This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
Design and Implementation of Software for Resistance Welding Process Simulations
Technical Paper
2003-01-0978
ISSN: 0148-7191, e-ISSN: 2688-3627
Annotation ability available
Sector:
Language:
English
Abstract
Based on long time engineering research and dedicated collaborations with industry, a new welding software, SORPAS, has been developed for simulation of resistance projection and spot welding processes applying the powerful finite element method (FEM).
In order to make the software directly usable by engineers and technicians in industry, all of the important parameters in resistance welding are considered and automatically implemented into the software. With the specially designed graphic user interface for Windows, engineers (even without prior knowledge of FEM) can quickly learn and easily operate and utilize the software. All industrial users, including welding engineers from DaimlerChrysler, Volkswangen, PSA Peugeot Citroen, VOLVO, Siemens, ABB and so on, have started using the software just after taking a one-day training course.
With the user-friendly facilities for flexible geometric design of work pieces and electrodes as well as process parameter settings similar to real machine settings, the software has been readily applied in industry for supporting product development and process optimization. After simulation, the dynamic process parameters are graphically displayed. The distributions of temperature, current, stress and deformation in the materials are displayed in color, which can be animated like slow-motion video. The software has been extensively verified and today applied in various industries including automotive, electronics and other metal processing industries as well as welding equipment manufacturers.
Recommended Content
Citation
Zhang, W., "Design and Implementation of Software for Resistance Welding Process Simulations," SAE Technical Paper 2003-01-0978, 2003, https://doi.org/10.4271/2003-01-0978.Also In
References
- Roberts D. K. Roberts J. E. Wells A. A. Fundamental Resistance Welding Investigations British Welding Journal 3 1958 117 126
- Archer G. R. Calculations for Temperature Response in Spot Welding Welding Journal Research Supplement 8 1960 327s 330s
- Greenwood J. A. Temperatures in Spot Welding British Welding Journal 3 1961 316 322
- Rice W. Funk E. J. An Analytical Investigation of the Temperature Distributions during Resistance Welding Welding Journal Research Supplement 4 1967 175s 186s
- Cho H. S. Cho Y. J. A Study of the Thermal Behavior in Resistance Spot Welds Welding Journal Research Supplement 6 1989 236s 244s
- Nied H. A. The Finite Element Modeling of the Resistance Spot Welding Process Welding Journal Research Supplement 4 1984 123s 132s
- Tsai C. L. Jammal O. A. Papritan J. C. Dickinson D. W. Modeling of Resistance Spot Weld Nugget Growth Welding Journal Research Supplement 2 1992 47s 54s
- Zhang W. Kristensen T. F. “Finite Element Modeling of the Heat Development in Resistance Welding” The 8th Int. Conf. on the Joining of Materials, JOM-8 Helsingør, Denmark May 1997 226 233
- Zhang W. Hallberg H. Bay N. “Finite Element Modeling of Spot Welding Similar and Dissimilar Metals” The 7th Int. Conf. on Computer Technology in Welding San Francisco, USA July 1997 364 373
- Kristensen L. Zhang W. Malberg M. Bay N. “Verification of an FEM Program for Spot Welding” The AWS Conference on Resistance Welding: Theory and Applications Chicago, USA October 1997 182 208
- Zhang W. Bay N. “Finite Element Modeling Aided Process Design in Resistance Welding” 8th Int. Conf. on Computer Technology in Welding Liverpool, UK June 1998 36 1 11
- Zhang W. “Finite Element Modeling of Resistance Welding Processes” The 9th Int. Conf. on the Joining of Materials, JOM-9 Helsingør, Denmark May 1999 54 59
- Kristensen L. Zhang W. Bay N. “Influence of Geometric Parameters on Weld Quality in Resistance Projection Welding” The 9th Int. Conf. on the Joining of Materials, JOM-9 Helsingør, Denmark May 1999 112 117
- Zhang W. Kristensen L. “Finite Element Modeling of Resistance Spot and Projection Welding Processes” The 9th Int. Conf. on Computer Technology in Welding Detroit, Michigan September 1999 15 23
- Kristensen L. Zhang W. Bay N. “Studies of Geometric Parameters in Projection Welding of Different Material Combinations” 18th DVS-Sondertagung “Widerstandsschweissen 2001” Duisburg, Germany May 2001 76 80
- Wanheim T. Bay N. A model for friction in metal forming processes Annals of the CIRP 27 1978 189 194