Energy storage spot welding simulation

What is welding structure simulation?

With our welding structure simulation, you will be able to see an individual welding processes (weld, spot) and the behavior of the welded assembly during welding. The simulation model can represent conventional welding processes (resistance spot welding, laser welding, arc welding, etc.) as well as additive manufacturing (e.g. AM-DED).

How is a spot weld performed?

This means the spot weld is performed as experiment and simulation. The contact function then is adjusted during some simulation iterations until the nugget evolution matches with the experiment result. Kaars [3,4] extended the method from temperature dependent function to temperature and pressure dependent function for the contact resistance.

How a resistance spot welding model can be used to predict RSW quality?

The model can directly generate process signal data with accurate quality indexes, which supports solving the problem of insufficient labeled data in model training for RSW quality prediction. Resistance spot welding (RSW) is a widely applied joining method for the manufacture of thin-walled structures, especially for automotive body assembly.

What is the mechanism of heat generation during resistance spot welding?

The mechanism of heat generation during resistance spot welding is as follows: At the beginning the contact resistance starting at room temperature is high. This initializes the first joule heating in the contact zone and the attached material.

How does resistive spot welding work?

This dependence is done through a *DEFINE_FUNCTION. Resistive spot welding is a process where 2 electrodes are used to both apply some pressure and pass an electric current through the workpieces to be welded.

Can FE model adapt to different welding parameters?

Moreover, the FE model developed can also adapt to variations in sheet thickness and welding parameters. Table 4 lists the simulation error for the optimized FE model when it is directly applied to different stack-ups, welding currents, and welding times.