Finite Element Analysis for Transient Thermal Characteristics of Resistance Spot Welding Process with Three Sheets Assemblies

This project built a two dimensional finite element (FE) model for resistance spot welding (RSW) process of Mild steel with three sheets assemblies instead of conventional two sheets stack ups on practical aspect of industry applications. The thermal-electrical coupling method was implemented to investigate transient thermal characteristics during resistance spot welding history with commercial software code, namely ANSYS. Temperature dependency electrical and thermal material properties, phase change as well as convection boundary condition were taken into consideration throughout the coupling procedure. The temperature distribution changes of three sheets assemblies were obtained and transient thermal characteristics were analyzed during RSW thermal-electrical coupled history. Moreover, nugget formation was particularly viewed and discussed under appropriate welding contact condition and other experimental physical parameters.