The simulation code, SPHriction-3D, uses an innovative parallelization strategy on the graphics processing unit (GPU). In this work, we describe an advanced meshfree computational framework that can be used to determine numerically optimized process parameters while minimizing defects in the friction stir weld zone. However, due to the computational complexity of the multi-physics problem, process parameter optimization has been a goal that is out of reach of the current state-of-the-art simulation codes. There is currently a need for an efficient numerical optimization strategy for the quality of friction stir welded (FSW) joints. Results for temperature fields, surface and weld formation as well as process forces are shown and validated. The resolution reached allows not only simulating the joining of two sheets into one and real tooling geometries but also burr and internal void formation. In this study a Coupled Eulerian-Lagrangian (CEL) approach with Abaqus V6.14 is used for modeling the whole FSW process within one continuous model. Hereby such a model will be a valuable assistance for process and especially tool development. A validated numerical process model may be helpful for closing this gap as well as for an isolated assessment of individual influences and phenomena. The lack of understanding mainly arises from the adverse observability of the actual process with phenomena like material flow and deposition, large material deformations plus their complex thermo-mechanical interactions determining the weld formation and its mechanical properties. Although friction stir welding (FSW) has made its way to industrial application particularly in the last years, the FSW process, its influences and their strong interactions among themselves are still not thoroughly understood.
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