Welding sequence optimisation in the automotive industry: A review

2019 ◽  
Vol 233 (17) ◽  
pp. 5945-5952
Author(s):  
Varshan Beik ◽  
Hormoz Marzbani ◽  
Reza Jazar
Keyword(s):  
Automotive Industry ◽  
Spot Welding ◽  
Fast Rate ◽  
Welding Process ◽  
Future Research ◽  
Automotive Body ◽  
Welding Sequence ◽  
Common Technique ◽  
The Common

Spot welding is the most common technique used to join sheet metals in the automotive industry due to the fast rate of production. Optimising the welding process including the sequence, number and location of the welds would significantly improve the quality of the final product and production cost. This paper presents an overview on the available methods to plan and optimise various aspects of the welding process including welding sequence, weld quantity and location. Firstly, the welding concept in the automotive industry is briefly reviewed. Secondly, the welding process optimisation with emphasis on the welding sequence is discussed. The common gaps and challenges are identified and, lastly, future research to plan and optimise the welding sequence in the automotive body is outlined.

Optimizing spot welding parameters in a sheet metal assembly by neural networks and genetic algorithm

2007 ◽  
Vol 221 (7) ◽  
pp. 1175-1184 ◽  
Author(s):  
M Hamedi ◽  
M Shariatpanahi ◽  
A Mansourzadeh
Keyword(s):  
Neural Networks ◽  
Spot Welding ◽  
Welding Process ◽  
Welding Current ◽  
The Body ◽  
Welding Parameters ◽  
Automotive Body ◽  
Body In White ◽  
Assembly Operations

Deformation of the spot-welded sub-assemblies in assembly operations and the gap between the matching sub-assemblies have been quality concerns specifically in the automotive industry. Overall quality of the car body and its sub-assemblies, apart from quality of each stamped part, depends markedly on the welding process. This paper considers optimization of three important process parameters in the spot welding of the body components, namely welding current, welding time, and gun force. In this research, first the effects of these parameters on deformation of the sub-assemblies are experimentally investigated. Then neural networks and multi-objective genetic algorithms are utilized to select the optimum values of welding parameters that yield the least values of dimensional deviations in the sub-assemblies. Welding sub-assemblies with the optimized set of parameters brought all of them into the tolerance range. The proposed approach can be utilized in manufacturing sub-assemblies that can fit and match better with adjacent parts in the automotive body. It enhances quality of the joint and will result in improving overall quality of the body in white.

scholarly journals Análisis de la resistencia de piezas soldadas por el proceso de resistencia eléctrica

2020 ◽  
pp. 1-9
Author(s):  
José Antonio Medina-Mendoza ◽  
Gerardo Méndez-Macías ◽  
Naieli Herrera-Reyes
Keyword(s):  
Automotive Industry ◽  
Electrical Resistance ◽  
Spot Welding ◽  
International System ◽  
Stress Test ◽  
Welding Process ◽  
Hydraulic Press ◽  
Metal Parts ◽  
Automotive Parts

A stay has been carried out in a metalworking company located in the Valle de Aguascalientes Industrial Park, in order to carry out a study that can reflect the state of manufacture of various metal parts that involve an electrical resistance welding process. The manufacturing area is called Automotive and has 5 welding machines of various brands and capacities in which different models of automotive parts are manufactured for various clients of the automotive industry in Aguascalientes Mexico. The study focuses on the review of the process based on the regulations that are handled in the company and that are the JIS B 1196 referring to spot welding, from which two main characteristics are extracted to guarantee the quality of the product and that are the resistance to weld stress and torsional strength. The manufacturing standards used determine that every hour a stress test must be carried out on the different manufactured parts according to their classification, welding is tested on 6M, 8M and 10M nuts of the international system applying loads in a brand FORSE DX-2.5 model hydraulic press and one hundred percent tests torque on parts with 6M nuts welded, which are tested in a devise of our own design. The data taken for the evaluation were obtained in the company's metrology laboratory and showed a very marked dispersion, although said data apparently did not exceed the established limits. A review and evaluation of the process was carried out and limits and improvements were proposed that guarantee good quality of the products. Some practices that can affect quality were found, they are described and a solution is proposed to prevent them from being carried out in the process.

Analysis of Electromagnetic Inverse Model of Resistance Spot Welding

2010 ◽  
Vol 160-162 ◽  
pp. 974-979
Author(s):  
Nai Feng Fan ◽  
Zhen Luo ◽  
Yang Li ◽  
Wen Bo Xuan
Keyword(s):  
Resistance Spot Welding ◽  
Regularization Method ◽  
Spot Welding ◽  
Influence Factors ◽  
Great Influence ◽  
Welding Process ◽  
Inverse Model ◽  
Resistance Spot ◽  
Inversion Theory

Resistance spot welding (RSW) is an important welding process in modern industrial production, and the quality of welding nugget determines the strength of products to a large extent. Limited by the level of RSW quality monitor, however, RSW has rarely been applied to the fields with high welding quality requirements. Associated with the inversion theory, in this paper, an electromagnetic inverse model of RSW was established, and the analysis of influence factors, such as the layout of the probes, the discrete program and the regularization method, was implemented as well. The result shows that the layout of the probe and the regularization method has great influence on the model. When the probe is located at the y direction of x-axis or the x direction of y-axis and Conjugate Gradient method is selected, a much better outcome can be achieved.

scholarly journals Numerical Simulation Mode of Spot Contact Welding Processes

2021 ◽  
pp. 85-91
Author(s):  
А.С. Угловский ◽  
И.М. Соцкая ◽  
Е.В. Шешунова
Keyword(s):  
Spot Welding ◽  
Low Carbon Steel ◽  
Welding Process ◽  
Welding Parameters ◽  
Low Carbon ◽  
Detailed Data ◽  
Welding Quality ◽  
Welding Processes ◽  
Contact Welding

Цель рассмотрения численного метода заключалась в получении подробных данных, позволяющих оценить проведение сварочного процесса: изменение объёма сварного шва, радиуса сварного шва, радиуса зоны термического влияния. При проведении моделирования авторами выведены зависимости параметров точечной сварки низкоуглеродистой стали толщиной до 3,2 мм. Данные зависимости будут определять качество сварных швов. Соответствующее сочетание параметров точечной сварки обеспечит прочное соединение и хорошее качество сварки. The purpose of the numerical method consideration was to obtain detailed data allowing evaluating the performance of the welding process: changing the volume of the weld, the radius of the weld, the radius of the weld-affected zone. During the simulation the authors have derived dependencies of the parameters of spot welding of low-carbon steel up to 3.2 mm thick. These dependencies will determine the quality of the welds. The correct combination of spot welding parameters will ensure a firm joint and good welding quality.

Application of TOPSIS and ANOVA Methods to Evaluate the Electrical Resistance Spot Welding Process Parameters of AISI 1020 Steel

2020 ◽  
Vol 12 (4) ◽  
Author(s):  
Harshavardhana Natarajan ◽  
Sundar Singh Sivam Sundarlingam Paramasivam ◽  
Durai Kumaran ◽  
G. Balakumaran ◽  
R. Naveen
Keyword(s):  
Spot Welding ◽  
Hold Time ◽  
Welding Process ◽  
Current Control ◽  
Production Costs ◽  
Steel Plates ◽  
Test Results ◽  
Electrode Current ◽  
The Cost

Deformation and deterioration of the electrode caused by chemical reaction is resistant to AISI 1020 with caps screw electrodes. In this study, squeeze, weld, hold time, current and pressure is evaluated for the nugget diameter. OP1is the surface waviness, OP2 is the force, OP3 is the nugget height and OP4 is welded by spot welding on steel plates. AISI 1020 steel plates with thicknesses of 0.8 mm and 1.5mm for connecting the cap screw electrode, current and clock sensor with current control for 120 kVA capacitors are connected. The cycle welding currents of 5, 10, 15, 20 and 25 were selected and increased from 8 kA to 10 kA is done during the welding process. In this study, OP1 to OP4 are selected and the verification experiment is performed in an optimal state to observe the development accuracy. Based on confirmation of test results, it was determined to develop a model that can be effectively used to predict the size of weld surface thereby improving the quality of the weld and calculating the cost of the top screw head. The welded joints of two electrodes are exposed to weld radius. The groove, force and valve height are calculated by the ingot detector, dynamometer and ultrasonic. This allows the workstation to be welded to the desired contour while reducing its production costs.

scholarly journals Quality assurance on the example of the welding process for gear lever

2018 ◽  
Vol 19 (9) ◽  
pp. 219-224
Author(s):  
Stanisław Pałubicki
Keyword(s):  
Quality Assurance ◽  
Continuous Improvement ◽  
Automotive Industry ◽  
Welding Process ◽  
Product Selection ◽  
Production Processes ◽  
The Stability ◽  
Gear Lever ◽  
Manufacturing Stage

Quality is one of the basics of product selection by customers. Therefore, the main area of quality management is the identification of customers, their requirements and expectations. This is especially important in the automotive industry. Today's enterprises, wanting to strengthen their market position by improving the quality of their products, constantly control their products. Systems responsible for monitoring production allow to ensure the course of production processes in supervised conditions. The monitoring and recording of events that occur during production is of key importance. This is the basis for analyzing the stability of the production process, which is a key aspect of continuous improvement of quality. Thanks to this approach, it is possible to prevent the generation of costs related to the removal of defective products created at the manufacturing stage, as well as to reduce the number of complaints.

scholarly journals On-Line Spot Welding Quality Prediction with Analysis of Welding Parameters

2020 ◽  
Vol 3 (1) ◽  
pp. 127-140
Author(s):  
Emin Cantez ◽  
İsmail Atalay ◽  
Oğuz Alper İsen ◽  
Serkan Aydın
Keyword(s):  
Machine Learning ◽  
Automotive Industry ◽  
Spot Welding ◽  
Welding Parameters ◽  
Quality Prediction ◽  
Welding Quality ◽  
Important Place ◽  
Machine Learning Methods ◽  
On Line

Spot welding is one of the metal joining technologies and has an important place especially in the automotive industry. A passenger car has average 5000 spots. Destructive inspection is carried out at certain periods to check these spots. However, not all parts can be checked. In this work, welding parameters were collected and analyzed. By applying different machine learning methods, the quality of the spot welding was tried to be estimated and the results were compared.

scholarly journals MULTI-OBJECTIVE OPTIMIZATION OF THE RESISTANCE SPOT-WELDING PROCESS PARAMETERS FOR THE WELDING OF DUAL-PHASE STEEL DP500

2021 ◽  
Vol 55 (2) ◽  
pp. 201-206
Author(s):  
Aleksija Djuric ◽  
Dragan Milčić ◽  
Damjan Klobčar ◽  
Biljana Marković
Keyword(s):  
Automotive Industry ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Dual Phase Steel ◽  
Mechanical Characteristics ◽  
Welding Process ◽  
Dual Phase ◽  
Multi Objective Optimization ◽  
Multi Objective ◽  
Resistance Spot

Resistance spot welding (RSW) is still the most used form of welding in the automotive industry, primarily for welding steel. One of the advanced steels used in the automotive industry is dual-phase steel, so it is important to properly select the welding parameter for these steels. Therefore, this paper presents multi-objective optimization in the RSW welding process of DP 500 steel. The paper considers three different mechanical characteristics i.e., the failure load (F), failure displacement (l) and weld nugget diameter (D), as all these welding characteristics play significant roles in evaluating the quality of spot welding. The results show that the welding current is the most influential parameter with respect to the mechanical characteristics. The effect of welding time on the weld quality is the least significant. The optimal parameters for welding DP 500 steel obtained in this paper are weld current 8 kA, electrode force 4.91 kN and weld time 400 ms.

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