Study on the Thermal Expansion Displacement during Spot Welding Depending on the Multi-Physical Coupling Finite Element Model

2014 ◽  
Vol 941-944 ◽  
pp. 2007-2011
Author(s):  
Cai Ping Liang ◽  
Yong Bing Li
Keyword(s):  
Finite Element ◽  
Thermal Expansion ◽  
Finite Element Model ◽  
Spot Welding ◽  
Welding Process ◽  
Physical And Mechanical Properties ◽  
Element Model ◽  
Temperature Dependent ◽  
Monitoring And Forecasting

An incremental and thermal electro-mechanical coupled finite element model has been presented in this study for predicting spot nugget size, gap between workpieces, and thermal expansion displacement during spot welding process. Approximate temperature dependent material properties, including physical and mechanical properties, have been considered. The spot nugget shape and the thermal expansion displacement were obtained by simulation. The solutions showed that the displacement of workpieces was directly related to the quality of solder joints and can be as a monitoring parameter of spot weld quality. These calculations provide a theoretical reference for nugget quality monitoring and forecasting by electrode expansion displacements.

A Thermal Model for Ultrasonic Welding of Thermoplastics

2007 ◽  
Author(s):  
S.-F. Ling ◽  
X. Li ◽  
Z. Sun
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Equivalent Circuit Model ◽  
Welding Process ◽  
Element Model ◽  
Ultrasonic Welding ◽  
Joint Interface ◽  
Mems Devices ◽  
Transient Heating ◽  
Temperature Distributions

Ultrasonic welding is one of the most popular techniques for joining thermoplastics and plays an important role in MEMS applications such as fabrication and packaging of MEMS devices. In this paper, an attempt was made to further understand the heating mechanism during ultrasonic welding. Firstly, the equation governing heat generation was derived assuming adiabatic heating. A thermal equivalent circuit model was also developed to describe the heat transfer process from the joint interface into the surroundings, and the governing equation of temperature distribution in the welding sample was deduced. Finite element method was then engaged to solve these equations to reveal the transient heating behaviour. Lastly, temperatures of the joint interface and the point adjacent to the joint were measured. The temperatures of the point adjacent to the joint calculated from finite element model are matched well with the experimental results. Based on the correlation, the temperature distributions of welding samples can be derived from the finite element model. Since the new developed model can be used to obtain the dynamic temperature distributions of welding samples during ultrasonic welding, the model provides an effective way for detailed understanding of the thermal behaviours and monitoring of the ultrasonic welding process.

Consideration of micro-finite element model for multiscale resistance spot welding analysis

2017 ◽  
Vol 2017.30 (0) ◽  
pp. 292
Author(s):  
Hiroyuki Kuramae ◽  
Tomoya Niho ◽  
Hirochika Aramaki ◽  
Kengo Oya ◽  
Tomoyoshi Horie
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Element Model ◽  
Resistance Spot

The Finite Element Analysis on the Compression Splicing Position of Strain Clamp in Guy Tower

2014 ◽  
Vol 680 ◽  
pp. 249-253
Author(s):  
Zhang Qi Wang ◽  
Jun Li ◽  
Wen Gang Yang ◽  
Yong Feng Cheng
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Stress Distribution ◽  
Finite Element Model ◽  
Equivalent Stress ◽  
Element Model ◽  
Element Analysis ◽  
Elastic Plastic ◽  
The Finite Element Analysis

Strain clamp is an important connection device in guy tower. If the quality of the compression splicing position is unsatisfied, strain clamp tends to be damaged which may lead to the final collapse of a guy tower as well as huge economic lost. In this paper, stress distribution on the compressible tube and guy cable is analyzed by FEM, and a large equivalent stress of guy cable is applied to the compression splicing position. During this process, a finite element model of strain clamp is established for guy cables at compression splicing position, problems of elastic-plastic and contracting are studied and the whole compressing process of compressible position is simulated. The guy cable cracks easily at the position of compressible tube’s port, the inner part of the compressible tube has a larger equivalent stress than outside.

Modal Analysis of BT Spindle-Toolholder Interface Based on Abaqus/Standard

2013 ◽  
Vol 662 ◽  
pp. 632-636
Author(s):  
Yong Sheng Zhao ◽  
Jing Yang ◽  
Xiao Lei Song ◽  
Zi Jun Qi
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Modal Analysis ◽  
Dynamic Characteristics ◽  
High Speed ◽  
Element Model ◽  
Contact Theory ◽  
High Speed Machining ◽  
The Finite Element Model

The quality of high speed machining is directly related to dynamic characteristics of spindle-toolholder interface. The paper established normal and tangential interactions of BT spindle-toolholder interface based on finite element contact theory, and analysed free modal in Abaqus/Standard. Then the result was compared with the experimental modal analysis. It shows that the finite element model is effective and could be applied in the future dynamic study of high-speed spindle system.

scholarly journals Determination of Nugget Size in Resistance Projection Welding: Numerical Method with Experimental Measurements

2018 ◽  
Author(s):  
Danial Mohammad Rezaei ◽  
Behzad Heidarshenas ◽  
Fazel Baniasadi
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Element Model ◽  
Temperature Dependent ◽  
Projection Welding ◽  
Nugget Diameter ◽  
Electrode Force ◽  
Weld Current ◽  
Weld Time

The aim of this paper is to at first evaluate the influence of three key parameters including weld current, weld time and electrode force on nugget diameter and tensile strength in resistance projection welding. Then, a 2-D axis-symmetric finite element model is developed to simulate the projection welding and predict the nugget diameter. Finally, the FEM results are compared to experimental data to verify the simulation model and simulated results. In the finite element model, the temperature-dependent material properties were taken into account.  

scholarly journals Visualization of the Process of Processing Welds by a Deformation Wave

2020 ◽  
pp. short39-1-short39-7
Author(s):  
Andrey Kirichek ◽  
Sergey Barinov ◽  
Alexandr Yashin
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Visual Information ◽  
Calculated Data ◽  
Welding Process ◽  
Element Model ◽  
Temperature Fields ◽  
Subsequent Stage ◽  
Deformation Wave ◽  
Complex Process

The aim of the paper is to obtain a unified finite element model of a complex process, which makes it possible to obtain visual information related to the influence of the welding process parameters on the results of the process of wave strain hardening of the weld material. Modeling of sequentially executed technological processes of different physical nature - welding and hardening, makes it possible to obtain more general and objective visual information about the process as a whole. Modeling in the Ansys software package is performed in stages, with the output of an earlier stage of modeling acting as the input data of the subsequent stage. At the first stage, the problem of visualizing the process of forming a weld is solved with the possibility of calculating temperature fields, stress and strain fields during heating and cooling of the welded workpiece. At the second stage, the calculated data is imported into the finite element model of processing welds with a deformation wave. A finite element model makes it possible to build microhardness maps for selected (dangerous) sections and visually monitor the change in stresses and strains in welded workpieces, depending on the technological modes of hardening by a deformation wave. The obtained visual information allows for a qualitative and quantitative assessment of the result of a complex process, which contributes to an increase in the bearing capacity and performance of the product as a whole.

A Real-Time Neural Network Estimator for Workpiece Thermal Expansion Errors

2000 ◽  
Author(s):  
A. D. Yoder ◽  
R. N. Smith
Keyword(s):  
Neural Network ◽  
Finite Element ◽  
Thermal Expansion ◽  
Finite Element Model ◽  
Real Time ◽  
Element Model ◽  
Precision Machining ◽  
Machining Processes ◽  
The Neural Network ◽  
The Finite Element Model

Abstract The importance of predicting and reducing thermal expansion errors in workpieces is becoming greater as better precision machining processes are developed. An artificial neural network model to estimate the workpiece thermal expansion errors in real-time during precision machining operations is developed and compared with experimental results. A finite element model of workpiece thermal expansion has been created to predict expansions in a thin cylinder undergoing a turning process. The neural network has been trained using finite element model solutions over a range of conditions to allow for changing machining parameters. To realize “on-line” capability, the measurable values of heat flux into the workpiece, surface heat transfer coefficient, and tool location are used as inputs and the expansion as the output for the neural network. The estimations of the network are compared with experimental results from a turning process on a large diameter aluminum cylinder. There is reasonable agreement between measured and estimated expansions with an average error of 18%. The neural network has not been trained at the cutting conditions used during the experiment. The speed of the neural network estimation is much greater than the solution to the finite element model. The finite element model required over 15 minutes to solve on a Pentium 133Mhz computer. The neural network calculated the expansions easily at 1 Hz during the experiment on the same computer. With real-time estimation using measurable data, compensation can be made in the tool path to correct for these errors. The application of this method to precision machining processes has the capability of greatly reducing the error caused by workpiece thermal expansions.

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