This example problem shows how to simulate the friction stir welding (FSW) process. Several characteristics of FSW are presented, including tool-workpiece surface interaction, heat generation due to friction, and plastic deformation. A nonlinear direct coupled-field analysis is performed, as thermal and mechanical behaviors are mutually dependent and coupled together during the FSW process.
Because it is often difficult to find a full set of engineering data to simulate the FSW process, the problem emphasizes the simulation rather than the numerical results. A simplified version of the model created by Zhu and Chao [1] illustrates the FSW simulation method.
The following features and capabilities are highlighted:
Direct structural-thermal analysis using coupled-field solid elements
Plastic heat generation in coupled-field elements
Frictional heat generation using contact elements
Contact elements with bonding capability
The following topics are available:
You can also perform this example analysis entirely in the Ansys Mechanical Application. For more information, see Friction Stir Welding (FSW) Simulation in the Mechanical Technology Showcase: Example Problems.