Research Papers

Evaluation of the Role of Eddy Current in Resistance Spot Welding

[+] Author and Article Information
M. Abu-Aesh

Department of Mechanical Engineering, College of Engineering, University of Bahrain, P.O. Box 32038, Isa-Town 32038, Kingdom of Bahraindr_abu_aesh2@yahoo.co.uk

Moataza Hindy

Department of Mechanical Engineering, College of Engineering, University of Bahrain, P.O. Box 32038, Isa-Town 32038, Kingdom of Bahrainm1_hendi@yahoo.com

J. Manuf. Sci. Eng 131(6), 061007 (Nov 20, 2009) (5 pages) doi:10.1115/1.4000434 History: Received April 15, 2006; Revised October 08, 2009; Published November 20, 2009; Online November 20, 2009

Extensive work had been conducted on spot-welding due to its rapidly increasing industrial importance. The resistance spot-welding involves complicated phenomena, as several effects are found in the process, e.g., temperature, surface roughness, pressure, and eddy current effects. Most of the work exerted for analyzing the spot-welding process neglect the effect of the eddy current generated during the flow of the huge welding main current through the assembly of electrodes and work sheets. This work presents an analytical method to investigate the generation of eddy current and to determine the total effective welding current in spot-welding. The current distribution on the work sheet when it is fed by a conducting electrode is also investigated. The obtained current formula is based on electromagnetic principles, where a very strong magnetic field is generated in the core of the electrodes as well as in the materials of work sheets due to the flow of very high amperage. The final resultant effective current is the superposition of the electrode welding current and the induced eddy current in the electrode and work piece assembly. The results offer a viable mathematical model, which can be applied for a precise prediction of the effective value of welding current in spot-welding processes, if applied in a comprehensive model including all involved effects.

Copyright © 2009 by American Society of Mechanical Engineers
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Grahic Jump Location
Figure 1

Representative sketch of the resistance spot welding process

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Figure 2

Magnetic field generated in a metallic electrode carrying a current I

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Figure 3

Eddy current induced by the generated magnetic field in a work piece element

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Figure 4

Resultant eddy current Ie

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Figure 5

Representative sketch of the eddy currents generated by a circular magnetic field in a work piece ring element

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Figure 6

Distribution of the eddy current Ie along the radius r

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Figure 7

Superposition of the welding and eddy currents: (a) welding, (b) eddy, and (c) effective currents




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