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. Race 07 Wtcc Game Download Full.

The resulting rapid rise in interface temperature is exploited to produce high-quality 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.

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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.

Abaqus/CAE is used to extract the outer surface of the pipes, reseed the surface, and remesh the pipe regions. This process employs the Abaqus Scripting Interface command, which is used to extract orphan mesh parts representing the deformed pipes. These parts are then passed to the command. This command creates a geometric Part object from the orphan mesh imported earlier. Once the profile of the deformed part has been created, options in the Mesh module are used to remesh the part.

Elsawin Installation Guide. The new mesh results in a new Abaqus/Standard analysis, and the map solution procedure maps state variables from the previous analysis (see ). The pipes are modeled as axisymmetric.

The element formulation used is the fully coupled temperature-displacement axisymmetric elements with twist degrees of freedom (element types CGAX4HT and CGAX3HT), where the twist degree of freedom enables modeling of rotation and shear deformation in the out-of-plane direction. The hybrid formulation is required to handle the incompressible nature of the material during the plastic flow. The mesh is divided into two regions for each pipe. In the region near the weld interface, smaller elements are created (see ). During the remeshing process, the region near the weld surface is recalculated so that the new flash region is also meshed with smaller elements (see ). The material model defined for this example approximates the high-temperature behavior of Astroloy, where it is reported by Soucail et al. (1992) using a Norton-Hoff constitutive law to describe the temperature and strain-rate viscoplastic behavior.

A similar model is defined in Abaqus as a rate-dependent perfectly plastic material model. For the loading in this model, these material parameters result in the onset of local plastic flow only after the interface temperature has exceeded roughly 1200�C, near the material solidus temperature of 1250�C. Above this temperature the Mises flow stress is highly sensitive to variations in temperature and strain rate. A special adjustment in the flow stress at high strain rates is necessary to avoid divergence during the iteration procedure of the nonlinear solution. In the material model definition an extreme case of stress data is defined when the strain rate is 1.0 � 10 6 s �1.