Skip to main content
SpringerLink
Log in

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

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

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.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Ruiz D C, Batalha G F, Study of a failure mode criterion for resistance spot welding. II Brazilian Congress of Manufacturing Engineering COBEF, Joinville, SC, 2004

  2. Cruz J, Torres E (2015) A methodology for modeling and control of weld bead width in the GMAW process. J Braz Soc Mech Sci Eng 37(5):1529–1541. https://doi.org/10.1007/s40430-014-0299-8

    Article  Google Scholar 

  3. Dutra J, Silva R, Savi B, Marques C, Alarcon O (2016) New methodology for AC-pulsed GMAW parameterization. J Braz Soc Mech Sci Eng 38:99–107

    Article  Google Scholar 

  4. Rocha L, Paiva AP, Paiva EJ, Balestrassi P (2015) Comparing DEA and principal component analysis in the multiobjective optimization of P-GMAW process. J Braz Soc Mech Sci Eng 38(8):2513–2526. https://doi.org/10.1007/s40430-015-0355-z

    Article  Google Scholar 

  5. Siqueira R, Oliveira A, Riva R, Abdalla A, Baptista C, Lima M (2014) Mechanical and microstructural characterization of laser-welded. J Braz Soc Mech Sci Eng 37(1):133–140. https://doi.org/10.1007/s40430-014-0175-6

    Article  Google Scholar 

  6. Husain N, Khodaparast H, Snaylam A, James S, Dearden G, Ouyang H, Finite-element modelling and updating of laser spot weld joints in a top-hat structure for dynamic analysis. Proc. IMechE Vol. 224 Part C: J. Mechanical Engineering Science (2010). https://doi.org/10.1243/09544062JMES178, 220, 8, 1099, 1108

  7. Llanos C, Hurtado R, Alfaro S (2015) FPGA-based approach for change detection in GTAW welding process. J Braz Soc Mech Sci Eng 38(3):913–929. https://doi.org/10.1007/s40430-015-0371-z

    Article  Google Scholar 

  8. Zhang Y, Taylor D (2001) Optimization of spot-welded structures. Finite Elem Anal Des 37(12):1013–1022. https://doi.org/10.1016/S0168-874X(01)00046-4

    Article  MATH  Google Scholar 

  9. Xu S, Deng X (2004) An evaluation of simplified finite element models for spot-welded joints. Finite Elem Anal Des 40(9-10):1175–1194. https://doi.org/10.1016/j.finel.2003.08.006

    Article  Google Scholar 

  10. Donders S, Brughmans M, Hermans L, Tzannetakis N (2005) The effect of spot weld failure on dynamic vehicle performance. Sound Vib 39(4):16–25

    Google Scholar 

  11. Bhatti Q, Ouisse M, Cogan S (2011) An adaptive optimization procedure for spot-welded structures. Comput Struct 89(17-18):1697–1711. https://doi.org/10.1016/j.compstruc.2011.04.009

    Article  Google Scholar 

  12. Ertas A, Sonmez F (2010) Design optimization of spot-welded plates for maximum fatigue life. Finite Elem Anal Des 47(4):413–423. https://doi.org/10.1016/j.finel.2010.11.003

    Article  Google Scholar 

  13. Karagoulis, M J. A nuts-and-bolts approach to the control of resistance spot welding. Welding Journals, 1994. 73, (7), 27–31

  14. Mazur W, Kyriakopoulos A, Bott N, West D (2016) Use of modified electrode caps for surface quality welds in resistance spot welding. J Manufacturing Process 22:60–73. https://doi.org/10.1016/j.jmapro.2016.01.011

    Article  Google Scholar 

  15. Vignesh K, Perumal AE, Velmurugan P (2017) Optimization of resistance spot welding process parameters and microstructural examination for dissimilar welding of AISI 316L austenitic stainless steel and 2205 duplex stainless steel. Int J Adv Manuf Technol 93(1-4):455–465. https://doi.org/10.1007/s00170-017-0089-4

    Article  Google Scholar 

  16. Yürük A, Kahraman N (2017) Weld zone characterization of stainless steel joined through electric resistance spot welding. Int J Adv Manuf Technol 92(5-8):2975–2986. https://doi.org/10.1007/s00170-017-0335-9

    Article  Google Scholar 

  17. Ouisse M, Cogan S (2010) Robust design of spot welds in automotive structures: a decision-making methodology. Mech Syst Signal Process 24(4):1172–1190. https://doi.org/10.1016/j.ymssp.2009.09.012

    Article  Google Scholar 

  18. Chen S, Sun T, Jiang X, Qi J, Zeng R (2016) Online monitoring and evaluation of the weld quality of resistance spot welded titanium alloy. J Manufacturing Process 23:183–191. https://doi.org/10.1016/j.jmapro.2016.06.003

    Article  Google Scholar 

  19. Vargas, J. H. Study of the formation, geometry and resistance of the point in resistance welding: a statistical approach. Mechanical engineering department, dissertation 2006. University of Brasilia, 143p

  20. Wang R, Shang D (2005) Low-cycle fatigue life prediction of spot welds based on hardness distribution and finite element analysis. Int J Fatigue 31(3):508–514. https://doi.org/10.1016/j.ijfatigue.2008.04.009

    Article  MathSciNet  Google Scholar 

  21. Donders S, Brughmans M, Hermans L, Liefooghe C, Auweraer V, Desmet W (2006) The robustness of dynamic vehicle performance to spot weld failures. Finite Elem Anal Des 42(8-9):670–682. https://doi.org/10.1016/j.finel.2005.10.012

    Article  Google Scholar 

  22. Takeda N, Kita Y, Papalambros Y, Optimization of welded structures with structural hot spot stress constraints. 9th World Congress on Structural and Multidisciplinary Optimization. June 13–17, 2011, Shizuoka, Japan

  23. Pan N, Sheppard S (2002) Spot welds fatigue life prediction with cyclic strain range. Int J Fatigue 24(5):519–528. https://doi.org/10.1016/S0142-1123(01)00157-8

    Article  Google Scholar 

  24. Lin S, Pan J, Wung P, Chiang J (2006) A fatigue crack growth model for spot welds under cyclic loading conditions. Int J Fatigue 28(7):792–803. https://doi.org/10.1016/j.ijfatigue.2005.08.003

    Article  Google Scholar 

  25. Pan N, Sheppard S (2003) Stress intensity factors in spot welds. Eng Fract Mech 70(2):671–684. https://doi.org/10.1023/A:1007461430066

    Google Scholar 

  26. Moharrami R, Hemmati B (2017) Numerical stress analysis in resistance spot-welded nugget due to post-weld shear loading. J Manuf Process 27:284–290. https://doi.org/10.1016/j.jmapro.2017.05.007

    Article  Google Scholar 

  27. Mirzaei F, Ghorbani H, Kolahan F (2017) Numerical modeling and optimization of joint strength in resistance spot welding of galvanized steel sheets. Int J Adv Manuf Technol 92(9-12):3489–3501. https://doi.org/10.1007/s00170-017-0407-x

    Article  Google Scholar 

  28. Wan X, Wang Y, Zhao D (2016) Multi-response optimization in small scale resistance spot welding of titanium alloy by principal component analysis and genetic algorithm. Int J Adv Manuf Technol 83(1-4):545–559. https://doi.org/10.1007/s00170-015-7545-9

    Article  Google Scholar 

  29. Zhang Y, Taylor D. Optimization of spot-welded structures. Finite Elem Anal Des 2001; 37(12): 1013–1022

  30. Bhatti QI, Ouisse M, Cogan S (2011) An adaptive optimization procedure for spot-welded structures. Comput Struct 89(17-18):1697–1711. https://doi.org/10.1016/j.compstruc.2011.04.009

    Article  Google Scholar 

  31. Ertas AH, Sonmez FO. Optimization of spot-weld joints. Proc Inst Mech Eng Part C: J Mech Eng Sci 2009; 223(3): 545–555, DOI: https://doi.org/10.1243/09544062JMES1171

  32. Venter G, Beck A, Silva M (2014) A simple hierarchical procedure for parameter identification in robust topology optimization. J Braz Soc Mech Sci Eng 38(2):679–689. https://doi.org/10.1007/s40430-014-0271-7

    Article  Google Scholar 

  33. Xiang Y, Wang Q, Fan Z, Fang H (2006) Optimal crashworthiness design of a spot welded thin-walled hat section. Finite Elem Anal Des 42(10):846–855. https://doi.org/10.1016/j.finel.2006.01.001

    Article  Google Scholar 

  34. Silveira M, Fancello E (2015) The use of numerical optimization in the Blanks Soldiers project. Science & Engineering Journal 24(1):9–19

    Google Scholar 

  35. Riley W, George A. Design, analysis and testing of a formula SAE car chassis. SAE Technical Paper 2002–01-3300, 2002. doi: https://doi.org/10.4271/2002-01-3300

  36. Norberg E, Lövgren S (2011) Topology optimization of vehicle body structure for improved ride & handling. Linköping University, Dissertation

    Google Scholar 

  37. Chae SW, Kwon KY, Lee TS (2002) An optimal design system for spot welding locations. Finite Elem Anal Des 38(3):277–294. https://doi.org/10.1016/S0168-874X(01)00064-6

    Article  MATH  Google Scholar 

  38. Hasegawa H, Sasaki H, Uehara H, Kawamo K (2007) Optimization of spot-weld positions for vehicle design by using hybrid meta-heuristics. Int J Veh Des 43(1–4):151–172. https://doi.org/10.1504/IJVD.2007.012301

    Article  Google Scholar 

  39. Pinheiro H, Study of the correlation between the current of shunt and the geometry of the spot weld as a function of performance in low carbon steel sheet and thickness of 0.8 mm. Technology College SENAI CIMATEC, Dissertation, Salvador, Brazil, 2010

Download references

Author information

Authors and Affiliations

  1. Composites Center Technology (CCT), University Federal of Itajubá (UNIFEI), Av. BPS, 1303, Pinheirinho, Itajubá, 37500 903, Brazil

    D. M. Junqueira & A. C. Ancelotti

  2. Numerical Simulation Center (NSC), University of São João Del Rei, São João Del Rei, Brazil

    M. E. Silveira

Authors
  1. D. M. Junqueira
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. M. E. Silveira
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. A. C. Ancelotti
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to D. M. Junqueira.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Junqueira, D.M., Silveira, M.E. & Ancelotti, A.C. Analysis of spot weld distribution in a weldment—numerical simulation and topology optimization. Int J Adv Manuf Technol 95, 4071–4079 (2018). https://doi.org/10.1007/s00170-017-1555-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-017-1555-8

Keywords

Search

Navigation