Sharif Digital Repository

Effects of frustum, cubic and triangle tool pin profiles on the friction stir welding (FSW) of poly(methyl methacrylate) (PMMA) were studied by experimental analysis and thermomechanical simulations. It is shown that employing pins with a low contact surface area form macrocracks and voids along the joint line. Edged-type pins locally stir the polymer and cause tunnel defects which are formed at the root of the joint. In contrast, pins with relatively smooth and large surface area would yield a defect-free weldment if an appropriate processing condition is employed. Mechanical examinations in longitudinal (LS) and transverse (TS) directions indicate that the highest tensile strength (LS = 59... 

A thermo-mechanical model has been developed for modeling of hot extrusion processes. Accordingly, an admissible velocity field was first proposed by means of stream function method and then, extrusion pressure as well as temperature variations within the metal and the die were predicted employing a combined upper bound and Petrov-Galerkin finite element analysis. In order to evaluate the model predictions, hot extrusion of AA6061-10%SiCp was considered under both isothermal and non-isothermal conditions and the predicted force-displacement diagrams under various extrusion conditions were compared with the experimental ones and reasonable consistency was found between the two sets of results... 

In this study, the effects of mold constraints and cooling rate on residual stress were analyzed during the shaped casting process. For this purpose, an H-shaped sample was designed in which the contraction of its middle portion is highly restricted by the mold during the cooling process. The effects of an increasing cooling rate combined with mold constraints were analyzed by reducing the thickness of the middle portion in the second sample. A three-dimensional coupled temperature-displacement analysis was performed in finite-element code ABAQUS to simulate residual stress distribution, and then numerical results were verified by the hole-drilling strain-gauge method. It was concluded that... 

In this paper an integrated model has been utilized to predict thermo-mechanical behavior during friction stir welding of an aluminum alloy. A finite element code, ABAQUS, is employed to solve the governing equations of heat conduction and plastic deformation, while a rigid - viscoplastic material behavior is utilized and effects of different thermal and mechanical boundary conditions are considered in the simulation. To assess the accuracy of the model, predicted results have been compared with experimental data and good agreement has been observed  

An integrated mathematical model was developed to study the thermo-mechanical behavior of strips and work-rolls during warm rolling process of steels. A two-dimensional finite element analysis was first employed to solve for the thermo-mechanical response of the rolled strip under steady-state conditions. The calculated roll pressure and temperature fields were then used to apply proper boundary conditions for solving the governing thermo-mechanical problem for the work-roll. The obtained results indicate that in warm strip rolling of steels, the thermal and mechanical stresses developed within the work-roll are comparable; however, the more significant influence is due to heating and... 

In the present work, the feasibility of friction stir welding (FSW) of poly(methyl methacrylate) sheets was studied experimentally and theoretically by employing thermomechanical simulations. The effect of processing parameters including tool plunge depth, tilt angle, tool rotational speed (w), and transverse velocity (v) was investigated to determine suitable conditions to attain sound and defect-free joints. It is shown that a low tool plunge depth of 0.2 mm and a tilt angle of 2° provide suitable material flow to gain sound joints. By controlling the heat input into stir zone by increasing the tool rotational speed and decreasing linear velocity, the formation of defects can be minimised.... 

This research investigates the relationship between the microstructures of thermomechanically affected zone (TMAZ) and heat input in friction stir welding (FSW) of 5086 aluminum alloy. First, welding heat input has been predicted using a three-dimensional finite element analysis; then, welding experiments have been carried out on annealed and work-hardened conditions to study the developed microstructures and the mechanical properties of the welded metal. The results show that the temperature field in the FSW process is asymmetrically distributed with respect to the welding line. Also, both experimental and predicted data illustrates that peak temperatures are higher on the advancing side... 

In this paper, a thermo-mechanical model has been used to predict the temperature history and residual stress distribution in gas tungsten arc welding of AA5251 plates. This model has also been utilized to estimate the residual stresses under different welding sequences, while in the model the effect of temperature on material properties were taken into account. In order to verify the predictions, residual stresses within the welded samples and weld pool geometry were experimentally measured employing hole drilling and macro-examination of weld cross-section, respectively. The comparison between numerical and experimental data shows a reasonable agreement. The predictions show that the... 

A finite element analysis was developed to determine thermomechanical behaviours of strip and work-roll during cold rolling process under practical rolling conditions. The velocity field was first obtained using a rigid-plastic finite element formulation and then it was used to assess the strain and stress distributions within the strip and at the same time, a thermal finite element model based on streamline upwind Petrov-Galerkin scheme was employed to predict temperature distribution within the metal being rolled. In the next stage, the predicted temperature and stress fields at the contact region of strip/work-roll were employed as the boundary conditions to evaluate the thermomechanical... 

In this study, a thermo-mechanical model was utilized to investigate the effects of welding parameters on the distribution of residual stresses in dissimilar TIG welds of low carbon and ferritic stainless steels. To solve the governing thermal and mechanical problems, a finite element program, ANSYS, was employed while the different aspects such as welding sequence and dilution were considered in the numerical solution. To validate the predictions, the model results were compared with the residual stresses measured by X-ray diffraction technique and a reasonable agreement was found. The results show that the magnitude of tensile residual stresses decrease as the welding current increases... 

In this work, the effect of tool geometric parameters on thermo-mechanical behaviour in friction stir welding of AA5086 has been investigated. For doing so, the thermo-mechanical responses of material during welding with different tools have been predicted by a three-dimensional finite-element model using the finite-element code ABAQUS. In addition, welding experiments have been carried out to study the developed microstructures and the mechanical properties of welded alloy. The results show that tool geometry significantly affects the energy input, deformation pattern, plunge force, microstructures, and mechanical properties of the joint. The conical tool with the shoulder angle of 2° has... 

A thermo-mechanical model has been developed to establish a coupled heat conduction and plastic flow analysis in hot-rolling process. This model is capable of predicting temperature, strain, and strain rate distributions during hot rolling as well as the subsequent static recrystallization fraction and grain size changes after hot deformation. Finite element and neural network models are coupled to assess recrystallization kinetics after hot rolling. A new algorithm has been suggested to create differential data sets to train the neural network. The model is then used to predict histories of various deformation variables and recrystallization kinetics in hot rolling of AA5083. Comparison... 

An integrated model based on finite-element method has been proposed to examine the mechanical and thermal responses of strips and work-rolls in tandem and reverse cold rolling operations. The model has been developed such that the influence of various process parameters, such as lubrication, rolling speed, frictional state and back-up rolls, can be examined. Thermal behaviors of the rolled material and the work-rolls have been analyzed using stream-line upwind Petrov-Galerkin approach, in order to make the model applicable to high-speed rolling processes, as well. The results have been compared to the actual on-line measurements and shown to be of acceptable accuracy. Such modeling approach... 

The effect of welding current and polarity, i.e. AC and DCEN, on imposed thermal cycles, mechanical properties, microstructural events and residual stresses was investigated in GTA welding of AA5052. A three-dimensional thermo-mechanical model was utilized to evaluate thermal responses and residual stresses distribution in the weldments. Tensile testing and hardness measurements were also conducted to study the effect of welding polarity on the mechanical properties of components. Microstructural observations utilizing optical microscopy were carried out to assess the microstructural evolutions. The results show that wide varieties of microstructures are produced in DCEN sample from cells at... 

In this work, the thermomechanical responses during the dissimilar friction stir welding of aluminum alloys have been evaluated employing a three-dimensional model and the finite element software ABAQUS. Furthermore, welding experiments have been conducted under different working conditions and the temperature variations during and after welding as well as the produced residual stresses in various positions of the welded samples were measured using hole-drilling technique. The model results were then examined by experimental data, and a reasonable agreement was observed. It is found that tool rotational speed significantly affects the amount of maximum tensile residual stress while traverse... 

In this work, thermo-mechanical behavior and microstructural evolution in similar and dissimilar friction stir welding of AA6061-T6 and AA5086-O have been investigated. Firstly, the thermo-mechanical behaviors of materials during similar and dissimilar FSW operations have been predicted using three-dimensional finite element software, ABAQUS, then, the mechanical properties and the developed microstructures within the welded samples have been studied with the aid of experimental observations and model predictions. It is found that different strengthening mechanisms in AA5086 and AA6061 result in complex behaviors in hardness of the welded cross section where the hardness variation in similar... 

Prediction of the thermo-mechanical behavior of machine-tool spindles is essential in the reliable operation of high speed machine tools. In particular, the performance of these high speed spindles is dependent on their thermal behavior. The main source of heat generation in the spindle is the friction torque in angular contact ball bearings. This paper presents an effort to develop a comprehensive model of high speed spindles that includes viable models for the mechanical and thermal behavior of its major components, i.e., bearings, shaft and housing. Spindle housing and shaft are treated as six-degree-of-freedom Timoshenko beam elements. Bearings are modeled as two-node elements with five...