• Proceedings of the KSME Conference
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• 2007.05a
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• pp.1499-1504
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• 2007

Spot-welding is widely used to construct passenger car bodies in automotive industry. Occasionally severe spot-weld distortions in sub-assembly make further spot-weld difficult. In this paper, distortions for various spot-weld conditions are measured using coordinate measuring machine. Then, based on finite element solution for unit translation or unit rotation of nugget edge, equivalent loads for spot-weld distortions are determined. They can be used to predict the spot-weld distortion using finite element method.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2011.04a
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• pp.538-543
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• 2011

In this paper, optimal spot weld layout design of the shock tower structure is performed for increasing fatigue life of spot weld and fatigue life of shock tower simultaneously. To predict the fatigue life, linear static analysis is conducted then fatigue analysis is performed by applying random vibration load. To optimize the spot weld layout, design variables that have an effect on spot weld fatigue life are selected. Based on the DOE table, spot weld fatigue analysis is conducted. Finally, response surface model is made from fatigue analysis results and optimized spot weld layout model which increases fatigue life of sport weld and fatigue life of shock tower is determined.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.22 no.1
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• pp.148-159
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• 1998

Spot welding palys a key role in increasing productivity and weight reduction of the final products. This paper proposes a systematic approach on the design of spot weld configuration, dealing with the requried number and location of spot weld joints under the given design parameters, such as the applied loads, lap area, and individual spot weld strength. The optimal design of a spot-welded joint is postulated as a state when the safety factors of all spot weld points (i) are evenly distributed and (ii) reach maximum value. A CAD program is developed to arrange the optimal location of each spot weld based on the derived objective function and constraints. The CAD tool integrates the optimization procedure with Finite Element Analysis (FEA) code through an interface. The interface automatically provides geometrical data and mesh configuration for different spot weld locations to FEA model. It also extracts the transmitted load of each spot weld from the FEA code, and allows the optimization code predict an improved arrangement of spot weld locations. The feasibility of the developed approach is demonstrated by the selected examples.

• Transactions of the Korean Society for Noise and Vibration Engineering
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• v.21 no.9
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• pp.798-804
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• 2011

In this paper, optimal spot weld layout design for a shock tower structure is presented. This design increases the fatigue life of the spot-welds thereby increasing the fatigue life of the shock tower itself. In order to predict the fatigue life, a quasi-static analysis has been conducted then a fatigue analysis was performed through the application of random vibration loads. In order to optimize the spot weld layout, the design variables that have an effect on the spot weld fatigue life were determined. A spot weld fatigue analysis was then conducted based on the experiment design. Finally, a response surface model was made using the fatigue analysis results and an optimized spot weld layout model, one that increases the fatigue life of the spot welds and thereby the fatigue life of the shock tower, was developed.

• Transactions of Materials Processing
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• v.23 no.5
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• pp.282-288
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• 2014

It is difficult to control welding variables during spot welding of non-ferrous metals like aluminum because of the low electrical resistance of the material. It has been suggested that a solid state welding process such as friction stir spot welding or extru-spot welding can be used to spot weld aluminum plates. In the extru-spot welding, there is a need to increase the weld strength by improving the shape of the welding die. The current study shows that the weld strength for an extru-spot welding can be increased by using a pin placed on the inside of the upper electrode in the welding die. In the current study, the deformed shape of the insert rivet and the stress distribution in the welding zone were analyzed by simulation. Extru-rivet spot welding experiments were performed by changing the height of pin on the inside of the upper electrode. From the experimental result, it is shown that the weld strength for an extru-rivet spot welding can be increased by adjusting the height of the pin. The optimal shape of the deformed rivet after the extru-rivet spot welding can be observed from the simulation results. The deformed shape of the insert rivet can also be controlled by the height of pin.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2012.04a
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• pp.361-366
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• 2012

In this paper, we propose the efficient technique that reduces the number of spot-welds and increases the structural rigidity by using the topology optimization technique. Eigen value analysis is used to evaluate the rigidity of the optimized model. As a first step, the topology optimization is performed to find optimal spot-weld distributions. In this study, the design objective is to maximize the weighted frequencies. The volume fractions of the weld components are used as design constraints, and also the densities of each element in the individual design space are used as design variables. And then, to consider the possibility of spot-weld failure, the contribution rate analysis was performed by using the orthogonal array method of DOE. The spot-welds in the rear panel part are reinforced according to estimation results of the contribution rate analysis. Finally, we obtained optimized spot-weld layout model which has the reduced number of spot-welds and the improved dynamic stiffness.

• International Journal of Automotive Technology
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• v.7 no.5
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• pp.579-584
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• 2006

Aluminum Resistance Spot Weld(Al RSW) is an enabling technology for body assembly of low mass fraction vehicles. Due to the unreliable durability of spot-welded joints, applications of Al RSW are limited. This study presents experimental investigation on the use of a post-weld cold working process to improve the fatigue strength of Al RSW. The post-weld cold working process includes special shaped indenters that are pressed or driven into the structure to induce compressive residual stresses. The mechanical properties of the post-weld cold worked Al RSW were investigated, including the experimental results of fatigue and micro-hardness tests. Comparisons of the mechanical properties and qualitative results between the as-welded RSW specimens and the post-weld cold worked RSW specimens are discussed. The post-weld cold worked Al RSW samples had an increase in both microhardness and fatigue life.

• Proceedings of the KWS Conference
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• 2007.11a
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• pp.73-75
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• 2007

The resistance spot weld is among the most common automotive weld method, now a constant current type is the most common used types. A constant current type have a weak point which can not deal with a defect occurrence by external factors, and recently the adaptive resistance spot weld have been applied around the advanced automotive company. This technology can maintain a stable weld quality through a suitable control the current and weld time with weld environment. In this research, the adaptive resistance spot weld is applied to high strength steels, and its application possibility and weld characteristics are presented.

• Transactions of the Korean Society of Mechanical Engineers
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• v.10 no.2
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• pp.241-246
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• 1986

A new method of on-line monitoring of spot weld quality is proposed by analysing weld votage signal. Weld voltage signal has been modeled by autoregressive model which is suitable for on-line modeling scheme, and order of the model is determined by F-test. From the chosen model, strength. Upon experimental results, it has been shown that fundamental frequency dispersion of weld voltage can be used as a good parameter like maximum thermal expansion in on-line monitoring of spot weld quality. Microcomputer implementation of the proposed monitoring method is also developed and presented.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.22 no.3
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• pp.554-561
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• 1998

Vehicle body structures are formed by thousands of spot welds and fatigue failure of vehicle structures occur near the spot welds after driving a long way at a durability test road. It is necessary to know accurately the reason of the fatigue failure of the spot weld in the developing stage in order to reinforce it. Many investigations have been done regarding the strength of spot welded joints, contributing to understand its fatigue strength. In developing process, a fatigue failed spot welded area can be repaired by $CO_2$ welding or another method to continue the test. To know the effect of reinforcing these welds, several methods of welding were analyzed and compared to spot welding. With the results of this test, the appropriate repair method can be used instead of spot welding during the development of new car and best design guide can be given for the strength. In this study, fatigue and static tensile tests are made and microstructure is investigated for the purpose of estimating the strength of welded joints by using spot welded and $CO_2$ plug welded specimens. The tested specimens are of two types : Tensile-shear type(TS) and L-tension type(LT).