Numerical Simulation of Sheet to Cylindrical Tube Single-Sided Spot Welding

With the promotion of lightweight structure, hydroformed tubes have been widely used in the automobile industry. In order to join different parts, sheet to tube single-sided spot welding (SSSW) is proposed. In the present study, numerical simulation method is employed, and an electrical-thermal mechanical coupled finite element model is established for predicting the nugget size and shape of sheet to cylindrical tube SSSW. Because of the welding deformation, doughnut weld nugget is formed and the course of the welding deformation can be reflected by the electrode displacement.