DESIGN ANALYSIS OF SHEET METAL WELDED JOINT BASED ON

DESIGN ANALYSIS OF SHEET METAL WELDED JOINT

BASED ON TRANSIENT THERMAL CONDITION

LAU LI YING

B051010051

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

2014


DESIGN ANALYSIS OF SHEET METAL WELDING JOINT

BASED ON TRANSIENT THERMAL CONDITION

This report submitted in accordance with requirement of the Universiti Teknikal

Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering

(Manufacturing Design) (Hons.)

by

LAU LI YING

B051010051

901017-08-5652

FACULTY OF MANUFACTURING ENGINEERING

2014


BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA

TAJUK: Design Analysis of Sheet Metal Welded Joint Based on Transient Thermal Condition

SESI PENGAJIAN: 2013/14 Semester 2 Saya LAU LI YING mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:

1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan

untuk tujuan pengajian sahaja dengan izin penulis. 3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan

pertukaran antara institusi pengajian tinggi.

4. **Sila tandakan ( )

SULIT

TERHAD

TIDAK TERHAD

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia sebagaimana yang termaktub dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)

(TANDATANGAN PENULIS)

Alamat Tetap:

571, Jalan Sekolah

Kampung Tawas

30010 Ipoh, Perak

Tarikh: _23 Jun 2014_____________

Disahkan oleh:

(TANDATANGAN PENYELIA)

Cop Rasmi: Tarikh: _______________________

** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai SULIT atau TERHAD.

DECLARATION

I hereby, declared this report entitled “Design Analysis of Sheet Metal Welded Joint

Based on Transient Thermal Condition” is the results of my own research except as

cited in references.

Signature : ___________________________

Author’s Name : LAU LI YING

Date : 23th

June 2014

APPROVAL

This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a

partial fulfillment of the requirements for the degree of Bachelor of Manufacturing

Engineering (Manufacturing Design) (Hons.). The member of the supervisory is as

follow:

________________________

i

ABSTRAK

“Resistance spot welding” adalah satu proses yang cepat, mudah diautomasikan dan

mudah dikekalkan tetapi mempunyai produktiviti yang tinggi. Disebabkan oleh

kelebihan ini, penggunaan “resistance spot welding” dalam automotif industri adalah

sangat tinggi. Hampir 90% daripada pemasangan bahagian-bahagian automotif

logam menggunakan proses penyambungan ini. Projek ini telah dijalankan untuk

menyelidik parameter reka bentuk kepingan logam kimpalan berdasarkan kepada

keadaan haba sementara. Selain itu, keadaan haba fana kepingan logam yang

dianalisis dan faktor keselamatan dicadangkan pada akhir projek. Parameter reka

bentuk termasuk beberapa kimpalan tempat , dimensi , bahan dan ketebalan kepingan

logam. Keadaan mantap dan fana terma analisis dijalankan ke atas aloi aluminium

5182 kepingan logam dengan dimensi 120mm × 60mm, ketebalan 1mm hingga 6mm

dan tempat kimpalan dua hingga lime. Gabungan ketebalan kepingan logam dengan

bilangan tempat kimpalan yang sesuai akan dicadangkan selepas simulasi dan

analisis. CAD model dan analisis kepingan logam telah dijalankan dengan

menggunakan perisian ANSYS. Keputusan analisis haba adalah fluks haba, tindak

balas siasatan dan faktor keselamatan. Pemarkahan dilakukan untuk menentukan

bilangan kimpalan yang sesuai bagi setiap ketebalan kepingan logam. Ia didapati

bahawa dua tempat kimpalan sesuai untuk ketebalan 1mm, 2mm, 4mm, dan 6mm

bagi dimensi tersebut di atas. Bagi lembaran logam dengan 3mm dan 5mm

ketebalan , lima dan dua tempat kimpalan sesuai masing-masing.

ii

ABSTRACT

Resistance spot welding is a fast, easily automated and easily maintained process

with high productivity. These advantages result in the highly usage of resistance spot

welding in automotive industrial. Almost 90% of the assembly of automotive parts

are using this joining process. This project was performed to investigate the design

parameters of sheet metal welded joint based on transient thermal condition. Also,

the transient thermal condition of the sheet metal is analysed and the factor of safety

is proposed at the end of the project. The design parameters included are number of

spot welding, dimension, material and thickness of sheet metal. Steady state and

transient thermal analysis were conducted on aluminium alloy 5182 sheet metal with

dimension 120mm×60mm, thickness 1mm to 6mm and number of spot weld two to

five. Suitable combination of thickness of sheet metal with number of spot weld is

proposed after the simulation and analysis. The CAD model and analysis of sheet

metal was performed by using ANSYS software. The results of both the thermal

analysis were heat flux, reaction probe and factor of safety. Scoring is done to

determine the number of spot weld for each thickness of the sheet metal. It is found

that two number of spot weld is suitable for thickness of 1mm, 2mm, 4mm, and 6mm

for the dimension mentioned above. As for sheet metal with thickness 3mm and

5mm, five and two spot weld is suitable respectively.

iii

DEDICATION

To my beloved parents, siblings, and friends for their love and support.

iv

ACKNOWLEDGEMENT

I would like to express my sincere thanks of appreciation to my co-supervisor, Dr.

Taufik for his guidance and encouragement for completing this report. I am so

grateful for his patient and tolerance of my naive mistakes.

I acknowledge my sincere gratitude to my parents and family members for their love,

support and advices motivation.

Last but not least, my special thanks are extended to every single individual who

kindly provide assistance and spiritual support to me without hesitations.

v

TABLE OF CONTENTS

Abstrack i

Abstract ii

Dedication iii

Acknowledgement iv

Table of Contents v

List of Tables ix

List of Figures viii

List of Abbreviations, Symbols and Nomenclatures xi

CHAPTER 1: INTRODUCTION 1

1.1 Background 1

1.2 Problem Statement 2

1.3 Objectives 3

1.4 Scope 3

1.5 Report Organization 4

1.6 Project Schedule 4

CHAPTER 2: LITERATURE REVIEW 6

2.1 Sheet Metal 6

2.1.1 Sheet Metal Forming 6

2.1.2 Sheet Metal Joining Process 9

2.1.3 Applications of Sheet Metal in Manufacturing 11

2.2 Welding Metallurgy 13

2.2.1 Resistance Spot Welding 14

2.2.2 Nugget Formation of Resistance Spot Welding 16

2.2.3 Resistance Spot Welding Parameters 17

2.2.4 Applications of Welding Metallurgy in Manufacturing 18

2.3 Materials 18

2.3.1 Materials in Welding Metallurgy 18

2.3.2 Aluminium Alloy 20

vi

2.3.3 Aluminium Alloy 5182 21

2.3.4 Plastic Condition of Aluminium Alloy 22

2.4 Heat Transfer in Welding 22

2.4.1 Convection 23

2.4.2 Conduction 24

2.4.3 Radiation 25

2.4.4 Thermal Theory and Concepts 26

2.4.4.1 Steady State Condition 26

2.4.4.2 Transient Condition 26

2.4.4.3 Heat Flux 27

2.5 Design and Analysis 27

2.6 Other Researches 28

2.7 Summary 30

CHAPTER 3: METHODOLOGY 31

3.1 Methodology Flow Chart 31

3.2 Phase 1 33

3.2.1 Title Selection 33

3.2.2 Problem Identifications 33

3.3 Phase 2 33

3.3.1 Literature Review 33

3.3.2 Data Collecting 34

3.3.2.1 Calculations of Convection Coefficient 34

3.4 Phase 3 36

3.4.1 Steady-State Thermal Analysis 37

3.4.2 Transient Thermal Analysis 42

3.5 Phase 4 49

3.6 Summary 50

CHAPTER 4: RESULTS AND DISCUSSION 51

4.1 Result 51

4.1.1 Steady State Thermal Analysis 51

4.1.1.1 Total Heat Flux 52

vii

4.1.1.2 Reaction Probe 53

4.1.1.3 Factor of Safety 55

4.1.2 Transient Thermal Analysis 57

4.1.2.1 Total Heat Flux 57

4.1.2.2 Reaction Probe 58

4.1.2.3 Factor of Safety 60

4.2 Discussion 61

4.3 Summary 66

CHAPTER 5: CONCLUSION AND RECOMMENDATION 68

5.1 Conclusion 68

5.2 Recommendation for Future Study 69

REFERENCES 70

APPENDICES 75

A Drawing of sheet metal with thickness 1mm and two numbers of spot welds

B Drawing of sheet metal with thickness 2mm and three numbers of spot welds

C Drawing of sheet metal with thickness 3mm and four numbers of spot welds

D Drawing of sheet metal with thickness 4mm and five numbers of spot welds

E Drawing of sheet metal with thickness 5mm and two numbers of spot welds

F Drawing of sheet metal with thickness 6mm and two numbers of spot welds

G Report of steady state thermal analysis

H Report of transient thermal analysis

viii

LIST OF TABLES

1.1 Project Schedule for Final Year Project I 5

1.2 Project Schedule for Final Year Project II 6

2.1 Overview of Material with Joining Process 19

2.2 Typical Forms and Uses of Aluminium Alloys 20

2.3 Chemical Composition of Alumimiun Alloy 5182 21

2.4 Welding Parameters and Welding Cycle 29

3.1 Data Obtained 34

4.1 Total Heat Flux from Steady State Thermal Analysis 52

4.2 Reaction Probe from Steady State Thermal Analysis 54

4.3 Factor of Safety for Steady State Thermal Analysis 55

4.4 Total Heat Flux for Transient Thermal Analysis 57

4.5 Reaction Probe of Transient Thermal Analysis 58

4.6 Factor of Safety for Transient Thermal Analysis 60

4.7 Number of Spot Weld That Fulfil the Requirements 63

4.8 Scoring for Sheet Metal with Thickness 1mm 63






4.14 Number of Spot Welds Recommended for Each Thickness of Sheet Metal 66

ix

LIST OF FIGURES

2.1 Schematic of Shearing Process 7

2.2 Punching and Blanking 7

2.3 Schematic Diagram of Deep Drawing 8

2.4 V-Shape Bending 8

2.5 Metal Stamping Products of Key To Metals Brazil. 9

2.6 Types of Seam Joint 10

2.7 Rivet 10

2.8 Bolt and Nut 11

2.9 Clinching Joint Cross-Section 11

2.10 Major Panels of Car Body 12

2.11 Draw and Redraw Method of Can Manufacture 13

2.12 Master Chart of Welding and Allied Processes 14

2.13 Welding Cycle 16

2.14 Nugget in Resistance Spot Welding 17

2.15 Temperature Range for Plastic Condition for Aluminium Spot Welding 22

2.16 Schematic of Convection 23

2.17 Natural Convection and Forced Convection 24

2.18 Schematic Diagram of Heat Conduction across a Wall 25

2.19 Schematic Diagram of Steady State Heat Conduction 26

2.20 Schematic Diagram of Transient Conduction 27

2.21 Test Piece 29

3.1 Methodology Flow Chart. 32

3.2 Steady State Thermal Analysis. 37

3.3 Sheet Metal with Thickness 4mm and 3 Spot Welds. 37

3.4 Meshing of 3D Model. 38

3.5 Steady State Thermal Analysis Constraint. 38

3.6 Setting for Temperature Constraint. 38

3.7 Setting for Convection Constraint. 39

x

3.8 Transient Thermal Analysis with Solution. 39

3.9 Result of Reaction Probe of Steady State Thermal Analysis. 40

3.10 Result of Total Heat Flux of Steady State Thermal Analysis. 40

3.11 Transferred Solution from Steady State Thermal Analysis to Static Structural

Analysis. 41

3.12 Static Structural Analysis Setting. 41

3.13 Result of Factor of Safety for Steady State Thermal Analysis. 42

3.14 Transient Thermal Analysis. 42

3.15 3D Model of 6mm Thick Sheet Metal with 5 Spot Welds. 43

3.16 Mesh Generation. 43

3.17 Meshed 3D Model. 44

3.18 Temperature Constraint Setting. 44

3.19 Convection Constraint Setting. 45

3.20 Solution of Transient Thermal Analysis. 45

3.21 Solution of Reaction Probe for Transient Thermal Analysis. 46

3.22 Solution of Total Heat Flux for Transient Thermal Analysis. 46

3.23 Data Transferred from Transient thermal Analysis to Static Structural

Analysis. 47

3.24 Static Structural Analysis Setting for Transient Thermal Analysis. 47

3.25 Solution Setting for Static Structural Analysis in Transient Thermal Analysis.

48

3.26 Result of Factor of Safety for Transient Thermal Analysis. 49

4.1 Average Total Heat Flux for Steady State Thermal Analysis. 53

4.2 Reaction Probe for Steady State Thermal Analysis. 55

4.3 Average Factor of Safety for Steady State Thermal Analysis. 56

4.4 Average Total Heat Flux for Transient Thermal Analysis. 58

4.5 Average Reaction Probe of Transient Thermal Analysis. 59

4.6 Average Factor of Safety for Transient Thermal Analysis. 61

xi

LIST OF ABBREVIATIONS, SYMBOLS AND

NOMENCLATURE

- Rate of Conduction Heat Transfer (W)

- Rate of Convection Heat Transfer (W)

- Surface Area

- Temperature of Colder Object

- Temperature of Hotter Object

- Fluid Bulk Temperature

- Surface Temperature

- Thickness of Heat Transfer

A - Heat Transfer Area

Al - Aluminium

Cu - Copper

Fe - Iron

g - Gravitational Acceleration (m/s2)

h - Convection Heat Transfer Coefficient (W/m2.K)

I - Electric Current (Ampere)

k - Thermal Conductivity of Material (W/m.K)

Lc - Characteristic Length

Mg - Magnesium

Mn - Manganese

Nu - Nusselt Number

Pr - Prandtl number

Q - Total Energy (Joule)

R - Resistance (Ohm)

RaL - Rayleigh Number

Si - Silicon

t - Time (Second)

v - Kinematic Viscosity of fFuid (m2/s)

Zn - Zinc

1

CHAPTER 1

INTRODUCTION

This chapter discussed the general idea of thermal transient condition for resistance

spot welding of sheet metal. Others elements that included in this chapter are

problem statement, objective, scope, and report organization.

1.1 Background

Sheet metal working are normally undergoes cold condition compared to formed

under hot condition. This is because sheet metal has a lower resistance to

deformation when heated (Boljanovic, 2004). The sheet metal forming processes

included roll forming, stretch forming, drawing, stamping, rubble-pad forming,

spinning, superplastic forming, poem forming, explosive forming and magnetic-pulse

forming (Kalpakjian and Schmid, 2009).

Many methods have been used in joining materials together which are adhesive

bonding, mechanical joining, fusion welding, solid state bonding welding, friction

welding, electromagnetic welding, brazing and roll bonding (Imaizumi, 1996).

Resistance spot welding is one of the welding processes that have been used broadly

in sheet metal joining (Cho and Cho, 1989). It is also the most commonly method

that used in joining car body steel component (Kowieski et al., 2012). Some of the

advantages of this welding process are high speed, suitability for automation industry

and high productive assembly lines (Cho and Cho, 1989).

2

When a structure or part is produced by welding process, a non-uniform temperature

distribution is created in the structure or part. A rapid thermal expansion and

contraction in weld and the surrounding areas during welding process results in this

temperature distribution. Thus, inhomogenous plastic deformation and residual

stresses in the weldment is formed when the structure is cold (Armentani and et. al.,

2006).

1.2 Problem Statement

Resistance spot welding process include the combination of thermal, electrical,

mechanical and metallurgical phenomena. It is a complicated welding process (Nied,

1983). The complexity of this welding process had led to some difficulties in

understanding the thermal behavior in the weldment (Cho and Cho, 1989).

After resistance spot welding process, the residual stress and strain will remain in the

weldment due to the deformation during the welding process. Upon electrode force

and heating, stress and strain will be created and changed. A numbers of researches

of the mechanical features for resistance spot welding process are being done. As a

conclusion from the researches, the factors that might lead to the failure of resistance

spot welding are residual stress, welding schedule, nugget size, welding parameters,

thickness, material properties and gap (Wang et al., 2009).

Due to the complexity of resistance spot welding, the actual setting of resistance spot

welding such as current and welding time is determined by trial and error most of the

time (Saleem and et. al.). At the same time, the number of spot welds needed for a

particular dimension is also a factor that leads to failure (Ertas and Sonmez, 2008).

During resistance spot welding, sheet metal experienced change of temperature.

Different amount of spot weld generated produced different amount of heat energy. It

cannot be denied that thermal condition is one of the factors that need to be

considered in resistance spot welding. Thus, there is a need to analyse a sheet metal

3

welded joint within the factor of safety based on transient thermal condition where

the number of spot welds need to be determine.

1.3 Objectives

The objectives of this project are:

a. To investigate the design parameter of sheet metal welded joint.

b. To analyze the transient thermal condition.

c. To propose the factor of safety of sheet metal welded joint.

1.4 Scope

In this project, the sheet metal welded joint is created by using resistance spot

welding. The design parameters that investigated are material, dimension and

thickness of sheet metal that used in this project. The material of the sheet metal is

aluminium alloy 5182 with thickness between 1mm-6mm. The dimension of the

sheet metal in this project is 120mm x 60mm. The numbers of spot welds are vary

from two spot welds to five spot welds.

This project study the thermal condition of the sheet metal after spot welding joint is

formed. The transient thermal condition was analyzed using software ANSYS.

Steady state and transient thermal analysis were conducted in order to obtain total

heat flux, reaction probe and factor of safety. These results were used in determine

the number of spot welds that are suitable for each thickness with the dimension

mentioned above.

4

1.5 Report Organization

This report consists of three chapters where Chapter 1 of this report is introduction.

This chapter included the general idea of transient thermal condition of resistance

spot welding and the part included. This chapter also discussed the problem

statement, objectives, scope, report organization and project schedule.

Chapter 2 is literature review where the review of previous studies that done by other

researchers were included in this chapter. This chapter discussed the parameter of

spot welding, thickness and materials of sheet metal. Also, this chapter included the

design and analysis software that been used to carry out this project.

Chapter 3 methodology described the method that used to achieve the objectives. A

flow chart is presented to illustrate the steps and overall process flow of this project.

The steps in carried out the analysis using ANSYS were discussed in this chapter too.

Chapter 4 included the results and discussion for this project. The results obtained

from the analysis were tabulated and discussed. The suitable numbers of spot welds

were suggested at the end of this chapter.

Chapter 5 summarize the whole report and recommend for future work that can be

done regarding to this project.

1.6 Project Schedule

Table 1.1 shows the project schedule of Final Year Project 1.

5

Tab

le 1

.1:

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.

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8

9

10

11

12

13

14

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6

Tab

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.2:

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I.

Task

A

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(2013/2

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1

2

3

4

5

6

7

8

9

10

11

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13

14

Cre

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6

CHAPTER 2

LITERATURE REVIEW

This chapter is discussed the concepts and theory of sheet metal forming and joining

process and welding metallurgy. This chapter also discussed the transient thermal

condition of resistance spot welding. Also, other researches that had been done by

other researchers are included in this chapter too.

2.1 Sheet Metal

According to The Aluminium Association, aluminium sheet is a product that is

rectangular in cross-sectional and form, with thickness more than 0.20mm and less

than 6.30mm. A sheet is known as plate if the thickness exceed or more than 6.30mm

(The Aluminium Association, 2007).

2.1.1 Sheet Metal Forming

The methods that are most often being used for sheet metal forming are shearing,

punching and blanking, deep drawing, bending and other processes (Boljanovic,

2004). Among the methods, shearing, punching and blanking are cutting process.

A shearing process is used to cut off sheet metal material with the usage of punch,

die and blank holder (Ishiguro et al., 2009). Figure 2.1 shows the schematic of

7

shearing process. The sheet metal experienced shearing process or being cut by the

punch and die where force is added. This process is usually used to produce various

opening in a sheet metal (Kalpakjian and Schmid, 2009).

Figure 2.1: Schematic of Shearing Process (Stuart, 2002-2013)

Blanking and punching (also known as piercing) are both shearing process. The main

difference of these two processes is the scrap. Figure 2.2 shows the difference

between punching and blanking operations. Punching operation is whereby the scrap

the part that had been cut out. The workpiece of blanking is called a blank. This is

the part which cut off during the process (Totre et al., 2013).

Figure 2.2: Punching and Blanking (Khan and Haque, 2011)

Deep drawing is process where the sheet metal is forced to flow between the surfaces

of punch and die by adding force through the punch. This process is a compression-

tension forming process (Kaonga, 2009). Figure 2.3 shows the schematic of deep

drawing. Through deep drawing process, a flat sheet metal is formed into cylindrical,

conic, or boxed-shape.

Documents

DESIGN ANALYSIS OF SHEET METAL WELDED JOINT BASED ON