Hybrid numerical modeling of Friction Assisted Joining

A hybrid non-linear numerical model of the thermal field produced during Friction Assisted Joining process of Metal-polymers hybrid joints is developed. The model uses experimental processing loads (plunging load and torque) measured during an experimental campaign as inputs. A hybrid approach was used to simulate the contact between the tool and the metal sheet. Indeed, the plunging load was simulated as a prescribed load acting on the punch while the friction heat owing to the interaction of the rotating tool with the metal sheet was simulated as a distributed heat flux over the tool-metal contact surface. This enabled a dramatic reduction of the complexity of the model along with a short simulation runtime. During experimental tests, an IR camera was used to measure the real temperature evolution. These data were used to calibrate and validate the FE model. The results indicated that the developed model can accurately predict the temperature field on the upper metal surface. Thus, it can be readily used to forecast the temperature evolution and distribution and the metal-polymer interface, which is the most influencing factor that determines the mechanical behavior of this type of joints.