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The modeling and process analysis of resistance spot welding on galvanized steel sheets used in car body manufacturing

Hamidinejad, S. M ; Sharif University of Technology

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  1. Type of Document: Article
  2. DOI: 10.1016/j.matdes.2011.06.064
  3. Abstract:
  4. In this study, the resistance spot welding (RSW) process of the galvanized interstitial free (IF) steel sheets and galvanized bake hardenable (BH) steel sheets, used in the manufacturing of car bodies, has been modeled and optimized. The quality measure of a resistance spot welding joint is estimated from the tensile-shear strength. Furthermore, four important process parameters, namely welding current (WC), welding time (WT), electrode force (EF), and holding time (HT) are considered as the factors influencing the quality of the joints. In order to develop an accurate relationship between the process inputs (4-component vectors) and the response output (tensile-shears strength) at first a linear regression model was utilized but the residuals analysis revealed a non-linear behavior. Therefore, an artificial neural network (ANN) was proposed because the ANNs are capable of mapping the non-linear systems. A back propagation neural network model was developed to analyze RSW process and the interaction effects of the parameters. In the second phase of this research, Genetic Algorithm with the fitness function based on an ANN model was employed as an optimization procedure for determining a set of process parameters; as a result, the maximum joint strength was obtained. Optimization results showed high compatibility with the actual experimental data
  5. Keywords:
  6. A. Ferrous metals and alloys ; D. Welding ; Artificial Neural Network ; Back propagation neural networks ; Car bodies ; Car body manufacturing ; Electrode force ; Experimental data ; Ferrous metals and alloys ; Fitness functions ; G. Destructive testing ; Galvanized steel sheets ; Holding time ; Interaction effect ; Interstitial free steel ; Joint strength ; Linear regression models ; Nonlinear behavior ; Optimization procedures ; Process analysis ; Process inputs ; Process parameters ; Quality measures ; Resistance spot welding ; Second phase ; Welding current ; Automobile manufacture ; Galvanizing ; Linear regression ; Linear systems ; Metallurgy ; Optimization ; Railroad cars ; Spot welding ; Stainless steel ; Steel sheet ; Tensile strength ; Tensile testing ; Welding ; Neural networks
  7. Source: Materials and Design ; Volume 34 , February , 2012 , Pages 759-767 ; 02641275 (ISSN)
  8. URL: http://www.sciencedirect.com/science/article/pii/S0261306911004729