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

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Abstract

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%.

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Data availability

The data that support the findings of this study are available from the corresponding author, upon reasonable request.

Code availability

In this study, ABAQUS 16.4-1 and PYTHON 3.4.1 have been used to simulate the direct-drive friction welding using remeshing technique. The PYTHON code of the proposed remeshing algorithm and ABAQUS simulation files are available from the corresponding author, upon reasonable request.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Tarbiat Modares University, Tehran, Iran

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

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  1. J. Hashemi Khosrowshahi
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  2. M. H. Sadeghi
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  3. A. Rasti
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Correspondence to M. H. Sadeghi.

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Khosrowshahi, J.H., Sadeghi, M.H. & Rasti, A. Numerical simulation of plastic deformation in direct-drive friction welding of AISI 4140 and ASTM A106 steel tubes. Archiv.Civ.Mech.Eng 20, 116 (2020). https://doi.org/10.1007/s43452-020-00113-2

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  • DOI: https://doi.org/10.1007/s43452-020-00113-2

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