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Fundamental analysis of the in situ simulation of resistance spot welding processes

电阻点焊过程原位模拟的基础分析

基本信息

批准号：
389519796
负责人：
Professor Dr.-Ing. Uwe Füssel
金额：
--
依托单位：
Professur für Fügetechnik und Montage
依托单位国家：
德国
项目类别：
Research Grants
财政年份：
2018
资助国家：
德国
起止时间：
2017-12-31 至 2021-12-31
项目状态：
已结题

来源：
https://gepris.dfg.de/gepris/projekt/389519796?language=en
关键词：
Fundamental analysis situ simulation resistance

项目摘要

Resistance spot welding is a joining process for metallic materials which is simple to implement, highly productive and reliable. Due to its high economy and the achievable low cycle times, resistance spot welding is increasingly used for demanding welded joints, such as the joining of light metal sheets, thin-plate thick-plate connections, mixed compounds and coated sheets. With tighter tolerance zones in combination with a steady increase in quality requirements the necessity of a secure control of the process occurs. Even the requirement of a quality assessment of each individual welding point is possible. Destructive testing procedures cannot be used for this 100% inspection. Nondestructive testing methods (NDT) are currently being developed and used in the first practical applications. But, NDT always involves additional equipment and organizational effort. In addition to NDT, a large number of object-specific data and parameters are available due to the digitization of production over the entire process chain (e.g. from the sheet metal on the coil to the finished car-body). These data can be used in the future for the simulation-based analysis of each individual workpiece in each process step. This new approach can significantly reduce the effort for destructive or non-destructive testing. For this purpose, an in-situ simulation (a process-related, real-time-capable simulation, implemented in the welding inverter), of the resistance welding process is carried out with the process data and parameters valid for the current workpiece. Critical welds can be identified automatically and selected for further testing. Furthermore, the in-situ simulation with allows the machine operator an intuitive "insight" into the welded connection by visualizing the weld nugget that has just been created. In addition, pre-simulations can be carried out "in-situ", i.e. on the machine, for example for the determination of welding range diagrams or parameter adjustments.The aim of this research project is to develop, implement and test suitable model approaches for the in-situ simulation of resistance spot welding processes. Finally, the potential of in-situ simulation will be investigated and evaluated experimentally.

电阻点焊是一种实施简单、生产率高且可靠的金属材料连接工艺。由于其高经济性和可实现的低循环时间，电阻点焊越来越多地用于要求苛刻的焊接接头，例如轻金属板、薄板厚板连接、混合化合物和涂层板的连接。随着公差范围的缩小以及质量要求的稳步提高，对过程进行安全控制的必要性就出现了。甚至可以要求对每个单独的焊接点进行质量评估。破坏性测试程序不能用于此 100% 检查。无损检测方法（NDT）目前正在开发中并首次投入实际应用。但是，无损检测总是涉及额外的设备和组织工作。除了无损检测之外，由于整个流程链（例如从卷材上的金属板到成品车身）的生产数字化，还可以获得大量特定于对象的数据和参数。这些数据将来可用于对每个工艺步骤中的每个工件进行基于仿真的分析。这种新方法可以显着减少破坏性或非破坏性测试的工作量。为此，使用对当前工件有效的工艺数据和参数对电阻焊工艺进行现场模拟（与工艺相关的实时模拟，在焊接逆变器中实现）。可以自动识别关键焊缝并选择进行进一步测试。此外，现场模拟允许机器操作员通过可视化刚刚创建的焊点来直观地“洞察”焊接连接。此外，可以在“原位”（即在机器上）进行预模拟，例如用于确定焊接范围图或参数调整。该研究项目的目的是开发、实施和测试用于电阻点焊工艺原位模拟的合适模型方法。最后，将通过实验研究和评估原位模拟的潜力。