FEM simulation for friction spot joining process

Abstract

Friction spot welding (FSJ) process is very complicated in the aspects of material flow, heat generation and joining mechanism. Compared with the friction stir welding (FSW) process for a butt joint, the FSJ process is used to join two pieces of plate in the direction of thickness. Although there are several papers describing simulation models for the FSW process, we cannot find any papers relating to simulation models for the FSJ process.

In order to simulate the FSJ process efficiently, an axis-symmetric two-dimensional FEM model with an adaptive re-meshing algorithm is proposed. By using the proposed model, temperature distribution, joining shape of the transverse section including toe flash on the surface and hook on the joining interface, can be simulated. The simulated results agree well with those of the experiment. Furthermore, effects of clamp position and stirring direction on material flow and joining shape are investigated.

Keywords:

• friction spot joining
• FEM simulation
• axis-symmetric model
• joining shape
• material flow
• stirring direction
• clamp position