Title: Finite element analysis of ultrasonic insertion of SiC fibre in aluminium alloy 6061

Authors: Amir Siddiq; Elaheh Ghassemieh

Addresses: Mechanical Engineering Department, The University of Sheffield, Sir Frederick Mappin Building, Mappin Street, Sheffield, S1 3JD, UK. ' Mechanical Engineering Department, The University of Sheffield, Sir Frederick Mappin Building, Mappin Street, Sheffield, S1 3JD, UK

Abstract: In this work, a computational framework has been proposed to successfully simulate the fibre embedding using ultrasonic consolidation process. The main components of the proposed computational approach are a developed constitutive model and a friction model which are especially suitable for the condition of ultrasonic process. The effect of different process parameters, such as velocity of sonotrode, displacement amplitude of ultrasonic vibration and applied loads are studied. The presented work especially focuses on the quality of the developed weld and the fibre coverage due to the plastic flow around the fibre. The areas of maximum plastic flow predicted by the simulation are confirmed by the EBSD microstructural studies.

Keywords: finite element analysis; FEA; plastic flow; friction work; ultrasonic consolidation; SiC fibres; aluminium alloys; silicon carbide; simulation; constitutive models; friction modelling; sonotrode velocity; displacement amplitude; ultrasonic vibration; embedded fibres; microstructure; weld quality.

DOI: 10.1504/IJMATEI.2011.042876

International Journal of Materials Engineering Innovation, 2011 Vol.2 No.3/4, pp.182 - 202

Published online: 07 Oct 2011 *

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