Factor analysis of deformation in resistance spot welding of complex steel sheets based on reverse engineering technology and direct finite element analysis

Liu, Xiangbo; Wei, Yanhong; Wu, Haijiang; Zhang, Tao

doi:10.1016/j.jmapro.2020.06.028

Cited by 13 publications

(5 citation statements)

References 17 publications

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“…Zhao, W et al [21] adopted the inherent strain model (ISM), the large heat source model (LHM), and the moving heat source model (MHM) to simulate the welding distortions and residual stresses in a large welded structure of underframe. Liu X et al [22,23] used the nite element method to project the residual stress and deformation during the spot welding of the automobile wall panels, and the simulated were consistent with the experimental results.…”

Section: Introductionmentioning

confidence: 59%

Numerical simulation research on welded residual stress and distortion of aero-engine afterburner lobe mixer with different welding sequences

Jin

Chen

Liu

et al. 2023

Int J Adv Manuf Technol

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Most thin-walled parts of aero-engines with intricate surfaces, such as lobe mixer, are welded using tungsten inert gas (TIG), which will certainly induce stress and distortion, causing a serious in uence on assembly accuracy. The objective of this study was to establish a nite element model to optimize TIG wire ller welding sequence for an aero-engine lobe mixer composed of GH3044 nickel-based superalloy at the thickness of 2 mm. A new method for optimizing residual stress and deformation in the welding of large-size components was proposed.We carried out a 2 mm thickness plate TIG wire ller welding experiment to obtain the ideal process parameters and validate the heat source model and thermal boundary condition, and also designed a set of frock clamp.The stress and distortion of the lobed mixer were analyzed under various welding sequences based on the established nite element model. The results of the study showed that the peak residual stress difference of the lobe mixer is smaller using such a xture. Different welding sequences affected the stress uniformity throughout the structural member. The symmetrical welding of single weld was a better process, with a peak distortion of only 0.54 mm and uniform stress distribution.

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Section: Introductionmentioning

confidence: 59%

Numerical simulation research on welded residual stress and distortion of aero-engine afterburner lobe mixer with different welding sequences

Jin

Chen

Liu

et al. 2023

Int J Adv Manuf Technol

Self Cite

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“…However, there has been no research on how the effect of surface roughness on the strength of mild steel dissimilar joints with stainless steel. The existing literature highlights the influence of material combinations, welding parameters [34], intermetallic compound formation, surface contamination, and HAZ effects on surface roughness.…”

Section: Literature Review and Problem Statementmentioning

confidence: 99%

Optimization of resistance spot welding with surface roughness dissimilar mild steel with stainless steel

Ariyanto,

Sukardin,

Renreng

et al. 2023

EEJET

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Resistance spot welding plays a critical role in the manufacture dissimilar material industry. However, there are differences in mechanical properties between mild steel and satinless steel so as to reduce the quality of welded joints. In order for differences in mechanical properties to be corrected, surface roughness was treated. The aim of this study was to optimize the welding parameters of DRSW with surface roughness by analysis using the Taguchi and Anova Methods. In this study discusses about investigates the Resistance spot welding parameters on weld geometry, mechanical properties, and SEM EDS on dissimilar materials of mild steel and stainless steel. The material thickness of the mild steel and stainless steel are 1 mm, respectively. The process parameters of the resistance spot welding joint used, example; surface roughness, current, welding time, and electrode force. Quality welding joint test results include weld geometry, mechanical properties, and SEM EDS. Weld geometry testing to determine the weld nugget profile. The mechanical properties test was shear tensile test, while the SEM EDS included macrostruture and microstructure observations. The results showed the highest nugget diameter 6.65 mm highest shear tensile strength 7.66 kN. The most influential parameter is current by 75.08 %, then surface roughness by 12.35 %. The highest tensile strength has fewer defects. Surface roughness treatment before welding is very good to make welding quality joints between mild steel and quality stainless steel increase. Surface roughness treatment was very good to be included when making welding procedures for welding engineers for welding processes resistance spot welding dissimilar mild steel with stainless steel.

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“…In welding TWIP steel, an increase in welding current worsens the LME [17] but reduces the tensile residual stress in the weld [18]. Simulations of welding DX56D steel sheets show that the tensile residual stresses in the resistance spot welds cause warpage deformation in the steel sheets, which affects the assembly of the parts [19].…”

Section: Introductionmentioning

confidence: 99%

Effects of Sheared Edge and Overlap Length on Reduction in Tensile Fatigue Limit before and after Hydrogen Embrittlement of Resistance Spot-Welded Ultra-High-Strength Steel Sheets

Yagita,

Abe

2023

Metals

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The effects of a sheared edge and overlap length on the reduction in the tensile fatigue limit before and after hydrogen embrittlement of resistance spot-welded ultra-high-strength steel sheets were investigated. Ultra-high-strength steel sheets with sheared and laser-cut edges were subjected to resistance spot welding followed by hydrogen embrittlement via cathodic hydrogen charging and subjected to static tensile shear and fatigue tests. The distance between the resistance spot weld and the sheared and laser-cut edges was changed by changing the overlap length, and the influence of the weld position was investigated. In the tensile shear test, the maximum load decreased with decreasing overlap length and the maximum load decreased with hydrogen embrittlement, but the effect of hydrogen embrittlement was smaller than that in the fatigue test. In the fatigue test, the fatigue mode changed from the width direction to the sheared edge direction with the increase in the repeated load. Even if the overlap length was reduced, the fracture changed to the sheared edge direction. In the specimens with sheared edges, the effect of fatigue limit reduction due to hydrogen embrittlement was greater than in the specimens with laser surfaces. In particular, the effect was greatest when the fatigue mode was changed via hydrogen embrittlement.

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Factor analysis of deformation in resistance spot welding of complex steel sheets based on reverse engineering technology and direct finite element analysis

Cited by 13 publications

References 17 publications

Numerical simulation research on welded residual stress and distortion of aero-engine afterburner lobe mixer with different welding sequences

Numerical simulation research on welded residual stress and distortion of aero-engine afterburner lobe mixer with different welding sequences

Optimization of resistance spot welding with surface roughness dissimilar mild steel with stainless steel

Effects of Sheared Edge and Overlap Length on Reduction in Tensile Fatigue Limit before and after Hydrogen Embrittlement of Resistance Spot-Welded Ultra-High-Strength Steel Sheets

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