This example examines the inertia friction welding process of the pipes shown in. The specific arrangement considered is the resulting as-welded configuration shown in. In this weld process kinetic energy is converted rapidly to thermal energy at a frictional interface. The resulting rapid rise in interface temperature is exploited to produce high-quality welds.
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Abaqus Welding Interface Crack
Weld sequence optimization with Abaqus Welding Interface. Of modeling and simulation helped weld engineers for critical assessment of a series of cracked welds.
In this example the weld process is simulated, and the initial temperature rise and material plastic flow are observed. An important factor in the process design is control of the initial speed of the flywheel so that, when the flywheel stops, the temperature rises to just below the melting point, which in turn results in significant flow of material in the region of the weld joint.
Understanding the friction, material properties, and heat transfer environment are important design aspects in an effective inertia welding process; therefore, simulation is a helpful tool in the process design. The principal interaction occurs at the weld interface between the pipes; however, a secondary concern is the possibility of contact of weld flash with the side of the pipes. The weld-interface friction behavior is assumed to follow that described by Moal and Massoni (1995), where the ratio of shear stress to the prescribed pressure is observed to be a complex function of interface slip rate. The heat generation from the frictional sliding, combined with plastic deformation, contributes to the temperature rise in the pipes. At each remesh point the current model configuration represents a significant change in the pipes' shape and in the current analysis mesh.