Abstract
The accurate prediction of the thermo-mechanical fields such as temperature, contact stress, and strain fields is strongly related to the thermo-mechanical properties, material constitutive model, and particularly friction behaviour in simulations of friction welding. In this work, the influence of friction modelling on the interface temperature, burn-off rate, and other process variables in linear friction welding (LFW) is investigated using finite element (FE) simulations in ABAQUS. Sliding model and sliding-sticking model are respectively used to characterise the friction condition. Results show that a greater friction heat flux is predicted by the sliding model with an invariable friction coefficient and the sliding–sticking model with a fixed limited shear stress, resulting in an overestimation of the temperature and burn-off rate compared to the experimental results. Additionally, the average friction heat flux decreases with a decrease in friction coefficient and limited shear stress. Under the investigated welding parameters, the sliding model with the variable-dependent friction coefficient and sliding–sticking model limited by material shear flow stress provide more accuracy in simulations of LFW. The accuracy of friction models in predicting thermo-mechanical condition at the interface is further validated by comparing the plastic deformation zone morphology. The distribution of temperature and strain fields at the interface can be simulated more reasonably by using the sliding–sticking model limited by material shear flow stress, which suitably represents the friction of the sliding–sticking behaviour during LFW.
Published Version
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