A Framework to Simulate Friction Stir Additive Manufacturing (FSAM) Using the Finite Element Method.

Defining an accurate friction model without having the mesh distortion in an optimized computational time has always been a significant challenge for modelling solid-state natural processes. The presented paper proposes an Eulerian frictional-based solid static model for the accurate modeling of sliding and sticking conditions for the friction stir additive manufacturing process (FSAM). For the frictional behavior, a modified friction model is proposed to investigate the sliding and sticking conditions during the process. The magnesium alloy is selected as the workpiece material and AZ31B-F is employed as the filler material. Two different subroutines, Dflux and Sfilm, are used in order to simulate the heat flux during the process. The convection and emission during the process are determined using the Goldak double ellipsoidal model. DC3D8 and C3D8R elements are employed as the thermal and mechanical models, respectively. The results indicated that the temperature sharply increased up to 870 °C in the first and the second layers. After that, the increasing rate becomes slower with a maxim temperature of 1310 °C. A linear cooling behavior is obtained at the cooling step. The stress results indicated that the tool and the filler material pressure play a significant role in increasing the stress at the center of the workpiece. On the sides of the workpiece, a peak stress is also obtained due to the clamping force. At the cooling phase for the center of the workpiece, the longitudinal residual stress of 5 MP and transverse residual stress of 7 MPa (compression) are achieved. The distortion of the workpiece is also investigated and a maximum value of 0.13 mm is obtained. To wrap up, it should be noted that by implementing an accurate sliding/sticking condition in a frictional based model, a more comprehensive investigation about frictional interactions and their influence on thermal and mechanical behavior can be carried out.