Multi-physics and non-linear modeling using COMSOL

8/16/2019 Multi-physics and non-linear modeling using COMSOL

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Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune

Multi-physics and nn-linear mdeling using!"MS"#

Venkat Perumal

Siemens ec!nolo"# an$ Ser%ices Pri%ate Limite$

&esearc! an$ ec!nolo"# Center, ' (0, )eonics, *lectronics Cit#

+an"alore 50100, n$ia

%enkates.aran/siemens/com

mailto:[email protected]:[email protected]


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$ntrductin

!e ke#note resentation .ill co%er t!e follo.in" toics

Mo$elin" of riction Stir el$in" 4S rocess

6on-linear mo$elin" of ol#meric structure

7lication buil$in" for comosite structures

Pa"e 2


3/34


%S& descriptin

%rictin Stir &elding '%S&( is relatively advanced

metal )ining technlgy *r+s in the slid state

,int types

S is .i$el# accete$ 8oinin" rocess for aluminum, ma"nesium, titanium allo#s

Pin

Shoulder

el$in" b# frictional an$ lastic%iscous $issiation

S!oul$er: ;enerate frictional !eat an$ re%ents material

e3

Pa"e 3

http://www.twi-global.com/http://www.twi-global.com/


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ma"e courtes#: 1/ .../siemens/com , 2/ .../t.i-"lobal/com

%S& inds applicatin in several industries due t

its technlgical advancements ver the

cnventinal prcesses

Pa"e >

7erosace1 Mobilit#1

S!i buil$in"2 *ner"#1

http://www.twi-global.com/technical-knowledge/published-papers/nz-fabricators-begin-to-use-friction-stir-welding-to-produce-aluminium-components-and-panels-august-2006/http://www.twi-global.com/technical-knowledge/published-papers/nz-fabricators-begin-to-use-friction-stir-welding-to-produce-aluminium-components-and-panels-august-2006/


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eat generatin due t the pin and shulder

.../comsol/com

P/ Cole"ro%e et al/, Procee$in"s of t!e 2n$ nternational S#mosium on riction Stir el$in", ;ot!enbur", S.e$en, 2000

eat generatin in %S& is gverned y the rictin

et*een the shulder and *r+piece and the

*r+piece plasticity

Pa"e 5

eat generatin due t shulder 'q shoulder (

eat generatin due t pin tl 'q pin(

qshoulder q pin

? @eat "eneration $ue to t!e friction bet.een

t!e s!oul$er an$ t!e .orkiece is function of

t!e

µ- friction coefficient

n A for"e force 4from e


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emperature dependant yield strength the

allys is an imprtant input mdel

Pa"e

0

20

40

60

80

100

120

140160

180

125 130

167

Thermal conductivity (W/m-k

!hemical cmpsitin '*t .( aluminum allys1

Al !u Mg !r %e Mn Si i n 3esiduals

AA4041 95/(-9(/ 0/15-0/> 0/(-1/2 0/0>-0/35 0/0D0 0/002 0/>-0/( 0/0015 0/0025 0/15

AA556 9>/2-9D 0/10 2/-3/ 0/0003 0/00> 0/005 0/00> 0/0015 0/002 0/15

AA05 (D/1-91/> 1/2-2 2/1-2/9 0/1(-0/2( 0/005 0/003 0/00> 0/0020 5/1-/1

Variation of #iel$ stren"t! .it! temerature2 !ermal con$ucti%it# of t!e allo#s

1/ !tt:.../mat.eb/com2/ Perumal, V/42010/ Dissimilar Metal Friction Stir Welding of Aluminum to Magnesium Alloys. 4=octoral $issertation/ &etrie%e$ from

!tt:sc!olarcommons/sc/e$uet$22>3

2D5 3D5 >D5 5D5 ,D5 DD5 (D5

0

50

100

150

200

250

300

!!6061

-T6

emerature 4)

Eiel$ stren"t! 4MPa

http://www.matweb.com/http://www.matweb.com/


7/34Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune

The backing plate efect was simulated bythe appropriate convective heat transercoe!cient "h#

The "ackin# $late e%ect &a' 'imulated "y the a$$ro$riate convective heat tran'ercoe)cient (h to 'ave the com$utational time

1

2

2 B 3

2 B 3

>

2

1

1 Constant temerature

2 Con%ecti%e surface

3 &a$iation

> Outflo.

qshoulder q pin

5 5

5 @eat source

Pa"e D



! linear i'otro$ic hardenin# model i' u'ed to model the lar#e 'train$la'ticity

$lasto%plastic behavior coupling o theworkiece with thermal to address the multi%physics nature o &'(

Pa"e (

σ#s0 is t!e initial #iel$ stress, an$

k is t!e isotroic !ar$enin"

mo$ulus/

7 %alue for *tiso isotroic tan"ent

mo$ulus section for in t!e

lasticit# re"ion

!tts:.../comsol/co/in

*lasto lastic be!a%ior of t!e .orkiece



!n auto me'hin# o$tion &a' u'ed to me'h the #eometry* +ackin# $late i'

e,cluded to reduce the com$utational time ho&ever taken care "y the heattran'er coe)cient

$lements around the tool)workpieceinterace are smaller than rest o theworkpiece

Pa"e 9

.lementty$e

o* oelement'

Tetrahedral 4821

Trian#ular 100

.d#e 84

3erte, 8

uality 0*0



'hear layer around the pin tool has beenmodeled to represent the typical highstrain rate in &'(

5n the 'tickin# condition the velocitycom$onent vector'

in'ide the 'hear layer are #iven a' unction o thei tan#ential velocity cau'ed "y the rotational

motion ii tran'lational velocity o the material in ,

direction1

10

&hereu -, com$onent o velocityv- y com$onent o velocity

ω-an#ular velocity o tool in (rad/'

uweld - &eldin# velocity (mm/' - ram$in# actor or the 'hear layer Strain rate and e%ective 'train rate can "e

e,$re''ed a' ollo&'

7elcity and strain cmpnents

S!ear la#er aroun$ t!e in2

Velocit# insi$e t!e s!ear la#er aroun$ t!e in: Source: Sc!mi$t, @ et al/,

Mo$ellin" an$ Simulation in Materials Science an$ *n"ineerin", Vol/ 12,

200>, / 1>3 A 15D/

19 :*+* Schmidt ;* :attel Science and Technolo#y o Weldin# and ;oinin# 3ol



&'( simulation set up used or **6061+ ,nitialparameters have been arrived based on someprior data

Gemetric dimensins r therm-mechanical analysis.

ool in uer $iameter 10/32 mm

ool in lo.er $iameter /3( mm

ool in !ei"!t 2/>0 mm

ool s!oul$er $iameter 25/>0 mm

Plate siFe 150 mm



-esults and discussion



The weld surace with ree rom .ash wasobtained at optimal heat input conditions

5ma#e o a !!6061 "utt &eld Eoint ater 800 r$m 20 mm/min eed

rate

Pa"e 13

=irection of tool tra%erse

Bn'ucce''ul &eld' at lo&r$m and hi#h eed rate'

.*#* == r$m and F10mm/min

eed rate'

Bn'ucce''ul &eld' at hi#hr$m

level' re#ardle'' o theeed

rate

5ma#e o a !!6061 "utt &eld Eoint ater == r$m 0 mm/min eedrate("ottom ri#ht

The &eld 'urace 'ho&' im$ro$er (lo& heatin$ut at == r$m and 0 mm/min re'ultin# in

Gno &eldH ormation

*


14/34Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, PunePa"e 1>

$sthermal temperature cnturs sh* pea+

temperature inside the *eld nugget

AA 4041 ally8 900 3:M and 20 mm/min

emerature isot!erm of t!e 7l late emerature at t!e cross section

COMSOL Conference, 29-30 October, 2015, Pune



The calibration o the model was perormed usingthermocouple measurements at the /*

Side Parameter' .,$erimental Tem$erature (C

Simulation Tem$erature (C

I .rror

!dvancin# 1100 r$m 0mm/min

64 628 0*4

Jetreatin# 616 61= 0*16

!e ma



id plane o the nugget remains hot and lesshot at distances ahead o the tool

Pa"e 1



The increment in the weld nuggettemperature is proportional with thestrain rate

1D

Strain rate i' o"tained or di%erent toolrotational '$eed' =00 to 800 r$mK thetool traver'e '$eed &a' ke$t con'tanto 1= mm/min*

5t i' o"'erved that the e%ective 'trainrate increa'e' &ith increa'e in the toolrotational velocity*

Strain rate i' o"tained or di%erent&eld '$eed' o 101=060120mm/min and the tool rotational '$eed&a' ke$t con'tant o 800r$m*

The 'train rate decrea'e' a' thetraver'e '$eed increa'e'*

500 ,00 D00 (00 900>0

50

,0

D0

(0

300

>00

500

,00

D00

(00

900

Strain rate 41semerature 4)

ool rotational see$ 4rm

Strain rate 41s

emerature 4)

10 20 30 40 50 60 70 80 90

90

92

94

96

98

100

102

Strain rate (1/s)

Temperature (K)

Tool traverse speed (mm/min)

Strain rate (1/s)

Temperature (K)



The nu##et tem$erature o the !!==4 alloy i' the hi#he't com$ared to that o the !! 6061

and !! 0= alloy' &hich can "e attri"uted to the yield 'tren#th and thermal conductivitydi%erence'*

**575 alloy showed highest nuggettemperature than **6061 and 7075 alloys due toyield strength diferences

Pa"e 1(

-100 -80 -60 -40 -20 0 20 40 60 80 100400

=00

600

00

800

!! ==4!! 6061

!! 0=

4istance rom the weld center "mm#

Temperature "#

!dv* 'ide Jet* 'ide

!! ==4 8=1 84

!! 0= 44 4

!! 6061 0 2

!dv* 'ide Jet* 'ide

!! ==4 0= 682!! 0= 60 612

!! 6061 628 61=

6u""et temerature

@7H temerature



,n aluminum alloys the heat generation isgovernedby both the .ow stress and thermal conductivity

The rotational velocity o the tool&a'

'&e$t rom lo& to hi#h r$m or acon'tant eed rate o 20 mm/min

Lor !!==4 !! 0= 00-== r$m

re'ulted in TMT'olidu'

Lor !!6061 the T'olidu' &a' reachedat 1100 r$m &here no &eldin# &a'ormed* !l'o at lo& r$m level' N==r$m

Pa"e 19

!tt:asm/mat.eb/com

!tt:.../$i%a-ortal/or"smas!"et$i%a2:51515>GLL*J01/$f

7llo# 4emeratureKC emerature 4)

775D5> 03 (D

7701 5(3 (5

77D0D5 >DD D50

00 =00 00 00 1100 100 1=00600

6=0

00

=0

800

8=0

00

!! ==!! 0=!! 6061

Tool rotational '$eed (r$m

Peak Tem$erature (C

Soli$us temerature

http://asm.matweb.com/http://asm.matweb.com/



odeling o the non%linear behavior using'8

Elastomers

Ooo'e cro'' linkin# o amor$hou' Ooo'e ,ation o $olymer chain "y the chemical

"ond' re'ult' in hi#hly ela'tic "ehavior a"ove the#la'' tran'ition tem$erature T#9

Elastomers exhibit viscoelastic behavior

Qree$ < 5 the 'tre'' i' held con'tant the 'trainincrea'e'

&ith time*

Jela,ation < 5 the 'train i' held con'tant the'tre''

decrea'e' &ith time*

3i'coela'tic material $ro$ertie' have 'tron#de$endence on

Viscoelastic nature of elastomer

ma"e ref/ Lakes &/S , Viscoelastic materials

Cree an$ reco%er# be!a%ior of elastomer

Stress an$ strain %ersus time lot

Pa"e 20



9iscoelastic models in '8

Reneralied >a,&ellmodel

Standard linear 'olidmodel

Celvin 3oi#t model Pure >a,&ell model

n ure ma



:on linear hyperelastic simulation odamper elastomer

7 !#er or ;reen elastic material is an i$eall# elastic

material/

Stress-strain relations!i $eri%e$ from a

Strain



Mney 3ivlin t* parameter mdel >

Onl# a nearl# incomressible %ersion is a%ailable/

*lastic strain ener"# $ensit# is .ritten in terms of t!e t.o in%ariants of

t!e $eformation tensors 14Cel an$ 24Cel an$ t!e elastic %olume ratio

el

Mostl# use$ mo$el $urin" finite element anal#sis/

&elation bet.een t!e Moone# material arameters, s!ear an$ Eoun"Ns

mo$ulus are,

;0 24C10C01

*0 4C10C01

/yperelastic model used in simulation

Material prperties re?uired r tp and ase

dy>

Eoun"Ns mo$ulus

Poissons ratio =ensit#

Material :rperties re?uired r damper>

Moone# &e%lin mo$el arameter C10 Moone# &e%lin mo$el arameter C01 Eoun"Ns mo$ulus Poissons ratio nitial bulk mo$ulus =ensit#

Pa"e 23


24/34


ontact ormulations in '8

o sol%e t!e contact roblems t.o t#es of aroac! is use$

7u"mente$ La"ran"ian met!o$

Penalt# Contact Met!o$

Augmented #agrangian methd

+# $efault COMSOL sol%es contact roblem usin" 7LM, in a Se"re"ate$ a#/

n

Contact ressure %ariable

$" ;a $istance bet.een $estination an$ source boun$ar#

Pn Gser $efine$ enalt# factor

:enalty !ntact Methd

!min Minimum element siFe on t!e contact air/

δ Constant enalt# factor o *stimate$ contact ressure; Clearance bet.een t!e arts

n PenaliFe$ contact ressure , Value of enalt# factor in 7LM $oes not affect

t!e accurac# but it influences t!e con%er"ence/

Penalt# contact met!o$ $oes not reuire e


25/34


/yperelastic model results showedincreased de.ection level thanviscoelastic model

Viscoelastic mo$el @#erelastic mo$el

Pa"e 25


26/34


COMSOL 7P 47lication Pro"rammin" nterface .!ic! is an interface

base$ on a%a, is use$ to $e%elo custom alication base$ on COMSOL

7n initial ;G is built base$ on a mo$el of a simle Q&ectan"ular +lockN,

!a%in" a oint force actin" on t!e e$"e

inal ;G is built base$ on a mo$el of QMec!anical PartN, !a%in" acombination of forces an$ moments actin" on it

@alin-sai Mo$el, a semi-emirical mo$el c!osen base$ on its accurac#

an$ aroriateness, is use$ to $e%elo al"orit!m to calculate Comosite

Material roerties

omposite structures application buildingusing '8

&ef/ Venkates.aran et al/, 201> COMSOL Conference, +an"alore

Pa"e 2


27/34


.!ere,

M comosite material mo$ulus E 22, G12 or R23

fiber material mo$ulus E f , Gf or Rf

matri< material mo$ulus E m, Gm, or Rm

@alin-sai euations are t!e !an$# forms of @illNs "eneraliFe$ self-

consistent mo$el results .it! en"ineerin" aro


28/34


$@:U $@


29/34


$@


31/34


VSG7LH6; M*S@

esh visuali>ation in =


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The modelin# o riction 'tir &eldin# $roce'' ha' enhancedthe under'tandin# o the $roce'' and re'ulted in reducin#the e,$erimental run'

The 'election o a$$ro$riate model and $arameter' i' thekey in modelin# the non-linear re'$on'e o the $olymeric'tructure

;!3! !P5 o$tion in QU>SUO ena"led the $re and $o't$roce''in# RB5 or com$o'ite 'tructure'H modelin#

oncluding remarks

Pa"e 33


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!uthor thank'<

:ande 3 (Je'earch Rrou$ :eadSiemen' Tech* and Service' Pvt* Otd* +an#aloreor hi' in$ut' a$$roval

Qhethan Javi +JSiemen' Tech* and Service' Pvt* Otd* +an#aloreor hi' contri"ution on vi'coela'tic/hy$erela'ticmodelin# re'ult'

*cknowledgment

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Multi-physics and non-linear modeling using COMSOL

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