developments and applications of numerical simulation in ......projection welding of srew nuts...
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Developments and applications of numerical simulation in resistance welding
Greitmann, Martin; Nielsen, Chris Valentin; Zhang, Wenqi
Publication date:2013
Link back to DTU Orbit
Citation (APA):Greitmann, M. (Author), Nielsen, C. V. (Author), & Zhang, W. (Author). (2013). Developments and applications ofnumerical simulation in resistance welding. Sound/Visual production (digital)
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1IIW Essen 2013, C-III©2013 M. J. Greitmann, Hochschule Esslingen
Martin GreitmannHochschule Esslingen University of Applied SciencesGermany
Chris V. Nielsen and Wenqi ZhangSWANTEC Software and Engineering ApSDenmark
Developments and Applications of Numerical Simulation in
Resistance Welding
IIW-Doc. III-1680-13
2IIW Essen 2013, C-III©2013 M. J. Greitmann, Hochschule Esslingen
Resistance spot welding (material: DC04; t1=0.8mm / t2=1.5 mm)
Quality assurance numerical process analysis
Spotwelder (1997)
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Numerical Simulationresistance welding
SYSWELD ® (FRAMASOFT S.A./FRAMATOME)
SPOTSIM ® (RWTH Aachen, Tula State University)
SPOTWELDER ® (MPA Stuttgart)
SORPAS ® (SWANTEC Software and Engineering ApS)
Software:
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Resistance WeldingMODEL FOR NUMERICAL ANALYSIS
Geometry Material data ( Young’s modulus, µ, ... )
Electrode force
Structure mechanicModel
Stress distribution
Deformation
Temperature-
fieldDesign
Welding current Material data ( cp, Rk,, ... )
Electric-thermalModel
Temperature distribution
Numerical process analysis
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5IIW Essen 2013, C-III©2013 M. J. Greitmann, Hochschule Esslingen
Mechanical Model - Machine
Numerical process analysis
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Data base
physical material properties
electrical resistivity thermal conductivity heat capacity cp
Numerical process analysis
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Data basemechanical material properties
Numerical process analysis
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Database
Material Resistance
and Contact Resistance
20
40
60
80
100
120
140
µ
180
Ele
ctric
al R
esis
tanc
e
0 400 800 1200 °C 2000
Temperature
RAlloy ( t1 = t2 = 1.25 mm; AlMg0.4Si1.2 )RContact Resistanc ( Model: MPA Stuttgart )RAlloy + RContact Resistanc
Temperature
Co
nta
ct
Re
sis
tan
ce
Numerical process analysis
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Measurement - transition resistance
ISO 18594
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0 1 2 3 4 5 6 7 8
CuFe2P, t = 0,6 mmCuFe2P, t = 0,4 mmCuFe2P, t = 0,2 mm
CuNi3Si1Mg, t = 0,6 mmCuNi3Si1Mg, t = 0,4 mmCuNi3Si1Mg, t = 0,2 mm
CuNiCo1Si, t = 0,4 mmCuNiCo1Si, t = 0,2 mm
CuSn8, t = 0,6 mmCuSn8, t = 0,4 mmCuSn8, t = 0,2 mm
CuZn37, t = 0,6 mmCuZn37, t = 0,4 mmCuZn37, t = 0,2 mmE-Cu58, t = 0,6 mmE-Cu58, t = 0,4 mmE-Cu58, t = 0,2 mm
CuCrAgFeTiSi, t = 0,4 mmCuCrAgFeTiSi, t = 0,2 mm
Übergangswiderstand / m
Transition resistance (copper alloys)
(MPA Stuttgart)Transition resistance
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11IIW Essen 2013, C-III©2013 M. J. Greitmann, Hochschule Esslingen
Numerical process analysisHot staking process
Resistance welding of commutator segments with hook geometry
12IIW Essen 2013, C-III©2013 M. J. Greitmann, Hochschule Esslingen
Numerical process analysisHot staking process
Resistance welding of commutator segments
slot geometry hook geometry
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13IIW Essen 2013, C-III©2013 M. J. Greitmann, Hochschule Esslingen
Numerical process analysisHot staking process
1984 R. Schwab (doctoral thesis): Numerical simulation of Hot Staking process
commutator segments with slot geometry
temperature field temperature-time-curve
(Schweißen und Schneiden, 38 (1986), Heft 8, S. 365-369)
14IIW Essen 2013, C-III©2013 M. J. Greitmann, Hochschule Esslingen
Numerical process analysisHot staking process (2012)
(Lanier)
Resistance welding of commutator segments with hook geometry
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15IIW Essen 2013, C-III©2013 M. J. Greitmann, Hochschule Esslingen
Numerical process analysisHot staking process (2012)
(Lanier)
Resistance welding of commutator segments with hook geometry
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Numerical process analysiselectrotecnic application
wire termination
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W-Elektrode
W-Elektrode
CuSn6 -Gabel
CuL -Draht
Numerical process analysiselectrotechnic application
FEM Model & Process
(Dötzer)
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Numerical process analysiselectrotechnic application
(Dötzer)
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19IIW Essen 2013, C-III©2013 M. J. Greitmann, Hochschule Esslingen Projection Welding - Joint Geometry
Stress distribution(von Mises)
Numerical process analysiselectrotechnic application
Projection welding
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Numerical process analysiselectrotechnic application
Calculated projection deformation and temperature distribution
(Kußmaul, Blind, Zeng, Greitmann, Schäfer, 1991)
Database: Temperature-dependent stress-strain behaviour of the used projection
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calculated movement and temperature distribution
Numerical process analysiselectrotechnic application
(Vichniakov, Herold, Greitmann, Roos, 2002 in Mathematical modelling of the weld phenomena )
2001 Alexei Vichniakov (doctoral thesis): numerical simulation of projection welding
22IIW Essen 2013, C-III©2013 M. J. Greitmann, Hochschule Esslingen
(Bschorr, Cramer, SLV München NL der GSI mbH)
Numerical process analysisprojection welding of srew nuts
Projection welding: srew nuts onto high strength steel sheet
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23IIW Essen 2013, C-III©2013 M. J. Greitmann, Hochschule Esslingen
(Bschorr, Cramer, SLV München NL der GSI mbH)
Numerical process analysisprojection welding of srew nuts
Optimization of srew nut geometry
old new
24IIW Essen 2013, C-III©2013 M. J. Greitmann, Hochschule Esslingen
• Square nut welding
Numerical process analysisprojection welding
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25IIW Essen 2013, C-III©2013 M. J. Greitmann, Hochschule Esslingen
circular saw
stellite hard facing
1920 1960
Brazing (CuAg solder)
resistance welding Laser beam welding
1985 1992
band saw(grinded)
padsaw
padsaw
Numerical process analysisCarbide tipped saw blade
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FE-Model (geometry)
FE-Model
ElektrodeTrägersegment
HartmetallElektrodenbacken
Experimental setup
Numerical process analysisCarbide tipped band saw
(Greitmann, Wink)
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Current distribution
A
A
Temperature field
time: 70 ms
Videoclip
Numerical process analysisCarbide tipped band saw
(Greitmann, Wink)
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Carbide tipped saw band
Hartmetall
Sägeband
Numerical process analysisCarbide tipped band saw
(Greitmann, Wink)
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29IIW Essen 2013, C-III©2013 M. J. Greitmann, Hochschule Esslingen
Längsschnitt
Realtime-Bildfolgezeit
5 ms
Konturabstand 100 °C
Temperatur-bereich
0°C bis 2000 °C
nach 70 msVideoclip
Numerical process analysisCarbide tipped band saw
(Greitmann, Wink)
30IIW Essen 2013, C-III©2013 M. J. Greitmann, Hochschule Esslingen
APPLICATION
Spot Welding
Numerical process analysisresistance spot welding
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31IIW Essen 2013, C-III©2013 M. J. Greitmann, Hochschule Esslingen
Numerical process analysisresistance spot welding (1996)
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Example: Variable sheet thickness
Numerical process analysisresistance spot welding (1996)
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100
200
300
400
µ
600
Res
ista
nce
0 10 20 30 40 50 60 ms 80
Time
Pickle: 12% NaOH/60°C/60s Pickle: 12% NaOH/60°C/60s; cleanednatural SurfacePickle: 25% NaOH/65°C/60s; cleanedbrushed surface
Alloy: AlMg0.4Si1.2; ( t = 1.25 mm )
Spot welding Aluminium
Numerical process analysisresistance spot welding
(Greitmann, Kessler, 1990)
34IIW Essen 2013, C-III©2013 M. J. Greitmann, Hochschule Esslingen
Aluminium sheets with variable surface conditions (contact resistance)
Numerical process analysisresistance spot welding (1996)
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Temperature distribution
Numerical process analysisresistance spot welding
(Greitmann, Wink)
36IIW Essen 2013, C-III©2013 M. J. Greitmann, Hochschule Esslingen
local temperature–time history
0
200
400
600
800
1000
1200
1400
1600
1800
0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0
Time
Tem
per
atu
re
Position 1 Position 2
Position 3 Position 4
Position 5 Position 6
Position 7 Position 8
Position 9 Position 10
Position 11 Position 12
Position 13
Sheet material: DX54D+Z100 Sheet thickness: 1,0 mmElektrode material: CuCrZrDome radius: 40 mmElektrode force: 2,5 kNWelding current: 8 kACurrent-flow time: 240 ms
s
°C
current flow time
Numerical process analysisresistance spot welding
(Greitmann, Wink)
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37IIW Essen 2013, C-III©2013 M. J. Greitmann, Hochschule Esslingen
Spot welding 3-sheets
Numerical process analysisresistance spot welding
38IIW Essen 2013, C-III©2013 M. J. Greitmann, Hochschule Esslingen
Microstructure and hardness distribution
Spot welding 1.5 mm DP600 steel sheets
Measured micro hardness comparing to simulated hardness near the weld nugget
Macrograph of real weld comparing to simulated weld nugget and martensite distribution
Numerical process analysisresistance spot welding
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Weldability Lobe Welding process window
Welding current
Fo
rce
Minimum weld size
Acceptable
weld size
Expulsion
Zone
TypicalNugget failures
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Weld process optimization
Undersizedweld
Acceptable
weld size
Expulsion
Zone
Sorpas®
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Weld Schedule Specifications with optimal welding parameters
Weld PlanningWeld Schedule Specification
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Spot welding – Electrode misalignmet
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Projection welding Longitudinal embossment
44
Square nut projection welding
23
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3D simulation of weld strength testing
• Tensile shear test of weld strength after welding
46
3D simulation of weld strength testing
• Tensile shear test of weld strength with SORPAS® 3D
Tensile shear weld strength test curve simulated by SORPAS® 3D
Tensile shear weld strength curve in ISO 14273:2000.
24
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3D simulation of weld strength testing
• Cross tension test of weld strength after welding
48
3D simulation of weld strength testing
• Cross tension test of spot weld strength
Cross tension weld strength test curve simulated by SORPAS® 3D
Cross tension weld strength curve in ISO 14272:2000.
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Resistance WeldingNumerical Simulation
• Process simulation – Weldability of materials, weld nugget sizes
– Electrode geometry and coatings
• Process optimisation – Weld growth curves
– Weldability lobes - welding process windows
• Process planning – Optimal welding process parameters
• Weld quality and properties after welding– Microstructures and hardness
– Weld strengths and fracture modes
• Welding with adhesives– Fluid adhesives
– Solid polymer or plastics