FSW_experts(sysweld搅拌摩擦焊高阶教程)
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Friction Stir Welding Modeling using SYSWELD V2008.1
REFERENCE MANUAL March 2008
Copyright © ESI Group, 2009. All rights reserved.
Steps
1: Meshing 2: Model-set-up with the advisor 3: Run computation 4: Post-processing
Copyright © ESI Group, 2009. All rights reserved.
Step 2: Input deck for model (cont.)
THERMOFLUID.DAT file (Norton bຫໍສະໝຸດ Baiduhavior law):
First table 20 is K ;; Welded sheets Second table 30 is m (exponent) ;;Table for coefficients K(MPa) et m 10 / 2 -20 -30 20 / 1 20. 632.624 200. 441.196 300. 145.506 400. 83.74 470. 58.23 30 / 1 20. 0.005 200. 0.02256 300. 0.07081 400. 0.127487 470. 0.14661 ;; BACKING PLATE ;; Table for coefficients K(MPa) et m 110 / 2 -120 -130 120 / 1 20. 100. 1000. 100. 130 / 1 20. 1. 1000. 1.
Copyright © ESI Group, 2009. All rights reserved.
Step 1: mesh
Visual Mesh Two meshes are required:
One tetrahedron mesh for fluid/heat transfer analysis
Tool surface: pin and shoulder (skin elements) Tool rotation (rad/sec) Friction law R: exponent MU: coefficient % of heat generated by friction transferred to the part
Copyright © ESI Group, 2009. All rights reserved.
Copyright © ESI Group, 2009. All rights reserved.
Step 2: Input deck for model
THERMOFLUID.DAT file:
KX KY KZ: Thermal conductivity RHO: density C: specific heat Remark: temperature dependant if negative
Dummy properties for backing plate
Copyright © ESI Group, 2009. All rights reserved.
Step 4: Computation
No comments
Copyright © ESI Group, 2009. All rights reserved.
Step 5: Post-processing
In the current version of Sysweld, post-processing of fluid/heat transfer is not integrated. Thus, a specific SIL procedure has been developed to generate a post file (.fdb) for this application. Note that the post-processing of metallurgical and thermo-mechanical are included of course in the current version. C C C C C C C C C C C C C C Values on the block SS : valeurs moyennes dans le bloc SS -------------------------------SS(1) - SS(6) strain rate : taux de deformation moyen SS(7) equivalent strain rate : taux de deformation equivalent moyen SS(8) - SS(13) deviator : deviateur moyen SS(14) dissipated energy : puissance dissipée moyenne SS(15)- SS(17) thermal flux: flux thermique moyen values at the gauss points in the block SS: valeurs aux points de gauss dans le bloc SS ------------------------------------------SS(1) - SS(6) plastic strain rate : taux de deformation SS(7) equivalent plastic strain rate : taux de deformation equivalent SS(8) - SS(13) deviator: deviateur SS(14) dissipated energy : puissance dissipée SS(15)- SS(17) thermal flux: flux thermique
Only the surface of the tool is meshed. To apply boundary conditions, surface (skin) meshes are necessary. In case a backing plate is used, the two meshes must be coincident.
DEFINITION Norton law parameters Friction Stir Welding Sim in table 10 OPTION THERMAL SPATIAL FLOW RESTART GEOMETRY MATER PROP ELEMENT GROUP $SHEETS$ / KX KY KZ -40 RHO -50 C -60 FLUID 10 ELEMENT GROUP $BACKING$ / KX KY KZ -140 RHO -150 C -160 FLUID 110 MEDIA Thermal contact TCNT / SURA $INF$ SURB $BACKING_SUP$ SETPOINT 100. between sheets and backing plate (see heat CFCT / CONTA $TOOL$ KZ 20. R 1. MU 1. H 0.5 transfer manual)
One hexahedron extruded mesh for metallurgy and mechanical analysis
The tool is filled with elements to performed a steady state analysis but those elements are deactivated. The rows of elements must be aligned with the velocity The backing plate should not be used in this simulation
REFERENCE MANUAL March 2008
Copyright © ESI Group, 2009. All rights reserved.
Steps
1: Meshing 2: Model-set-up with the advisor 3: Run computation 4: Post-processing
Copyright © ESI Group, 2009. All rights reserved.
Step 2: Input deck for model (cont.)
THERMOFLUID.DAT file (Norton bຫໍສະໝຸດ Baiduhavior law):
First table 20 is K ;; Welded sheets Second table 30 is m (exponent) ;;Table for coefficients K(MPa) et m 10 / 2 -20 -30 20 / 1 20. 632.624 200. 441.196 300. 145.506 400. 83.74 470. 58.23 30 / 1 20. 0.005 200. 0.02256 300. 0.07081 400. 0.127487 470. 0.14661 ;; BACKING PLATE ;; Table for coefficients K(MPa) et m 110 / 2 -120 -130 120 / 1 20. 100. 1000. 100. 130 / 1 20. 1. 1000. 1.
Copyright © ESI Group, 2009. All rights reserved.
Step 1: mesh
Visual Mesh Two meshes are required:
One tetrahedron mesh for fluid/heat transfer analysis
Tool surface: pin and shoulder (skin elements) Tool rotation (rad/sec) Friction law R: exponent MU: coefficient % of heat generated by friction transferred to the part
Copyright © ESI Group, 2009. All rights reserved.
Copyright © ESI Group, 2009. All rights reserved.
Step 2: Input deck for model
THERMOFLUID.DAT file:
KX KY KZ: Thermal conductivity RHO: density C: specific heat Remark: temperature dependant if negative
Dummy properties for backing plate
Copyright © ESI Group, 2009. All rights reserved.
Step 4: Computation
No comments
Copyright © ESI Group, 2009. All rights reserved.
Step 5: Post-processing
In the current version of Sysweld, post-processing of fluid/heat transfer is not integrated. Thus, a specific SIL procedure has been developed to generate a post file (.fdb) for this application. Note that the post-processing of metallurgical and thermo-mechanical are included of course in the current version. C C C C C C C C C C C C C C Values on the block SS : valeurs moyennes dans le bloc SS -------------------------------SS(1) - SS(6) strain rate : taux de deformation moyen SS(7) equivalent strain rate : taux de deformation equivalent moyen SS(8) - SS(13) deviator : deviateur moyen SS(14) dissipated energy : puissance dissipée moyenne SS(15)- SS(17) thermal flux: flux thermique moyen values at the gauss points in the block SS: valeurs aux points de gauss dans le bloc SS ------------------------------------------SS(1) - SS(6) plastic strain rate : taux de deformation SS(7) equivalent plastic strain rate : taux de deformation equivalent SS(8) - SS(13) deviator: deviateur SS(14) dissipated energy : puissance dissipée SS(15)- SS(17) thermal flux: flux thermique
Only the surface of the tool is meshed. To apply boundary conditions, surface (skin) meshes are necessary. In case a backing plate is used, the two meshes must be coincident.
DEFINITION Norton law parameters Friction Stir Welding Sim in table 10 OPTION THERMAL SPATIAL FLOW RESTART GEOMETRY MATER PROP ELEMENT GROUP $SHEETS$ / KX KY KZ -40 RHO -50 C -60 FLUID 10 ELEMENT GROUP $BACKING$ / KX KY KZ -140 RHO -150 C -160 FLUID 110 MEDIA Thermal contact TCNT / SURA $INF$ SURB $BACKING_SUP$ SETPOINT 100. between sheets and backing plate (see heat CFCT / CONTA $TOOL$ KZ 20. R 1. MU 1. H 0.5 transfer manual)
One hexahedron extruded mesh for metallurgy and mechanical analysis
The tool is filled with elements to performed a steady state analysis but those elements are deactivated. The rows of elements must be aligned with the velocity The backing plate should not be used in this simulation