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Numerical simulation of plastic deformation in direct-drive friction welding of AISI 4140 and ASTM A106 steel tubes

Khosrowshahi J. Hashemi, Sadeghi M. H., Rasti A.

Archives of Civil and Mechanical Engineering

2020

Vol. 20, no. 4

268--280

Direct-drive friction welding of ASTM A106 and AISI 4140 steel tubes has been investigated both experimentally and numerically. A remeshing technique was implemented to accurately simulate highly distorted flashes during the FE simulation. The results revealed that the circumferential thermal expansion led to a higher contact pressure at the inner diameter of the interface and consequently, inner flashes were formed up to 18% larger than the outer ones. The maximum temperature was also located at the outer diameter of the interface in the first moments of the process, then it moved towards the center of the section where there was a balance between the higher slipping rate at the outer section and greater pressure at the inner section of the joint. Validation tests showed the capability of the FE model in terms of temperature, flash cross-section, and axial shortening with the maximum difference of 18.6%.