A holistic Approach on the Simulation of Rotary-Friction-Welding

The contribution deals with a new holistic approach on the process simulation of Rotary Friction Welding (RFW). The main focus in this regard is on the proper determination of process parameters for new pairs of weld partners in a complete virtual manner. Basis of the simulation is a Carreau fluid material law coupled with the heat transfer problem. The plastic deformations of the flash are mapped by Lagrangian formulated finite elements involving sophisticated remeshing procedures in order to avoid spurious element distortions. A penalty contact approach in conjunction with a regularized Coulomb friction law is able to predict the interface forces in a very robust way. A selfwritten code is capable of simulating the whole process in adequate computation times, taking advantage of the general axial symmetry of the problem. After summarized derivation of the governing equations and the utilized material, a practical example is considered in order to demonstrate the performance of the model. A qualitative comparison of the flash shape with an experimental sample and an exemplary influence study of the process parameters conclude the paper.