Shape optimization of square weld nut in projection welding

Han, Giyeol; Ha, Sangun; Marimuthu, Karuppasamy Pandian; Murugan, Siva Prasad; Park, Yeong-Do; Lee, Hyungyil

doi:10.1007/s00170-021-06771-7

Cited by 5 publications

(8 citation statements)

References 7 publications

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“…Setdown merupakan nilai deformasi yang terjadi pada perubahan ketinggian kaki nut pada plat setelah proses pengelasan. Nilai ini menggambarkan tingkat penetrasi nut akibat proses pengelasan Metode perhitungan yang digunakan untuk mengukur nilai set down , dapat dijelaskan pada formula di bawah ini [18][19] :…”

Section: Setdownunclassified

Optimasi Parameter Pengelasan pada Proses Pengelasan Tahanan Listrik Komponen Bracket Rear Console untuk Peningkatan Masa Pakai Elektroda

Jatikusuma,

Al Huda

2022

teknobiz

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Penelitian ini diawali dengan pengamatan terhadap beberapa kondisi yang terjadi pada proses pengelasan tahanan listrik bracket rear console. Kondisi permukaan benda kerja yang kasar, torsi yang besarnya 4,5 kali standar minimum, press separation yang besarnya 2,5 kali standar minimum, berkurangnya material elektroda sedalam1 mm saat dresser untuk setiap 200 cycle pengelasan. Kondisi saat ini termasuk dalam kondisi standar yang sangat tinggi atau bahkan sudah mencapai kondisi berlebih. Kondisi tersebut memberikan peluang untuk dilakukan optimasi parameter pengelasan sehingga didapat kondisi baru yang lebih rendah dari kondisi sebelumnya namun dengan tetap memperhatikan 4 faktor kualitas [setdown, torsi, press separation, welding length] sekaligus dapat membuat masa pakai elektroda mengalami peningkatan. Optimasi parameter pengelasan dilakukan dengan melakukan 2 variasi penurunan tekanan elektroda (3,2 MPa & 2,9 MPa) dan mengkombinasikan dengan 2 variasi penurunan arus (6120 A & 5780 A) serta melakukan pengamatan hasil proses pengelasan terhadap 4 faktor kualitas. Kombinasi tekanan elektroda 2,9 MPa dan arus 6120 A memberikan hasil yang terbaik. Permasalahan kondisi permukaan yang kasar dapat teratasi, kedalaman dresser berkurang menjadi 0,4 mm untuk setiap 250 cycle, terjadi peningkatan masa pakai elektroda 25 %. Pengamatan terhadap rata-rata 4 faktor kualitas: setdown 87 %, torsi 80 Nm, press separation 7866 N, welding length 3,3 mm. Hasil pengelasan dengan parameter baru masih memenuhi standar kriteria pengelasan yang digunakan, sehingga kondisi optimasi dapat untuk diaplikasikan pada aktual proses produksi.

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Section: Setdownunclassified

Optimasi Parameter Pengelasan pada Proses Pengelasan Tahanan Listrik Komponen Bracket Rear Console untuk Peningkatan Masa Pakai Elektroda

Jatikusuma,

Al Huda

2022

teknobiz

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“…For this, some small grouped protrusions (3 or 5 simultaneous protrusions) are printed on the surfaces of one of the components by mechanical pressing, which will be the effective electrical contact points. The dimensions of the projection (0.5 to 1.5 mm) are determined according to the thickness and characteristics of the materials to be welded [4][5]. When the current passes through the protrusions, they heat up quickly until they melt, and the subsequent pressing causes their flattening and the simultaneous formation of several welded points.…”

Section: Introductionmentioning

confidence: 99%

“…During the rapid heating under the resistive effect of the electric current, the flow limit of the material drops suddenly, leading to its flattening and the expansion of the heated area. Therefore, a progressive adjustment of the projection dimensions and the welding regime parameters values is necessary to obtain a correct joint [5][6][7]. At the same time, it is necessary to remove contaminating elements from the surfaces to be welded (grease and oxide films) that can significantly reduce the quality of welds, especially in the case of multi-point joints [7][8].…”

Section: Introductionmentioning

confidence: 99%

The Multipoint Relief Projection Study

2023

PSEN

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Projection welding is a joining process based on the electrical resistance of metal components that have small protrusions on the areas where assembly is desired. In this case, the welding electrodes that ensure the transfer of the electric current have a flat geometry, which allows uniform pressing of the areas with protrusions, which have the role of ensuring the concentration of the current lines for the formation of welding points. Excessive deformation can cause the protrusions to collapse rapidly, causing greater dispersion of the current and limiting the effect of localized heating and melting, and welding no longer occurs. The process is widely used in the electrical, electronic, automotive, food and construction industries, etc. The paper analyzes the effect of regime parameter values during the resistance welding process on the joints made between 2 steel components with surfaces protected by aluminization. The surface of one of the components was imprinted with 5 equidistant protrusions created by plastic deformation to concentrate the electric current lines and achieve melting points with a limited surface area. The thin layer of aluminum deposited on the surfaces of the parts has the role of protection against corrosion, but it produces hard compounds located on the welding interface. The chemical micro-composition analyzes performed with the EDAX method highlighted the diffusion effects of chemical elements in the welding area and the formation of hard compounds Al-rich loccated on the fusion line of the welded points. The microstructure of the welded areas was analyzed and the fracture strength tests of some welded samples were performed to establish the most suitable values of the welding process for this application.

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“…Such problems can be avoided by VOLUME 32 (YEAR XXXII) 2021 setting the optimal distance between the projections (to four times their diameter). Usually, the projection shape and height (0.5 to 1.5mm) are established based on the material thickness, elongation, and yield strength [3], [4]. In projection welding the nut leg geometry is decisive for the joint resistance (the optimum value is less than 0.2mm) [4].…”

Section: Introductionmentioning

confidence: 99%

“…Usually, the projection shape and height (0.5 to 1.5mm) are established based on the material thickness, elongation, and yield strength [3], [4]. In projection welding the nut leg geometry is decisive for the joint resistance (the optimum value is less than 0.2mm) [4]. Due to the fast decrease in the yield strength value of the material during heating, many tests are required to adjust the right values of the welding parameters [5]- [7].…”

Section: Introductionmentioning

confidence: 99%

Case Study About Resistance Projection Welding of Aluminized Steel Parts

Voiculescu

Oprea

Vasile

2021

AWET

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Resistance projection welding is a non-polluting mechanized process used to obtain an assembly between similar or dissimilar metallic materials. The main advantages of this welding process are the possibility to achieve many different welded points at the same time and the long life of the electrodes compared to the spot-welding process. The paper analyses the effects of thin aluminium coating existing on mild steel parts of on the correct formation of welding points when assembling moulds for the manufacture of baking bread. From optical and electron microscopy analyses it resulted that some adjacent welded points show an interrupted fusion line, sprinkled with elongated islands of aluminium-rich compounds. The paper presents the effect of changing the values of the welding parameters on the weld spot size, in correlation with the Al-rich inclusions that appear on the weld fusion zone. The best results have been obtained when the welding parameters values were the follows: electrode pressure of 2.6 bar, welding power of 19.18kVA and welding time of 7ms. The problems that occur when electric resistance welding of parts with aluminium coating have been highlighted, being useful for specialists who make products using this welding process.

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Shape optimization of square weld nut in projection welding

Cited by 5 publications

References 7 publications

Optimasi Parameter Pengelasan pada Proses Pengelasan Tahanan Listrik Komponen Bracket Rear Console untuk Peningkatan Masa Pakai Elektroda

Optimasi Parameter Pengelasan pada Proses Pengelasan Tahanan Listrik Komponen Bracket Rear Console untuk Peningkatan Masa Pakai Elektroda

The Multipoint Relief Projection Study

Case Study About Resistance Projection Welding of Aluminized Steel Parts

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