Optimal design of electrode cooling system for resistance spot welding with the response surface method

Lai, Xinmin; Luo, Aifang; Zhang, Yan Song; Chen, G. L.

doi:10.1007/s00170-008-1478-5

Cited by 14 publications

(10 citation statements)

References 3 publications

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“…Furthermore, an optimal design of an electrode cooling system is also adopted to improve the cooling effect and prolong electrode life. However, according to the previous research [11] that cap cooling improvement might not be sufficient for welding of thin gage steel.…”

Section: Introductionmentioning

confidence: 91%

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Resistance Spot Welding of Ultra-Thin Automotive Steel

Zhao¹,

Zhang

Lai

et al. 2013

Journal of Manufacturing Science and Engineering

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One of the major challenges in spot welding of ultra-thin gage steel (e.g., <0.6mm) is the short cap life. Because of the elevated temperature developed at the electrode/sheet interface, the electrodes often require dressing or replacement within a fraction of the time when welding more traditional automotive gage steel (>0.75mm). In this study, the method of inserting flexible strips between the electrode and workpiece in resistance spot welding of 0.4 mm thick galvanized SAE1004 steel sheet has been adopted in order to reduce electrode tip temperature and improve weld quality. The effect of the inserted strips on the Joule heat generation and temperature distribution has been analyzed analytically. Then, because of the difficulties in measuring the experimental electrode tip temperature, a finite element model has been employed to estimate temperature distributions within the weld zone. The effects of the process variables (i.e., strip material and thickness) on the cap temperature and weld quality were modeled. Experiments were also conducted to validate the modeling results. Test data and modeling results showed that the presence of the strip significantly facilitated weld initiation and growth and decreased the rate of electrode degradation. Of the materials investigated, the desirable strip for resistance spot welding 0.4 mm thick galvanized SAE1004 steel was determined to be 0.12 mm thick Cu55Ni45 alloy.

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Section: Introductionmentioning

confidence: 91%

“…(11), the temperature at the electrode tip, @E, is decreased by using the strips. However, it is difficult to estimate @P quantitatively by the analytical method due to the nonlinearity of the RSW process, and a series of assumptions and simplifications made in the formulations.…”

Section: Electrode Tip Temperaturementioning

confidence: 99%

Resistance Spot Welding of Ultra-Thin Automotive Steel

Zhao¹,

Zhang

Lai

et al. 2013

Journal of Manufacturing Science and Engineering

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“…They used the response surface method with a central composite design and studied the response of bead width, depth to width ratio of bead, weld fusion zone area, and depth of penetration. Lai et al [5] applied the response surface method for the optimization of resistance spot welding. The response parameters they selected for the study were the electrode diameter and the effect on the electrode during the cooling process.…”

Section: Literature Reviewmentioning

confidence: 99%

Multi-Objective Welding-Parameter Optimization Using Overlaid Contour Plots and the Butterfly Optimization Algorithm

2022

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Distortion and residual stress are two unwelcome byproducts of welding. The former diminishes the dimensional accuracy while the latter unfavorably affects the fatigue resistance of the components being joined. The present study is a multi-objective optimization aimed at minimizing both the welding-induced residual stress as well as distortion. Current, voltage, and welding speed were the welding parameters selected. It was observed that the parameters that minimize distortion were substantially different from those that minimized the residual stress. That is, enhancing dimensional accuracy by minimizing distortion results in an intensification of residual stresses. A compromise between the two objectives was therefore necessary. The contour plots produced from the response surfaces of the two objectives were overlaid to find a region with feasible parameters for both. This feasible region was used as the domain wherein to apply the novel butterfly optimization algorithm (BOA). This is the first instance of the application of the BOA to a multi-objective welding problem. Weld simulation and a confirmatory experiment based on the optimum weld parameters thus obtained corroborate the efficacy of the framework.

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“…There are several studies in scientific literature related to the measurement system analysis on RSW processes, such as: Wan et al [37]; Degidi et al [38]; Wang et al [39]; Xia et al [40]; Simončič, & Podržaj [15]; Al-Jader et al [41]; Lei et al [42]; Lai et al [43]; Podržaj et al [11].…”

Section: A Gage Study Applied In Shear Test To Identify Variation Caumentioning

confidence: 99%

A Gage Study Applied in Shear Test to Identify Variation Causes from a Resistance Spot Welding Measure System

2018

SV-JME

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Resistance welding processes, especially spot welding, have wide applicability in the industry, especially in the automotive sector, due to its fast execution and the non-use of consumables. In addition, the search for quality improvement of the final product is incessant and, in a capable process, there should be no error related to the measurements. In this study, the NGR&R was used by the ANOVA method to identify the variation components of the measurement system in the shear test for two quality characteristics: tensile-shear strength and ultimate strain. The experiments were conducted on a hot dip galvanized steel by using design of experiments to select the parts in order to represent the real amplitude of the process. From the results it was possible to verify that one of the destructive test machines used in this study has a strong variability, evidencing that some adjustments and improvements are necessary in the coupling of the specimens for steels with coating layers (such as galvanized steel, which has a layer of zinc).

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Optimal design of electrode cooling system for resistance spot welding with the response surface method

Cited by 14 publications

References 3 publications

Resistance Spot Welding of Ultra-Thin Automotive Steel

Resistance Spot Welding of Ultra-Thin Automotive Steel

Multi-Objective Welding-Parameter Optimization Using Overlaid Contour Plots and the Butterfly Optimization Algorithm

A Gage Study Applied in Shear Test to Identify Variation Causes from a Resistance Spot Welding Measure System

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