An Incrementally Coupled Thermo-Electro-Mechanical Model for Resistance Spot Welding

Resistance spot welding (RSW) is a widely used joining process for fabricating sheet metal assemblies in automobile industry. In comparison with other welding processes, RSW is fast and easy for automation. Spot welding process involves electrical, thermal, and mechanical interactions. These make the whole welding procedure highly nonlinear and difficult to model. This article presents the modelling and simulation of spot welding, using finite element analysing tool, ANSYS. A two-dimensional axisymmetric model was used to model the thermo-electro-mechanical coupling of process. In order to improve accuracy, material properties were defined temperature-dependent in simulation. Through simulation, the thermal history of the process was predicted. Development of weld nugget during process and effect of process parameters on nugget formation were investigated. Also contact area radius was obtained at different welding stages. Weld nugget sizes were obtained by numerical modelling showed good agreement with ex...