Finite element analysis of the thermo-mechanical behavior of the resistance spot welding

Vural, M.

doi:10.12748/uujms/20131710

Cited by 3 publications

(3 citation statements)

References 12 publications

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“…Interface contact of both base metal has 14.3 -37.7 x 106 S/m (siemen/metter) electrical conductivity. Mechanical and physical properties of base metal and electrode are presented in table 4 [11][12]. Mesh design is shown in Fig.…”

Section: Methodsmentioning

confidence: 99%

Study on Nugget Growth in Resistance Spot Welding of Thin Aluminum A1100 Using Welding Simulation

Baskoro

Edyanto

Amat

et al. 2018

MSF

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Resistance spot welding (RSW), generally which is one of the most often used to joint metal plate in the automotive and aviation industries. RSW welding process involves electrical, thermal mechanical, metallurgy, and complex surface phenomenon. Unlike the other welding processes, weld joint formation in RSW process occurs very quick (in milli-seconds) and took place between the workpieces overlap each other. Welding simulation allows visual examination of the weld joint without having to perform an expensive experiment. Weld nugget size is the most important parameter in determining the mechanical behavior of welded joints in RSW process. The quality and strength of the weld joint in RSW process is predominantly determined by the shape and size of the weld nugget. Simulation modeling of RSW process performed using ANSYS Parametric Design Language (APDL) module based on the finite element method (FEM), embedded in ANSYS Workbench. Electrical and transient-thermal interaction was developed to study the weld nugget growth on resistance spot welding of aluminum A1100 metal plate with a thickness of 0.4 mm respectively. Weld nugget diameter can be well predicted by using this simulation model from the temperature distribution during the welding process. Welding is performed by varying the weld current (1 kA and 2 kA) and the welding time for each electric current, which are start from 0.5, 1.0, and 1.5 cycle time. Nugget diameter for each of the welding parameters from the simulation modelling were 4,276 mm, 4,372 mm, 4,668 mm, 5,616 mm and 5,896 mm. Weld expulsion occurred for the specimen with welding current 2 kA and welding time 1.5 cycle time, characterized by the decreasing of the tensile-shear strength of the specimen.

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Section: Methodsmentioning

confidence: 99%

Study on Nugget Growth in Resistance Spot Welding of Thin Aluminum A1100 Using Welding Simulation

Baskoro

Edyanto

Amat

et al. 2018

MSF

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“…Corresponding material characteristics were employed to conduct the model calculation, which included mechanical characteristics such as Young's modulus and yield stress, physical characteristics such as density, thermal conductivity, thermal expansion coefficient and specific heat capacity, as well as the electrical characteristics such as electrical conductivity. 18,19) In addition, considering the relation between the latent heat and enthalpy of the parent metal sheets, the latent heat value, which was 2.72 × 10 − 5 J/Kg, 20) was combined into the enthalpy setting. Moreover, the tangent modulus of the electrode was respectively 1 800 MPa.…”

Section: Fe Model and Boundary Conditionsmentioning

confidence: 99%

“…Zhao et al 27) and Zhang 28) used an average pressure of the nodes to replace the contact pressures; however, this can induce more errors because the contact pressure of different nodes had more differences. In addition, in some previous works, 6,20,29) the mesh was so sparse in some key zones, which made the calculation of contact area inaccurate and deteriorated the accuracy of the calculations. Because some contributions may not seriously consider all conditions setting during the calculation, as well as other simplicities, such as no considering the friction between different contact surfaces, setting the density of metal to be a constant without considering the temperature variation, the numerical calculation and simulation results of nugget size and other key process variables had more errors, which significantly limited the generality and consistency of the model calculation and simulation results.…”

Section: Heat and Electrical Contactmentioning

confidence: 99%

Analysis of Process Signals of Resistance Spot Welding for DP590 Steel Using Numerical Calculation

Zhou

Wang

et al. 2022

ISIJ Int.

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Although the finite element (FE) numerical calculation model has been extensively employed in analyzing metal characteristics, very few works use it to analyze features of the main process signals during the resistance spot welding (RSW) process. Hence, its generality was seriously restricted. In this work, a 2D FE model, which coupled thermal, electrical and mechanical fields, was established with reasonable meshing and parameters and boundary conditions. The parent metal used dual phase (DP) 590 steel, which is commonly employed in automobile lightweight manufacturing process. An actual experiment with the same conditions as the numerical calculation was conducted. The dynamic resistance and electrode displacement obtained from numerical calculation and actual experiment were seriously compared and analyzed. Many important characteristics of process signals have been reasonably explained by combining the results obtained from numerical calculation and experiments. The reasonability and accuracy of the FE numerical calculation were not only verified after the welding process but also examined in depth during the intermediate welding process. Hence, the work can effectively enlarge the applications of the FE model and strengthen the correlation between control strategy design, online quality estimation using main process signals and FE numerical calculation during the RSW process.

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Revealing the Influence of Microstructural Features on the Hardness Heterogeneity of Resistance Spot Welded Ultra-Low-Carbon Steel

Pawar,

Singh,

Kaushik

et al. 2022

SSRN Journal

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Finite element analysis of the thermo-mechanical behavior of the resistance spot welding

Cited by 3 publications

References 12 publications

Study on Nugget Growth in Resistance Spot Welding of Thin Aluminum A1100 Using Welding Simulation

Study on Nugget Growth in Resistance Spot Welding of Thin Aluminum A1100 Using Welding Simulation

Analysis of Process Signals of Resistance Spot Welding for DP590 Steel Using Numerical Calculation

Revealing the Influence of Microstructural Features on the Hardness Heterogeneity of Resistance Spot Welded Ultra-Low-Carbon Steel

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