Process Simulation Model of a Flexible Clamping Technology for Sheet Metal Parts

The use of a running clamping technology enables clamping with a welding robot during laser welding in the body-in-white shop. Unlike common clamping fixtures, clamping is operated force-controlled. In this paper a FE-simulation method of the clamping process with the running clamping technology is presented. The method is applied to a clamping experiment with aluminum L-specimens. Objective of this simulation method is the prediction of the clamping force required to close the gap between sheet metal part flanges. A closed gap between flanges is necessary to achieve a proper weld seam. Furthermore, stresses and strains as well as potential plastic strains emerging during the clamping process can be identified using FE-simulation. In this contribution the simulation method is described in detail including assumptions and simplifications, due to the transfer from real experiment to virtual model, as well as important parameters of contact modeling. Comparison of simulation results to experimental investigations shows a reasonable correspondence.