resistance spot welding - · pdf filecoupled analysis for resistance spot welding resistance...
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Resistance Spot Welding
New process type resistance spot welding
X- and C-guns can be used
1
Coupled Analysis for Resistance Spot Welding
Resistance spot welding processes are calculated using an electric-
thermal-metallurgical-mechanical coupled analysis
2
Electrical Properties
Simufact.material GUI has been extended to manage electrical properties of
materials including multi-phase material models
3
Definition of Weld Spots
It is possible to define point sequences, robot orientation and pauses
between single weld sequences
4
Robot Dialog (C-gun/X-gun)
Robot dialog has been adjusted for resistance spot welding specifics
5
Electrode Database
All standard electrodes (according to ISO 5821) can be imported from the
provided database
Positioning of electrodes from the GUI
6
Process Parameters for Resistance Spot Welding
Separate welding-parameter object
Clamp force and electrical current can be defined as time dependent table
7
Electrical Contact Conductivity
The conductivity can be defined between electrodes and components and
components between each other
The conductivity can be defined as a constant value or with a temperature-
dependent table
Bay-Wanheim equation can also be applied for automatic calculation
After glue contact is achieved the resistance is deactivated
8
Automatic Calculation Steps in Simufact.welding
The actual process will be calculated in six steps depending on the robot,
geometries etc.
For a limited number of weld points these six steps will be performed to
simulate the spot weld process and to create a spot weld joint.
9
Step 1: The lower electrode is move to the reference point and can get
into contact with the lower sheet. During this step a local mesh refinement
can be used.
Automatic Calculation Steps in Simufact.welding
Step 2: Closing of the upper electrode
Step 3: Activation of the clamp force on the upper electrode. The lower
electrode is fixed. This closes the electric circuit.
10
Automatic Calculation Steps in Simufact.welding
Step 4: Activation of the electrical current with a constanc clamp
force. The lower electorde is fixed.
11
Automatic Calculation Steps in Simufact.welding
Step 5: Deactivation of the electrical current. The clamp force is still
activated.
12
Automatic Calculation Steps in Simufact.welding
Step 6: Removal of the welding gun
It is possible to model a load test after the process simulation to
investigate the local material behavior during testing
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