Numerical Simulation of Fuzzy Control for Resistance Spot Welding by Monitoring Electrode Temperature(Physics, Processes, Instruments & Measurements)

概要

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It is well known that resistance spot welding is a complex process in which coupled interactions exist between electrical, thermal, mechanical, and metallurgical phenomena. Because of this complexity, it is very difficult to obtain insightful information of welding process through the most ambitious experiments alone. In this paper, the thermo-elastic-plastic FEM is used to simulate the process of resistance spot welding. The effect of the welding current and squeezing force on the properties of spot welding is examined, in particular, from the aspect of the relation between the electrode temperature and the nugget formation in spot welding. Through this study, it is found that a sound nugget can be achieved when the electrode temperature is controlled within an acceptable range. Based on this knowledge, a fuzzy control method in which the welding current is modified in real time by monitoring electrode temperature is proposed. It is demonstrated that sound spot welding joints with large enough nuggets can be achieved by using the proposed fuzzy control method. It is also shown that the weldability lobe can be expanded by employing the fuzzy control.
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