Journal of Computational Physics 270 (2014) 478–489 Contents lists available at ScienceDirect Journal of Computational Physics www.elsevier.com/locate/jcp Implicit Geometry Meshing for the simulation of Rotary Friction Welding D. Schmicker a,∗ , P.-O. Persson b , J. Strackeljan a a Otto-von-Guericke University of Magdeburg, Universitätsplatz 2, 39106 Magdeburg, Germany b University of California, Berkeley, 970 Evans Hall 3840, Berkeley, CA 94720-3840, USA article info abstract Article history: Received 11 September 2013 Received in revised form 26 March 2014 Accepted 5 April 2014 Available online 13 April 2014 Keywords: Rotary Friction Welding simulation Implicit Geometry Meshing Carreau fluid law Computational fluid dynamics The simulation of Rotary Friction Welding (RFW) is a challenging task, since it states a coupled problem of phenomena like large plastic deformations, heat flux, contact and friction. In particular the mesh generation and its restoration when using a Lagrangian description of motion is of significant severity. In this regard Implicit Geometry Meshing (IGM) algorithms are promising alternatives to the more conventional explicit methods. Because of the implicit description of the geometry during remeshing, the IGM procedure turns out to be highly robust and generates spatial discretizations of high quality regardless of the complexity of the flash shape and its inclusions. A model for efficient RFW simulation is presented, which is based on a Carreau fluid law, an Augmented Lagrange approach in mapping the incompressible deformations, a penalty contact approach, a fully regularized Coulomb-/fluid friction law and a hybrid time integration strategy. The implementation of the IGM algorithm using 6-node triangular finite elements is described in detail. The techniques are demonstrated on a fairly complex friction welding problem, demonstrating the performance and the potentials of the proposed method. The techniques are general and straight-forward to implement, and offer the potential of successful adoption to a wide range of other engineering problems.  2014 Elsevier Inc. All rights reserved. 1. Introduction Rotary Friction Welding (RFW) is a solid state welding process widely used in the automotive, aeronautic and railway industries. In this joining process, typically one part is clamped while the other one is spinning and pressed onto the weld surface. Once enough frictional heat is generated, the spindle breaks and the two parts are forged together [14,15]. The main bonding mechanisms are diffusion and in case of two dissimilar materials the formation of intermetallic phases. Since no additives are needed during the procedure, the weld is quite uncontaminated in comparison to conventional arc welding processes. Other major benefits are the symmetry of the joint, the stability of the process, the short cycle times and the smaller heat affected zone [31]. Besides RFW, other processes such as Friction Stir Welding (FSW) [7], Linear Friction Welding (LFW), Inertia Friction Welding (IFW) and Orbital Friction Welding (OFW) exist, differing mainly in the relative kinematic movement of the weld partners. The motivation for modeling these joining processes includes more understanding of the physics [12,17], prediction of process parameters [32,33], tool optimization [20–22] and microstructure and defect modeling [16,27]. Most of the proposed * Corresponding author. E-mail address: david.schmicker@ovgu.de (D. Schmicker). http://dx.doi.org/10.1016/j.jcp.2014.04.014 0021-9991/ 2014 Elsevier Inc. All rights reserved.