Nugget Formation during Resistance Spot Welding using Finite Element Model

Authors: Jawad Saleem, Abdul Majid, Kent Bertilsson, Torbjörn Carlberg, Nazar Ul Islam

Abstract:

Resistance spot welding process comprises of electric, thermal and mechanical phenomenon, which makes this process complex and highly non-linear and thus, it becomes difficult to model it. In order to obtain good weld nugget during spot welding, hit and trial welds are usually done which is very costly. Therefore the numerical simulation research has been conducted to understand the whole process. In this paper three different cases were analyzed by varying the tip contact area and it was observed that, with the variation of tip contact area the nugget formation at the faying surface is affected. The tip contact area of the welding electrode becomes large with long welding cycles. Therefore in order to maintain consistency of nugget formation during the welding process, the current compensation in control feedback is required. If the contact area of the welding electrode tip is reduced, a large amount of current flows through the faying surface, as a result of which sputtering occurs.

Keywords: Resistance spot welding, Finite element modeling, Nugget formation, Welding electrode, Numerical method simulation,

Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1330959

References:

[1] Larry Jeffus "Welding principals and applications" Fourth edition Thomson Learning 1999, pp. 678-681.
[2] J.E Vargas, M.A Wolff, L.O Vilarinho "Comparison between AC and MF-DC resistance spot welding by using high speed filming" Journal of Achievement in Materials and Manufacturing Engineering Volume 24 Issue 1 September 2007.
[3] J.A. Greenwood, "Temperature in Spot Welding", British Welding Journal, 1961, 9, 316-322.
[4] A.F. Houchens, R, E. Page, W. H. Yang, "Numerical Modeling of resistance Spot Welding, Numerical Modeling of Manufacturing Process", The Welded Annual Meeting of the American Society of Mechanical Engineering Atlanta, Georgia, 1977, 117-129.
[5] Nied H.A "Finite element modeling of resistance spot welding process" Weld. Journal . Vol. 63, no. 4, pp. 123s-132s. Apr. 1984.
[6] J.E Gould "An Examination of Nugget Development during Spot Welding, Using Both Experimental and Analytical Techniques" Supplement to the Welding Journal Januay 1987.
[7] H.Huh and W.J. Kang "Electrothermal analysis of electric resistance spot welding by a 3-D finite element method" Journal of material technology (63) 1997, pp.672-677.
[8] R.J Bowers, T.W Eagar "Non- uniform Current Distribution In Spot Welding" Americam welding society ASW Sheet Metal Welding Conference, Detroit, MI October 1986.
[9] MA. Ninshu and Murakawa "Numerical and Experimental Study on Nugget Formation in Resistance Spot Welding for High Strength Steel Sheets in Automobile Bodies" Transactions of Joining and Welding Research Institute (JWRI), Vol.38 (2009) No. 2.
[10] J.A Khan, L. Xu, and Y.J Chao "Prediction of nugget development during resistance spot welding using coupled thermal-electricalmechanical model" Science and technology of welding and joining ,1999 Vol.04 No: 04.
[11] ZhigangHoua, SooKimb,*, Yuanxun Wang a, Chunzhi Li c, Chuanyao Chena "Finite element analysis for the mechanical features of resistance spot welding process" Journal of Materials Processing Technology 185 (2007) 160-165.
[12] GuoZhong "Finite element analysis of resistance spot welding process" Chinese Control and Decision Conference,CCDC 2009.
[13] M.Hamedi, H Pashazadeh "Numerical study of the nugget formation in resistance spot welding "International Journal of Mechanics, Issue 1 Volume 2 ,2008 .
[14] Hamid Eisazadeh a,*, Mohsen Hamedi b, AyobHalvaee "New parametric study of nugget size in resistance spot welding process using finite element method". Materials and Design 31 (2010) 149-157.
[15] Thakur.A.G, Rasane.A.R, Nandedkar.V.M "Finite element analysis of resistance spot welding nugget formation" International Journal of Applied Engineering and Research, Dindigul, Volume 1 , No: 3,2010 .
[16] ComsolMultiPhysics 4.2,http://www.comsol.com. Last access().
[17] COMSOL Multiphysics 3.5a: User's Guide 3.5a.
[18] Meranda Saleem "Control and power supply for resistance spot welding " thesis submitted in partial fulfillment for degree of PhD University of Western Ontario London, Ontario, Canada.
[19] User Manual "TEC600 Spot Welding Unit ver.3.xx-p".by IBEROBT.