Study of Nugget Formation in Resistance Spot Welding using FEA 

A.G. Thakur1 , A.R. Rasane 2 , V. M. Nandedkar 3

 1 Mechanical Engineering Department, SRES’s College of Engineering, Kopargaon, Nasik, Maharashtra, India. 2Mechanical Engineering Department, Pune Vidyarthi Griha’s College of Engineering, 203, Dindori Road, Mhasrul, Nasik 422004, Maharashtra, India. 3 Production Engineering Department, Shri S.G.G.S. Institute of Engineering & Technology, Nanded, 431606, India.
[2] Corresponding author; Email:
Resistance spot welding (RSW) is a highly efficient production method that is particularly well suited for mass production. By using the finite element method (FEM), the temperatures at which the nugget is formed can be predicted, and this also helps the study of the behaviour of the materials at high temperatures. The finite element analysis simulation of the process requires modelling of complex interactions between electrical, thermal, metallurgical and mechanical phenomena. A 2D coupled axisymmetric FEM model has been developed to analyze the transient thermal behaviours of process using the ANSYS software. A coupled structural-thermoelectric analysis is performed to simulate the thermal characteristics of RSW process. The objectives of the simulation for such a process are to understand the physics of the process, to develop a predictive tool, and reduce the number of experiments for the optimisation of welding parameters. The distribution and changes in temperature and contact pressure are obtained through this analysis.
Resistance Spot Welding, Coupled Analysis, weld nugget, Temperature distribution

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