Multi-Physics and Non-Linear Modeling Using COMSOL

Multi-physics and non-linear modeling using
COMSOL
Venkat Perumal
Siemens Technology and Services Private Limited
Research and Technology Center, # 80, Keonics, Electronics City
Bangalore 560100, India
venkateswaran.p@siemens.com
COMSOL Conference, 29-30 October, 2015, Pune
Unrestricted/ Siemens AG 2015. All rights reserved
Introduction
The keynote presentation will cover the following topics
Modeling of Friction Stir Welding (FSW) process
Non-linear modeling of polymeric structure
Application building for composite structures
Page 2
Friction Stir Welding (FSW) is relatively advanced

metal joining technology works in the solid state
FSW is widely accepted joining process for aluminum, magnesium, titanium alloys
FSW description
Joint types
Shoulder
Pi
n
Welding by frictional and plastic/viscous dissipation
Shoulder: Generate frictional heat and prevents material

expulsion
Pin: Deform material and generate plastic/

viscous heat
Ref: http://www.twi-global.com
Perumal, V.(2010). Dissimilar Metal Friction Stir Welding of Aluminum to Magnesium Alloys. (Doctoral dissertation). Retrieved from http://scholarcommons.sc.edu/etd/2243
Page 3
FSW finds application in several industries due to

its technological advancements over the
conventional processes
Aerospace1
Ship building2
Mobility1
Energy1
Image courtesy: 1. www.siemens.com , 2. www.twi-global.com
Page 4
Heat generation in FSW is governed by the friction

between the shoulder and workpiece and the
workpiece plasticity
Heat generation due to the pin and shoulder
Heat generation due to shoulder (qshoulder)
Heat generation due to the friction between

the shoulder and the workpiece is function of
the
- friction coefficient
Fn forge force (from experiments &
estimation)
Heat generation due to pin tool (qpin)
As surface area of the shoulder

- angular velocity (rad/s)
r- radial distance (x2+y2)0.5
Heat generation due to pin tool (qpin) is the the
function of the
Pin radius (rp)
- angular velocity (rad/s)
(T) temperature dependent yield
strength of the workpiece
qshoulder
qpin
www.comsol.com
P. Colegrove et al., Proceedings of the 2nd International Symposium on Friction Stir Welding, Gothenburg, Sweden, 2000
Page 5
Temperature dependant yield strength of the

alloys is an important input model
Chemical composition (wt .%) of aluminum alloys 1
Al
Cu
Mg
Cr
Fe
Mn
Si
AA6061
95.8-98.6
0.15-0.4
0.8-1.2
0.04-0.35
0.070
0.002
0.4-0.8
AA5754
94.2-97
0.10
2.6-3.6
0.0003
0.004
0.005
AA7075
87.1-91.4
1.2-2
2.1-2.9
0.18-0.28
0.005
0.003
Ti
0.15
0.004
0.0015
0.15
0.004
0.0020 5.1-6.1
Thermal conductivity (W/m-k)

AA6061
-T6
200
150
Yield strength (MPa)

100
50
0
275
375
475
575
675
775
Residuals
0.0015 0.0025
300
250
Zn
180
160
140
120
100
80
60
40
20
0
0.002
167
125
130
875
Temperature (K)
Variation of yield strength with temperature 2
Thermal conductivity of the alloys
1. http://www.matweb.com
2. Perumal, V.(2010). Dissimilar Metal Friction Stir Welding of Aluminum to Magnesium Alloys. (Doctoral dissertation). Retrieved from
http://scholarcommons.sc.edu/etd/2243
Page 6
The backing plate effect was simulated by

the appropriate convective heat transfer
coefficient (h)
The backing plate effect was simulated by the appropriate convective heat transfer
coefficient (h) to save the computational time
1
2
2&3
2&3
Constant temperature
Convective surface
Radiation
Outflow
Heat source
2
1
qshoulder
Page 7
qpin
Elasto-plastic behavior coupling of the

workiece with thermal to address the multiphysics nature of FSW
A linear isotropic hardening model is used to model the large strain
plasticity
ys0 is the initial yield stress, and

k is the isotropic hardening
modulus.
A value for Etiso isotropic tangent
modulus section for in the
plasticity region
Elasto plastic behavior of the workpiece
https://www.comsol.co.in/
Page 8
Elements around the tool/workpiece

interface are smaller than rest of the
workpiece
An auto meshing option was used to mesh the geometry. Backing plate is
excluded to reduce the computational time, however, taken care by the heat
transfer coefficient
Element
type
Tetrahedral
48219
Triangular
10033
Edge
Page 9
No. of
elements
847
Vertex
38
Quality
0.70
Shear layer around the pin tool has been

modeled to represent the typical high
strain rate in FSW
Velocity and strain components
In the sticking condition the velocity
component vectors
inside the shear layer are given as function of the
i) tangential velocity caused by the rotational
motion &
ii) translational velocity of the material in x
direction1
Shear layer
Shear layer around the pin2
where,
u -x component of velocity
v- y component of velocity
-angular velocity of tool in (rad/s)

uweld- welding velocity (mm/s)
- ramping factor for the shear layer
Strain rate and effective strain rate can be

expressed as follows
Velocity inside the shear layer around the pin: Source: Schmidt, H et al.,
Modelling and Simulation in Materials Science and Engineering, Vol. 12,
2004, pp. 143 157.
[1] H.B. Schmidt, J. Hattel, Science and Technology of Welding and Joining Vol:10(2005),pp:176-186.
[2] Basil M. Darras, Experimental and analytical study of friction stir processing, (2005). University of Kentucky Master's Thesis.
10
FSW simulation set up used for AA6061: Initial

parameters have been arrived based on some
prior data
Geometric dimensions for thermo-mechanical analysis.
Tool pin upper diameter
10.32 mm
Tool pin lower diameter
6.38 mm
Tool pin height
2.40 mm
Tool shoulder diameter
25.40 mm
Plate size
150 mm x100 mm x 6.1 mm
Simulation Parameters
RPM 500, 575, 600, 700, 800, 900, 1000,
and 1100.
Feed rate (in mm/min) 10, 15, 20, 30, 50,
and 80.
Experimental Parameters
RPM 575, 800, and 1100.
Feed rate (in mm/min) 10, 15, 20, 30, and
50.
Page 11
Results and discussion
The weld surface with free from flash was

obtained at optimal heat input conditions
Image of a AA6061 butt weld joint after 800 rpm, 20 mm/min feed
rate
Successful weld
Exit
start
25 mm
Unsuccessful welds at low

rpm and high feed rates
E.g., 575 rpm and >10
mm/min
feed rates
Unsuccessful welds at high
rpm
levels regardless of the
feed Unsuccessful weld
rate
Direction of tool traverse

Image of a AA6061 butt weld joint after 575 rpm, 30 mm/min feed
rate
(bottom right)
The weld surface shows improper (low) heat

input at 575 rpm and 30 mm/min resulting in
no weld formation
Page 13
Isothermal temperature contours show peak

temperature inside the weld nugget
AA 6061 alloy, 800 RPM and 20 mm/min
Temperature isotherm of the Al plate
Page 14
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Temperature at the cross section
The calibration of the model was performed using

thermocouple measurements at the HAZ
The maximum deviation between the experimental and the simulated temperatures in HAZ is
about 1%
Comparison of the surface temperature from the IR pyrometer

and simulation
Side
Advancing
Retreating
Page 15
Parameters
1100 rpm, 30
mm/min
Thermocouple measurement locations in HAZ
Experimental
Temperature (K)
Simulation
Temperature (K)
634
628
0.94
616
615
0.16
% Error
Mid plane of the nugget remains hot and less

hot at distances ahead of the tool
Page 16
The increment in the weld nugget

temperature is proportional with the
strain rate
900
80
800
70
700
Strain rate (1/s)
600
60
500
50
Strain rate (1/s)

Temperature (K)
400
300
900
40
500
600
700
800
Strain rate is obtained for different tool

rotational speeds 500 to 800 rpm; the
tool traverse speed was kept constant
Temperature (K)
of 15 mm/min.
It is observed that the effective strain
rate increases with increase in the tool
rotational velocity.
Tool rotational speed (rpm)

102
Strain rate (1/s)

Temperature (K)
100
Temperature (K)Strain rate is obtained for different
weld speeds of 10,15,30,60,120

mm/min and the tool rotational speed
was kept constant of 800rpm.
98
96
Strain rate (1/s)

94
The strain rate decreases as the

traverse speed increases.
92
90
10
20
30
40
50
60
70
80
90
Tool traverse speed (mm/min)

17
AA5754 alloy showed highest nugget

temperature than AA6061 and 7075 alloys due to
yield strength K differences
The nugget temperature of the AA5754 alloy is the highest compared to that of the AA 6061
and AA 7075 alloys, which can be attributed to the yield strength and thermal conductivity
differences.
800
700
AA 5754
AA 6061
AA 7075
Temperature (K)
Nugget temperature
Adv. side
Ret. side
AA 5754
851
847
AA 7075
744
743
AA 6061
730
727
600
HAZ temperature
500
Adv. side
Ret. side
AA 5754
705
682
AA 7075
630
612
AA 6061
628
615
400
-100 -80 -60 -40 -20 0
20 40 60 80 100
Distance from the weld center (mm)
Page 18
In aluminum alloys, the heat generation is

governed
by both the flow stress and thermal conductivity
900
850
The rotational velocity of the tool

was
swept from low to high rpm for a
constant feed rate of 20 mm/min
Peak Temperature (K)
For AA5754 & AA 7075, 300-575 rpm
800
750
700
resulted in T<Tsolidus
650
For AA6061, the Tsolidus was reached

at 1100 rpm, where no welding was
formed. Also at low rpm levels 575
rpm
600
300
AA 5757
AA 7075
AA 6061
500
700
900
1100
1300
1500
Tool rotational speed (rpm)

Solidus temperature
Alloy
AA5754
AA6061
AA7075
(TemperatureC)
603
583
477
Temperature (K)
876
856
750
http://asm.matweb.com
http://www.diva-portal.org/smash/get/diva2:515154/FULLTEXT01.pdf
Page 19
Modeling of the non-linear behavior using

COMSOL
Elastomers
Loose cross linking of amorphous
Loose fixation of polymer chain by the chemical
bonds results in highly elastic behavior above the
glass transition temperature [Tg]
Elastomers exhibit viscoelastic behavior
Creep : If the stress is held constant, the strain

increases
with time.
Creep and recovery behavior of elastomer

Stress and strain versus time plot
Relaxation : If the strain is held constant, the

stress
decreases with time.
Viscoelastic nature of elastomer
Viscoelastic material properties have strong

Page
20
dependence
on
COMSOL
Conference, 29-30 October, 2015, Pune
Image ref. Lakes R.S , Viscoelastic materials
Viscoelastic models in COMSOL

Viscoelastic models
Pure Maxwell model
Kelvin Voigt model
Standard linear solid

model
In pure maxwell model only

one spring and dashpot is
connected in series
Here, spring = dashpot
= spring + dashpot
Only one spring-dashpot

branch is connected in
parallel
s = s spring + s dashpot
e = e spring = e dashpot
Zener model, or 3
parameter model
Placing a spring in parallel
with the Maxwell model
Generalized Maxwell
model
More spring dashpot

pair gives better
solution
In the present simulation, Pure Maxwell model with shear modulus and relaxation time is used.
Page 21
Non linear hyperelastic simulation of

damper elastomer
A hyper or Green elastic material is an ideally elastic

material.
Stress-strain relationship derived from a
Strain Energy Density Function
A strain energy density function relates strain energy

density
of a material to the deformation gradient.
Unlike other materials such as metal and ceramics there is

no
linear relationship between stress and strain in Elastomers
inNeo- Hookean
Mooney
Rivlin state.
2 parameter
hyperelastic
<30%
100% in tension 30% in
compression
Mooney Rivlin 5 and 9 parameters 30-200%

Ploynomial function of order N
300%
Feasible to model up to
Arruda Boyce
<300%
Ogden
<700%
Page 22
Neo-Hookean
Mooney-Rivlin
Yeoh
Arruda-Boyce
Mooney-Rivlin is a commonly used model
for polymers
Blatz-Ko
polymers,
moderate stretch
levels
Ogden
Polyurethane
foams
High stretch
levels
Hyperelastic model used in simulation
Mooney Rivlin two parameter model :

Only a nearly incompressible version is available.
Elastic strain energy density is written in terms of the two invariants of

the deformation tensors I1(Cel) and I2(Cel) and the elastic volume ratio
Jel
Material properties required for top and base

body:
Youngs modulus
Poisson's ratio
Density
Material Properties required for damper:
Mostly used model during finite element analysis.
Mooney Revlin model parameter C10

Mooney Revlin model parameter C01
Youngs modulus
Poisson's ratio
Initial bulk modulus
Density
Relation between the Mooney material parameters, shear and Youngs

modulus are,
G0 = 2(C10+C01)
E0 = 6(C10+C01)
Page 23
Contact formulations in COMSOL

To solve the contact problems two types of approach is used
Augmented Lagrangian method
Penalty Contact Method
Augmented Lagrangian method

By default COMSOL solves contact problem using ALM, in a Segregated Way.
Tn = Contact pressure variable
dg = Gap distance between destination and source boundary
Pn = User defined penalty factor
Penalty Contact Method

hmin
To
G
= Minimum element size on the contact pair.

= Constant penalty factor
= Estimated contact pressure
= Clearance between the parts
Tnp = Penalized contact pressure , Value of penalty factor in ALM does not affect
the accuracy but it influences the convergence.
Penalty contact method does not require extra variable for the contact
pressure. Penalty contact method speeds up the solving process but it is
less exact. Contact pressure estimated from penalty contact formulation
COMSOL Conference, 29-30 October,
2015,
Pune
Unrestricted/
Siemensformulation.
AG 2015. All rights reserved
is not as
precise
as the Augmented
Lagrangian
Page 24
Hyperelastic model results showed

increased deflection level than
viscoelastic model
Viscoelastic model
Page 25
Hyperelastic model
Composite structures application building

using COMSOL
COMSOL API (Application Programming Interface) which is an interface

based on Java, is used to develop custom application based on COMSOL
An initial GUI is built based on a model of a simple Rectangular Block,
having a point force acting on the edge
Final GUI is built based on a model of Mechanical Part, having a
combination of forces and moments acting on it
Halpin-Tsai Model, a semi-empirical model chosen based on its accuracy
and appropriateness, is used to develop algorithm to calculate Composite
Material properties
Ref. Venkateswaran et al., 2014 COMSOL Conference, Bangalore
Page 26
Haplin-Tsai Model to calculate the

composite properties using rule of
mixture
Halpin-Tsai equations are the handy forms of Hills generalized selfconsistent model results with engineering approximations to make them
suitable for the designing of composite materials.
where,
M = composite material modulus E22, G12 or 23
= fiber material modulus Ef, Gf or f
= matrix material modulus Em, Gm, or m
Page 27
User interface for pre-processing
INPUT INTERFACE
Page 28
User interface for post processing
INTERFACE FOR POSTPROCESSING OF

RESULTS
Page 29
Stress plot in a GUI
SIMULATION ON A SIMPLE BLOCK

Page 30
Mesh visualization in GUI
VISUALIZING MESH
Page 31
Contour stress plot in GUI
Page 32
CONTOUR PLOT
Concluding remarks
The modeling of friction stir welding process has enhanced

the understanding of the process, and resulted in reducing
the experimental runs
The selection of appropriate model and parameters is the

key in modeling the non-linear response of the polymeric
structure
JAVA API option in COMSOL enabled the pre and post

processing GUI for composite structures modeling
Page 33
Acknowledgment
Author thanks:
Hande V (Research Group Head)
Siemens Tech. and Services Pvt. Ltd., Bangalore
for his inputs & approval
Chethan Ravi, BR
Siemens Tech. and Services Pvt. Ltd., Bangalore
for his contribution on viscoelastic/hyperelastic
modeling results
Page 34

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Multi-physics and non-linear modeling using

COMSOL Conference, 29-30 October, 2015, Pune

Unrestricted/ Siemens AG 2015. All rights reserved

COMSOL Conference, 29-30 October, 2015, Pune

Unrestricted/ Siemens AG 2015. All rights reserved

Friction Stir Welding (FSW) is relatively advanced

Welding by frictional and plastic/viscous dissipation

Shoulder: Generate frictional heat and prevents material

Pin: Deform material and generate plastic/

COMSOL Conference, 29-30 October, 2015, Pune

Unrestricted/ Siemens AG 2015. All rights reserved

FSW finds application in several industries due to

Image courtesy: 1. www.siemens.com , 2. www.twi-global.com

COMSOL Conference, 29-30 October, 2015, Pune

Unrestricted/ Siemens AG 2015. All rights reserved

Heat generation in FSW is governed by the friction

Heat generation due to shoulder (qshoulder)

Heat generation due to the friction between

Heat generation due to pin tool (qpin)

As surface area of the shoulder

COMSOL Conference, 29-30 October, 2015, Pune

Unrestricted/ Siemens AG 2015. All rights reserved

Temperature dependant yield strength of the

Thermal conductivity (W/m-k)

Yield strength (MPa)

Variation of yield strength with temperature 2

Thermal conductivity of the alloys

COMSOL Conference, 29-30 October, 2015, Pune

Unrestricted/ Siemens AG 2015. All rights reserved

The backing plate effect was simulated by

COMSOL Conference, 29-30 October, 2015, Pune

Unrestricted/ Siemens AG 2015. All rights reserved

Elasto-plastic behavior coupling of the

ys0 is the initial yield stress, and

Elasto plastic behavior of the workpiece

COMSOL Conference, 29-30 October, 2015, Pune

Unrestricted/ Siemens AG 2015. All rights reserved

Elements around the tool/workpiece

COMSOL Conference, 29-30 October, 2015, Pune

Unrestricted/ Siemens AG 2015. All rights reserved

Shear layer around the pin tool has been

Shear layer around the pin2

-angular velocity of tool in (rad/s)

Strain rate and effective strain rate can be

COMSOL Conference, 29-30 October, 2015, Pune

Unrestricted/ Siemens AG 2015. All rights reserved

FSW simulation set up used for AA6061: Initial

Tool pin lower diameter

Tool pin height

Tool shoulder diameter

150 mm x100 mm x 6.1 mm

COMSOL Conference, 29-30 October, 2015, Pune

Unrestricted/ Siemens AG 2015. All rights reserved

Results and discussion

COMSOL Conference, 29-30 October, 2015, Pune

Unrestricted/ Siemens AG 2015. All rights reserved

The weld surface with free from flash was

Unsuccessful welds at low

Direction of tool traverse

The weld surface shows improper (low) heat

COMSOL Conference, 29-30 October, 2015, Pune

Unrestricted/ Siemens AG 2015. All rights reserved

Isothermal temperature contours show peak