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Heating of electrodes during spot resistance welding in FEM calculations

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Języki publikacji
EN
Abstrakty
EN
Due to the fact that many factors influence the electrode life, it is difficult to assess this impact experimentally. The study presents the analysis of the impact of individual factors on the heating of selected electrodes at specific operating parameters. The analysis was based on a SORPAS programme, intended for calculations related to resistance welding, in particular, to spot welding. In selected cases FEM calculations were verified experimentally through measurements of electrode temperature during welding cycles. The calculations were carried out for 1 + 1 mm and 2 + 2 mm plates made of steel DX52, for hard and soft parameters. The analysis involved various designs of an electrode tip (outer diameters of electrodes of 13, 16 and 20 mm as well as a bevel angle of 60° and 120° – in case of electrodes with flat working parts, and an end radius of 50 mm – in case of spherical electrodes). The tests also concerned the impact of the “height” of an electrode working area (i.e. the distance from the cooling duct of 10.5 mm and 3 mm) on temperature distribution in an electrode.
Rocznik
Strony
86--100
Opis fizyczny
Bibliogr. 33 poz., rys., tab., wykr.
Twórcy
autor
  • Instytut Spawalnictwa Gliwice, Electronic Welding Devices Department, Bł. Czesława 16-18, 44-100 Gliwice, Poland
autor
  • Wrocław University of Technology, Faculty of Mechanical Engineering, Institute of Machine Technology and Automation, Łukasiewicza 5, 50-371 Wrocław, Poland
Bibliografia
  • [1] M. Truex, J. Seme, The role of tip dressing in modern auto body construction, Welding Journal (December) (2008).
  • [2] H.J. Krause, Elektrodenstandzeit beim Widerstandspunktschweissen, Schweissen und Schneiden 5 (1976) 187.
  • [3] D. Maatz, Department RWMA Q&A, Welding Journal (May) (2009).
  • [4] A. Cyunczyk, et al., New methodology of production of precipitation-hardened copper alloys, Biuletyn IMN 2 (1970).
  • [5] M. Rühle, Herstellung Und Eigenschaften von dispersionsgehärtetem Kupfer. Teil I, II. Heft 5, 8, 1970.
  • [6] A.K. Nikolajev, et al., Fizičeskije, mechaničeskije, ekspluatacjonnyje i technologies kije svojstva elektodnych splavov, Cvetnyje Metally 11 (1974).
  • [7] F. Słomczyński, Technology of production of forged and bent electrodes. Report from research work. No. 72/TL-05.1.3/417A/ 852/INOP/MPM Poznań, 1972.
  • [8] Z. Bartnik, Wł. Kaczmar, Z. Koralewicz, Influence of welding rate on heating of spot electrodes, Przegląd Spawalnictwa 3 (1982).
  • [9] Z. Bartnik, L. Krynicki, Z. Koralewicz, Cooling of welding machine electrodes with low-temperature medium, Przegląd Spawalnictwa 7 (1990).
  • [10] Z. Bartnik, W. Derlukiewicz, Factors affecting live of spot resistance welding electrodes, Przegląd Spawalnictwa 7 (2006).
  • [11] M. Niemiec, Electral – group of copper alloys for resistance welding. Spajanie 2/5/2004, 2004.
  • [12] K.S. Yeung, P.H. Thornton, Transient thermal analysis of spot welding electrodes, Welding Journal (January (Suppl.)) (1999).
  • [13] R.J. Bowers, C.D. Sorensen, T.W. Eager, Electrode in geometry in spot resistance welding, Welding Journal (February (Suppl.)) (1990).
  • [14] B.H. Chang, Y. Zhou, Numerical Study on the Effect of Electrode Force in Small-scale Resistance Spot Welding, Elsevier Science, 2003.
  • [15] J. Senkara, H. Zhang, Resistance Welding Fundamentals and Applications, CRC Press, 2011.
  • [16] H. Zhigang, I.S. Kim, J.S. Son, H.H. Kim, J.H. Seo, K.C. Jang, D.K. Lee, J.M. Kuk, A study on numerical analysis of the resistance spot welding process, Journal of Achievements in Materials and Manufacturing Engineering 1 (January/February (1/2)) (2006).
  • [17] K.R. Chan, N. Scotchmer, J.C. Bohr, I. Khan, M.L. Kuntz, Y. Zhou, Effect of electrode geometry on resistance spot welding of AHSS, in: SMWC XII Session 7-4, Livonia, MI, 2006.
  • [18] K.R. Chan, Save time and Money with resistance welding simulation software, Welding Journal (July) (2008).
  • [19] X.M. Lai, A.H. Luo, Y.S. Zhang, G.L. Chen, Optimal design of electrode cooling system for resistance spot welding with the response surface method, International Journal of Advanced Manufacturing Technology (2009).
  • [20] Z.H. Rao, S.M. Liao, H.L. Tsai, P.C. Wang, R. Stevenson, Mathematical modelling of electrode cooling in resistance spot welding, Welding Journal (May (Suppl.)) (2009).
  • [21] M. Bogomolny, M.P. Bendsoe, J.H. Hattel, A Shape Optimization Study for Tool Design in Resistance Welding, Springer-Verlag, 2008.
  • [22] Z. Mikno, Z. Bartnik, Sz. Kowieski, Resistance spot welding of advanced high strength steel of complex welding program, in: The 6th International Seminar on Advances in Resistance Welding, 22–24 September, Hamburg, Germany, 2010.
  • [23] S. Kowieski, Z. Mikno, A. Pietras, Welding of advanced high-strength steels, Biuletyn of Instytut Spawalnictwa in Gliwicach 3 (2012).
  • [24] http://www.swantec.com/.
  • [25] W. Zhang, Design and implementation of software for resistance welding process simulations, in: SAE Technical Paper 2003-01- 0978, 2003, http://dx.doi.org/10.4271/2003-01-0978.
  • [26] C.V. Nielsen, W. Zhang, L.M. Alves, N. Bay, P.A.F. Martins, Modelling of Thermo-electro-mechanical Manufacturing Processes with Applications in Metal Forming and Resistance Welding, Springer, 2012.
  • [27] Z. Mikno, Selected cases of controlling spot resistance welding process, Biuletyn of Instytut Spawalnictwa in Gliwice 2 (2005).
  • [28] Z. Mikno, Intensification of cooling in resistance welding with mist cooling, Przegląd Spawalnictwa 9–10 (2006).
  • [29] Z. Mikno, Mist cooling in resistance welding, in: Conference Materials for 1st International Congress of Welding and Joining Technologies & 17th Technical Sessions on Welding- 77, 9 October 2008, Madrid, Spain, 2008.
  • [30] Z. Mikno, FEM simulation of spot resistance welding – analysis of selected cases, in: Conference Materials for International Conference on Welding and Joining Technologies, 11–13 June 2009, Ankara/Turkey, 2009.
  • [31] A. Ambroziak, M. Korzeniowski, T. Sudoł, Modelling of spot resistance welding process, in: Research Works ‘‘Mechanika’’ issue .30. Spajanie materiałów we współczesnej technice, Publishing house of Politechnika Warszawska, Warszawa, 2010.
  • [32] J. Kocimski, P. Kustroń, M. Korzeniowski, A. Ambroziak, An investigation of ultrasonic wave behavior in multilayered, inhomogeneous, in: Media of Resistance Spot Welding Set-up, Proceedings of the 5th International Conference on Advances in Production Engineering, Warsaw, 2010.
  • [33] PN-M-69020: 1974 Welding Engineering. Classification of quality of spot welds.
Uwagi
PL
Opracowanie ze środków MNiSW w ramach umowy 812/P-DUN/2016 na działalność upowszechniającą naukę
Typ dokumentu
Bibliografia
Identyfikator YADDA
bwmeta1.element.baztech-38b623eb-bf7d-494e-97c2-657170c8478e
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