Evaluation of heat transfer within numerical models of resistance spot welding using high-speed thermography

Abstract The paper presents a mathematical model and simulation of resistance spot welding (RSW) of a binary alloy during the final solidification process. After analyzing the heat distribution and heat transfer process, the authors established assumptions for a planar front solidification model. Following the application of initial and boundary conditions, the model is developed numerically to describe the thermal distribution in the resistance spot welding system as a function of position and time. For each value in the time array, a heat transfer profile through the welding sheet is calculated as a piecewise function. The model is further executed with Python, which allows customized inputs of resistance spot welding parameters. Finally, the heat transfer model is simulated with COMSOL Multiphysics in the specific example of 1050 mild steel. Heat transfer module is applied to the proposed mathematical model, and simulation of temperature profile and thermal gradient of the welding zones are developed. The simulation further confirms the mathematical model and provides a demonstration that the temperature decreases through both the water-cooled welding tips and thermal diffusion to the surrounding metal sheets, leading to adjacent heat-affected zones. The model is intended for predicting the resistance spot welding nugget solidification process, as well as to help analyze the effects of welding parameters to achieve a weld nugget of optimal size.

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Modeling heat-transfer processes of resistance spot welding

Bulletin of the Russian Academy of Sciences Physics ◽

10.3103/s1062873816060344 ◽

2016 ◽

Vol 80 (6) ◽

pp. 742-745 ◽

Cited By ~ 1

Author(s):

A. V. Skidanenko

Keyword(s):

Heat Transfer ◽

Resistance Spot Welding ◽

Spot Welding ◽

Resistance Spot ◽

Transfer Processes

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Resistance spot welding of precoated steel sheet: Computational heat-transfer analysis

Metallurgical and Materials Transactions B ◽

10.1007/bf02663392 ◽

1994 ◽

Vol 25 (3) ◽

pp. 415-423 ◽

Cited By ~ 2

Author(s):

Ching-Chou Chen ◽

Tzu-Chien J. Hsu ◽

New-Jen Ho

Keyword(s):

Heat Transfer ◽

Resistance Spot Welding ◽

Spot Welding ◽

Steel Sheet ◽

Heat Transfer Analysis ◽

Resistance Spot

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Study of Pneumatic Force Servo System for Resistance Spot Welding

Volume 5B: 38th Mechanisms and Robotics Conference ◽

10.1115/detc2014-34807 ◽

2014 ◽

Author(s):

Bo Wang ◽

Tao Wang ◽

Wei Fan ◽

Yu Wang

Keyword(s):

Resistance Spot Welding ◽

Spot Welding ◽

High Speed ◽

High Performance ◽

Pulse Width Modulation ◽

Servo System ◽

Servo Drive ◽

Force System ◽

Resistance Spot ◽

Modulation Control

The purpose of this paper is to develop a pneumatic servo drive mechanism, which is the basis of high performance pneumatic servo gun for resistance spot welding. In order to increase the output force and reduce costs, booster cylinder and high speed solenoid valve are included in the system. In this paper, a mathematical model of the pneumatic force servo system is derived. Pulse-Width-Modulation control scheme is given to control the solenoid valves. Computer simulation results and experimental results show that the designed pneumatic servo force system has a good performance, which verifies the feasibility of the designed scheme.

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