FEM Simulation of Spot Welding Process (report IV) : Characteristics of Electrode Displacement and Nugget Formation(Mechanics, Strength & Structure Design)
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The real time measurement of the electrode displacement during spot welding is very important to control the spot welding process in order to get a sound weld. In this report, the electrode displacement and nugget formation during spot welding were investigated numerically by means of the finite element method. Important parameters characterizing the relationship between electrode displacement and nugget formation were introduced based on experiment and numerical analysis. The effects of welding current, squeezing force and plate thickness on the electrode displacement and nugget formation were clarified. Through the present study, the following conclusions were drawn: (1) The time when the electrode displacement reaches the maximum value is closely related to the timing of nugget formation and it is influenced by the welding current, the squeezing force and the plate thickness, (2) The formation of a sound spot weld with nugget size between 4√t and 5√t can be detected by monitoring the time when the electrode displacement at the top reaches the maximum value.
- Transactions of JWRI
Transactions of JWRI 29(1), 73-80, 2000-07