A robust simulation of Direct Drive Friction Welding with a modified Carreau fluid constitutive model

The Carreau type fluid constitutive equation is derived from a Norton-Bailey law wherein the temperature dependency is accounted for by a Johnson-Cook power approach. Its main benefit is the stable and robust simulation of the process and the physical palpability of the utilized material parameters. Using a special element formulation on the general axisymmetric frame in conjunction with an Augmented Lagrange bulk viscosity term, a purely displacement based form of the numerical solution procedure is applicable. A penalty contact approach together with a regularized friction law allow for an efficient determination of the interface pressure and friction forces. The model's performance is demonstrated by means of a test problem highlighting the potential of adopting it to industrial applications later on.