Finite Element Simulation of Resistance Spot Welding Process

2003 ◽  
Author(s):  
Manabu Fukumoto ◽  
Hiroki Fujimoto ◽  
Kazuo Okamura ◽  
Kiyoyuki Fukui
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Resistance Spot ◽  
Element Simulation

A Comparative Study of Single-Phase AC and Multiphase DC Resistance Spot Welding

2004 ◽  
Vol 127 (3) ◽  
pp. 583-589 ◽  
Author(s):  
Wei Li ◽  
Daniel Cerjanec ◽  
Gerald A. Grzadzinski
Keyword(s):  
Finite Element ◽  
Comparative Study ◽  
Simulation Model ◽  
Finite Element Simulation ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Single Phase ◽  
Welding Process ◽  
Welding Current ◽  
Element Simulation

This paper presents a comparative study of the AC and MFDC resistance spot welding process. Both experiments and finite element simulation were conducted to compare the weld size and energy consumption. The experiments were performed on two identical spot welding machines, one with a single phase ac and the other with a mid-frequency DC weld control. The machines were instrumented such that both the primary and secondary voltage and current signals could be collected for energy calculation. The finite element simulation model was developed to understand the underlying mechanisms of the difference between the ac and MFDC processes. The effect of the current waveform was investigated by using the actual process measurements as an input to the simulation model. It is shown that the MFDC process generally produces larger welds than the AC process with the same root-mean-square welding current. However, this difference is more prominent when the welding current is relatively low. Overall, the AC welding process consumes more energy to make a same sized weld than the MFDC process. The larger the welding current is used, the less efficient the AC welding process will become. The differences between the two welding processes are caused by the contact resistance behavior and the electrical inductance in the AC welding process.

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

2007 ◽  
Vol 185 (1-3) ◽  
pp. 160-165 ◽  
Author(s):  
Zhigang Hou ◽  
Ill-Soo Kim ◽  
Yuanxun Wang ◽  
Chunzhi Li ◽  
Chuanyao Chen
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Element Analysis ◽  
Resistance Spot

Finite Element Analysis for Mechanical Characteristics of Resistance Spot Welding Process with Three Sheets Assemblies

2012 ◽  
Vol 233 ◽  
pp. 369-373
Author(s):  
Zhen Zhen Lei ◽  
Hong Tae Kang ◽  
Jiu Hua Wang ◽  
Lian Cheng Ren ◽  
Yong Gang Liu
Keyword(s):  
Finite Element ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Mechanical Characteristics ◽  
High Stress ◽  
Welding Process ◽  
Fe Analysis ◽  
Stress Strain ◽  
Resistance Spot ◽  
Three Sheets

This project is focused on the finite element (FE) analysis for mechanical characteristics of resistance spot welding (RSW) process with three sheets stack up instead of conventional two sheets assemblies because of its wide application in automobile industry. It is proved that the protuberances region localized in the nugget area induced in the welding process are more inclined to have fatigue failure such as cracks and fracture. Local stress and strain distributions for three sheets stack up under quasi-static tension load are investigated by both experiments and FE analysis with commercial software code ANSYS and NASTRAN. The high stress/strain value is concentrated at the edges of nugget instead of nugget center from cross section view and stress/strain distribution at the center region of the weld nugget is relatively low. The FE analysis has effectively verification with the experiments results.

THERMOMECHANICAL ANALYSIS OF THE RESISTANCE SPOT-WELDING PROCESS

2018 ◽  
Vol 10 (5) ◽  
pp. 449-455 ◽  
Author(s):  
Habib Lebbal ◽  
Lahouari Boukhris ◽  
Habib Berrekia ◽  
Abdelkader Ziadi
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Thermomechanical Analysis ◽  
Resistance Spot
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