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.

电阻点焊接是金属材料的连接过程，该过程易于实施，高效且可靠。由于其高经济性和可实现的低周期时间，电阻焊接越来越多地用于苛刻的焊接接头，例如轻质金属板，薄板厚板连接，混合化合物和涂层板的连接。随着更紧密的公差区与质量要求的稳定增长相结合，因此需要安全控制该过程。即使对每个焊接点进行质量评估的要求也是可能的。破坏性测试程序不能用于此100％检查。当前正在开发和使用非损害测试方法（NDT）。但是，NDT始终涉及其他设备和组织努力。除NDT外，由于整个过程链中的生产数字化（例如，从线圈上的钣金到完成的车体），还可以提供大量特定于对象的数据和参数。这些数据将来可以用于每个过程步骤中每个工件的基于仿真的分析。这种新方法可以大大减少破坏性或非破坏性测试的努力。为此，对当前工件有效的过程数据和参数进行了电阻焊接过程（在焊接逆变器中实现的一个与过程相关的，具有实时能力的模拟，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，带有原位模拟，可以通过可视化刚刚创建的焊接金块来对焊接连接进行直观的“见解”。此外，可以在机器上进行“原位”，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，实施和测试适合模型的方法，以实现对阻力焊接过程的原位模拟。最后，将通过实验研究和评估原位模拟的潜力。