• Journal of Power System Engineering
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• v.19 no.2
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• pp.70-77
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• 2015

Nowadays, car manufacturers applied many high strength steels such AHSS or UHSS to car bodies for weight lightening. Therefore, a variety of applied steel sheet to car bodies increased and the needs of simulation to evaluate weldability also increased in order to reduce the cost and time. In this study, resistance spot welding simulations for DP 780 Steel with 1.0 and 1.4 mm thickness were conducted with respect to lobe curve. 2 regression models to estimate tensile shear strength were suggested and they were second order polynomial regression model and optimized second order regression model. The performance of these models was evaluated in terms of the coefficient of determinant and average error rate.

• Journal of Welding and Joining
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• v.19 no.5
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• pp.499-505
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• 2001

In order to classify the mechanical phenomena of thermal elasto-plastic behavior on the multi-spot welded joints, this study has tried to carry out three-dimensional thermal elasto-plastic analysis on them. However, because the shape of multi-spot welded joints is not taxi-symmetric, unlike the cafe of single-spot welded joint, the solution domain for simulation should be three dimension. Therefore, in this paper, firstly, the three-dimensional thermal elasto-plastic program is developed by an iso-parametric finite element method. Secondly, from the results analyzed by developed program, this has clarified mechanical characteristics and their production mechanism on single and multi-spot waled joints. Moreover, it has been intended to make clear effects of pitch length on welding residual stresses, plastic strain of multi-spot welded joints.

• Journal of Welding and Joining
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• v.21 no.4
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• pp.80-86
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• 2003

Arc-spot welding is generally used in joining of precise parts such as case and core in electric compressor. It is important to control joining deformation in electric compressor because clearance control of micrometer order is needed for excellent airtightness and anti-nose. The countermeasures for this deformation in field have mainly been dependent on rule of try and error by operator's experience because of productivities. For control this deformation problem without influence on productivities, development of exact simulation model should be needed. In this study, on the basis of previous study, the analysis model io predict deformation of precise order in arc-spot welded structure with non-uniform stiffness is brought up through feedback and tuning between monitoring data and analysis results. For this, deformation monitoring system was built and boundary condition considering mechanical melting temperature was applied.

• 제어로봇시스템학회:학술대회논문집
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• 1988.10a
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• pp.370-373
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• 1988

Althouah there have been many attempts to control weld quality in resistance spot welding processes, design method for an on-line feedback controller based upon process dynamics has not been suggested. This is due to the fact that the resistance spot welding is a highly complicated process, whice involves the interaction of electrical, thermal, mechanical and metallurgical phenomena. In this paper, an optimal control method based on FDM model with shunt effect is presented, which can regulate the nugget size, at the same time minimizing the control heat input. Optimal PI gain of the controller were determined by numerical optimization. Simulation results show that, as a result of the proposed optimal control, the weld nugget can be made to approach a desired nugget size with less control heat input than that required for the conventional spot welding process in the face of the shunt effect.

• Journal of Welding and Joining
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• v.8 no.1
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• pp.62-69
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• 1990

Being focused on the recent studies that the fatigue strength of resistance spot weldmentes can be improved by using ellipsoidal weld nuggets, the voltage and temperature distribution in resistance spot weldments were simulated for the various rectangular electrodes which had the different aspect ratio of the contact area. Because the electrode shape was not axi-symmetric, the solution domain for simulation should be three dimensional. A series of experiments were carred out to verify the analytically obtained temperature distribution in the weldment. From the calculational and experimental results, it could be revealed that the nugget took the form of ellipsoid, while both results showed a considerable discrepancy for the high aspect ratio.

• Journal of the Korean Institute of Telematics and Electronics S
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• v.35S no.7
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• pp.103-108
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• 1998

In this paper, we atempt to control the nonlinear power system for resistance spot welders to be a fully linearizesd system by applying the recently developed nonlinear feedback linearization techniques. the controller proposed in this paper is computationally simple. In addition, the easy gain tuning as well as the high dynamic performance of resistance spot welding systems can be obained simulaneously. To illustrate the dynamic performance of our controller further, we present some simulation results.

• The Transactions of the Korean Institute of Power Electronics
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• v.15 no.3
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• pp.218-225
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• 2010

This paper deals with a method to minimize the welding time for an AC spot welding system. The spot welding system using a conventional SCR type circuit has a disadvantage of slow control speed and no precise current control. Therefore, recently, the using of inverter type welding system is increasing. Conventional welding machine adopts several tens of switching devices connected in parallel to obtain a huge current of several thousands ampere with a short welding time. This paper analyzed a welding system consisting with 4 IGBT switches for a full-bridge inverter and conventional 60 [Hz] transformer. The simulation and experimental results show the validity of the proposed method.

• Journal of Welding and Joining
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• v.20 no.4
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• pp.484-490
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• 2002

The formation and stability of stationary laser weld keyholes were investigated using a numerical simulation. The effect of multiple reflections in the keyhole was estimated using the ray tracing method, and the free surface profile, flow velocity and temperature distribution were calculated numerically. In the simulation, the keyhole was formed by the displacement of the melt induced by evaporation recoil pressure, while surface tension and hydrostatic pressure opposed cavity formation. A transition mode having the geometry of the conduction mode with keyhole formation occurred between the conduction and keyhole modes. At laser powers of 500W and greater, the protrusion occurred on the keyhole wall, which resulted in keyhole collapse and void formation at the bottom. Initiation of the protrusion was caused mainly by collision of upward and downward flows due to the pressure components, and Marangoni flow had minor effects on the flow patterns and keyhole stability.bility.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.458-461
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• 2009

Thermo-mechanical simulation of the Friction Stir Spot Welding (FSSW) processes was performed for the AA5083-H18 sheets, utilizing commercial Finite Element Method (FEM) and Finite Volume Method (FVM) which are based on Lagrangian and Eulerian formulations, respectively. The Lagrangian explicit dynamic FEM code, PAM-CRASH, and the Eulerian Computational Fluid Dynamics (CFD) FVM code, STAR-CD, were utilized to understand the effect of pin geometry on weld strength and material flow under the unsteady state condition. Using FVM code, material flow pattern near the tool boundary was analyzed to explain the weld strength difference between the weld by cylindrical pin and the weld by triangular pin, while the frictional energy concept using the FEM code had limitation to explain the weld strength difference.

• Journal of Welding and Joining
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• v.33 no.6
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• pp.21-26
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• 2015

Recently, application of UHSS(Ultra High Strength Steels) whose tensile strength is over 1000MPa to car body structure are growing due to great needs for light weighting and improved crash worthiness. However, their poor weldability is one of obstacles to expand selecting to car body. In this study, effect of Phosphorus contents on resistance spot weldability of high elongation DP980 steel whose Si content is over 1% was investigated. The cross tension strength (CTS) was decreased showing partial interface fracture as Phosphorus content increase because of solidification segregation of Phosphorus. In order to improve resistance spot weldability by modification of welding condition, in-situ post-weld heating pulse was introduced after main pulse. The optimum cooling time between main and post pulse and post-pulse current condtion were determined through FEM welding simulation and DOE tests. The CTS was increased about 1.5 time showing plug fracture. The decrease of Phosphorus segregation was found to be a major reason for weld ductility and CTS improvement.