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

17.09.2015 13