Numerical methods in simulation of resistance welding

Chris Valentin Nielsen, Paulo A.F. Martins, Wenqi Zhang, Niels Oluf Bay

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Finite element simulation of resistance welding requires coupling betweenmechanical, thermal and electrical models. This paper presents the numerical models and theircouplings that are utilized in the computer program SORPAS. A mechanical model based onthe irreducible flow formulation is utilized to simulate plastic deformation and the resulting distribution of stress, a thermal model based on transient heat transfer is used to determine thedistribution of temperature, and a steady-state electrical model is employed to calculate thedistribution of electrical potential and current density. From a resistance welding point of view, the most essential coupling between the above mentioned models is the heat generation by electrical current due to Joule heating. The interaction between multiple objects is anothercritical feature of the numerical simulation of resistance welding because it influences thecontact area and the distribution of contact pressure. The numerical simulation of resistancewelding is illustrated by a spot welding example that includes subsequent tensile shear testing
Original languageEnglish
Title of host publicationProceedings of the VI International Conference on Coupled Problems in Science and Engineering
EditorsBernhard A. Schrefler, Eugenio Oñate, Manolis Papadrakakis
Place of PublicationBarcelona
PublisherInternational Center for Numerical Methods in Engineering
Publication date2015
Publication statusPublished - 2015
Event6th International Conference on Coupled Problems in Science and Engineering - Venice, Italy
Duration: 18 May 201520 May 2015
Conference number: 6


Conference6th International Conference on Coupled Problems in Science and Engineering
Internet address


  • Resistance Welding
  • Finite Element Method
  • Electro-Thermo-Mechanical
  • Phase Changes
  • Hardness
  • Damage

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