Numerical modeling based on coupled Eulerian-Lagrangian approach and experimental investigation of water jet spot welding process

Spot welding is one of the most convenient processes to create a quick and permanent joint between lightweight industrial metallic parts and is an integral part of manufacturing processes especially in auto-motive industry. Currently, electrical resistance welding is the most applied method in spot welding. However it has some limitations. For instance, welding of metals with far melting points and oxidization of surfaces. Alternative methods such as explosive welding,laser spot welding,and impact spot welding have been introduced to over-come the limitations of conventional methods of spot welding. The latter proposes high quality, steady and reliable connection between parts by creating solid phase bonding and interlock between surfaces. For this purpose, a high velocity projectile or slug of water impacts a predetermined point and a permanent connection would be created at the neighboring zone. The high pressure produced by impact of liquid jet with solid surfaces, lasts for very short intervals of time and is followed by a rapid radial flow of the liquid at speeds which may be several times higher than the impact speed itself .Eulerian analysis is a suitable technique for problems in which the material undergoes extreme deformations, especially in modeling of fluid flow. Through an eulerian analysis in FEM, the nodes are completely fixed in space and the material flows through elements which will remain undeformed during the analysis. This advantage would let the material to experience extreme deformations and strain rates, with elimination of the possibility of element distortion. On the other hand, in Lagrangian analysis nods are fixed within the material and the material boundary coincides with elements boundaries. Therefore the elements would deform, as the material deforms. The Lagrangian
technique is well suited for the problems in which the material is in solid state. Nevertheless, in case of problems in which the strain rate in solid medium is too high and the material acts like a fluid medium

In this simulation CEL method has been used and you can see a figure of parts in assembly at below

Dynamic explicit step , surface to surface contact with frictional behavior has been used to define the real behavior between two plates. Uniform material assignment is used to model water as eulerian part with initial velocity. During the impact flyer plate move through the base plate and we can recognize a huge stress between two plate in the contact zone and this stress causes a joint between plates. You can see some figures of this simulation at below

You can provide CAE ,INP,and English video files of this simulation here. The cost of these files is Twenty-Two Euros. you can click on the bellow bottom to beginning process

You can purchase the tutorial through a PayPal account, a Visa, or a Master card,  just before payment,send me an email to this address: karampourp@gmail.com