A multi-coupled finite element analysis of Resistance Spot Welding process
A two-dimensional axisymmetric finite element model is developed to analyze the transient thermal and mechanical behaviors of the Resistance Spot Welding (RSW) process using commercial software ANSYS. Firstly a direct-coupled electrical-thermal Finite Element Analysis (FEA) is performed to analyze the transient thermal characteristics of the RSW process. Then based on the thermal results a sequential coupled thermo-elastic-plastic analysis is conducted to determine the mechanical features of the RSW process. The thermal history of the whole process and the temperature distribution of the weldment are obtained through the analysis. The mechanical features, including the distributions of the contact pressure at both the faying surface and the electrode-workpiece interface, the stress and strain distributions in the weldment and their changes during the RSW process, the deformation of the weldment and the electrode displacement are also calculated.
Key wordsFinite Element Analysis (FEA) Resistance Spot Welding (RSW) electrical-thermal coupling thermo-elastic-plastic analysis thermal behavior mechanical feature
Unable to display preview. Download preview PDF.
- Nied, H.A. The finite element modeling of the resistance spot welding process, Welding Journal, Vol.63, No.4, 1984, 123–132.Google Scholar
- Cho, H.S. and Cho, Y.J., A study of the thermal behavior in resistance spot welds, Welding Journal, 1989, Vol.68, No.6, 236–244.Google Scholar
- Browne, D.J., Chandler, H.W., Evans, J.T. and Wen, J., Computer simulation of resistance spot welding in aluminum: part I, Welding Journal, Vol.743, No.10, 339–344.Google Scholar
- Yeung, K.S. and Thornton, P.H., Transient thermal analysis of spot welding electrodes, Welding Journal Vol.78, No.1, 1999, 1–6.Google Scholar
- Xing J.T., Price, W.G. and Chen, Y.G., A numerical method for simulating nonlinear fluid-rigid structure interaction problems, Acta Mechanica Solida Sinica, Vol. 18, No. 2, 2005, 95–109.Google Scholar
- Vogler, M. and Sheppard, S., Electrical contact resistance under high loads and elevated temperatures, Welding Journal, Vol.72, No.6, 1993, 231–238.Google Scholar
- Ueda, Y., Kim, Y.C. and Yuan, M.G., A predicting method of welding residual stress using source of residual stress (report I), Transaction of JWRI, Vol.18, No.1, 1989, 135–141.Google Scholar
- Zou, M., Foundation of Welding Theory and Process, Press of Beihang University, Beijing, 1994.Google Scholar
- Tsai, C.L., Dai, W.L., Dickinson, D.W. and Papritan, J.C., Analysis and development of a real-time control methodology in resistance spot welding, Welding Journal, Vol.70, No.12, 1991, 339–351.Google Scholar