Analysis and Development of A Real-Time Control Methodology in Resistance Spot Welding

Tsai, C. L.; Dai, Weng L.; Dickinson, D. W.

doi:10.4271/910191

Cited by 66 publications

(66 citation statements)

References 7 publications

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“…To consider practical conditions, the temperaturedependent material properties in Table 1 [9,13] are adopted in the finite element analysis. Also, the elastoplastic material properties as shown in Figure 3 are considered.…”

Section: Problem Statementmentioning

confidence: 99%

Numerical Analysis of Joule Heating Behavior and Residual Compressive Stress around Crack Tip under High Electric Load

Liu

2017

Modelling and Simulation in Engineering

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Section: Problem Statementmentioning

confidence: 99%

Numerical Analysis of Joule Heating Behavior and Residual Compressive Stress around Crack Tip under High Electric Load

Liu

2017

Modelling and Simulation in Engineering

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“…One of the general electrical equations used for calculation of electrical contact resistance is [7,12]:…”

Section: Contact Materials Propertiesmentioning

confidence: 99%

“…Loulou et al [6] used the temperature history for different points to predict the electrical and thermal contact properties. Although Tsai [7] used ANSYS software to predict electrode voltage and displacement, the simulation was mostly based on thermal-electrical aspect. He showed the feasibility of a real-time control methodology by the use of FEA.…”

Section: Introductionmentioning

confidence: 99%

A Review of Finite Element Analysis (FEA) of Resistance Spot Welding (RSW)

Jafari

Arayee

Senkara

2016

Przegląd Spawalnictwa

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Modeling RSW was studied by many researchers with considering different electrical, thermal, and mechanical phenomena such as formation of temperature field and welding nugget growth. This paper is a review of the most important efforts in the field of FEA of RSW, by investigating present finite element method (FEM) studies. After a brief introduction on FEA studies on RSW, such numerical solution methods as FEM and FDM (Finite Difference Method) are compared. Governing electrical, thermal, and mechanical equations are then discussed. A brief investigation about applicable algorithms is presented as a procedure for numerical solution. The importance of credible material properties is emphasized and predicted results in different studies are discussed. The final two parts are about recent issues in RSW FEA process and review of special cases such as multiple-sheet, single-sided welding, shunting effect, and covered models. Conclusions and suggestions about future studies are also provided.

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“…They include such researches as simulation of thermal and electrical distribution (Huh [13], Archer [14], Greenwood [15], Tsai [16]), prediction of the electrical and thermal contact properties and contact radius (Loulou et al [17], Okuda [18]), growth of nugget and thermal deformations (Nied [19] ,Gould [20], Ma [24]), or electro-thermal and mechanical analysis (Zhang [21], Hou [25], Hamedi [26]), to number only a few. Although most of these studies have included different thermal, electrical and mechanical aspects of the RSW process, not many utilized models for finite element analyzing of shunting effect [22][23]27]. Since there is no symmetry in the configuration in that case because of the existence of shunting current, 1D or 2D axisymmetric models used in previous FEA studies for single RSW are of less use.…”

Section: Finite Element Analysis (Fea)mentioning

confidence: 99%

A Review of Shunting Effect in Resistance Spot Welding

Jafari

Senkara

Arayee

2016

Przegląd Spawalnictwa

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Studies on shunting effect in resistance spot welding (RSW) have not been widely performed and limited researches were devoted to some aspects of it. Shunting effect in RSW occurs when the electrical current passes through the preceded spot welds in the case of multi-spot welding. The amount of this current depends mostly on weld spacing, and to some extent, on the number and size of previous spot welds. The phenomenon causes some changes in the quality of shunted weld, such as nugget diameter decrease with consecutive reduction of mechanical strength due to changes in electrical current distribution and temperature distribution. Recently some efforts have been made to develop equations for determine the relationship between the input welding parameters and the quality of spot welds. However, the problem needs deeper research and analysis. The paper reviews different approaches performed for simulation and analysis of shunting in RSW.Keywords: resistance spot welding, shunting, review StreszczenieBadania efektu bocznikowania prądu przy punktowym zgrzewaniu rezystancyjnym (RSW) nie były dotąd szeroko prowadzone i niewiele badań było niektórym jego aspektom. Zjawisko bocznikowania w trakcie RSW pojawia się w sytuacji przepływu prądu elektrycznego przez poprzedzające zgrzeiny w przypadku zgrzewania wieloseryjnego. Wielkość prądu bocznikowania zależy głównie odległości pomiędzy zgrzeinami i w pewnej mierze od ilości i wymiarów poprzedzających zgrzein. Zjawisko to powoduje różnicę jakości bocznikowanej zgrzeiny, poprzez zmniejszenie średnicy jej jądra zgrzeiny, co skutkuje obniżeniem wytrzymałości mechanicznej. Zmiany te są skutkiem zmian rozkładu prądu zgrzewania i temperatury. Ostatnio podjęto starania dla opracowania równań opisujących zależność pomiędzy parametrami wejścio-wymi zgrzewania z bocznikowaniem prądu a jakością zgrzein. Zagadnienie to wymaga jednak głębszych badań i analiz. Niniejsze opracowanie stanowi przegląd prac o różnym podejściu do symulacji i analizy RSW z efektem bocznikowania prądu.Słowa kluczowe: zgrzewanie rezystancyjne punktowe, bocznikowanie prądu, stan zagadnienia

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Analysis and Development of A Real-Time Control Methodology in Resistance Spot Welding

Cited by 66 publications

References 7 publications

Numerical Analysis of Joule Heating Behavior and Residual Compressive Stress around Crack Tip under High Electric Load

Numerical Analysis of Joule Heating Behavior and Residual Compressive Stress around Crack Tip under High Electric Load

A Review of Finite Element Analysis (FEA) of Resistance Spot Welding (RSW)

A Review of Shunting Effect in Resistance Spot Welding

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