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首页> 外文期刊>Journal of Manufacturing Processes >Factor analysis of deformation in resistance spot welding of complex steel sheets based on reverse engineering technology and direct finite element analysis
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Factor analysis of deformation in resistance spot welding of complex steel sheets based on reverse engineering technology and direct finite element analysis

机译：基于逆向工程技术的复合钢板电阻点焊变形因子分析及直接有限元分析

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Direct finite element analysis of continuous spot welding was implemented with reverse geometric models of the actual stamping parts that comprise the back-side panel. This reverse panel showed apparent gaps after assembly and yielded to the electrodes and fixtures during welding, causing significant deformations. We acquired the total residual deformation in continuous simulation through a 3-D comparison between the original panel and the final deformed panel. This total deformation indicates that the deformations in the two processes offset with each other. We also performed a spot welding experiment and measured the actual residual deformation to validate the total deformation in simulation. They show good agreement in terms of deformation trend and magnitude. Finally, we designed seven comparative simulations to investigate the influence of the clamping pressure, electrode force, and spot welding sequence on the residual deformation. The results show that the sole increase of clamping pressure causes a deformation reduction in plate P4, while that of electrode force causes a deformation increase in P3. When the welding sequences of processes 1 and 2 are both reversed, the plate with the lowest deformation changes from P4 to P3. The final deformations in parts with multiple processes and multiple spot welds result from nonlinear interaction among many factors. The influence of a single factor change on the final deformation will be balanced by the remaining factors. This is why the fluctuations in total deformation are not significant between the standard simulation and each of the seven comparative simulations. The value of this article lies in the parameters optimization of spot welding based on reverse engineering and direct finite element analysis.
机译：用倒侧面板的实际冲压部件的反向几何模型实现了连续点焊接的直接有限元分析。该反向面板在组装后显示出明显的间隙，并在焊接期间产生电极和固定装置，从而导致显着的变形。我们通过原始面板和最终变形面板之间的3-D比较来实现连续模拟中的总残留变形。这种总变形表明两种过程中的变形彼此偏移。我们还进行了现场焊接实验，并测量了实际残留变形以验证模拟中的总变形。它们在变形趋势和幅度方面表现出良好的一致性。最后，我们设计了七个比较模拟，以研究夹紧压力，电极力和点焊序列对残余变形的影响。结果表明，夹紧压力的唯一增加导致板P4的变形降低，而电极力的变形导致P3的变形增加。当过程1和2的焊接序列都反转时，具有最低变形的板从P4到P3变化。具有多种方法和多点焊缝的零件的最终变形是由于许多因素之间的非线性相互作用。单个因素变化对最终变形的影响将由其余因素平衡。这就是为什么总变形的波动在标准仿真和七个比较模拟中的每一个之间不显着。本文的价值在于基于逆向工程和直接有限元分析的点焊参数优化。

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