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However, spot welding copper cannot be simply accomplished with the traditional copper-alloy spot
welding electrode because the heat created in the electrodes and the work piece are way too alike.
Investigation of geometric effects in spot-weld modeling and a new spot-weld model for finite
element crash simulations. (Under the direction of DR. HOWIE FANG) Vehicle crashworthiness is a
critical issue to the automotive industry because it is related to the human safety in the events of
crashes. A low power or stereo microscope typically employs objective lenses of 50x or less. It is
used. The shell elements were considered rigid, because the authors did not observe any fracture or
deformation during the experiments. In the situation of MS deformation is less than the load. One
has to restrict the use of approximations and assumptions on simulation models to ensure simulations
reflect the real world scenarios. The MPC forces were converted to line forces (force per unit arc
length) and line forces to structural stresses according to plate theory. The interface stiffness used in
a contact algorithm is based on the stiffness values of the slave and master surfaces, whichever is
smaller. The Mild Steel Peel samples before and after Peel test are shown in fig:4.13. The stainless
steel 304 Peel. For example, it is commonly used to join steel panels. The zinc-coated steel was
analyzed to have the following components. The resulting strength, residual stresses, and material
properties in a spot-weld may be different from those of the parent sheets. This characteristic made
the weldability sensitive to the electrode force in the welding current range of 8 to 9 kA; however, a
very stable weld zone was achieved at welding currents greater than 10 kA. The process tape also
increases weldability owing to its high electrical resistance, which compensates for the low resistivity
of aluminum alloy and facilitates the resistance control of the weld zone. Therefore, this model is
mesh-independent and can be embedded in meshes of any size. Figure 3.9 shows the schematic
representation of the octagonal mesh of new spot-weld model. Figure 4 shows an electrode (type R)
with the Cr-Cu component used in the experiment. In the point-to-point connection, a single beam or
spring element is used to model the link connecting two points on the joining sheets. The end nodes
of the hat section were constrained for all the six degrees of freedom. Weldability analysis of DC
spot welding according to conditions. The characteristics of the main parameters associated with
weld strength and welding defects were investigated and the weld lobe curve was derived through
welding experiments. In the case of 2 mm mesh, different folding patterns were observed between
the octagonal and nine-node models. The only variable in that welding is pressure and time. A
computer program is developed in this study to ease the effort in generating the spot-weld models.
The Fractography of shear test broken sample spot welded at electrode pressure of 70 Psi is. This
guarantees that the heat is created in the work pieces rather than the electrodes. Shear test is carried
out at Universal test machine (UTS). In particular, the pre-force time is defined as the positive value
when the magnitude of the electrode force changes from force 1 to force 2 during the main current
time. Table 13, Table 14 and Table 15 are lobe curves as functions of the main current time. There are
many metals are used in industries and in other fabrication fields. An FE model of a spot-weld
should represent and should be able to transmit the forces and stresses generated, calculate the
energy absorbed, and provide similar results to those of an actual spot-weld.
In the explicit methods, the new value is defined in terms of values that are already known. Although
folds were at the crushing end for both models, folds for the octagonal model are not as smooth as
those for the nine-node model. Remember that the formula is applicable to low carbon steels and
may not be correct for other. Black smith fire Electric current Chemical reaction. It is important in
film and sheet products where failures from this type. When the two parts are mated together, these
projections are the high points that first make contact. Mild Steel and Stainless steel 304 Samples are
welded by spot welding machine. But this affects accuracy as a pressure wave that propagates
further than one cell in one time step will move to the region that has no defined influence on the
pressure. This is a type of resistance welding where the spot welds are made at regular intervals on
overlapping sheets of metal. Shear strength is one of the mechanical properties of a material which is
determined by either. Note that from the first issue of 2016, this journal uses article numbers instead
of page numbers. In particular, the pre-force time is defined as the positive value when the magnitude
of the electrode force changes from force 1 to force 2 during the main current time. Graph is plotted
between the Pressure and Weld Nugget Diameter. Help new students to deal with the Netherlands
and the Dutch Language. More Related Content What's hot Basics in Maintenance Basics in
Maintenance raghuttam Planned Maintenance. The suitability of mild steel and stainless steel for
spot welding depends mainly on 3 factors-. I am indebted to University of North Carolina at
Charlotte for supporting me financially throughout my master?s degree. The shear test behavior of
mild steel and stainless steel 304 shear test is shown in fig 4.9 and 4.10. Shell elements were inserted
between the spokes that are formed by the rigid bars. SS shear sample spot welded at 2-SEC, (c)
Before Test, (d) After Test. No sparks or fire hazards are present and there is no thermal stress to the
part. MS Peel sample spot welded at 4-SEC, (g) Before Test, (h) After Test. It is also observed that
the spot-weld locations and remeshing around the spot-welds affect the behavior of the new spot-
weld model and deserve further investigation. After the initial peak loads, the crushing forces for
both models do not significantly differ from each other in magnitude, but differ in the locations of
peak loads. Page 61. Lobe curve according to main current time (300 ms). SS is also high
deformation and load than the MS. SS sample require the. The nugget weld size formed during the
welding process can be evaluated by peel test, there. Figure 4.19: Graph of Peel Test Mild Steel with
pressure variation. I would like to express my gratitude to my parents, Dr. Anil Jayawant and Mrs.
Archana Jayawant, who always supported my vision, inspiration until now, in all aspects of my
education. It is an easy process to learn that most DIYers can do at home.
The weld is created by using an electric current to heat the two pieces of metal until they are hot
enough to fuse together. The reason is that when the mesh size increases, the element sizes in the re-
meshing zone are also increased based on Page 65. For the nine-node model, folding started in the
middle and successive folding was developed in both directions from midway. It can be seen that the
crushing force reached maximum at the beginning and decreased significantly at 2 ms. Due to self
impact of folds and development of a Page 42. SS shear sample spot welded at 75PSI, (c) Before
Test, (d) After Test. Weldability analysis of DC spot welding according to conditions. At 500 ms,
interfacial fracture occurred at the current condition of 9 kA, and expulsion occurred under all
current conditions. For industrial applications, the lobe curve is used as the evaluation standard, as
illustrated in Figure 5. The application of the pre-force time was found to lower the weld strength. A
peel test is performed between two substrates bonded together with an adhesive. The. This process
tape protects the electrode from contamination by the aluminum alloy, considerably extending the
service life of the electrode. The results of component analysis at each point are summarized in Table
17. International Journal of Production Research, Vol. 43, No. 21, 2005. Set the microscope on a flat
surface in a stable and comfortable position. In case of penalty based contact, when a penetration is
found, a force proportional to penetration depth is applied to resist and ultimately eliminate the
penetration. International Journal of Environmental Research and Public Health (IJERPH). Rigid bar
elements transfer three translational and one rotational degree of freedom. For example, if we
consider equation 2 3y x (3.2) It can be written as ( )y f x (3.3) Page 24. This universal testing
machine is a kind of tensile, shear, Bend, Compression tester which. Figure 8 a illustrates the results
of the SEM-EDS analysis performed at different points in dissimilar metal RSW of zinc-coated steel:
Figure 8 b at point 1 inside the zinc-coated steel sheet (SGARC 440); Figure 8 c at point 2 inside the
IMC layer; and Figure 8 d at point 3 inside the aluminum alloy sheet (Al 6K32). So although spot
welding is ideal for certain applications, there are a variety of reasons one might want to consider an
alternative process. Our line rejection is less than 500 PPM and we have achieved Zero MARU 'A'
Defect. Table 16 shows that the weld strength was very low and no button fracture appeared in the
RSW of aluminum alloy to uncoated steel, demonstrating the existence of weldability problems
without any regularity that would allow the identification of the effects of welding conditions on
weldability. The four models studied were the single bar, single-bar with spoke- patterned radial bars
on each sheet, multiple-bar connections, and solid-element welds. The Peel test behavior of mild
steel and stainless steel 304 Peel test is shown in fig 4.19 and 4.20. However, since force 2 did not
have significant effects on both weld strength and weld defects below 5 kN, force 2 was fixed to 5
kN. Till point A, area of contact is directly proportional to the displacement and varies linearly. When
sample is break the test is stopped and maximum stress is. Figure 4.20: Graph of Peel Test Stainless-
Steel 304 with pressure variation. Dimensions of Mild Steel and Stainless Steel for Peel test used is
given in the table 3.2.
Structural stiffness of a joint was taken as the basis for all of the comparisons. Properties of the
springs are determined from actual spot-weld properties. (d) Volume element model - Solid elements
are used to connect shell elements. Please note that many of the page functionalities won't work as
expected without javascript enabled. Over the past 100 years, spot welding has been the foremost
joining process in the construction of steel cars. Most resistance spot welds are made in very short
time periods. Thus more time is required to solve equations by implicit method but it is more stable
Page 25. Feature papers are submitted upon individual invitation or recommendation by the
scientific editors and must receive. It explains the basic features such as updated weld processes,
new graphic format for General Electrode Engineering Co., Inc. (GEECO) KVA Resistance Welding
Supply 15.. Read Content Spot Welder SAFE WORK PROCEDURE - Pembinatrails.ca Allow tongs
and tips to cool before touching. This can also be seen from the histories of absorbed energy shown
in Figure 5.12. For models with 7 spot-welds and 3 mm mesh (Figure 5.13), the folding started from
the crushing end for both models. When sample is break the test is stopped and maximum stress is. A
rigid plate was used as the impactor to crush the columns. Resistance Spot Welding of Aluminum
Alloy and Carbon Steel with Spooling Process Tapes. The difference in the zinc content in the IMC
layer was verified by SEM-EDS analysis. The tensile lap-shear test specimens were prepared in the
shape illustrated in Figure 3, with a steel sheet fixed underneath an aluminum alloy sheet with an
overlap length of 40 mm and the following sheet thicknesses: SGARC 440, 1.4 mm and 1.0 mm; Al
6K32, 1.6 mm and 1.0 mm. Three pairs of specimens for the tensile shear test, peel test, and cross-
sectional examination were prepared. The second part analyzed material variation and spot-weld
location. Investigation of geometric effects in spot-weld modeling and a new spot-weld model for
finite element crash simulations. (Under the direction of DR. HOWIE FANG) Vehicle
crashworthiness is a critical issue to the automotive industry because it is related to the human safety
in the events of crashes. Peel test is performed on universal testing machine (UTS) that is fully
computer operated. The peaks in crush forces around 5 mm correspond to the deformation of the
lobes and formation of the second folds. Figure 5.20 Crushing force histories of the hat section with
8 spot-welds and 2 mm mesh Figure 5.21 Histories of absorbed energy for the hat section with 8
spot-welds and 2 mm mesh Page 57. The pressure exerted by the tongs and the electrode tips on the
workpiece has a great effect on. Typically, a vehicle consists of hundreds of components joined by
spot- welds. For components with complex geometries, if their meshes do not match, unrealistic
spot-weld models may result. Figure 4.27: Result of Mild Steel at 70 (Psi) after Peel test by SEM.
The resulting strength, residual stresses, and material properties in a spot-weld may be different from
those of the parent sheets. Lobe curve according to main current time (400 ms). Since aluminum has
a low resistance it takes extremely high levels of current to weld the material. In isotropic hardening,
the yield strength changes due to plastic deformation but the yield strengths in tension and
compression are always equal. The time-step size of explicit method limits the advance of pressure
steps to a unit cell per time. Miller is a world-class manufacturer of spot welders, offering a complete
array of both symmetrical and asymmetrical tongs and tips. The weldability was evaluated in terms
of expulsion, TSS, and fracture mode. Stainless Steel 304 it is possible to find the optimum
conditions that are appropriate.
During 3 to 6 ms interval, the deformation is through the second spot-weld from impacting end in
nine-node model which tries to resist it hence a small upward trend can be seen. Compared to the
case with seven spot-welds, there are fewer folds in the eight spot-weld models. The experimental
results in Table 5 and Table 7 show that the DeltaSpot specimen was welded at a lower current and
had a wider plug fracture case than that of the inverter DC specimen. MianHusnainIqbal2 ROBOT
PERCEPTION FOR AGRICULTURE AND GOOD PRODUCTION1.1.pdf ROBOT
PERCEPTION FOR AGRICULTURE AND GOOD PRODUCTION1.1.pdf
RudraPratapSingh871925 Gate-Level Simulation Methodology Improving Gate-Level Simulation
Performance Gate-Level Simulation Methodology Improving Gate-Level Simulation Performance
suddentrike2 Microstrip Bandpass Filter Design using EDA Tolol such as keysight ADS and An.
Journal of Functional Morphology and Kinesiology (JFMK). This is similar to the case of the models
with 2 mm mesh. So although spot welding is ideal for certain applications, there are a variety of
reasons one might want to consider an alternative process. Typically, a vehicle consists of hundreds
of components joined by spot- welds. The end nodes of the hat section were constrained for all the
six degrees of freedom. Further, it can be confirmed that DeltaSpot welding achieves better weld
strength than inverter DC spot welding even at a relatively low welding current. Resistance Spot
Welding of Aluminum Alloy and Carbon Steel with Spooling Process Tapes. Metals. 2019; 9(4):410.
At 200 X and 400X due to the shear test surface is deformed starish marks are seen on surface.
Compared to single point connections or quadrilateral shaped brick elements, the octagonal shaped
model is closer to the actual circular shape of the real spot-weld nuggets. There are several
advantages of the new spot-weld model: 1. Intermetallic compound (IMC) layer thickness
measurement: ( a ) Zinc-coating steel; ( b ) non-coating steel. SS Peel sample spot welded at 3-SEC,
(e) Before Test, (f) After Test. They used specimen with different lengths but the weld diameter and
sheet thickness were all the same. Get Document BODY SHOP EFFICIENCY TAKEN
SERIOUSLY - Car-o-liner.com To steady when the spot weld was well executed. Graph is plotted
between the time and Weld Nugget Diameter. In Chapter 5, comparisons are provided for the model
designed in this study and the existing model based on crush forces, total absorbed energy, and
folding patterns. One of the measurements of crashworthiness is the total amount of energy that a
structure absorbs during an impact. In the FEM, a complex region defining a continuum is
discretized into simple geometric shapes called elements. I would like to express my gratitude to my
parents, Dr. Anil Jayawant and Mrs. Archana Jayawant, who always supported my vision, inspiration
until now, in all aspects of my education. The vertical axis represents welding time or electrode
force; the horizontal axis represents welding current. Chapter 4 gives a detailed description of the FE
models used for simulation. The up-slope time, main current time, down-slope time, and current level
are related to the profile of the welding current. For the two models with 3 mm mesh, the time
histories of crushing forces are shown in Figure 5.23. Both curves follow a similar trend during the
entire history but with slight difference in the locations of peak loads. Figure 5.23 Crushing force
histories of the hat section with 8 spot-welds and 3 mm mesh The total energy absorption of the two
models is shown in Figure 5.24. Similar trend was observed for the first 6 ms and then there is a
slight difference between the two models. Place a small solid specimen onto the stage such as a
card. Because of this difference in spot-weld locations, it required less force to initiate folding for
the nine-node model than for the octagonal models. Page 60. No effect of the component?s meshes
on the size and location of a spot- weld 2.
MS shear sample spot welded at 3-SEC, (e) (Before Test, (f) After Test. This process involves
pressure and an electric current which creates heat through the channel of current through resistive
materials like low carbon steels. Spot welding final year project of b.sc engineering in metallurgy and
materi. Siseho Simataa Phineous. 1.Introduction..Birds are part of nature and play an important role
within ecosystems..Some birds e.g vultures alert famers of dead carcasses on the. Samples lengths
are selected according to the jaws of Universal testing machine to provide. The vertical axis
represents welding time or electrode force; the horizontal axis represents welding current. A graph is
formed as the test runs between load and deformation. Read the data on the chart, you can A TIP
DRESSER WILL PAY DIVIDENDS. It is used in a wide range of industries but notably for the
assembly of sheet steel vehicle bodies. The evaluation of load redistribution at each spot was possible
by the use of a deformable link. Adjust the eyepieces for the correct interpapillary distance to suit
you. Figure 3.2: Welding Sample of Mild Steel and Stainless Steel 304 with Dimension for peel test.
It is used for variety of research design and issues to. Figure 4 shows an electrode (type R) with the
Cr-Cu component used in the experiment. If requirement is such that steady conditions should be
reached as soon as possible, damping is provided. An acceptable weld zone was achieved at currents
exceeding 14 kA as well. Figure 4.23: Graph of Peel Test Stainless-Steel 304 with pressure variation.
Optimization on Spot Weld Parameters in Resistance Spot Welding Process on AI. In the case of 2
mm mesh, different folding patterns were observed between the octagonal and nine-node models. It
is important in film and sheet products where failures from this type. An FE model of a spot-weld
should represent and should be able to transmit the forces and stresses generated, calculate the
energy absorbed, and provide similar results to those of an actual spot-weld. Although folds were at
the crushing end for both models, folds for the octagonal model are not as smooth as those for the
nine-node model. Projection welding is same as spot welding except a dimple is produced on work
pieces at the. Thereafter, the folding patterns are almost identical till the end of the simulation. Thus,
compared to a traditional spot welder, a clinching machine has a higher initial investment. But for
structures with complex geometries, mesh cannot be guaranteed to be congruent and the mesh sizes
and shapes on the joining sheets may not always be the same. Stainless-steel weld is more power full
than the Mild steel in both (time and pressure) sample. Table 4.8: Deformation in samples according
to the time difference in Peel test. The nine-node model is created by taking spot-weld locations
corresponding to new octagonal model as the basis. Figure 4.3 Aligning of centers for nine-node
model Actual spot-weld center Nearest node taken as center Rigid links Mesh pattern Page 37.
Therefore, in this study, weldability was evaluated based on the magnitude of the tensile shear
strength (TSS) measured by tensile shear testing.
SEM gives us information about surface by placing a sample with an electron beam. The. Microstrip
Bandpass Filter Design using EDA Tolol such as keysight ADS and An. Figure 4.25: Result of
Stainless Steel 304 at 70 (Psi) after shear test by SEM. The shear test behavior of mild steel and
stainless steel 304 shear test is shown in fig 4.7 and 4.8. Weight% 8.13 18.14 Balance 0.506 1.205
0.046 0.030 0.004. The first part illustrated the influence of geometric imperfections on spot- weld
failures and mapping history (how well is a FE model represents the real specimen). Single and
double hat columns with high strength steels and two types of dual-phase steels were used in the
analysis. In Table 4, when the main current time was 166 ms, interfacial fracture occurred at all
current conditions and expulsion occurred at the current condition of 13 kA. Hence, more folds were
formed between these two spot-welds in the nine-node model than octagonal model. Figure 4.7:
Graph of Mild Steel with Pressure variation. Fig: Sequence of operation in the friction welding
process 1)Left-hand component is rotated at high speed. 2). Welding of both Mild steel and stainless
steel for shear and peel test is doing by holding two. MIG welding is therefore referred to as a
semiautomatic welding process. Xiang et al. observed that the dimensions of spot-weld are important
to have accurate mean crush forces. Better geometric representation compared to the single-point
connections and area connections using quadratic or hexagonal elements 3. Fig: a) Components of an
ultrasonic welding machine. Weldability analysis of DeltaSpot welding according to conditions.
Team Introduction. Team Introduction--- Team Organization. If pressure waves are to be
investigated, negligible or no damping should be used so that the wave reflections can be accurately
followed. This increased stiffness in the nine-node model was due to the occurrence of the folds at
one-third tube length that turned the initial long crushing tube into two shorter sections. Figure 5.24
Histories of absorbed energy for the hat section with 8 spot-welds and 3 mm mesh Figure 5.25
shows development of folding in the two hat section models with 8 spot-welds and 4 mm meshes. It
was observed from the simulation results that folds were developed between two spot-welds.
Electrode Microscope trash out for better understanding to do the experimental work. In general, the
wider the acceptable weld zone, the better is the weldability. It is the macro structure of (50 X and
100 X) magnification. In addition, the welding schedules and specifications of actual automotive
assembly lines were considered in order to select and set the test range of all eight process
parameters. 3.1. Effect of DeltaSpot Welding in Improving Weldability In this study, a weldability
comparison was performed between inverter direct current (DC) spot welding and DeltaSpot
welding. The molten aluminum alloy provides wetting of the surface of heated carbon steel to form a
new alloy layer, namely, an IMC layer, which acts as a bonding layer equivalent to a nugget in same-
metal welding. Peel Test result shows the structure fractography of stainless steel 304 at the pressure
of 75. Mild Steel and Stainless-Steel 304 used in this experiment are famous because of their. Table
4.8: Deformation in samples according to the time difference in Peel test. The difficulty in generating
spot-weld models for FE analysis lies in the geometric difference between spot-welds and the
residing structure.