/title, Friction Stir Welding

/com ==========================================================
/com This is the input file for the analysis of Friction Stir
/com Welding
/com
/com ===========================================================
/com
/com
/com
/com
/com
/com

*******************************************************************
Set the "_geomgen" parameter appropriately (See Below)
Set "_geomgen" equals to "1" if user wants to create cdb files
Set "_geomgen" equals to "0" to run the analysis by reading cdb file
*******************************************************************

/config,nres,5000
/filname,fsw
_geomgen = 0
*if,_geomgen,eq,1,then
/prep7
/com, ***** Problem parameters ********
l=76.2e-03
w=31.75e-03
t=3.18e-03
r1=7.62e-03
h=15.24e-03
l1=r1
l2=l-l1
tcc1=2e06
tcc2=10

!Length of each plate,m

!Width of each plate,m
!Tickness of each plate,m
!Shoulder radius of tool,m
!Height of tool, m
!Starting location of tool on weldline
!Thermal contact conductance b/w plates,W/m^2'C
!Thermal contact conductance b/w tool &
!workpiece,W/m^2'C

fwgt=0.95

!weight factor for distribution of heat b/w tool

!& workpiece
fplw=0.8
!Fraction of plastic work converted to heat
uz1=t/4000
!Depth of penetration,m
nr1=3.141593*11 !No. of rotations in second load step
nr2=3.141593*45 !No. of rotations in third load step
uy1=60.96e-03 !Travelling distance along weld line
tsz=0.01
!Time step size
/com,==========================================================
/com, * Material properties
/com,==========================================================
/com, * Material properties for 304l stainless steel Plates
mp, ex,1,193e9
!Elastic modulus (N/m^2)
mp, nuxy,1,0.3
!Poisson's ratio
mp, alpx,1,1.875e-5 !Coefficient of thermal expansion,m/m'c
mp,qrate,1,fplw
!Fraction of plastic work converted to
!heat,80%
/com, *BISO material model
tb,biso,
1, 1 !Bilinear isotropic material
tbdata,1,290e6,2.8e9 !Yield stress & tangent modulus
mptemp,1,
0, 200, 400, 600, 800,1000
mpdata,kxx,1,1, 16, 19, 21, 24, 29,30 !therm cond.(W/m'C)
mpdata,c,1,1,
500, 540, 560, 590, 600,610 !spec heat(J/kg'C)

mpdata,dens,1,1,7894,7744,7631,7518,7406,7406

!kg/m^3

/com, * Material properties for PCBN tool

mp, ex,2,680e9
!Elastic modulus (N/m^2)
mp,nuxy,2,0.22
!Poisson's ratio
mp, kxx,2,100
!Thermal conductivity(W/m'C)
mp, c,2,750
!Specific heat(J/kg'C)
mp,dens,2,4280
!Density,kg/m^3
/com,==========================================================
/com, * Geometry
/com,==========================================================
/com, * Node for pilot node
n,1,0,0,h
/com, * Workpiece geometry (two rectangular plates)
block,0, w,-l1,l2,0,-t
block,0,-w,-l1,l2,0,-t
/com, * Tool geometry
cyl4,0,0,r1, 0,r1, 90,h
cyl4,0,0,r1, 90,r1,180,h
cyl4,0,0,r1,180,r1,270,h
cyl4,0,0,r1,270,r1,360,h
vglue,3,4,5,6
/com,==========================================================
/com, * Meshing
/com,==========================================================
et,1,SOLID226,11

!Coupled-field solid element,KEYOPT(1) is

!set to 11 for a structural-thermal analysis

allsel
lsel,s,,,4,5
lsel,a,,,14,19,5
lesize,all,,,22,5
lsel,s,,,16,17
lsel,a,,,2,7,5
lesize,all,,,22,1/5
lsel,s,,,1
lsel,a,,,3
lsel,a,,,6
lsel,a,,,8
lsel,a,,,13
lsel,a,,,15
lsel,a,,,18
lsel,a,,,20
lesize,all,,,44
lsel,s,,,9,
lsel,a,,,22
lesize,all,,,2
allsel,all
mshmid,2
!midside nodes dropped
vsweep,1
vsweep,2
vsel,u,volume,,1,2
mat,2
esize,0.0015
vsweep,all
allsel,all

/com,==========================================================
/com, * Contact Pairs
/com,==========================================================
/com, * Define Rigid Surface Constraint on tool top surface
et,2,TARGE170
keyopt,2,2,1

!User defined boundary condition on rigid

!target nodes

et,3,CONTA174
keyopt,3,1,1
keyopt,3,2,2
keyopt,3,4,2
keyopt,3,12,5

!To include Temp DOF

!To include MPC contact algorithm
!For a rigid surface constraint
!To set the behavior of contact surface as a
!bonded (always)
vsel,u,volume,,1,2 !Selecting Tool volume
allsel,below,volume
nsel,r,loc,z,h
!Selecting nodes on the tool top surface
type,3
r,3
real,3
esln
esurf
!Create contact elements
allsel,all
/com, * Define pilot node at the top of the tool
nsel,s,node,,1
tshape,pilo
type,2
real,3
e,1
!Create target element on pilot node
allsel
/com, * Define contact pair between two plates
et,6,TARGE170
et,7,CONTA174
keyopt,7,1,1
keyopt,7,4,3
mat,1
asel,s,,,5
nsla,,1
nplot
cm,tn.cnt,node
asel,s,,,12
nsla,,1
nplot
cm,tn.tgt,node
allsel,all
type,6
r,6
rmodif,6,14,tcc1
rmodif,6,35,1000
real,6
cmsel,s,tn.cnt

!Displacement & Temp dof

!To include Surface projection based method

!Creating component on weld side of plate1

!Creating component on weld side of plate2

!A real constant TCC,Thermal contact

!conductance coeffi. b/w the plates, W/m^2'C
!A real constant TBND,Bonding temperature
!for welding, 'C

nplot
esurf
type,7
real,6
cmsel,s,tn.tgt
esurf
allsel,all
/com, * Define contact pair between tool & workpiece
et,4,TARGE170
et,5,CONTA174
keyopt,5,1,1
!Displacement & Temp dof
keyopt,5,5,3
!Close gap/reduce penetration with auto cnof
keyopt,5,9,1
!Exclude both initial penetration or gap
keyopt,5,10,2
!Contact stiffness update each iteration
!based
!Bottom & lateral(all except top) surfaces of tool for target
vsel,u,volume,,1,2
allsel,below,volume
nsel,r,loc,z,0,h
nsel,u,loc,z,h
type,4
r,5
tb,fric,5,6
!Definition of friction co efficient at
!different temp
tbtemp,25
tbdata,1,0.4
!friction co-efficiet at temp 25
tbtemp,200
tbdata,1,0.4
!friction co-efficiet at temp 200
tbtemp,400
tbdata,1,0.4
!friction co-efficiet at temp 400
tbtemp,600
tbdata,1,0.3
!friction co-efficiet at temp 600
tbtemp,800
tbdata,1,0.3
!friction co-efficiet at temp 800
tbtemp,1000
tbdata,1,0.2
!friction co-efficiet at temp 1000
rmodif,5,9,500e6
!Max.friction stress
rmodif,5,14,tcc2
!Thermal contact conductance b/w tool and
!workpiece, 10 W/m^2'C
rmodif,5,15,1
!A real constant FHTG,the fraction of
!frictional dissipated energy converted
!into heat
rmodif,5,18,fwgt
!A real constant FWGT, weight factor for
!the distribution of heat between the
!contact and target surfaces, 0.95
real,5
mat,5
esln
esurf
allsel,all
!Top sufaces of plates nodes for contact
vsel,s,volume,,1,2
allsel,below,volume
nsel,r,loc,z,0
type,5
real,5
esln

esurf
allsel,all
/com,==========================================================
/com, * Boundary conditions
/com,==========================================================
tref,25
allsel
nsel,all
ic,all,temp,25

!Reference temperature 25'C

!Initial condition at nodes,temp 25'C

!Mechanical Boundary Conditions

!20% ends of the each plate is constraint
nsel,s,loc,x,-0.8*w,-w
nsel,a,loc,x,0.8*w,w
d,all,uz,0
!Displacement constraint in x-direction
d,all,uy,0
!Displacement constraint in y-direction
d,all,ux,0
!Displacement constraint in z-direction
allsel,all
!Bottom of workpiece is constraint in z-direction
nsel,s,loc,z,-t
d,all,uz
!Displacement constraint in z-direction
allsel,all
!Thermal Boundary Conditions
!Convection heat loss from the workpiece surfaces
vsel,s,volume,,1,2 !Selecting the workpiece
allsel,below,volume
nsel,r,loc,z,0
nsel,a,loc,x,-w
nsel,a,loc,x,w
nsel,a,loc,y,-l1
nsel,a,loc,y,l2
sf,all,conv,30,25
!Convection (high)heat loss from the workpiece bottom
nsel,s,loc,z,-t
sf,all,conv,300,25
allsel,all
!Convection heat loss from the tool surfaces
vsel,u,volume,,1,2
!Selecting the tool
allsel,below,volume
csys,1
nsel,r,loc,x,r1
nsel,a,loc,z,h
sf,all,conv,30,25
allsel,all
!Constraining all DOFs at pilot node except the Temp DOF
d,1,all
ddele,1,temp
allsel,all
cdwrite,db,fsw,cdb
fini
/exit,nosave
*else
cdread,db,fsw,cdb
*endif

/com,==========================================================
/com, * Solution
/com,==========================================================
/solu
antype,4
lnsrch,on

!Transient analysis
!Activating a line search to be used
!with Newton-Raphson (for contact
!problem)
cutcontrol,plslimit,0.15 !Controls time-step cutback during a
!solution,Maximum equivalent plastic
!strain allowed within a time-step is
!15%
autots,on
!Automatic time stepping
kbc,0
!Ramped loading within a load step
nlgeom,on
!Turn on large deformation effects
timint,off,struc
!Structural dynamic effects are turned
!off.
nropt,unsym
!Use full Newton-Raphson with
!unsymmetric matrices of elements
!Load Step1
time,1
nsubst,10,1000,10
d,1,uz,-uz1
outres,all,all
allsel
solve
!Load Step2
time,6.5
d,1,rotz,nr1
deltim,tsz,0.001,0.2
outres,all,10
allsel
solve
!Load Step3
time,29
d,1,rotz,nr2
d,1,uy,uy1
deltim,tsz,0.001,0.2
outres,all,10
solve
finish

!Tool plunges into the workpiece

!Rotation of tool, 60rpm

!Rotation of tool,60rpm
!Displacement of tool along weldline

/com,==========================================================
/com, * Post-Processing
/com,==========================================================
/com, * Total Plastic heat and Frictional heat variations
/post1
set,last
*get,nst,active,,set,nset !To get number of data sets on result
!file
!Total Plastic heat rate

esel,s,mat,,1

!Selecting the coupled elements on

!workpiece

etable,vlm1,volu
*dim,pha,array,nst,1
*do,i,1,nst,1
set,,,,,,,i
etable,pi,nmisc,5

!Volume of the each element

smult,psi,pi,vlm1
ssum
*get,ppi,ssum,,item,psi

!Plastic heat rate per unit volume on

!each element, PHEAT
!Multiplying Pl. heat rate per unit
!volume with the volume of
!corresponding element
!Summing up the Plastic heat rate
!Total Plastic heat rate on workpiece
!at a particular time

pha(i,1)=ppi
*enddo
parsav,all
allsel,all
!Total Frictional heat rate
esel,s,real,,5
esel,r,ename,,174
!Selecting the contact elements on
!workpiece
*dim,fht,array,nst,1
*do,i,1,nst,1
set,,,,,,,i
etable,fri,smisc,18

!Frictional energy dissipation per

!unitarea for an element, FDDIS
etable,are1,nmisc,58
!Area of each contact element
smult,frri,fri,are1
!Multiplying Fri. energy dissipation
!per unit area with the area of
!corresponding element
ssum
!Summing up the Frictional heat rate
*get,frhi,ssum,,item,frri !Total Frictional heat rate on
!workpiece at a particular time
fht(i,1)=frhi
*enddo
parsav,all
allsel,all
!Maximum temperature variation
*dim,tmax,array,nst,1
*do,i,1,nst,1
set,,,,,,,i
nsort,temp
*get,ti,sort,0,max
tmax(i,1)=ti
*enddo
parsav,all
finish

/post26
file,fsw,rst
numvar,200
solu,191,ncmit

!To get the maximum temperature

!solution summary data per substep to be

!stored for cumulative no. of iterations.

store,merge
!Merge data from results file
filldata,191,,,,1,1
realvar,191,191
parres,new,'fsw','parm'
vput,pha,10,,,pheat_nmisc
vput,fht,11,,,fric_heat
vput,tmax,12,,,max_temp
/show,png
plvar,10
/show,close
/show,png
plvar,11
/show,close
!Maximum temperature
/show,png
plvar,12
/show,close
finish

!Plot of Plastic heat rate against time

!Plot of Frictional heat rate against time
variation with time
!Plot of Maximum temperature against time

/post1
/rgb,index,100,100,100, 0
/rgb,index, 80, 80, 80,13
/rgb,index, 60, 60, 60,14
/rgb,index, 0, 0, 0,15
/replot
/plopts,date,0
/replot
/view, 1,0.48,-0.51 ,0.7
/ang, 1,-47.73
/replot
set,,,,,1
esel,s,mat,,1
/show,png
plnsol, u,z,0,1
plnsol, s,eqv,0,1

!Deflection after first load step

!Eqv. Stress after first load step

allsel,all
plnsol, temp,, 0,1 !Temperature after first load step
esel,s,real,,5
esel,r,ename,,174
plnsol, cont,sfric, 0,1!Fric. Stress after first load step
set,,, ,,6.5
plnsol, cont,sfric, 0,1!Fric. Stress after second load step
allsel,all
set,,, ,,6.5
plnsol, temp,, 0,1 !Temperature after second load step
set,last
plnsol, temp,, 0,1 !Temperature after last load step
esel,s,real,,6
esel,r,ename,,174
set,last
plnsol, cont,stat, 0,1 !Contact Status after last load step

/rep,fast
/show,close
allsel,all
finish