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A shape optimization study for tool design in resistance welding

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Abstract

The purpose of this study is to apply shape optimization tools for design of resistance welding electrodes. The numerical simulation of the welding process has been performed by a simplified FEM model implemented in COMSOL. The design process is formulated as an optimization problem where the objective is to prolong the life-time of the electrodes. Welding parameters like current, time and electrode shape parameters are selected to be the design variables while constraints are chosen to ensure a high quality of the welding. Surrogate models based on a Kriging approximation has been used in order to simplify the calculation of shape sensitivities and to generate a generic tool that can be interfaced with other simulation tools. An example numerical study shows the potential of applying optimal design techniques in this area.

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Authors and Affiliations

  1. Department of Mathematics, Technical University of Denmark, Building 303S, 2800, Lyngby, Denmark

    M. Bogomolny & M. P. Bendsøe

  2. Department of Mechanical Engineering, Technical University of Denmark, Building 425, 2800, Lyngby, Denmark

    J. H. Hattel

Authors
  1. M. Bogomolny
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  2. M. P. Bendsøe
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  3. J. H. Hattel
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Correspondence to M. Bogomolny.

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Bogomolny, M., Bendsøe, M.P. & Hattel, J.H. A shape optimization study for tool design in resistance welding. Struct Multidisc Optim 38, 185–194 (2009). https://doi.org/10.1007/s00158-008-0274-z

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  • DOI: https://doi.org/10.1007/s00158-008-0274-z

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