Abstract
A FEM based simulation model of the resistance spot welding process has been developed. The current simulation accounts for the non-uniform current density distribution in the sheet-electrode geometry and the elastoplastic deformation of the sheet due to electrode force, especially with spherical tip electrodes, since these effects are driven by and contribute to the main heat transfer analysis, which is governed by the internal heat generation within the sheet-electrode geometry as well as along the contact surfaces. The latent heat of transformation during melting or solidification, the variation of sheet/sheet contact resistance with temperature, and temperature dependent thermophysical material properties have been incorporated. The model also calculates the local time-temperature history of the sheet-electrode geometry that can be coupled with appropriate metallurgical reactions to determine metallurgical changes and subsequent mechanical properties in both the fusion zone and the HAZ.
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