Session: 03-08-02: Computational Modeling and Simulation for Advanced Manufacturing

Paper Number: 144626

144626 - Prediction of Temperature Distribution Using Coupled Eulerian Lagrangian (Cel) Finite Element Modelling of Plunging Stage During Additive Friction Stir Deposition 

Nowadays, the friction-based additive manufacturing process is gaining popularity for printing metallic materials in solid state without any melting or solidification. Friction-based additive manufacturing uses friction stir welding (FSW) and friction stir processing (FSP) technology. Additive friction stir deposition (AFSD) is a subdivision of friction-based additive manufacturing process that produces solid objects below the melting point. Because of its solid-state nature, AFSD has fewer residual stresses and is less susceptible to porosity, hot-cracking, and other flaws than conventional fusion-based metallic additive manufacturing. The AFSD is a low-temperature solid-state material deposition process, thereby providing a scalable and versatile, alternative to fusion-based additive methods. The AFSD process takes place in four stages i.e., plunging, dwelling, deposition and traversing. The plunging process in AFSD involves penetrating a revolving hollow tool into a substrate material, which produces high frictional heat at the tool-substrate contact. Understanding the temperature distribution during plunging is important for optimizing process parameters and assuring the quality of manufactured AFSD products.

In this work, a 3-Dimensional finite element model (FEM) is developed to predict the thermo-mechanical material deformation behavior during the plunging stage of the Additive Friction Stir Deposition (AFSD) process. The thermo-mechanical deformation process is simulated using Coupled Eulerian-Lagrangian (CEL) finite element framework. The CEL framework simulates the material deformation, especially in issues involving significant deformation or fluid-structure interaction. This approach successfully manages material flow and deformation by combining features of the Eulerian and Lagrangian frameworks.

The developed model considers the substrate as an Eulerian domain, and the rotating hollow tool has been incorporated using the lagrangian formulation. The CEL framework bridges the gaps by preventing the excessive mesh element distortion expected in the case of severe deformation problem such as AFSD. The study envisaged that the model is suitable for predicting the temperature distribution of the substrate material at any location. The model establishes a physics based relation between thermal evolution and phenomenological parameters such as tool rotational speed, frictional contact, and plastic dissipation during the AFSD process. The thermal profiles obtained from the developed model agree reasonably well with the experimental temperature measurements. The model accounts for the complex interaction between tool, substrate and process parameters. The developed model is capable of investigating the effects of numerous parameters on the temperature distribution and provides the significant insights for the process optimization and control. The study is first step towards modelling the whole AFSD process in a finite element model framework.

Presenting Author: Amit Raj Indian Institute of Technology Bombay

Presenting Author Biography: Dr. Amit Raj is currently working as a Post Doctoral Fellow in the Department of Metallurgical Engineering and Materials Science at Indian Institute of Technology Bombay, Mumbai, India.
Presently, he is working in the area of Friction based Additive Manufacturing predominantly on Additive Friction Stir Deposition (AFSD) process for last 2 years. Dr. Amit Raj has obtained his Ph.D. degree in Mechanical Engineering from Indian Institute of Technology Guwahati, India in 2020. In his past research work, he has worked on Finite Element Modelling of metal forming process, mainly on bulk forming process. During his PhD and Post PhD work, he has published a numerous Patents, Journal Papers, Book chapters and Conference papers. He has good expertise in FE Modelling and Simulation of manufacturing processes.

Authors:

Amit Raj Indian Institute of Technology Bombay
Abhishek Singh Dartmouth College Hanover
Rahul Jain Indian Institute of Technology Bhilai, India
Shashank Sharma University of North Texas
Anirban Patra Indian Institute of Technology Bombay
Krishnaiyengar Narasimhan Indian Institute of Technology Bombay
Narendra Dahotre University of North Texas