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Published in: The International Journal of Advanced Manufacturing Technology 2/2024

12-06-2023 | ORIGINAL ARTICLE

Orthogonal cutting to develop a damage law for severe plastic deformation processes: application to friction stir welding

Authors: Danilo Ambrosio, Vincent Wagner, Amevi Tongne, Gilles Dessein, Olivier Cahuc

Published in: The International Journal of Advanced Manufacturing Technology | Issue 2/2024

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Abstract

Damage laws built for numerical simulation are developed from mechanical testing, even if not consistently representative of extreme manufacturing conditions. A better representation of material plastic behavior may be withdrawn from orthogonal cutting, characterized by tool compressive and shearing actions on the workpiece during material removal and by an accessible tool-workpiece interaction zone. Thus, orthogonal cutting is used to develop the virtual frictional resistance (VFR) damage evolution law for an accurate description of chip generation mechanisms and extended to friction stir welding within the coupled Eulerian-Lagrangian framework. It considers the frictional resistance within an Eulerian material after full damage to substitute the mesh, explicitly describing the newly born interface interaction in a Lagrangian material. The damage law is inversely calibrated on orthogonal cutting tests allowing accurate chip generation mechanism predictions. The approach is then extended to a 3D friction stir welding model, improving the material flow simulation.

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Metadata
Title
Orthogonal cutting to develop a damage law for severe plastic deformation processes: application to friction stir welding
Authors
Danilo Ambrosio
Vincent Wagner
Amevi Tongne
Gilles Dessein
Olivier Cahuc
Publication date
12-06-2023
Publisher
Springer London
Published in
The International Journal of Advanced Manufacturing Technology / Issue 2/2024
Print ISSN: 0268-3768
Electronic ISSN: 1433-3015
DOI
https://doi.org/10.1007/s00170-023-11437-7

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