Contact Area Modeling and On-Line Estimation in Resistance Spot Welding

Manufacturing ◽  
2002 ◽  
Author(s):  
Wei Li
Keyword(s):  
Contact Area ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Process Conditions ◽  
Electrode Wear ◽  
Welding Time ◽  
Contact Areas ◽  
Resistance Spot ◽  
On Line

Contact areas at both electrode-to-sheet and sheet-to-sheet interfaces are important in the resistance spot welding process. Given electrode force and welding time, contact areas strongly affect the amount of electrical current needed to make a good weld. In production, process variation such as electrode wear and misalignment causes the contact areas to vary. This effect contributes largely to the quality variation of resistance spot welds. This paper proposes a model-based approach to contact area estimation in the resistance spot welding process. A finite element analysis procedure is used to characterize the contact area behaviors. Based on the understanding from the simulations, a lumped parameter model, together with its calibration and estimation procedures, is developed for on-line applications. The proposed method is demonstrated successful under various process conditions including electrode size, force, welding time and current. It provides important information for on-line monitoring and control of the resistance spot welding process.

Modeling and On-Line Estimation of Electrode Wear in Resistance Spot Welding

2004 ◽  
Vol 127 (4) ◽  
pp. 709-717 ◽  
Author(s):  
Wei Li
Keyword(s):  
Contact Area ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Welding Current ◽  
Estimation Algorithm ◽  
Contact Condition ◽  
Electrode Wear ◽  
Resistance Spot ◽  
On Line

Electrode wear is inherent in the resistance spot welding process. It determines the electrical and mechanical contact condition and thus strongly affects the resistance spot weld quality. A practical approach to minimizing the electrode wear effect is to compensate the welding current as the electrodes wear. However, the existing methods for welding current compensation rely on either a predetermined stepper schedule or an expulsion detection algorithm. These methods are not reliable since the welding current is not determined based on the contact condition for each weld made in the welding process. This paper presents an on-line electrode wear estimation approach to determining the contact condition and the welding current needed to make every weld a good weld during the entire life of the electrodes. In the study, an incrementally coupled finite element simulation was first formulated to analyze the contact area behavior in the resistance spot welding process. A lumped parameter model was then developed to characterize the contact area change with the dynamic resistance measurement. A calibration and an estimation algorithm were subsequently devised for on-line applications. The proposed approach has been validated with experimental data. The results have shown that the estimation algorithm is robust under various process conditions including both welding current and electrode force.

Effect of Resistance Spot Welding Parameters on the Austenitic Stainless Steel 304 Grade by Using 23 Factorial Design

2011 ◽  
Vol 216 ◽  
pp. 666-670 ◽  
Author(s):  
Prachya Peasura
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Welding Current ◽  
Welding Time ◽  
Tensile Shear ◽  
Resistance Spot ◽  
Electrode Force

This research was study the effect of resistance spot welding process on physical properties. The specimen was austenitic stainless steel sheet of 1 mm. The experiments with 23 factorial design. The factors used in this study are welding current at 8,000 and 12,000 Amp, welding time at 8 and 12 cycle and electrode force were set at 1.5 and 2.5 kN. The welded specimens were tested by tensile shear testing according to JIS Z 3136: 1999 and macro structure testing according to JIS Z 3139: 1978. The result showed that the welding current, welding time and electrode force had interaction on tensile shear and nugget size at 95% confidential (P value < 0.05). Factors affecting the tensile shear are the most welding current of 12,000 amp., welding time of 8 cycle and electrode force of 2.5 kN. were tensile shear of 9.83 kN. The nugget size was maximum at 7.15 mm. on welding current of 12,000 amp., welding time of 12 cycle and electrode force of 1.5 kN This research can bring information to the foundation in choosing the appropriate parameters to resistance spot welding process.

On-line Quality Estimation in Resistance Spot Welding

1999 ◽  
Vol 122 (3) ◽  
pp. 511-512 ◽  
Author(s):  
Wei Li ◽  
S. Jack Hu ◽  
Jun Ni
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Selection Procedure ◽  
Resistance Force ◽  
Dynamic Resistance ◽  
Electrode Wear ◽  
Size Estimation ◽  
Resistance Spot ◽  
Electrode Displacement ◽  
On Line

A neural network model is developed for on-line nugget size estimation in resistance spot welding. The variables used consist of features extracted from both controllable process input variables and on-line signals. A systematic signal and feature selection procedure is developed. The three commonly observed on-line signals, dynamic resistance, force, and electrode displacement, have been proven to carry similar information. Thus, only dynamic resistance is used in the model. The obtained model has been demonstrated to be robust over various welding conditions including electrode wear. [S1087-1357(00)01204-1]

scholarly journals Review on Techniques for On-Line Monitoring of Resistance Spot Welding Process

2013 ◽  
Vol 2013 ◽  
pp. 1-6 ◽  
Author(s):  
Yanhua Ma ◽  
Pei Wu ◽  
Chuanzhong Xuan ◽  
Yongan Zhang ◽  
He Su
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Resistance Spot ◽  
On Line

scholarly journals General Approach for Inline Electrode Wear Monitoring at Resistance Spot Welding

Processes ◽  
2021 ◽  
Vol 9 (4) ◽  
pp. 685
Author(s):  
Christian Mathiszik ◽  
David Köberlin ◽  
Stefan Heilmann ◽  
Jörg Zschetzsche ◽  
Uwe Füssel
Keyword(s):  
Contact Area ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Electrode Wear ◽  
Actual Process ◽  
Welding Quality ◽  
Process Data ◽  
Resistance Spot ◽  
Electrode Length ◽  
Wear Modes

Electrodes for resistance spot welding inevitably wear out. In order to extend their service life, the tip-dressing process restores their original geometry. So far, however, the point in time for tip-dressing is mainly based on experience and not on process data. Therefore, this study aims to evaluate the in-situ or inline wear during the welding process without using additional sensors, and to base the timing for tip-dressing on continuous process monitoring, extending electrode life even further. Under laboratory conditions, electrode wear is analyzed by topographical measurements deepening the knowledge of the known main wear modes of resistance-spot-welding electrodes, mushrooming and plateau forming, and characterizing an electrode length delta over the number of spot welds. In general, electrode wear results in deformation of the electrode contact area, which influences process parameters and thereby weld quality. The conducted tests show correlation between this deformed contact area and the electrode length delta. The study shows that this electrode length delta is visible in actual process data, and can therefore be used as a criterion to characterize the wear of electrodes. Furthermore, this study gives reason to question commonly used spot-welding quality criteria and suggests different approaches, such as basing spot-welding quality on the possibility of nondestructive testing.

Study on Nugget Growth in Resistance Spot Welding of Thin Aluminum A1100 Using Welding Simulation

2018 ◽  
Vol 929 ◽  
pp. 191-199
Author(s):  
Ario Sunar Baskoro ◽  
Andreas Edyanto ◽  
Muhammad Azwar Amat ◽  
Hakam Muzaki
Keyword(s):  
Weld Joint ◽  
Cycle Time ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Metal Plate ◽  
Weld Nugget ◽  
Welding Time ◽  
Resistance Spot ◽  
Nugget Growth

Resistance spot welding (RSW), generally which is one of the most often used to joint metal plate in the automotive and aviation industries. RSW welding process involves electrical, thermal mechanical, metallurgy, and complex surface phenomenon. Unlike the other welding processes, weld joint formation in RSW process occurs very quick (in milli-seconds) and took place between the workpieces overlap each other. Welding simulation allows visual examination of the weld joint without having to perform an expensive experiment. Weld nugget size is the most important parameter in determining the mechanical behavior of welded joints in RSW process. The quality and strength of the weld joint in RSW process is predominantly determined by the shape and size of the weld nugget. Simulation modeling of RSW process performed using ANSYS Parametric Design Language (APDL) module based on the finite element method (FEM), embedded in ANSYS Workbench. Electrical and transient-thermal interaction was developed to study the weld nugget growth on resistance spot welding of aluminum A1100 metal plate with a thickness of 0.4 mm respectively. Weld nugget diameter can be well predicted by using this simulation model from the temperature distribution during the welding process. Welding is performed by varying the weld current (1 kA and 2 kA) and the welding time for each electric current, which are start from 0.5, 1.0, and 1.5 cycle time. Nugget diameter for each of the welding parameters from the simulation modelling were 4,276 mm, 4,372 mm, 4,668 mm, 5,616 mm and 5,896 mm. Weld expulsion occurred for the specimen with welding current 2 kA and welding time 1.5 cycle time, characterized by the decreasing of the tensile-shear strength of the specimen.

Statistical Investigation on Resistance Spot Welding Quality Using a Two-State, Sliding-Level Experiment

2000 ◽  
Vol 123 (3) ◽  
pp. 513-520 ◽  
Author(s):  
Wei Li ◽  
Shaowei Cheng ◽  
S. Jack Hu ◽  
Justin Shriver
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Current ◽  
Statistical Investigation ◽  
Process Conditions ◽  
Electrode Wear ◽  
Weld Quality ◽  
Process Variables ◽  
Resistance Spot ◽  
Quality Variation

Quality variation in resistance spot welding is a major concern in the automotive industry. The relationship between weld quality and various process conditions, including abnormal process conditions, has not yet been systematically studied. This paper investigates this relationship using a newly developed two-stage, sliding-level experiment. In the experiment, welding current is treated as a “slid factor” whose settings are determined based on those of other process variables. Engineering knowledge is applied in statistical model selection. From the analysis, it is found that abnormal process conditions, such as axial misalignment, angular misalignment, poor fitup, edge weld, and electrode wear, significantly affect weld size and thus cause large variation in the weld quality. Although they may help increase the weld size in some cases, abnormal process conditions generally lead to a less robust process. In order to minimize the effects of the abnormal process conditions, a robust parameter design is formulated using the statistical models developed from the experimental data. The analysis suggests that high current and large electrodes should be used for reducing the weld quality variation. Developed in this study, the new experimental design and analysis procedures can also be applied to other processes, where the process variables are inter-dependent.

The Influence of Welding Parameters on Effected the Complete for Resistance Spot Welding on Mild Steel

2011 ◽  
Vol 214 ◽  
pp. 113-117 ◽  
Author(s):  
Prachya Peasura
Keyword(s):  
Mild Steel ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Welding Current ◽  
Welding Parameters ◽  
Welding Time ◽  
Tensile Shear ◽  
Resistance Spot ◽  
Electrode Force

This research was study the effect of resistance spot welding process on physical properties. The specimen was mild steel sheet metal. The experiments with full factorial design. The factors used in this study are welding current, welding time and electrode force. The welded specimens were tested by tensile shear testing according to JIS Z 3136: 1999 and macro structure testing according to JIS Z 3139: 1978. The result showed that both of welding current, welding time and electrode force had interaction on tensile shear and nugget size at 95% confidential (P value < 0.05). Factors affecting the tensile shear and nugget size are the most welding current 10,000 amp., welding time 10 cycle and electrode force 1 kN. were tensile shear 7.13 kN. and nugget size maximum 6.75 mm. This research can bring information to the foundation in choosing the appropriate parameters to resistance spot welding process.

THERMOMECHANICAL ANALYSIS OF THE RESISTANCE SPOT-WELDING PROCESS

2018 ◽  
Vol 10 (5) ◽  
pp. 449-455 ◽  
Author(s):  
Habib Lebbal ◽  
Lahouari Boukhris ◽  
Habib Berrekia ◽  
Abdelkader Ziadi
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Thermomechanical Analysis ◽  
Resistance Spot
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