An Improved Numerical Modeling for Resistance Spot Welding Process and Its Experimental Verification

[+] Author and Article Information
O. P. Gupta, Amitava De

Department of Mechanical Engineering,IIT Kharagpur, India

J. Manuf. Sci. Eng 120(2), 246-251 (May 01, 1998) (6 pages) doi:10.1115/1.2830120 History: Received June 01, 1996; Revised January 01, 1997; Online January 17, 2008


A numerical model of resistance spot welding with spherical tip electrode is developed to incorporate the electro-thermal aspect as well as thermo-elasto-plastic behaviour inherent in this process. The electro-thermal aspect includes the Joule’s resistive heating along the contact surfaces and within the sheet-electrode system due to nonuniform current density distribution in the sheet-electrode. The elasto-plastic deformation of the sheet-electrode interface at higher temperature is included in the thermo-mechanical analysis. The interdependence of those two analyses has been taken care of The model is used to simulate the spot welding in low-carbon steel sheets of 1 mm and 2 mm thickness and HSLA steel sheet of 1 mm thickness. The results are compared with experimental data obtained as a part of this work and also with literature data. The comparison has shown a good agreement in all the cases. The results are later used to draw the thermal cycle curves at different location along the faying surface.

Copyright © 1998 by The American Society of Mechanical Engineers
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