Advanced Welding Process Simulation for Prediction and Control of Distortion and Residual Stresses in Automotive Sheet Metal Component Assembly

Welding simulations are transforming industrial manufacturing by enabling a predictive and first-time-right approach for process development. Advanced techniques such as Finite Element Analysis (FEA) help in accurate prediction of temperature distribution, residual stress, distortions and potential defects prior to physical welding which in turn support for addressing key challenges associated with Heat Affected Zones (HAZ) like distortion, fitment issues and post-weld cracking. Early integration of simulation in the development cycle significantly reduces lead time, enhances durability, and improves manufacturing efficiency. This study presents a simulation-based product development approach to mitigate post-weld crack generation issues in a complex multiple weld configuration of an automotive sheet metal assembly. The methodology adopts a two-stage framework: first, identifying the root cause of crack generating through baseline weld simulation; and second, implementing design optimizations to mitigate the issue as a sustainable solution. The baseline simulation conducted using the actual weld parameters and clamping conditions, successfully identified high-stress zones closely associated with observed crack formation. The simulated stress distribution was validated experimentally through X-ray Diffraction (XRD) measurements showing strong co-relation with the predicted results. Based on these insights, targeted design modification was introduced through simulation-based product development (SBPD) approach to reduce stress concentrations and minimize crack formation susceptibility. The work underlines the strategic benefits of integrating highly reliable welding simulations into product and process development. It demonstrates how simulation led insights can drive enhancements in weld quality, assembly accuracy and manufacturing robustness while delivering significant cost and performance benefits particularly within the demanding context of automotive production .