Predicting Dimensional Accuracy of Laser Welded Aluminum Add-On Body Parts

Abstract

Laser welding of complex aluminum add-on body parts such as vehicle doors, is a common joining technology in the automotive industry. Besides the many advantages (e.g. high processing speed) laser welding provides, temperature induced distortions are an important task to deal with. In the last twenty years, several simplified FE methods, which predict welding distortion (weld seams, spot welds) of large assemblies, were presented. In order to simulate the distortion of large car body components properly, realistic clamping conditions need to be considered [1, 2, 3]. Furthermore, the calibration process of simplified models has to be examined systematically, to find out their limits and achieve optimal simulation results [4]. In this paper, a new FE model is presented to predict distortion of laser welded structures, based on a shrinkage volume approach. Effective surface based clamping conditions (derived of the real clamping device) and effects of previous forming processes are considered. The simplified model was examined due to an extensive design of experiments. Not only simple, but even complex simulated specimens match with the experimental results very well.