Search results for: Numerical.

Authors: R. Haoui

Abstract:

The purpose of this work is to simulate the flow at the exit of Vulcan 1 engine of European launcher Ariane 5. The geometry of the propellant nozzle is already determined using the characteristics method. The pressure in the outlet section of the nozzle is less than atmospheric pressure on the ground, causing the existence of oblique and normal shock waves at the exit. During the rise of the launcher, the atmospheric pressure decreases and the shock wave disappears. The code allows the capture of shock wave at exit of nozzle. The numerical technique uses the Flux Vector Splitting method of Van Leer to ensure convergence and avoid the calculation instabilities. The Courant, Friedrichs and Lewy coefficient (CFL) and mesh size level are selected to ensure the numerical convergence. The nonlinear partial derivative equations system which governs this flow is solved by an explicit unsteady numerical scheme by the finite volume method. The accuracy of the solution depends on the size of the mesh and also the step of time used in the discretized equations. We have chosen in this study the mesh that gives us a stationary solution with good accuracy.

Keywords: Launchers, supersonic flow, finite volume, nozzles, shock wave.

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Authors: Ahmad Fahim Nasiry, Shigeo Honma

Abstract:

We examine two-dimensional oil displacement by water in a petroleum reservoir. The pore fluid is immiscible, and the porous media is homogenous and isotropic in the horizontal direction. Buckley-Leverett theory and a combination of Laplacian and Darcy’s law are used to study the fluid flow through porous media, and the Laplacian that defines the dispersion and diffusion of fluid in the sand using heavy oil is discussed. The reservoir is homogenous in the horizontal direction, as expressed by the partial differential equation. Two main factors which are observed are the water saturation and pressure distribution in the reservoir, and they are evaluated for predicting oil recovery in two dimensions by a physical and mathematical simulation model. We review the numerical simulation that solves difficult partial differential reservoir equations. Based on the numerical simulations, the saturation and pressure equations are calculated by the iterative alternating direction implicit method and the iterative alternating direction explicit method, respectively, according to the finite difference assumption. However, to understand the displacement of oil by water and the amount of water dispersion in the reservoir better, an interpolated contour line of the water distribution of the five-spot pattern, that provides an approximate solution which agrees well with the experimental results, is also presented. Finally, a computer program is developed to calculate the equation for pressure and water saturation and to draw the pressure contour line and water distribution contour line for the reservoir.

Keywords: Numerical simulation, immiscible, finite difference, IADI, IADE, waterflooding.

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Authors: Yang Liu, Jinfeng Wang, Hong Li, Wei Gao, Siriguleng He

Abstract:

A new numerical scheme based on the H1-Galerkin mixed finite element method for a class of second-order pseudohyperbolic equations is constructed. The proposed procedures can be split into three independent differential sub-schemes and does not need to solve a coupled system of equations. Optimal error estimates are derived for both semidiscrete and fully discrete schemes for problems in one space dimension. And the proposed method dose not requires the LBB consistency condition. Finally, some numerical results are provided to illustrate the efficacy of our method.

Keywords: Pseudo-hyperbolic equations, splitting system, H1-Galerkin mixed method, error estimates.

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Authors: Liu Xuedong , Liu Zhiyan

Abstract:

When the crisscross baffles and logarithmic spiral baffles are placed on the bottom of the stirred tank with elliptic bottom, using CFD software FLUENT simulates the velocity field of the stirred tank with elliptic bottom and bottom baffles. Compare the velocity field of stirred tank with bottom crisscross baffle to the velocity field of stirred tank without bottom baffle and analysis the flow pattern on the same axis-section and different cross-sections. The sizes of the axial and radial velocity are compared respectively when the stirred tank with bottom crisscross baffles, bottom logarithmic spiral baffles and without bottom baffle. At the same time, the numerical calculations of mixing power are compared when the stirred tank with bottom crisscross baffles and bottom logarithmic spiral baffles. Research shows that bottom crisscross baffles and logarithmic spiral baffles have a great impact on flow pattern within the reactor and improve the mixing effect better than without baffle. It also has shown that bottom logarithmic spiral baffles has lower power consumption than bottom crisscross baffles.

Keywords: Bottom baffle, Flow field, Numerical simulation, Stirred tank.

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Authors: Tudor Barbu

Abstract:

We present a robust nonlinear parabolic partial differential equation (PDE)-based denoising scheme in this article. Our approach is based on a second-order anisotropic diffusion model that is described first. Then, a consistent and explicit numerical approximation algorithm is constructed for this continuous model by using the finite-difference method. Finally, our restoration experiments and method comparison, which prove the effectiveness of this proposed technique, are discussed in this paper.

Keywords: Image denoising and restoration, nonlinear PDE model, anisotropic diffusion, numerical approximation scheme, finite differences.

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Authors: Wang Zhulin, Min Fuhong, Peng Guangya, Wang Yaoda, Cao Yi

Abstract:

In this paper, a magnetron memristor model based on hyperbolic sine function is presented and the correctness proved by studying the trajectory of its voltage and current phase, and then a memristor chaotic system with the memristor model is presented. The phase trajectories and the bifurcation diagrams and Lyapunov exponent spectrum of the magnetron memristor system are plotted by numerical simulation, and the chaotic evolution with changing the parameters of the system is also given. The paper includes numerical simulations and mathematical model, which confirming that the system, has a wealth of dynamic behavior.

Keywords: Memristor, chaotic circuit, dynamical behavior, chaotic system.

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Authors: M. Raciti Castelli, P. Cioppa, E. Benini

Abstract:

This paper presents a CFD analysis of the flow around a 30° inclined flat plate of infinite span. Numerical predictions have been compared to experimental measurements, in order to assess the potential of the finite volume code of determining the aerodynamic forces acting on a flat plate invested by a fluid stream of infinite extent. Several turbulence models and spatial node distributions have been tested and flow field characteristics in the neighborhood of the flat plate have been numerically investigated, allowing the development of a preliminary procedure to be used as guidance in selecting the appropriate grid configuration and the corresponding turbulence model for the prediction of the flow field over a twodimensional inclined plate.

Keywords: CFD, lift, drag, flat plate

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Authors: Raphael de Oliveira Garcia, Samuel Rocha de Oliveira

Abstract:

We have developed a new computer program in Fortran 90, in order to obtain numerical solutions of a system of Relativistic Magnetohydrodynamics partial differential equations with predetermined gravitation (GRMHD), capable of simulating the formation of relativistic jets from the accretion disk of matter up to his ejection. Initially we carried out a study on numerical methods of unidimensional Finite Volume, namely Lax-Friedrichs, Lax-Wendroff, Nessyahu-Tadmor method and Godunov methods dependent on Riemann problems, applied to equations Euler in order to verify their main features and make comparisons among those methods. It was then implemented the method of Finite Volume Centered of Nessyahu-Tadmor, a numerical schemes that has a formulation free and without dimensional separation of Riemann problem solvers, even in two or more spatial dimensions, at this point, already applied in equations GRMHD. Finally, the Nessyahu-Tadmor method was possible to obtain stable numerical solutions - without spurious oscillations or excessive dissipation - from the magnetized accretion disk process in rotation with respect to a central black hole (BH) Schwarzschild and immersed in a magnetosphere, for the ejection of matter in the form of jet over a distance of fourteen times the radius of the BH, a record in terms of astrophysical simulation of this kind. Also in our simulations, we managed to get substructures jets. A great advantage obtained was that, with the our code, we got simulate GRMHD equations in a simple personal computer.

Keywords: Finite Volume Methods, Central Schemes, Fortran 90, Relativistic Astrophysics, Jet.

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Authors: P. Mohajeri Khameneh, I. Mirzaie, N. Pourmahmoud, M. Rahimi, S. Majidyfar

Abstract:

Three dimensional simulations in tube in tube heat exchangers are investigated numerically in this study. In these simulations forced convective heat transfer and laminar flow of single-phase water are considered. In order to measure heat transfer parameters in these heat exchangers, FLUENT CFD Solver is used in this numerical method. For the purpose of creating geometry and exert boundary and initial conditions in the present model, finite volume method in Computational Fluid Dynamics is used in this study. In the present study, at each Z-location, variation of local temperatures, heat flux and Nusselt number at the whole tube is investigated in detail. Thereafter, averaged computational Nusselt number in this model is calculated. In addition, conceivable pressure drops have been obtained at each Z-location in this model. Then, pressure drop values in the present model are explored. Finally, all the numerical results for this kind of heat exchanger will be discussed precisely.

Keywords: Heat exchanger, Laminar flow, CFD, Nusseltnumber, Tube in tube, pressure drop.

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Authors: M. Alauddin, M. A. Ullah, M. Alom, M. N. Islam

Abstract:

The rivers in Bangladesh are highly unstable having loose boundaries, mild slope of water surface and bed, irregular siltation of huge sediment coming from upstream, among others. The groins are installed in the river bank to deflect the flowing water away from the vulnerable zones. The conventional groins are found to be unstable and ineffective. The combined groin having both impermeable and permeable components in the same structure improves the flow field to function better over others. The main goal of this study is to analyze the hydraulic characteristics induced by the combined groins of different alignments by using a 2D numerical model, iRIC Nays2DH. In this numerical simulation, the K-ε model for turbulence and Cubic Interpolation Pseudo-particle (CIP) method for advective terms are utilized. A particular flow condition is applied in the channel for all sets of groins with different alignments. The simulation results reveal that the combined groins alter the flow patterns considerably, with no significant recirculation of flow in the groin field. The effect of different alignments of groins is found somewhat different. Based on hydraulic features caused by the groins, the combined groin that aligns the permeable component towards slightly downstream performs better over others.

Keywords: Combined groin, alignment, hydraulic characteristics, numerical model.

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Authors: Adam Rabcewicz

Abstract:

Variational methods for optical flow estimation are known for their excellent performance. The method proposed by Brox et al. [5] exemplifies the strength of that framework. It combines several concepts into single energy functional that is then minimized according to clear numerical procedure. In this paper we propose a modification of that algorithm starting from the spatiotemporal gradient constancy assumption. The numerical scheme allows to establish the connection between our model and the CLG(H) method introduced in [18]. Experimental evaluation carried out on synthetic sequences shows the significant superiority of the spatial variant of the proposed method. The comparison between methods for the realworld sequence is also enclosed.

Keywords: optical flow, variational methods, gradient constancy assumption.

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Authors: Oladeinde Mobolaji Humphrey, Akpobi John

Abstract:

A mathematical model for the hydrodynamic lubrication of parabolic slider bearings with couple stress lubricants is presented. A numerical solution for the mathematical model using finite element scheme is obtained using three nodes isoparametric quadratic elements. Stiffness integrals obtained from the weak form of the governing equations were solved using Gauss Quadrature to obtain a finite number of stiffness matrices. The global system of equations was obtained for the bearing and solved using Gauss Seidel iterative scheme. The converged pressure solution was used to obtain the load capacity of the bearing. Parametric studies were carried out and it was shown that the effect of couple stresses and profile parameter are to increase the load carrying capacity of the parabolic slider bearing. Numerical experiments reveal that the magnitude of the profile parameter at which maximum load is obtained increases with decrease in couple stress parameter. The results are presented in graphical form.

Keywords: Finite element, numerical, parabolic slider.

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Authors: Manuel A. Guzman, Davide Forcellini, Ricardo Moreno, Diego H. Giraldo

Abstract:

Elastomeric bearings (EB) are used in many applications, such as base isolation of bridges, seismic protection and vibration control of other structures and machinery. Their versatility is due to their particular behavior since they have different stiffness in the vertical and horizontal directions, allowing to sustain vertical loads and at the same time horizontal displacements. Therefore, vertical, horizontal and bending stiffnesses are important parameters to take into account in the design of EB. In order to acquire a proper design methodology of EB all three, theoretical, finite element analysis and experimental, approaches should be taken into account to assess stability due to different loading states, predict their behavior and consequently their effects on the dynamic response of structures, and understand complex behavior and properties of rubber-like materials respectively. In particular, the recent large-displacement theory on the stability of EB formulated by Forcellini and Kelly is validated with both numerical simulations using the finite element method, and experimental results set at the University of Antioquia in Medellin, Colombia. In this regard, this study reproduces the behavior of EB under compression loads and investigates the stability behavior with the three mentioned points of view.

Keywords: Elastomeric bearings, experimental tests, numerical simulations, stability, large-displacement theory.

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Authors: N. Parandin, M. A. Fariborzi Araghi

Abstract:

in this paper, we propose a numerical method for the approximate solution of fuzzy Fredholm functional integral equations of the second kind by using an iterative interpolation. For this purpose, we convert the linear fuzzy Fredholm integral equations to a crisp linear system of integral equations. The proposed method is illustrated by some fuzzy integral equations in numerical examples.

Keywords: Fuzzy function integral equations, Iterative method, Linear systems, Parametric form of fuzzy number.

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Authors: Mostafa Jafarian Abyaneh, Khashayar Jafari, Vahab Toufigh

Abstract:

The cost of experiments on different types of concrete has raised the demand for prediction of their behavior with numerical analysis. In this research, an advanced numerical model has been presented to predict the complete elastic-plastic behavior of polymer concrete (PC), high-strength concrete (HSC), high performance concrete (HPC) along with different steel fiber contents under uniaxial compression. The accuracy of the numerical response was satisfactory as compared to other conventional simple models such as Mohr-Coulomb and Drucker-Prager. In order to predict the complete elastic-plastic behavior of specimens including softening behavior, disturbed state concept (DSC) was implemented by nonlinear finite element analysis (NFEA) and hierarchical single surface (HISS) failure criterion, which is a failure surface without any singularity.

Keywords: Disturbed state concept, hierarchical single surface, failure criterion, high performance concrete, high-strength concrete, nonlinear finite element analysis, polymer concrete, steel fibers, uniaxial compression test.

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Authors: M. Zarebnia, R. Parvaz

Abstract:

In this paper the Kuramoto-Sivashinsky equation is solved numerically by collocation method. The solution is approximated as a linear combination of septic B-spline functions. Applying the Von-Neumann stability analysis technique, we show that the method is unconditionally stable. The method is applied on some test examples, and the numerical results have been compared with the exact solutions. The global relative error and L∞ in the solutions show the efficiency of the method computationally.

Keywords: Kuramoto-Sivashinsky equation, Septic B-spline, Collocation method, Finite difference.

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Authors: Yue-Tzu Yang, Hsiang-Wen Tang, Jian-Zhang Yin, Chao-Han Wu

Abstract:

Three-dimensional incompressible turbulent fluid flow and heat transfer of pin fin heat sinks using air as a cooling fluid are numerically studied in this study. Two different kinds of pin fins are compared in the thermal performance, including circular and square cross sections, both are in-line and staggered arrangements. The turbulent governing equations are solved using a control-volume- based finite-difference method. Subsequently, numerical computations are performed with the realizable k - ԑ turbulence for the parameters studied, the fin height H, fin diameter D, and Reynolds number (Re) in the range of 7 ≤ H ≤ 10, 0.75 ≤ D ≤ 2, 2000 ≤ Re ≤ 126000 respectively. The numerical results are validated with available experimental data in the literature and good agreement has been found. It indicates that circular pin fins are streamlined in comparing with the square pin fins, the pressure drop is small than that of square pin fins, and heat transfer is not as good as the square pin fins. The thermal performance of the staggered pin fins is better than that of in-line pin fins because the staggered arrangements produce large disturbance. Both in-line and staggered arrangements show the same behavior for thermal resistance, pressure drop, and the entropy generation.

Keywords: Pin-fin, heat sinks, simulations, turbulent flow.

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Authors: Abdelaziz Khernane, Naceur Khelil, Leila Djerou

Abstract:

The aim of this work is to study the numerical implementation of the Hilbert Uniqueness Method for the exact boundary controllability of Euler-Bernoulli beam equation. This study may be difficult. This will depend on the problem under consideration (geometry, control and dimension) and the numerical method used. Knowledge of the asymptotic behaviour of the control governing the system at time T may be useful for its calculation. This idea will be developed in this study. We have characterized as a first step, the solution by a minimization principle and proposed secondly a method for its resolution to approximate the control steering the considered system to rest at time T.

Keywords: Boundary control, exact controllability, finite difference methods, functional optimization.

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Authors: Mohd Agos Salim Nasir, Ros Fadilah Deraman, Siti Salmah Yasiran

Abstract:

The Goursat partial differential equation arises in linear and non linear partial differential equations with mixed derivatives. This equation is a second order hyperbolic partial differential equation which occurs in various fields of study such as in engineering, physics, and applied mathematics. There are many approaches that have been suggested to approximate the solution of the Goursat partial differential equation. However, all of the suggested methods traditionally focused on numerical differentiation approaches including forward and central differences in deriving the scheme. An innovation has been done in deriving the Goursat partial differential equation scheme which involves numerical integration techniques. In this paper we have developed a new scheme to solve the Goursat partial differential equation based on the Adomian decomposition (ADM) and associated with Boole-s integration rule to approximate the integration terms. The new scheme can easily be applied to many linear and non linear Goursat partial differential equations and is capable to reduce the size of computational work. The accuracy of the results reveals the advantage of this new scheme over existing numerical method.

Keywords: Goursat problem, partial differential equation, Adomian decomposition method, Boole's integration rule.

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Authors: Ramy H. Mohammed

Abstract:

In heat sinks, the flow within the core exhibits separation and hence does not lend itself to simple analytical boundary layer or duct flow analysis of the wall friction. In this paper, we present some findings from an experimental and numerical study aimed to obtain physical insight into the influence of the presence of the shield and its position on the hydraulic and thermal performance of square pin fin heat sink without top by-pass. The variations of the Nusselt number and friction factor are obtained under varied parameters, such as the Reynolds number and the shield position. The numerical code is validated by comparing the numerical results with the available experimental data. It is shown that, there is a good agreement between the temperature predictions based on the model and the experimental data. Results show that, as the presence of the shield, the heat transfer of fin array is enhanced and the flow resistance increased. The surface temperature distribution of the heat sink base is more uniform when the dimensionless shield position equals to 1/3 or 2/3. The comprehensive performance evaluation approach based on identical pumping power criteria is adopted and shows that the optimum shield position is at x/l=0.43.

Keywords: Shield, Fin array, Performance evaluation, Heat transfer, Validation.

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Authors: K. Boumediene, S. E. Belhenniche

Abstract:

This article presents a numerical analysis of a turbulent flow past DTMB 4119 marine propeller by the means of RANS approach; the propeller designed at David Taylor Model Basin in USA. The purpose of this study is to predict the hydrodynamic performance of the marine propeller, it aims also to compare the results obtained with the experiment carried out in open water tests; a periodical computational domain was created to reduce the unstructured mesh size generated. The standard kw turbulence model for the simulation is selected; the results were in a good agreement. Therefore, the errors were estimated respectively to 1.3% and 5.9% for KT and KQ.

Keywords: propeller flow, CFD simulation, hydrodynamic performance, RANS

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Authors: Hadi Rezghi Maleki, Babak Abazadeh

Abstract:

In this paper, the effect of bolt clamping force on the fatigue behavior of bolted single lap joints of aluminum alloy 2024- T3 have been studied using numerical finite element method. To do so, a three dimensional model according to the bolted single lap joint has been created and numerical analysis has been carried out using finite element based package. Then the stress distribution and also the slip amplitudes have been calculated in the critical regions and the outcome have been compared with the available experimental fatigue tests results. The numerical results show that in low applied clamping force, the fatigue failure of the specimens occur around the stress concentration location (the bolted hole edge) due to the tensile stresses and thus fatigue crack propagation, but with increase of the clamping force, the fatigue life increases and the cracks nucleate and propagate far from the hole edge because of fretting fatigue. In other words, with the further increase of clamping force value of the joint, the fatigue life reduces due to occurrence of the fretting fatigue in the critical location where the slip amplitude is within its critical occurs earlier.

Keywords: Fretting fatigue, bolted single lap joint, torque tightening, finite element method.

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Authors: Yongxin Yuan, Jiashang Jiang

Abstract:

A new numerical method for simultaneously updating mass and stiffness matrices based on incomplete modal measured data is presented. By using the Kronecker product, all the variables that are to be modified can be found out and then can be updated directly. The optimal approximation mass matrix and stiffness matrix which satisfy the required eigenvalue equation and orthogonality condition are found under the Frobenius norm sense. The physical configuration of the analytical model is preserved and the updated model will exactly reproduce the modal measured data. The numerical example seems to indicate that the method is quite accurate and efficient.

Keywords: Finite element model, model updating, modal data, optimal approximation.

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Authors: Vaclav Dvorak

Abstract:

The article deals with experimental and numerical investigation of axi-symmetric subsonic air to air ejector with diffuser adapted for boundary layer suction. The diffuser, which is placed behind the mixing chamber of the ejector, has high divergence angle and therefore low efficiency. To increase the efficiency, the diffuser is equipped with slot enabling boundary layer suction. The effect of boundary layer suction on flow in ejector, static pressure distribution on the mixing chamber wall and characteristic were measured and studied numerically. Both diffuser and ejector efficiency were evaluated. The diffuser efficiency was increased, however, the efficiency of ejector itself remained low.

Keywords: Air ejector, boundary layer suction, CFD, diffuser.

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Authors: Taher M. Abou-deif, Mahmoud A. Fouad, Essam E. Khalil

Abstract:

The present paper was concerned primarily with the analysis, simulation of the air flow and thermal patterns in a lecture room. The paper is devoted to numerically investigate the influence of location and number of ventilation and air conditioning supply and extracts openings on air flow properties in a lecture room. The work focuses on air flow patterns, thermal behaviour in lecture room where large number of students. The effectiveness of an air flow system is commonly assessed by the successful removal of sensible and latent loads from occupants with additional of attaining air pollutant at a prescribed level to attain the human thermal comfort conditions and to improve the indoor air quality; this is the main target during the present paper. The study is carried out using computational fluid dynamics (CFD) simulation techniques as embedded in the commercially available CFD code (FLUENT 6.2). The CFD modelling techniques solved the continuity, momentum and energy conservation equations in addition to standard k – ε model equations for turbulence closure. Throughout the investigations, numerical validation is carried out by way of comparisons of numerical and experimental results. Good agreement is found among both predictions.

Keywords: Air Conditioning, CFD, Lecture Rooms, Thermal Comfort

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Authors: Prodromos E. Atlamazoglou

Abstract:

The method of moments combined with the method of symmetrical components is used for the analysis of interstitial hyperthermia applicators. The basis and testing functions are both piecewise sinusoids, qualifying our technique as a Galerkin one. The dielectric coatings are modeled by equivalent volume polarization currents, which are simply related to the conduction current distribution, avoiding in that way the introduction of additional unknowns or numerical integrations. The results of our method for a four dipole circular array, are in agreement with those already published in literature for a same hyperthermia configuration. Apart from being accurate, our approach is more general, more computationally efficient and takes into account the coupling between the antennas.

Keywords: Hyperthermia, integral equations, insulated antennas, method of symmetrical components.

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Authors: J. J. Cetina-Denis, R. M. López-Gutiérrez, R. Ramírez-Ramírez, C. Cruz-Hernández

Abstract:

This work addresses the problem of designing an algorithm capable of generating chaotic trajectories for mobile robots. Particularly, the chaotic behavior is induced in the linear and angular velocities of a Khepera III differential mobile robot by infusing them with the states of the H´enon chaotic map. A possible application, using the properties of chaotic systems, is patrolling a work area. In this work, numerical and experimental results are reported and analyzed. In addition, two quantitative numerical tests are applied in order to measure how chaotic the generated trajectories really are.

Keywords: Chaos, chaotic trajectories, differential mobile robot, Henons map, Khepera III robot, patrolling applications.

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Authors: Ilya Popov, Steven Hulshoff

Abstract:

A numerical investigation of the effects of nanosecond barrier discharge on the stability of a two-dimensional free shear layer is performed. The computations are carried out using a compressible Navier-Stokes algorithm coupled with a thermodynamic model of the discharge. The results show that significant increases in the shear layer-s momentum thickness and Reynolds stresses occur due to actuation. Dependence on both frequency and amplitude of actuation are considered, and a comparison is made of the computed growth rates with those predicted by linear stability theory. Amplitude and frequency ranges for the efficient promotion of shear-layer instabilities are identified.

Keywords: NS-DBD, plasma, actuator, flow control, instability, shear layer

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Authors: jianhua Hou, Changqing Yang, and Beibo Qin

Abstract:

A numerical method for solving nonlinear Fredholm integral equations of second kind is proposed. The Fredholm type equations which have many applications in mathematical physics are then considered. The method is based on hybrid function  approximations. The properties of hybrid of block-pulse functions and Chebyshev polynomials are presented and are utilized to reduce the computation of nonlinear Fredholm integral equations to a system of nonlinear. Some numerical examples are selected to illustrate the effectiveness and simplicity of the method.

Keywords: Hybrid functions, Fredholm integral equation, Blockpulse, Chebyshev polynomials, product operational matrix.

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Authors: Pradeep M., N. S. Mahesh, Raja Hussain

Abstract:

Resistance spot welding (RSW) has been used widely to join sheet metals. It has been a challenge to get required weld quality in spot welding of dissimilar thickness materials. Weld parameters are not generally available in standards for thickness beyond 4mm. This paper presents the welding process design and parameter optimization of RSW used in joining of low carbon steel sheet of thickness 0.8 mm and metal strips of cross section 10 x 5mm for electrical motor applications. Taguchi quality design was adopted for weld current and time optimization using L9 orthogonal array. Optimum process parameters (current- 3.5kA and time- 10 cycles) were obtained from the Taguchi analysis and shear test results. Confirmation experiment result revealed that the weld quality was within acceptable interval. Further, numerical simulation of RSW process was carried out with selected weld parameters to quantify the temperature at faying surface and check for formation of appropriate nugget. The nugget geometry measured after peel test and predicted from numerical validation method were similar and in accordance with the standards.

Keywords: Resistance spot welding, dissimilar thickness, weld parameters, Taguchi method, numerical modeling.

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