Nugget Formation during Resistance Spot Welding using Finite Element Model
Resistance spot welding process comprises of electric,
thermal and mechanical phenomenon, which makes this process
complex and highly non-linear and thus, it becomes difficult to model
it. In order to obtain good weld nugget during spot welding, hit and
trial welds are usually done which is very costly. Therefore the
numerical simulation research has been conducted to understand the
whole process. In this paper three different cases were analyzed by
varying the tip contact area and it was observed that, with the
variation of tip contact area the nugget formation at the faying
surface is affected. The tip contact area of the welding electrode
becomes large with long welding cycles. Therefore in order to
maintain consistency of nugget formation during the welding process,
the current compensation in control feedback is required. If the
contact area of the welding electrode tip is reduced, a large amount of
current flows through the faying surface, as a result of which
sputtering occurs.
[1] Larry Jeffus "Welding principals and applications" Fourth edition
Thomson Learning 1999, pp. 678-681.
[2] J.E Vargas, M.A Wolff, L.O Vilarinho "Comparison between AC and
MF-DC resistance spot welding by using high speed filming" Journal of
Achievement in Materials and Manufacturing Engineering Volume 24
Issue 1 September 2007.
[3] J.A. Greenwood, "Temperature in Spot Welding", British Welding
Journal, 1961, 9, 316-322.
[4] A.F. Houchens, R, E. Page, W. H. Yang, "Numerical Modeling of
resistance Spot Welding, Numerical Modeling of Manufacturing
Process", The Welded Annual Meeting of the American Society of
Mechanical Engineering Atlanta, Georgia, 1977, 117-129.
[5] Nied H.A "Finite element modeling of resistance spot welding process"
Weld. Journal . Vol. 63, no. 4, pp. 123s-132s. Apr. 1984.
[6] J.E Gould "An Examination of Nugget Development during Spot
Welding, Using Both Experimental and Analytical Techniques"
Supplement to the Welding Journal Januay 1987.
[7] H.Huh and W.J. Kang "Electrothermal analysis of electric resistance
spot welding by a 3-D finite element method" Journal of material
technology (63) 1997, pp.672-677.
[8] R.J Bowers, T.W Eagar "Non- uniform Current Distribution In Spot
Welding" Americam welding society ASW Sheet Metal Welding
Conference, Detroit, MI October 1986.
[9] MA. Ninshu and Murakawa "Numerical and Experimental Study on
Nugget Formation in Resistance Spot Welding for High Strength Steel
Sheets in Automobile Bodies" Transactions of Joining and Welding
Research Institute (JWRI), Vol.38 (2009) No. 2.
[10] J.A Khan, L. Xu, and Y.J Chao "Prediction of nugget development
during resistance spot welding using coupled thermal-electricalmechanical
model" Science and technology of welding and joining
,1999 Vol.04 No: 04.
[11] ZhigangHoua, SooKimb,*, Yuanxun Wang a, Chunzhi Li c, Chuanyao
Chena "Finite element analysis for the mechanical features of resistance
spot welding process" Journal of Materials Processing Technology 185
(2007) 160-165.
[12] GuoZhong "Finite element analysis of resistance spot welding process"
Chinese Control and Decision Conference,CCDC 2009.
[13] M.Hamedi, H Pashazadeh "Numerical study of the nugget formation in
resistance spot welding "International Journal of Mechanics, Issue 1
Volume 2 ,2008 .
[14] Hamid Eisazadeh a,*, Mohsen Hamedi b, AyobHalvaee "New
parametric study of nugget size in resistance spot welding process using
finite element method". Materials and Design 31 (2010) 149-157.
[15] Thakur.A.G, Rasane.A.R, Nandedkar.V.M "Finite element analysis of
resistance spot welding nugget formation" International Journal of
Applied Engineering and Research, Dindigul, Volume 1 , No: 3,2010 .
[16] ComsolMultiPhysics 4.2,http://www.comsol.com. Last access().
[17] COMSOL Multiphysics 3.5a: User's Guide 3.5a.
[18] Meranda Saleem "Control and power supply for resistance spot welding
" thesis submitted in partial fulfillment for degree of PhD University of
Western Ontario London, Ontario, Canada.
[19] User Manual "TEC600 Spot Welding Unit ver.3.xx-p".by IBEROBT.
[1] Larry Jeffus "Welding principals and applications" Fourth edition
Thomson Learning 1999, pp. 678-681.
[2] J.E Vargas, M.A Wolff, L.O Vilarinho "Comparison between AC and
MF-DC resistance spot welding by using high speed filming" Journal of
Achievement in Materials and Manufacturing Engineering Volume 24
Issue 1 September 2007.
[3] J.A. Greenwood, "Temperature in Spot Welding", British Welding
Journal, 1961, 9, 316-322.
[4] A.F. Houchens, R, E. Page, W. H. Yang, "Numerical Modeling of
resistance Spot Welding, Numerical Modeling of Manufacturing
Process", The Welded Annual Meeting of the American Society of
Mechanical Engineering Atlanta, Georgia, 1977, 117-129.
[5] Nied H.A "Finite element modeling of resistance spot welding process"
Weld. Journal . Vol. 63, no. 4, pp. 123s-132s. Apr. 1984.
[6] J.E Gould "An Examination of Nugget Development during Spot
Welding, Using Both Experimental and Analytical Techniques"
Supplement to the Welding Journal Januay 1987.
[7] H.Huh and W.J. Kang "Electrothermal analysis of electric resistance
spot welding by a 3-D finite element method" Journal of material
technology (63) 1997, pp.672-677.
[8] R.J Bowers, T.W Eagar "Non- uniform Current Distribution In Spot
Welding" Americam welding society ASW Sheet Metal Welding
Conference, Detroit, MI October 1986.
[9] MA. Ninshu and Murakawa "Numerical and Experimental Study on
Nugget Formation in Resistance Spot Welding for High Strength Steel
Sheets in Automobile Bodies" Transactions of Joining and Welding
Research Institute (JWRI), Vol.38 (2009) No. 2.
[10] J.A Khan, L. Xu, and Y.J Chao "Prediction of nugget development
during resistance spot welding using coupled thermal-electricalmechanical
model" Science and technology of welding and joining
,1999 Vol.04 No: 04.
[11] ZhigangHoua, SooKimb,*, Yuanxun Wang a, Chunzhi Li c, Chuanyao
Chena "Finite element analysis for the mechanical features of resistance
spot welding process" Journal of Materials Processing Technology 185
(2007) 160-165.
[12] GuoZhong "Finite element analysis of resistance spot welding process"
Chinese Control and Decision Conference,CCDC 2009.
[13] M.Hamedi, H Pashazadeh "Numerical study of the nugget formation in
resistance spot welding "International Journal of Mechanics, Issue 1
Volume 2 ,2008 .
[14] Hamid Eisazadeh a,*, Mohsen Hamedi b, AyobHalvaee "New
parametric study of nugget size in resistance spot welding process using
finite element method". Materials and Design 31 (2010) 149-157.
[15] Thakur.A.G, Rasane.A.R, Nandedkar.V.M "Finite element analysis of
resistance spot welding nugget formation" International Journal of
Applied Engineering and Research, Dindigul, Volume 1 , No: 3,2010 .
[16] ComsolMultiPhysics 4.2,http://www.comsol.com. Last access().
[17] COMSOL Multiphysics 3.5a: User's Guide 3.5a.
[18] Meranda Saleem "Control and power supply for resistance spot welding
" thesis submitted in partial fulfillment for degree of PhD University of
Western Ontario London, Ontario, Canada.
[19] User Manual "TEC600 Spot Welding Unit ver.3.xx-p".by IBEROBT.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:52901", author = "Jawad Saleem and Abdul Majid and Kent Bertilsson and Torbjörn Carlberg and Nazar Ul Islam", title = "Nugget Formation during Resistance Spot Welding using Finite Element Model", abstract = "Resistance spot welding process comprises of electric,
thermal and mechanical phenomenon, which makes this process
complex and highly non-linear and thus, it becomes difficult to model
it. In order to obtain good weld nugget during spot welding, hit and
trial welds are usually done which is very costly. Therefore the
numerical simulation research has been conducted to understand the
whole process. In this paper three different cases were analyzed by
varying the tip contact area and it was observed that, with the
variation of tip contact area the nugget formation at the faying
surface is affected. The tip contact area of the welding electrode
becomes large with long welding cycles. Therefore in order to
maintain consistency of nugget formation during the welding process,
the current compensation in control feedback is required. If the
contact area of the welding electrode tip is reduced, a large amount of
current flows through the faying surface, as a result of which
sputtering occurs.", keywords = "Resistance spot welding, Finite element modeling,
Nugget formation, Welding electrode, Numerical method simulation,", volume = "6", number = "7", pages = "1173-6", }
