Modelling of Spot Weld Features Using Solid Works and Experimental Modal Analysis of Resistance Spot Welded Thin Sheets of Low Carbon Steel Panels

Abstract

Resistance Spot Welding of thin (RSW) low carbon steel sheets are widely used in automotive, aero-space sectors, furniture, medical equipments, packaging and electronics industries. Although, RSW is well established for low thickness sheets and static design guidelines are well defined, the dynamic analysis of spot welded panels has not been studied in detail. In this paper, solid modeling is done using Solid Works incorporating all the spot weld geometrical features like thicknesses of the two sheets that are joined, over-lap distance, spot size, nugget height, pitch distance, orientation of spot weld axis with respect to fixed end axis and type of clamping. Step by step procedure has been described with emphasis on the choice of appropriate commands so that meshing is smooth and continuous. Dynamic analysis of RSW panel is then analyzed with respect to modal frequencies and mode shapes for the first four modes for different boundary conditions such as all ends free (FFFF), one end clamped, CFFF (Clamped-Free-Free-Free), two ends clamped CFCF, (Clamped-Free-Clamped-Free) and all ends clamped (C-C-C-C). Experimental Modal Analysis has also been carried out on spot welded panels using FFT analyzer. The results obtained from Solid works are in close agreement with experimental findings, thus validating the model.