Simulation of Friction Stir Extrusion using Smoothed Particle Hydrodynamics (SPH)

ADMT Journal

دوره 15، شماره 2، شهریور 2022، صفحه 15-22   

نوع مقاله: Original Article

شناسه دیجیتال (DOI): 10.30486/admt.2022.1938910.1310

نویسندگان

Mostafa Akbari^{* 1}؛ Mansour Hakimollahi²؛ parviz Asadi²؛ Hossein Rahimi Asiabaraki¹

¹Department of Mechanical Engineering, Technical and Vocational University (TVU), Tehran, Iran

²Ph.D. Gratuated , Department of Automotive Engineering Iran University of Science and Technology

چکیده

This research aims to construct a three-dimensional numerical model for modeling friction stir extrusion using the completely Lagrangian method, smoothed particle hydrodynamics (SPH). For extrusion simulations, the Finite Element Method (FEM) is extensively utilized; however, it has limitations due to excessive element deformation. Because the particle-based method eliminates the usage of volumetric elements, SPH can be a viable alternative. The performance of the SPH model was evaluated using different particle sizes. The results showed that the smaller particle size improves the temperature results as well as the shape of the wire produced. Then the mechanical and microstructural properties of the produced wires were investigated. The results show that the grain size in the center of the wire is larger than its perimeter due to the lower strain rate in this area. Increased strain reduces grain size in the produced microstructure by increasing nucleation sites during recrystallization, as is well known. The wire microhardness in the centre is 121 HV, whereas it is 129 HV in the periphery. Grain size is the main reason of increased hardness near the sample's periphery.

کلیدواژه‌ها

CEL؛ FSBE؛ Simulation؛ Microstructural؛ SPH

مراجع

• Evans, W. T., Gibson, B. T., Reynolds, J. T., Strauss, A. M., and Cook, G. E., Friction Stir Extrusion: A New Process for Joining Dissimilar Materials, Manufacturing Letters, Vol. 5, 2015, pp. 25-8.
• Buffa, G., Campanella, D., Fratini, L., and Micari, F., AZ31 Magnesium Alloy Recycling Through Friction Stir Extrusion process, International Journal of Material Forming, Vol. 9, 2016, pp. 613-8.
• Akbari, M., Asadi, P., Behnagh, R. A., Modeling of Material Flow in Dissimilar Friction Stir Lap Welding of Aluminum and Brass Using Coupled Eulerian and Lagrangian Method, The International Journal of Advanced Manufacturing Technology, Vol. 113, 2021, pp. 721-34.
• Akbari, M., Shojaeefard, M. H., Asadi, P., and Khalkhali, A., Wear Performance of A356 Matrix Composites Reinforced with Different Types of Reinforcing Particles, Journal of Materials Engineering and Performance, Vol. 26, 2017, pp. 4297-310.
• Asadi, P., Akbari, M., Numerical Modeling and Experimental Investigation of Brass Wire Forming by Friction Stir Back Extrusion, The International Journal of Advanced Manufacturing Technology, 2021.
• Dao, M. H., Lou, J., Simulations of Laser Assisted Additive Manufacturing by Smoothed Particle Hydrodynamics, Computer Methods in Applied Mechanics and Engineering, Vol. 373, 2021, pp. 113491.
• Meier, C., Fuchs, S. L., Hart, A. J., and Wall, W. A., A Novel Smoothed Particle Hydrodynamics Formulation for Thermo-Capillary Phase Change Problems with Focus on Metal Additive Manufacturing Melt Pool Modeling, Computer Methods in Applied Mechanics and Engineering, Vol. 381, 2021, pp. 113812.
• Zhang, C., Wang, J., Rezavand, M., Wu, D., and Hu, X., An Integrative Smoothed Particle Hydrodynamics Method for Modeling Cardiac Function, Computer Methods in Applied Mechanics and Engineering, Vol. 381, 2021, pp. 113847.
• Fuchs, S. L., Meier, C., Wall, W. A., and Cyron, C. J., A Novel Smoothed Particle Hydrodynamics and Finite Element Coupling Scheme for Fluid–Structure Interaction: The Sliding Boundary Particle Approach, Computer Methods in Applied Mechanics and Engineering, Vol. 383, 2021, pp. 113922.
• Lampropoulos, A. D., Manolakos, D. E., Application of SPH Method for Modeling of Metal Extrusion Process, Computational Particle Mechanics, 2021.
• Bagheri, B., Abdollahzadeh, A., Abbasi, M., and Kokabi, A. H., Numerical Analysis of Vibration Effect on Friction Stir Welding by Smoothed Particle Hydrodynamics (SPH), The International Journal of Advanced Manufacturing Technology, Vol. 110, 2020, pp. 209-28.
• Gingold, R. A., Monaghan, J. J., Smoothed Particle Hydrodynamics: Theory and Application to Non-Spherical Stars, Monthly Notices of the Royal Astronomical Society, Vol. 181, 1977, pp. 375-89.
• Ansari, M. A., Abdi Behnagh, R., Numerical Study of Friction Stir Welding (FSW) Plunging Phase Using Smoothed Particle Hydrodynamics (SPH), Modelling and Simulation in Materials Science and Engineering, Vol. 27, 2019.
• Bonet, J., Lok, T. S. L., Variational and Momentum Preservation Aspects of Smooth Particle Hydrodynamic Formulations, Computer Methods in Applied Mechanics and Engineering, Vol. 180, 1999, pp. 97-115.
• Kajtar, J., Monaghan, J. J., SPH Simulations of Swimming Linked Bodies, Journal of Computational Physics, Vol. 227, 2008, pp. 8568-87.
• Monaghan, J. J., Smoothed Particle Hydrodynamics, Reports on Progress in Physics, Vol. 68, 2005, pp. 1703-59.
• Meyghani, B., Awang, M., Emamian, S., Nor, M., and Pedapati, S. R., A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW), Metals, Vol. 7, 2017, pp. 450.
• Chakrabarty, R., Song, J., A Modified Johnson-Cook Material Model with Strain Gradient Plasticity Consideration for Numerical Simulation of Cold Spray Process, Surface and Coatings Technology, Vol. 397, 2020, pp. 125981.
• Balu Mahandiran, M., Vigneshkumar, M., Ashoka Varthanan, P., Abishek, S., Abdulriyazdeen, A., and Abilash, S., Investigation of Solid State Welding of Copper Nickel Alloy (Cu-Ni 90/10) Using FSW Process, IOP Conference Series: Materials Science and Engineering, Vol. 1145, 2021, pp. 012112.
• Wang, X., Gao, Y., McDonnell, M., and Feng, Z., On the Solid-State-Bonding Mechanism in Friction Stir Welding., Extreme Mechanics Letters, Vol. 37, 2020, pp. 100727.
• Akbari, M., Khalkhali, A., Keshavarz, S. M. E., and Sarikhani, E., Investigation of the Effect of Friction Stir Processing Parameters on Temperature and Forces of Al–Si Aluminum Alloys, Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications, Vol. 232, 2015, pp. 213-29.