Abstract

Spot welding is the most popular assembly method used in the automotive industry due to its simplicity, effectiveness, and low cost. Simulation techniques for spot welds play an essential role in today's aggressive vehicle development schedules, and the accuracy of the analysis impacts the quality of the design in terms of noise-vibration-harshness and durability. Using static and multiaxial low cycle fatigue analysis, this study focuses on three different spot weld modeling methods: Rigid spot weld, solid element spot weld, and umbrella spot weld. Spot weld modeling techniques were compared for specimens with different thickness levels and weld diameters, and under different loading conditions. In addition, the accuracy levels of spot weld modeling methods are presented by comparing the life found by multi-axial low cycle simulations with the fatigue tests.

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