2015 Volume 33 Issue 3 Pages 271-282
Interactions between elasto-plastic contact deformation, electric current and heat conduction produces complicated triply coupled effect in the resistant spot welding. Since the coupled effect affects weld strength, the coupled finite element analysis is required to determine welding parameters such as welding current, electrode force, welding time and electrode shape.
This paper discusses in detail the elasto-plastic contact, electric current and thermal conduction triply coupled analysis method. The coupled analysis method uses modified electrical contact resistance model, modified thermal contact resistance model and iterative partitioned coupled algorithm suitable for strong coupled problem. The validity of the method are discussed under the different condition such as welding current, electrode force, welding time, material and number of the steel sheets. The analysis result of nugget growth curve agrees very well with experimental result for two sheet welding. The validity is confirmed by not only nugget growth curve but also surface temperature of steel sheet and electrode for three sheet welding with high tension steel. The solution convergence is discussed for the iterative partitioned coupled algorithm and the conventional coupled algorithm. Since the coupled effect is strong for between electric current and thermal conduction, the choice of the coupled algorithm is important for the resistance spot welding analysis. Effect of elasto-plastic contact deformation, change of electric current distribution and thermal conduction on resistance spot welding are discussed from the viewpoint of coupled effect. The coupled model with ability to simulate the chain of coupled effect is required to improve the analysis reliability. The importance of temperature dependency of material property, electrical contact resistance, thermal contact resistance and latent heat effect are also discussed.