Introducing an Enhanced Friction Model for Developing Inertia Welding Simulation: A Computational Solid Mechanics Approach

Friction welding is a solid-state welding process that generates heat through mechanical friction between workpieces in relative motion to one another, with the addition of a lateral force called "upset" to plastically displace and fuse the materials. One of the key problems during modeling solid-state welding processes is the implementation of the friction model. Coulomb friction model was proposed by researchers for computational solid mechanics (CSMs) modeling of the process, however this law is based on the sliding motion. Norton friction model is also proposed by others, while simplifications and limitations are caused in coincidence with reality. In this paper, Norton friction model is modified to be employed in a computational solid mechanics model of inertia welding. A continuous remeshing technique is used to avoid the mesh distortion problem. Consequently, successful prediction of the temperature distribution, thermal history, equivalent plastic deformation, axial shortening and stress distribution is made. The comparisons between the results of this study and the literature showed that implementing the proposed methodology leads to achieving high accuracy results.