Direct Finite Element Analysis of the Stress Evolution and Interaction in Resistance Spot Welding with Multiple Processes and Multiple Spots Based on Reverse Engineering Technology

The current work achieved quantitative analysis of stress evolution and interaction in continuous spot welding processes that consider the stamping dimensional deviation. The reverse component that contains the stamping dimensional deviation was first established with reverse engineering technology. Then the two spot welding processes with twenty weld spots were simulated by the direct finite element analysis method. Welding experiment was conducted, and the actual residual deformation was measured by a 3D laser scanning system to validate the finite element model. The measured deformation shows good agreement with the simulated one. After that, the stress evolution was analyzed through the transient stress at a single spot weld and the peak stress during the entire welding process. The stress interaction between the spot welds in the same process and in the different processes was also analyzed. The results show that the stress interaction depends on the distance between the spot welds, the distribution of the spot welds, and the structure of the sheet metal parts. It is difficult to generalize a universal theorem to predict stress interaction. The value of the current research lies in its achievement in quantitative analysis of the stress evolution and interaction in components containing stamping dimensional deviation with direct finite element analysis, which can be extended to other complex components.