A Shape Optimization Study for Tool Design in Resistance Welding

Michael Bogomolny; Martin P. Bendsøe; Jesper Henri Hattel

doi:10.1007/s00158-008-0274-z

A Shape Optimization Study for Tool Design in Resistance Welding

Michael Bogomolny, Martin P. Bendsøe, Jesper Henri Hattel

Research output: Contribution to journal › Journal article › Research › peer-review

Abstract

The purpose of this study is to apply shape optimization tools for design of resistance welding electrodes. The numerical simulation of the welding process has been performed by a simplified FEM model implemented in COMSOL. The design process is formulated as an optimization problem where the objective is to prolong the life-time of the electrodes. Welding parameters like current, time and electrode shape parameters are selected to be the design variables while constraints are chosen to ensure a high quality of the welding. Surrogate models based on a Kriging approximation has been used in order to simplify the calculation of shape sensitivities and to generate a generic tool that can be interfaced with other simulation tools. An example numerical study shows the potential of applying optimal design techniques in this area.

Original language	English
Journal	Structural and Multidisciplinary Optimization
Volume	38
Issue number	2
Pages (from-to)	185-194
ISSN	1615-147X
DOIs	https://doi.org/10.1007/s00158-008-0274-z
Publication status	Published - 2009

Keywords

Electrode design
Spot welding
Kriging approximation
Shape optimization
Shape design
Resistance welding

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title = "A Shape Optimization Study for Tool Design in Resistance Welding",

abstract = "The purpose of this study is to apply shape optimization tools for design of resistance welding electrodes. The numerical simulation of the welding process has been performed by a simplified FEM model implemented in COMSOL. The design process is formulated as an optimization problem where the objective is to prolong the life-time of the electrodes. Welding parameters like current, time and electrode shape parameters are selected to be the design variables while constraints are chosen to ensure a high quality of the welding. Surrogate models based on a Kriging approximation has been used in order to simplify the calculation of shape sensitivities and to generate a generic tool that can be interfaced with other simulation tools. An example numerical study shows the potential of applying optimal design techniques in this area.",

keywords = "Electrode design, Spot welding, Kriging approximation, Shape optimization, Shape design, Resistance welding",

author = "Michael Bogomolny and Bends{\o}e, {Martin P.} and Hattel, {Jesper Henri}",

year = "2009",

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language = "English",

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T1 - A Shape Optimization Study for Tool Design in Resistance Welding

AU - Bogomolny, Michael

AU - Bendsøe, Martin P.

AU - Hattel, Jesper Henri

PY - 2009

Y1 - 2009

N2 - The purpose of this study is to apply shape optimization tools for design of resistance welding electrodes. The numerical simulation of the welding process has been performed by a simplified FEM model implemented in COMSOL. The design process is formulated as an optimization problem where the objective is to prolong the life-time of the electrodes. Welding parameters like current, time and electrode shape parameters are selected to be the design variables while constraints are chosen to ensure a high quality of the welding. Surrogate models based on a Kriging approximation has been used in order to simplify the calculation of shape sensitivities and to generate a generic tool that can be interfaced with other simulation tools. An example numerical study shows the potential of applying optimal design techniques in this area.

AB - The purpose of this study is to apply shape optimization tools for design of resistance welding electrodes. The numerical simulation of the welding process has been performed by a simplified FEM model implemented in COMSOL. The design process is formulated as an optimization problem where the objective is to prolong the life-time of the electrodes. Welding parameters like current, time and electrode shape parameters are selected to be the design variables while constraints are chosen to ensure a high quality of the welding. Surrogate models based on a Kriging approximation has been used in order to simplify the calculation of shape sensitivities and to generate a generic tool that can be interfaced with other simulation tools. An example numerical study shows the potential of applying optimal design techniques in this area.

KW - Electrode design

KW - Spot welding

KW - Kriging approximation

KW - Shape optimization

KW - Shape design

KW - Resistance welding

U2 - 10.1007/s00158-008-0274-z

DO - 10.1007/s00158-008-0274-z

M3 - Journal article

VL - 38

SP - 185

EP - 194

JO - Structural and Multidisciplinary Optimization

JF - Structural and Multidisciplinary Optimization

SN - 1615-147X

IS - 2

ER -