Analysis of spot weld distribution in a weldment—numerical simulation and topology optimization

  • D. M. Junqueira
  • M. E. Silveira
  • A. C. Ancelotti


An automobile’s structure takes about 3000 to 6000 spot welds, and resistance spot welding is the most widely used because of its simplicity. Because it is a process that greatly influences the overall production cost, the automotive industry tends to decrease spot welds present in vehicle structure. With this, the majority of automobiles are unable to achieve satisfactory results in safety tests, such as crash tests. In addition to affecting safety in impact cases, the reduction in the number of spot welds implies a reduction in torsional and longitudinal vehicle stiffness, making it unstable and noisy. In view of the need for more studies on the effects of this reduction, this study uses numerical simulation and topology optimization to help assess the most appropriate spot weld distribution in a weldment, to maintain the torsional stiffness within acceptable limits. Results showed that structures obtained by topology optimization can have better stiffness and compliance compared to non-optimized structures.


Spot weld Resistance spot welding FEM Weldment Topology optimization 


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© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  • D. M. Junqueira
    • 1
  • M. E. Silveira
    • 2
  • A. C. Ancelotti
    • 1
  1. 1.Composites Center Technology (CCT)University Federal of Itajubá (UNIFEI)ItajubáBrazil
  2. 2.Numerical Simulation Center (NSC)University of São João Del ReiSão João Del ReiBrazil

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