Abstract
Resistance spot welding (RSW) is the most common welding method in automotive engineering due to its low cost and high ability of automation. However, physical weldability testing is costly, time consuming and dependent of supplies of material and equipment. Finite Element (FE) simulations have been utilized to understand, verify and optimize manufacturing processes more efficiently. The present work aims to verify the capability of FE models for the RSW process by comparing simulation results to physical experiments for materials used in automotive production, with yield strengths from approximately 280 MPa to more than 1500 MPa. Previous research has mainly focused on lower strength materials. The physical weld results were assessed using destructive testing and an analysis of expulsion limits was also carried out. Extensive new determination of material data was carried out. The material data analysis was based on physical testing of material specimens, material simulation and comparison to data from literature. The study showed good agreement between simulations and physical testing. The mean absolute error of weld nugget size was 0.68 mm and the mean absolute error of expulsion limit was 1.10 kA.
Highlights
Resistance spot welding (RSW) is the primary joining method in automotive industry due to its low cost and high ability for automation
An efficient solution to meet such demands is the introduction of high strength (HSS) and ultra high strength (UHSS, sometimes referred to as advanced high strength steels, AHSS) in body-in-white components
Each experimental test was compared with a Finite Element (FE) simulation using the simulation method described above
Summary
Resistance spot welding (RSW) is the primary joining method in automotive industry due to its low cost and high ability for automation. (2015) Prediction and Verification of Resistance Spot Welding Results of Ultra-High Strength Steels through FE Simulations. The first numerical analyses of the RSW process were published in the early 1960s Both a one-dimensional model by Archer [2] and an axi-symmetrical model by Greenwood [3] were presented and calculated the temperature change in the weld zone. Nied [4] developed an axi-symmetrical FE model which used elastic material behavior and Nishiguchi and Matsuyama [5] implemented elasto-plastic material behavior Both designated welding simulation software and general simulations software have been used in published work. Dancette et al [16] showed good agreement between simulations and experiments for DP980 steel and Radakovic et al [17] showed results of DP780 in a study which focused on failure modes of spot welds. An investigation of the potential of a process planning tool based on FE simulations has been carried out
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