Design of welded joint based on transient thermal condition

Abstract

This paper presents the design of welded joint based on transient thermal condition. Resistance spot welding is a fast, easily automated and easily maintained process with high productivity. This paper was performed to investigate the design parameters of sheet metal welded joint based on transient thermal condition. The transient thermal condition of the sheet metal was analyzed and the factor of safety was proposed at the end of the project. The design parameters included were the number of spot welding, dimension, material and thickness of sheet metal. Aluminum 5182-H19 was used as a base material to study the mechanical properties and thermal behavior. The transient thermal analysis was conducted on aluminum alloy 5182-H19 sheet metal with dimension 120mm×60mm, thickness 1mm to 6mm and number of spot weld two to five. Suitable combination of thickness of sheet metal with number of spot weld is proposed after the simulation and analysis. The CAD model and analysis of sheet metal was performed by using ANSYS software. The results of both the thermal analysis were heat flux, reaction probe and factor of safety. Scoring concept was provided to determine the number of spot weld for each thickness of the sheet metal. It is found that two number of spot weld was suitable for thickness of 1mm, 2mm, 4mm, and 6mm. As a result, sheet metal with thickness 3mm and 5mm, five and two spot weld was suitable respectively.