Abstract
The Resistance Spot Welding (RSW) represents one of the most important welding processes. The resistance spot welding quality depends on the process parameters like welding current, electrode force and welding time and their chosen levels. In this work, the experimental part is validated by the simulation part, where the last will be used later for predicting the results for new data with a very acceptable percentage of accuracy. This study presents an experimental work of the resistance spot welding for two similar sheets of Austenitic Stainless Steels (AISI 304) that are intended to be held together in one point by the pressure of the electrodes, with high magnitude of electrical current to be applied, where the resistance spot welding parameters (welding current and welding time) are changeable to show each of the parameter’s action on the welded material properties (The Maximum Shear Load that the metal can be subject to besides The Nugget Zone Diameter of the welded contact area). The experimental work in this study delivers genuine and important data that will be the basis for the Fuzzy Logic Controller (FLC), which will be set up then. The Artificial Intelligence (which is presented by the fuzzy logic controller) role is to predict the optimal welded material parameters for any given resistance spot welding parameters, and to discover the probability of expulsion, failure, or breaking in the welding process before it takes place or happens, where in this study, the FLC predicted the optimum value of the maximum shear load for RSW, which occurs at the welding time=20 cycle and the welding current=8 KA, while the estimated optimum value of the Nugget Diameter by FLC for RSW is found at welding time=20 cycle and welding current=8 KA.This prediction will save the metal parts and the electrodes of welding, besides saving the cost and the effort
Highlights
There are different methods used for Spot Welding (SW), one of the most important used methods is the RSW, which is considered as an efficient joining process widely used for the fabrication of sheet metal assemblies [1]
The results reveal that the most important factor on the mechanical property of weld joint is the applied load compared to the current intensity and welding duration, but there was no prediction for the optimized factor and for the welding process performance by this study, which concentrated on allocating the most influential factor of this process
The aim of this study is to present a prediction for the welded metal sheets characteristics as a result of varying parameters of resistance spot welding, to predict the optimal welded material property for any given resistance spot welding parameters, besides, to foresee the probability of failure in the welding process before happening using simulation
Summary
There are different methods used for Spot Welding (SW), one of the most important used methods is the RSW, which is considered as an efficient joining process widely used for the fabrication of sheet metal assemblies [1]. The energy provided to the welding operation relies on current flow, resistance of the circuit, and length of time when the current is applied. This can be seen obviously by equation (1), which is shown belowProcesses, and Systems is designed for a first course or two-course sequence in manufacturing at the junior level in mechanical, industrial, and manufacturing engineering curricula. Given its coverage of engineering materials, it is suitable for materials science and engineering courses that emphasize materials processing. It may be appropriate for technology programs related to the preceding engineering disciplines. Most of the book\u2019s content is concerned with manufacturing processes
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