Finite element analysis for the mechanical features of resistance spot welding process

Zhong-jie, Hou; Kim, Ill-Soo; Wang, Yuanxun; Li, Chunzhi; Chen, Chuanyao

doi:10.1016/j.jmatprotec.2006.03.143

Cited by 91 publications

(62 citation statements)

References 12 publications

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“…Bottom of the lower electrode (19) Free surfaces of the weldments (20) 6 e and are body force and acceleration vectors respectively [22]. Mechanical dary conditions are provided in Table 3 according to Fig.…”

Section: Boundary Equationmentioning

confidence: 99%

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Experimental and numerical analysis of shunting effect in resistance spot welding of Al2219 sheets

Vardanjani¹,

Araee²,

Senkara³

et al. 2016

Bulletin of the Polish Academy of Sciences Technical Sciences

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Abstract. Few aspects of shunting effect have been studied so far. Shunting effect in resistance spot welding (RSW) occurs when the electrical current passes through the previous spot welds. Value of this current depends mostly on distance, number, and size of previous spot welds. This will cause some dimensional and metallurgical changes in welding nugget as well as heat affected zone (HAZ). In this study, shunting effect of RSW is considered by finite element method (FEM) and the results are compared to experiments performed on aluminum alloy 2219. Weld spacing together with welding current and time are considered to discover the effect of shunting current in the final quality of nugget. A three factor experiment design has been performed to find the significance of factors and interactive effects, as well as finite element model verification. Electrothermal and mechanical interactions are considered in the FEM. Experimental and numerical solutions have yielded similar results in terms of welding nugget properties. Asymmetry in electrical potential, temperature, stress distribution and geometry of shunted nugget is predicted and verified directly or indirectly. Intense effect of shunting current on nugget height, asymmetric growth of heat affected zone (HAZ) toward previous welding nugget, as well as concentration of alloying elements along grain boundaries are also discovered. Kim et al. [17]). Although most of these studies have included thermal, electrical and mechanical aspects of the RSW process, the asymmetry of shunting configuration due to existence of shunting (previous) nugget prohibits the use of 1D or 2D axisymmetric models.In this paper, shunting effect in RSW is investigated using FEM and the results are compared with experiments on AA2219. The influence of welding distance, current and time are investigated to consider shunting effect in final quality of the nugget. Experiments are designed inside the weldability range, while the results are compared to results of FEM after verification. have included thermal, electrical and mechanical aspects shunting configuration due to existence of shunting (prev 2D axisymmetric models. MethodsIn this paper, shunting effect in RSW is investigated using with experiments on AA2219. The influence of welding d investigated to consider shunting effect in final quality of inside the weldability range, while the results are compar

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Section: Boundary Equationmentioning

confidence: 99%

“…Table 5 and 6 provide chemical composition and important properties of 00 (electrodes), respectively. 6 e and are body force and acceleration vectors respectively [22]. Mechanical dary conditions are provided in Table 3 according to Fig.…”

Section: Materials Propertiesmentioning

confidence: 99%

Experimental and numerical analysis of shunting effect in resistance spot welding of Al2219 sheets

Vardanjani¹,

Araee²,

Senkara³

et al. 2016

Bulletin of the Polish Academy of Sciences Technical Sciences

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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].…”

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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“…Force is applied before, during, and after the application of electric current to maintain the electrical connectivity and to provide the pressure necessary to produce defect-free seam welds. This process involves strong interactions between electrical, thermal, metallurgical, and mechanical fields (Feng et al 1998;Feulvarch et al 2004;Hou et al 2007).…”

Section: Governing Equation and Boundary Conditionsmentioning

confidence: 99%

Analysis on Development of Transverse - Sectioned Weld Zone using FEM Verified with Multipulsed Resistance Seam Welding

Muhammad

Manurang

2013

Jou. Eng. Res.

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This paper details an investigation, through an experimental study, of the development of weld nuggets and a heat-affected zone (HAZ) in resistance seam welding (RSEW) using a numerical simulation approach. SYSWELD software for the simulation of heat treatment, welding, and welding assembly was utilized for the simulation process. The integrated Spot Weld Advisor (SWA) in SYSWELD was applied to simulate the RSEW model using a two-dimensional axis-symmetric FE model with customized electrode meshing. The thermal-mechanical-electrical characteristic and contact condition were taken into account throughout this study. The developed model comprised a transverse cross section for welding two layers of low carbon steel with a thickness of 1 mm. For the experimental verification, three-pulsed RSEW with two different current stages was carried out. It was discovered that this program code, Spotweld Advisor, when used with the meshing method, was capable of offering results that were in agreement with physical experiments.

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Finite element analysis for the mechanical features of resistance spot welding process

Cited by 91 publications

References 12 publications

Experimental and numerical analysis of shunting effect in resistance spot welding of Al2219 sheets

Experimental and numerical analysis of shunting effect in resistance spot welding of Al2219 sheets

A Review of Shunting Effect in Resistance Spot Welding

Analysis on Development of Transverse - Sectioned Weld Zone using FEM Verified with Multipulsed Resistance Seam Welding

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