Multiphysics simulation of the resistance spot welding detection using electromagnetic ultrasonic transverse wave
Resistance spot welding (RSW) quality substantially influences the autobody’s mechanical properties and safety performance. Nondestructive testing (NDT) method is widely used to evaluate the quality of RSW, but the traditional ultrasonic testing method has high requirements for coupling conditions a...
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| Published in | International journal of advanced manufacturing technology Vol. 110; no. 1-2; pp. 79 - 88 |
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| Main Authors | , , , |
| Format | Journal Article |
| Language | English |
| Published |
London
Springer London
01.09.2020
Springer Nature B.V |
| Subjects | |
| Online Access | Get full text |
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| Abstract | Resistance spot welding (RSW) quality substantially influences the autobody’s mechanical properties and safety performance. Nondestructive testing (NDT) method is widely used to evaluate the quality of RSW, but the traditional ultrasonic testing method has high requirements for coupling conditions and flat surface of the weld part. The electromagnetic acoustic transducer (EMAT) is a novel NDT technology, which has advantages of noncontact, no coupling media, and low requirements for surface flatness of the workpiece. Therefore, the electromagnetic ultrasonic transverse wave (EUTW) is developed to realize the evaluation of RSW quality in this paper. Under the COMSOL platform, the finite element method (FEM) modeling is proposed by multiphysics simulation. The multiphysical fields include electromagnetic field, acoustic field, and solid mechanics. The generation mechanism and propagation rules of EUTW in various spot welds are studied by simulation analysis. The correctness of FEM modeling is validated by EUTW experiments; results show that the experimental waveforms of EUTW are consistent with the simulation waveforms. Finally, an evaluation method of the nugget size of RSW is proposed based on the simulation and experiments analysis of EUTW detection of RSW with different nugget diameter and indentation depth. The approach presented in this paper can provide the theoretical foundation and new method for the noncontact, high efficient, and low-cost detection of RSW quality of the autobody. |
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| AbstractList | Resistance spot welding (RSW) quality substantially influences the autobody’s mechanical properties and safety performance. Nondestructive testing (NDT) method is widely used to evaluate the quality of RSW, but the traditional ultrasonic testing method has high requirements for coupling conditions and flat surface of the weld part. The electromagnetic acoustic transducer (EMAT) is a novel NDT technology, which has advantages of noncontact, no coupling media, and low requirements for surface flatness of the workpiece. Therefore, the electromagnetic ultrasonic transverse wave (EUTW) is developed to realize the evaluation of RSW quality in this paper. Under the COMSOL platform, the finite element method (FEM) modeling is proposed by multiphysics simulation. The multiphysical fields include electromagnetic field, acoustic field, and solid mechanics. The generation mechanism and propagation rules of EUTW in various spot welds are studied by simulation analysis. The correctness of FEM modeling is validated by EUTW experiments; results show that the experimental waveforms of EUTW are consistent with the simulation waveforms. Finally, an evaluation method of the nugget size of RSW is proposed based on the simulation and experiments analysis of EUTW detection of RSW with different nugget diameter and indentation depth. The approach presented in this paper can provide the theoretical foundation and new method for the noncontact, high efficient, and low-cost detection of RSW quality of the autobody. |
| Author | He, Ximing Wang, Xiaokai Guan, Shanyue Hua, Lin |
| Author_xml | – sequence: 1 givenname: Shanyue surname: Guan fullname: Guan, Shanyue organization: Hubei Key Laboratory of Advanced Technology for Automotive Components, Wuhan University of Technology, Hubei Collaborative Innovation Center for Automotive Components Technology – sequence: 2 givenname: Ximing surname: He fullname: He, Ximing organization: Hubei Key Laboratory of Advanced Technology for Automotive Components, Wuhan University of Technology, Hubei Collaborative Innovation Center for Automotive Components Technology – sequence: 3 givenname: Xiaokai surname: Wang fullname: Wang, Xiaokai email: wxk0919@whut.edu.cn organization: Hubei Key Laboratory of Advanced Technology for Automotive Components, Wuhan University of Technology, Hubei Collaborative Innovation Center for Automotive Components Technology – sequence: 4 givenname: Lin surname: Hua fullname: Hua, Lin organization: Hubei Key Laboratory of Advanced Technology for Automotive Components, Wuhan University of Technology, Hubei Collaborative Innovation Center for Automotive Components Technology |
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| Cites_doi | 10.1007/s10921-015-0319-3 10.1016/j.ndteint.2018.10.001 10.1063/1.347662 10.1016/j.ndteint.2011.08.007 10.1007/s00170-003-1599-9 10.1016/j.ndteint.2003.09.005 10.1016/S0924-0136(02)00409-0 10.1016/j.jmatprotec.2014.05.021 10.1007/s00170-015-7952-y 10.1063/1.1851393 10.1109/TUFFC.2011.2120 10.1109/20.951317 10.1016/j.matdes.2011.06.064 10.1016/j.ultras.2009.12.003 10.1016/j.sna.2005.07.026 10.1016/j.jmatprotec.2006.10.011 10.1016/j.ndteint.2012.03.002 10.1007/s00170-017-0665-7 10.1080/10589759.2016.1241251 10.1109/TUFFC.2010.1754 10.1016/j.ndteint.2012.06.004 10.1016/j.sna.2016.07.006 10.1109/58.148537 10.1007/s00170-017-0517-5 10.1016/j.ultras.2006.05.124 10.1016/j.ndteint.2012.02.005 10.1109/20.211323 10.1007/s00170-016-9588-y 10.1016/B978-0-12-477919-8.50010-8 10.1016/j.jmatprotec.2008.05.030 10.1121/1.381208 10.1016/j.ndteint.2014.03.007 |
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| Keywords | Finite element method (FEM) Electromagnetic ultrasonic transverse wave (EUTW) Multiphysics simulation Resistance spot welding |
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| SubjectTerms | Acoustic propagation Automotive bodies CAE) and Design Computer simulation Computer-Aided Engineering (CAD Coupling Electromagnetic fields Engineering Finite element method Flat surfaces Indentation Industrial and Production Engineering Mechanical Engineering Mechanical properties Media Management Modelling Nondestructive testing Original Article Resistance spot welding Simulation Solid mechanics Spot welds Transverse waves Ultrasonic testing Wave resistance Waveforms Welded joints Workpieces |
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| Title | Multiphysics simulation of the resistance spot welding detection using electromagnetic ultrasonic transverse wave |
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