The paperpresents experimental investigation studies that were conducted under varying Resistance spot welding parameters such as electrode force, welding current and welding time in order to establish their influence on spot weld quality. The quality characteristics are shear tensile strength and direct tensile strength of the spot welded joint has been considered. The process parameters were optimized to improve the nugget quality characteristics. The approach is based on Taguchi method, the signal-to-noise (S/N) ratio and the analysis of variance (ANOVA) are employed to study the performance characteristics in RSW process.The experimental data was extracted as per the the pattern of L 9 Orthogonal Array(OA).The data was analysed by using the signal-to-noise (S/N) ratio to get optimum level of spot welding parameters combination.Analysis of variance (ANOVA) and F-test has been used for determining most significant parameters affecting the spot weld quality characteristics. Confirmation tests with optimal levels of RSW process parameters are conducted to validate the test results. Experimental results have shown that the responses in RSWprocess can be improved significantly through this approach.
The objective of this work is to develop a numerical model of the resistance spot welding process with a flat cylindricallower electrode, enabling to predict accurately the spot weld geometry development. A 2D axisymmetric electro-thermo-mechanical finite element (FE) model is developed to study the effect of spot welding parameters on nugget size using ANSYS commercial software package. The nugget formation processes at the various welding conditions were investigated by both experimental measurement and FEM simulation.In order to improve the accuracy, temperature dependent properties of material are taken into account during the simulation. Experiments were carried out to verify the preciseness of simulation. Two different thicknesses of austenitic stainless steel sheets were used in the study. The FE predicted weld nugget sizes agreed well with the experimental results. Overall, the present work indicated that finite element analysis can be very useful as an off-line observation tool to estimate the influence of welding parameters on the welding quality and to predict or improve the welding quality.
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