Comparison of 3D and 2D numerical simulation of continuous-drive friction welding process

The 3D and 2D rigid-plastic thermo-mechanical cou-pled finite element models of continuous-drive friction welding process were developed.In 3D model, the tangential frictional-force in friction interface was considered.The transient temperature field, stress field and deformation field during the continuous-drive friction welding process of GH4169 rod are calculated respectively using these two models. The results of 3D and 2D simulation were com-pared. Meanwhile, both of the simulation results were compared with those of experiments. It's found that there is no appreciable difference in the calculated temperature between 3D and 2D simulation, and they both have a good agreement with the experimental results. But when compared to the results of 2D simulation, the calculated equivalent stress with 3D model is higher and more reliable, and the flash shape and axial shortening fit the experimental results better. So the 3D model can more accurately predict the friction welding process.