Numerical simulation of tensile strength of upset welded joints with experimental verification

Eisazadeh, Hamid; Esmailzadeh, Mousa

doi:10.1016/j.matdes.2009.12.011

Cited by 15 publications

(6 citation statements)

References 6 publications

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“…The following equation is used to calculate electrical contact resistivity [18]: (6) where is the applied eletrical current on electrode and is the maximum electrical current supplied in welding machine. The following equation is used to calculate electrical contact resistivity [18]: (7) where is the measured electrical contact resistance (ECR) of electrode-sheet interface at under constant mechanical pressure, is the characteristic thickness of contact surfaces (assumed equal to for certain aluminum alloys as reported by Sun [19]), is nominal contact area, and and are the average yield stress of contacting materials at and , respectively.…”

Section: Thermal Equationsmentioning

confidence: 99%

“…In Table 1, ϕ e is the voltage applied on electrode, ρ ES is the electrical contact resistivity between the electrode and sheet, Δϕ SS is the voltage drop between the sheets, ρ SS is the electrical contact resistivity between the weldments, and Δϕ Sh is the voltage drop in shunting nugget. For the application of the alternative current it can be assumed that [18]: (8) [2]. [19]), is nominal contact area, and and contacting materials at and , respectively.…”

Section: Introductionmentioning

confidence: 99%

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Experimental and numerical analysis of shunting effect in resistance spot welding of Al2219 sheets

Vardanjani¹,

Araee²,

Senkara³

et al. 2016

Bulletin of the Polish Academy of Sciences Technical Sciences

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Abstract. Few aspects of shunting effect have been studied so far. Shunting effect in resistance spot welding (RSW) occurs when the electrical current passes through the previous spot welds. Value of this current depends mostly on distance, number, and size of previous spot welds. This will cause some dimensional and metallurgical changes in welding nugget as well as heat affected zone (HAZ). In this study, shunting effect of RSW is considered by finite element method (FEM) and the results are compared to experiments performed on aluminum alloy 2219. Weld spacing together with welding current and time are considered to discover the effect of shunting current in the final quality of nugget. A three factor experiment design has been performed to find the significance of factors and interactive effects, as well as finite element model verification. Electrothermal and mechanical interactions are considered in the FEM. Experimental and numerical solutions have yielded similar results in terms of welding nugget properties. Asymmetry in electrical potential, temperature, stress distribution and geometry of shunted nugget is predicted and verified directly or indirectly. Intense effect of shunting current on nugget height, asymmetric growth of heat affected zone (HAZ) toward previous welding nugget, as well as concentration of alloying elements along grain boundaries are also discovered. Kim et al. [17]). Although most of these studies have included thermal, electrical and mechanical aspects of the RSW process, the asymmetry of shunting configuration due to existence of shunting (previous) nugget prohibits the use of 1D or 2D axisymmetric models.In this paper, shunting effect in RSW is investigated using FEM and the results are compared with experiments on AA2219. The influence of welding distance, current and time are investigated to consider shunting effect in final quality of the nugget. Experiments are designed inside the weldability range, while the results are compared to results of FEM after verification. have included thermal, electrical and mechanical aspects shunting configuration due to existence of shunting (prev 2D axisymmetric models. MethodsIn this paper, shunting effect in RSW is investigated using with experiments on AA2219. The influence of welding d investigated to consider shunting effect in final quality of inside the weldability range, while the results are compar

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Section: Thermal Equationsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Experimental and numerical analysis of shunting effect in resistance spot welding of Al2219 sheets

Vardanjani¹,

Araee²,

Senkara³

et al. 2016

Bulletin of the Polish Academy of Sciences Technical Sciences

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show abstract

“…They include such researches as simulation of thermal and electrical distribution (Huh [13], Archer [14], Greenwood [15], Tsai [16]), prediction of the electrical and thermal contact properties and contact radius (Loulou et al [17], Okuda [18]), growth of nugget and thermal deformations (Nied [19] ,Gould [20], Ma [24]), or electro-thermal and mechanical analysis (Zhang [21], Hou [25], Hamedi [26]), to number only a few. Although most of these studies have included different thermal, electrical and mechanical aspects of the RSW process, not many utilized models for finite element analyzing of shunting effect [22][23]27].…”

Section: Finite Element Analysis (Fea)mentioning

confidence: 99%

A Review of Shunting Effect in Resistance Spot Welding

Jafari

Senkara

Arayee

2016

Przegląd Spawalnictwa

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Studies on shunting effect in resistance spot welding (RSW) have not been widely performed and limited researches were devoted to some aspects of it. Shunting effect in RSW occurs when the electrical current passes through the preceded spot welds in the case of multi-spot welding. The amount of this current depends mostly on weld spacing, and to some extent, on the number and size of previous spot welds. The phenomenon causes some changes in the quality of shunted weld, such as nugget diameter decrease with consecutive reduction of mechanical strength due to changes in electrical current distribution and temperature distribution. Recently some efforts have been made to develop equations for determine the relationship between the input welding parameters and the quality of spot welds. However, the problem needs deeper research and analysis. The paper reviews different approaches performed for simulation and analysis of shunting in RSW.Keywords: resistance spot welding, shunting, review StreszczenieBadania efektu bocznikowania prądu przy punktowym zgrzewaniu rezystancyjnym (RSW) nie były dotąd szeroko prowadzone i niewiele badań było niektórym jego aspektom. Zjawisko bocznikowania w trakcie RSW pojawia się w sytuacji przepływu prądu elektrycznego przez poprzedzające zgrzeiny w przypadku zgrzewania wieloseryjnego. Wielkość prądu bocznikowania zależy głównie odległości pomiędzy zgrzeinami i w pewnej mierze od ilości i wymiarów poprzedzających zgrzein. Zjawisko to powoduje różnicę jakości bocznikowanej zgrzeiny, poprzez zmniejszenie średnicy jej jądra zgrzeiny, co skutkuje obniżeniem wytrzymałości mechanicznej. Zmiany te są skutkiem zmian rozkładu prądu zgrzewania i temperatury. Ostatnio podjęto starania dla opracowania równań opisujących zależność pomiędzy parametrami wejścio-wymi zgrzewania z bocznikowaniem prądu a jakością zgrzein. Zagadnienie to wymaga jednak głębszych badań i analiz. Niniejsze opracowanie stanowi przegląd prac o różnym podejściu do symulacji i analizy RSW z efektem bocznikowania prądu.Słowa kluczowe: zgrzewanie rezystancyjne punktowe, bocznikowanie prądu, stan zagadnienia

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“…One of the general electrical equations used for calculation of electrical contact resistance is [7,12]:…”

Section: Contact Materials Propertiesmentioning

confidence: 99%

A Review of Finite Element Analysis (FEA) of Resistance Spot Welding (RSW)

Jafari

Arayee

Senkara

2016

Przegląd Spawalnictwa

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Modeling RSW was studied by many researchers with considering different electrical, thermal, and mechanical phenomena such as formation of temperature field and welding nugget growth. This paper is a review of the most important efforts in the field of FEA of RSW, by investigating present finite element method (FEM) studies. After a brief introduction on FEA studies on RSW, such numerical solution methods as FEM and FDM (Finite Difference Method) are compared. Governing electrical, thermal, and mechanical equations are then discussed. A brief investigation about applicable algorithms is presented as a procedure for numerical solution. The importance of credible material properties is emphasized and predicted results in different studies are discussed. The final two parts are about recent issues in RSW FEA process and review of special cases such as multiple-sheet, single-sided welding, shunting effect, and covered models. Conclusions and suggestions about future studies are also provided.

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Numerical simulation of tensile strength of upset welded joints with experimental verification

Cited by 15 publications

References 6 publications

Experimental and numerical analysis of shunting effect in resistance spot welding of Al2219 sheets

Experimental and numerical analysis of shunting effect in resistance spot welding of Al2219 sheets

A Review of Shunting Effect in Resistance Spot Welding

A Review of Finite Element Analysis (FEA) of Resistance Spot Welding (RSW)

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