procedures in contact mechanics. Selected Papers from the Second International Conference on Advanced Computational Methods in Engineering (ACOMEN 2002), 2004. 168(1-2): p. 107-116.

25. Lee, M.C. and M.S. Joun, Adaptive triangular element generation and optimization-based smoothing, Part 1: On the plane. Advances in Engineering Software, 2008. 39(1): p. 25-34.

26. Borouchaki, H., et al., Surface mesh enhancement with geometric singularities identification. Unstructured Mesh Generation, 2005. 194(48-49): p. 4885-4894.

27. Mocellin, K., Contribution à la simulation numérique tridimensionnelle du forgeage à chaud: étude du contact et calcul multigrille. 1999, ENSMP: CEMEF Centre de Mise en Forme des Matriaux.

28. Delalondre, F., S. Guerdoux, and L. Fourment, 3D Simulation of Adiabatic Shear Bands in High Speed Machining. AIP Conference Proceedings, 2007. 908(1): p. 1137-1142.

29. Donea, J., S. Giuliani, and J.P. Halleux, An arbitrary lagrangian-eulerian finite element method for transient dynamic fluid-structure interactions. Computer Methods in Applied Mechanics and Engineering, 1982. 33(1-3): p. 689-723.

30. Magnin, B., Modelisation du remplissage des moules d'injection pour polymères thermoplastiques par une méthode Eulérienne-Lagrangienne Arbitraire. 1994, Ecole Nationnale Supérieure des Mines de Paris (Sophia-Antipolis).

31. Wang, H., et al., A Family of Eulerian-Lagrangian Localized Adjoint Methods for Multidimensional Advection-Reaction Equations. Journal of Computational Physics, 1999. 152(1): p. 120-163.

32. Bigot, E., Simulation tridimensionnelle du remplissage de corps minces par injection. 2001, ENSMP: CEMEF Centre de Mise en Forme des Matriaux.

33. Traoré, K., et al., Three-dimensional finite element simulation of ring rolling. 2001, NUMIFORM'2001, 7th Int. Conf. on Numerical Methods in Industrial Forming Processes: Toyohashi, Japon. p. K. Mori (Ed.), Balkema, Lisse,pp 595-600.

34. Bellet, M. and V.D. Fachinotti, ALE Method for solidification modelling. Computer Methods in Applied Mechanics and Engineering 2004. 193(39-41): p. 4355-4381.

35. Maury, B., Characteristics ALE Method for the Unsteady 3D Navier-Stokes Equations with a Free Surface. Comp. Fluid Dyn., 1996. 6: p. 175-188.

36. Boussetta, R., Estimateurs d'erreur et ramaillage adaptatif: application à la simulation 3D des procédés de mise en forme des matériaux. 2005, ENSMP: CEMEF Centre de Mise en Forme des Matriaux.

37. Huétink, J. Analysis of metal forming processes based on a combined Eulerian-Lagrangian finite element formulation. in International conference on Numerical methods in industrial Forming Processes. 1982: Pineridge Press.

38. Stocker, H.C., et al., Investigation of an improved ALE formulation using cases with analytical solutions. 1997.

39. Traoré, K., Simulation thermomécanique du laminage circulaire. Developpement d'une formulation quasi-Eulérienne tridimensionnelle sur une architecture parallèle. 2001, ENSMP: Sophia-Antipolis.

40. Srikanth, A. and N. Zabaras, Shape optimization and preform design in metal forming processes. Computer Methods in Applied Mechanics and Engineering, 2000. 190(13-14): p. 1859-1901.

41. Krok, J., An extended approach to error control in experimental and numerical data smoothing and evaluation using the meshless FDM, in Meshfree Computational Mechanics, Anonymous, Editor. 2002. p. 913-945.

42. Breitkopf, P., A. Rassineux, and P. Villon, An intruduction to Moving Least Squares Meshfree Methods, in Meshfree Computational Mechanics, Anonymous, Editor. 2002. p. 825-867.

43. Liszka, T. and J. Orkisz, The finite differences method at arbitrary irregular grids and its application in applied machanics, in Computers & Structures. 1980. p. 88-95.

44. Liszka, T., An interpolation method for an irregular net of nodes. International Journal for Numerical Methods in Engineering, 1984. 20: p. 1599-1612.

45. Zienkiewicz, O.C. and J.Z. Zhu, Superconvergence and the superconvergent patch recovery. Robert J. Melosh Medal Competition, 1995. 19(1-2): p. 11-23.

46. Zienkiewicz, O.C. and J.Z. Zhu, The superconvergent patch recovery (SPR) and adaptive finite element refinement. Computer Methods in Applied Mechanics and Engineering, 1992. 101(1-3): p. 207-224.

47. Brancherie, D. and P. Villon, Diffuse approximation for field transfer in non linear mechanics, in Revue Européenne de Mécanique Numérique. 2006. p. 571-587.

48. Zienkiewicz, O.C., B. Boroomand, and J.Z. Zhu, Recovery procedures in error estimation and adaptivity Part I: Adaptivity in linear problems. Computer Methods in Applied Mechanics and Engineering, 1999. 176(1-4): p. 111-125.

49. Boroomand, B. and O.C. Zienkiewicz, Recovery procedures in error estimation and adaptivity. Part II: Adaptivity in nonlinear problems of elasto-plasticity behaviour. Computer Methods in Applied Mechanics and Engineering, 1999. 176(1-4): p. 127-146.

50. Boroomand, B., O.C. Zienkiewicz, and P.L.z.a.J.T. Oden, Recovery procedures in error estimation and adaptivity: Adaptivity in non-linear problems of elasto-plasticity behaviour, in Studies in Applied Mechanics, Anonymous, Editor. 1998, Elsevier. p. 383-410.

51. Bäker, M., Finite element simulation of high-speed cutting forces. Journal of Materials Processing Technology, 2006. 176(1-3): p. 117-126.

52. Covington, J.L., Experimental and numerical investigation of tool heating during friction stir welding, in Department of Mechanical Engineering. 2005, faculty of Brigham Young University.

53. Covington, J.L., et al. Fundamental Characterization of Friction Stir Welding. 2004.

54. Record, J.H., Statistical investigation of friction stir processing parameter relationships, in Department of Mechanical Engineering. 2005, faculty of Brigham Young University. p. 87.

55. Oliphant, A.H., Numerical modeling of friction stir welding: a comparison of alegra and forge3, in Department of Mechanical Engineering. 2004, faculty of Brigham Young University. p. 133.

Table des Matières

Chapter I : Introduction: The FSW process

1 Process description

1.1 Friction welding processes: advantages and potential uses

1.2 Friction Stir Welding Process

2 Motivation and problem statement

2.1 Motivation and numerical objectives

2.2 Difficulties and background literature

Chapter II : Numerical Problem

1 Mechanical Equations

1.1 Continuity Equation

1.2 Motion Equation

1.3 Boundary conditions

2 Modelling the problem

2.1 Constitutive models

2.2 Friction law

2.3 Weak formulation of the mechanical problem

3 Thermal Equations

3.1 Global Heat Equation

3.2 Boundary Conditions

3.3 Weak formulation of the thermal problem

4 Forge3 Finite element formulation

4.1 Spatial discretization

4.2 Time discretization

4.3 Mechanical Resolution

4.4 Thermal resolution: the Galerkin Method

4.5 Remeshing procedure

Chapter III : Contact Improvement by tool smoothing

1 Contact Algorithm

1.1 Numerical Treatment of the Lagrangian Unilateral Contact

1.2 Formulation improvement

2 Tool Smoothing Procedure

2.1 Background

2.2 Principle: 2D explanation

2.3 The 3D problem

2.4 Remaining 3D difficulties

3 Benchmark test and application

3.1 Concave angle smoothing

3.2 Convex angle smoothing

3.3 Concave-convex angle smoothing

3.4 First application

Chapter IV : ALE formulation

1 Background

1.1 Lagrangian, Eulerian and ALE description

1.2 ALE method in literature

2 Mesh velocity computation

2.1 Background

2.2 Mesh adaptation

2.3 Boundary conditions

2.4 Non-adaptive formulation

2.5 Error-estimation and adaptive strategy

2.6 Adaptive formulation

3 Remapping step

3.1 Background

3.2 Nodal variables remapping

3.3 Remapping of variables stored at integration points (P0 remapping)

3.4 Comparisons and benchmark tests

4 Industrial Application

4.1 Orthogonal cutting

4.2 Flat rolling

Chapter V : Numerical results and experimental comparisons

1 Experimental equipment

1.1 FSW Machine

1.2 Dynamometer

1.3 Anvils

1.4 Tool Holder/RF Telemetry System

1.5 Electronic Depth Measurement and Control

1.6 Temperature measurement

1.7 Weld Process Data

2 Welding phase

2.1 Experiment description

2.2 Modelling

2.3 Experimental results

2.4 Stationary State and Eulerian Simulation

3 Transient States

3.1 Plunging phase

3.2 Further investigations and Tooling Design

Conclusions and prospects

Statistiques de consultation

Administrateurs de l'archive uniquement : éditer cet enregistrement