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Distortion Optimization through Welding Simulation in Electric Vehicle Aluminum Assemblies
ISSN: 0148-7191, e-ISSN: 2688-3627
Published April 02, 2019 by SAE International in United States
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Electric vehicle makers have largely relied on aluminum to make their cars lighter in hopes of offsetting the weight of the battery pack and reducing overall weight. Distortion of Aluminum welding is a big issue due to Aluminum’s high coefficient of expansion ratios.
This paper presents an effective numerical approach to minimize weld-induced distortion in Electrical Vehicle Aluminum assembly structures using welding sequence optimization. A numerical optimization framework based on genetic algorithms and Finite Element Analysis (FEA) is developed and implemented. The shrinkage method calibrated using transient approach, is used for the weld sequence optimization to reduce the computation time. The optimization results show that the proposed calibration approach can contribute substantially to reduce distortion by optimizing weld sequences. It enhances final aluminum assembly quality while facilitating and accelerating design and development.
CitationMao, T., Ding, P., Camanho, A., Peng, S. et al., "Distortion Optimization through Welding Simulation in Electric Vehicle Aluminum Assemblies," SAE Technical Paper 2019-01-0818, 2019, https://doi.org/10.4271/2019-01-0818.
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