General Approach for Inline Electrode Wear Monitoring at Resistance Spot Welding
General Approach for Inline Electrode Wear Monitoring at Resistance Spot Welding
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DOI：
10.3390/pr9040685
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发表时间：
2021-04-01
期刊：
影响因子：
3.5
通讯作者：
Fuessel, Uwe
中科院分区：
文献类型：
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作者：
Mathiszik, Christian;Koeberlin, David;Fuessel, Uwe
电阻点焊的电极不可避免地会磨损。为了延长其使用寿命，尖端修整过程恢复其原始几何形状。然而，到目前为止，尖端修整的时间点主要基于经验而不是过程数据。因此，本研究旨在评估焊接过程中的原位或在线磨损，而无需使用额外的传感器，并基于连续过程监测的尖端修整时间，进一步延长电极寿命。在实验室条件下，电极磨损分析地形测量深化电阻点焊电极，蘑菇和高原形成的已知的主要磨损模式的知识，并表征电极长度三角洲的点焊数量。通常，电极磨损导致电极接触区域的变形，这影响工艺参数，从而影响焊接质量。所进行的测试显示了该变形接触面积与电极长度Δ之间的相关性。研究表明，该电极长度增量在实际过程数据中是可见的，因此可以用作表征电极磨损的标准。此外，这项研究给出了质疑常用的点焊质量标准的理由，并提出了不同的方法，如基于点焊质量的无损检测的可能性。
Electrodes for resistance spot welding inevitably wear out. In order to extend their service life, the tip-dressing process restores their original geometry. So far, however, the point in time for tip-dressing is mainly based on experience and not on process data. Therefore, this study aims to evaluate the in-situ or inline wear during the welding process without using additional sensors, and to base the timing for tip-dressing on continuous process monitoring, extending electrode life even further. Under laboratory conditions, electrode wear is analyzed by topographical measurements deepening the knowledge of the known main wear modes of resistance-spot-welding electrodes, mushrooming and plateau forming, and characterizing an electrode length delta over the number of spot welds. In general, electrode wear results in deformation of the electrode contact area, which influences process parameters and thereby weld quality. The conducted tests show correlation between this deformed contact area and the electrode length delta. The study shows that this electrode length delta is visible in actual process data, and can therefore be used as a criterion to characterize the wear of electrodes. Furthermore, this study gives reason to question commonly used spot-welding quality criteria and suggests different approaches, such as basing spot-welding quality on the possibility of nondestructive testing.