A simple and robust moving mesh technique for the finite element simulation of Friction Stir Welding

The simulation of the Friction Stir Welding process is a complex problem which involves physical couplings between mechanics and heat transfer, very large deformations and strain rates in the stirring zone around the pin. To avoid mesh distortions or very large computing time due to the Arbitrary Lagrangian Eulerian technique usually proposed in the literature for the finite element method, a simple but robust moving mesh technique is proposed for the numerical modeling of the FSW process. It is based on a Eulerian formalism and the mesh is composed of 2 parts: a first one which is fixed around the stirring zone and a second one which includes the base material near the tool and moves with a rotational solid motion corresponding to the tool's velocity. Therefore, there are no mesh distortions and the Eulerian formalism leads to satisfying computing time. An example clearly evidences the efficiency and robustness of the moving mesh technique proposed for a 3D complex geometry of the tool. (C) 2012 Elsevier B.V. All rights reserved.