Assessment of resistance spot welding process quality using modal analysis

• Autorzy: Pikuła Janusz , Mikno Zygmunt , Fidali Marek , Kowieski Szymon , Żymełka Szymon

Identyfikatory

DOI

10.24425/ace.2025.153336

Warianty tytułu

PL

Ocena jakości procesu zgrzewania punktowego za pomocą analizy modalnej

• Języki publikacji: EN

Abstrakty

EN

The resistance spot welding is one of the main methods used to join thin-walled metal parts, while a number of factors adversely affect the process and thus the quality of the connections made. This article presents the study results of the possibility of applying modal analysis in the quality examination of welded parts by detecting the missing weld. It was aimed to determine this kind welding process imperfections influence on modal shapes and frequencies by the study of the dynamic properties of welded elements in the frequency domain. The research included real and numerical tests. The proposed testing method for spot welded constructions is a scientific novelty in the world, but the investigation results indicated, that the modal analysis may find application in detecting welding defects such as the lack of the welds. To assess the quality of the numerical models, the results obtained in the simulation and experimental test results were compared. The analysis involved the first five modes. The mode shapes in relation to the first five modal frequencies identified using the FEM analyses and the experimental tests was consistent with respect to element distortion. The differences indicate the satisfactory conformity of the numerical simulation results with the experimental test results. The article fundamentally demonstrates the applicability of the above-mentioned method to analyse the performance of all welds at once.

PL

Punktowe zgrzewanie oporowe jest jedną z głównych metod stosowanych do łączenia cienkościennych elementów metalowych, przy czym szereg czynników wpływa niekorzystnie na proces, a tym samym na jakość wykonanych połączeń. W artykule przedstawiono wyniki badań możliwości zastosowania analizy modalnej w analizy jakości zgrzewanych elementów w aspekcie wykrywania brakującej zgrzeiny. Celem było określenie wpływu tego typu niedoskonałości procesu zgrzewania na postać i częstotliwości drgań własnych poprzez badanie w dziedzinie częstotliwości właściwości dynamicznych elementów zgrzewanych. Badania obejmowały testy rzeczywiste i analizy numeryczne. Zaproponowana metoda badania konstrukcji zgrzewanych jest nowością naukową na świecie, a wyniki badań wskazały, że analiza modalna może znaleźć zastosowanie w wykrywaniu wad zgrzewalniczych takich jak brak zgrzein. Skuteczna weryfikacja wykonania danej zgrzeiny w zgrzewanym elemencie zależy od wielu czynników, w tym m.in. materiału i kształtu konstrukcji, lokalizacji zgrzein, miejsca wzbudzenia i pomiaru podczas jej badania. W związku z tym każda badana geometria będzie wymagać opracowania indywidualnych założeń wymuszeń i pomiaru, natomiast ogólne założenia stosowania analizy modalnej pozostają niezmienne. W celu oceny wyników modeli numerycznych, porównano wyniki uzyskane w symulacji i wyniki badań eksperymentalnych. Analiza wykazała, iż postaci drgań własnych w odniesieniu do pierwszych pięciu częstotliwości zidentyfikowanych za pomocą analiz MES i testów eksperymentalnych były zgodne pod względem odkształceń elementów. Różnice wskazują na zadowalającą zgodność wyników symulacji numerycznej z wynikami testów eksperymentalnych, a tym samym zasadne jest stosowanie MES w opracowaniu założeń do opracowania stanowiska pomiarowego konstrukcji zgrzewanych. Artykuł zasadniczo demonstruje możliwość zastosowania wyżej wymienionej metody do analizy jakości wszystkich spoin jednocześnie.

Słowa kluczowe

EN

finite element method; modal analysis; quality control; resistance spot welding; weld quality

PL

analiza modalna; zgrzeina; kontrola jakości; metoda elementów skończonych; zgrzewanie punktowe; zgrzewanie oporowe

• Wydawca: Komitet Inżynierii Lądowej i Wodnej PAN ; Politechnika Warszawska, Wydział Inżynierii Lądowej
• Czasopismo: Archives of Civil Engineering
• Rocznik: 2025
• Tom: Vol. 71, nr 1
• Strony: 311--326
• Opis fizyczny: Bibliogr. 43 poz., il., tab.

Twórcy

autor

Pikuła Janusz

• Łukasiewicz Research Network – Upper Silesian Institute of Technology, Gliwice, Poland

• https://orcid.org/0000-0003-3312-7537

autor

Mikno Zygmunt

• Łukasiewicz Research Network – Upper Silesian Institute of Technology, Gliwice, Poland

• https://orcid.org/0000-0002-8102-6020

autor

Fidali Marek

• Silesian University of Technology, Institute of Fundamentals of Machinery Design, Faculty of Mechanical Engineering, Gliwice, Poland

• https://orcid.org/0000-0002-3667-5582

autor

Kowieski Szymon

• Łukasiewicz Research Network – Upper Silesian Institute of Technology, Gliwice, Poland

• https://orcid.org/0000-0001-9083-9376

autor

Żymełka Szymon

• Silesian University of Technology, Institute of Fundamentals of Machinery Design, Faculty of Mechanical Engineering, Gliwice, Poland

• https://orcid.org/0000-0001-8039-8626

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