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Journal of Applied Mathematics and Physics, 2020, 8, 1715-1728 ISSN Online: 2327-4379 ISSN Print: 2327-4352 DOI: 10.4236/jamp.2020.89129 Sep. 3, 2020 1715 Journal of Applied Mathematics and Physics Nonlinear Finite Element Analysis and Optimum Design of Spot-Welded Joints and Weld-Bonded Joints Shengyong Zhang Department of Mechanical and Civil Engineering, College of Engineering and Sciences, Purdue University Northwest, Westville, USA Abstract Resistance spot welding and hybrid weld bonding have wide applications in the body work construction within the automobile industry. The integrity of the spot welds and applied adhesives determines the body assembly rigidity and dynamic performance. Incorporating contact nonlinearity and geometric nonlinearity, finite element analysis (FEA) have been carried out to investi- gate the structural stiffness and strength of both spot-welded and weld-bonded assemblies. Topology optimization has been performed to reveal the distri- butions of material effectiveness in the overlap regions and suggest a feasi- ble method for removing underutilized material for weight reduction. De- sign optimization has been conducted with an aim to reduce the maximum von Mises stress in the assembly to minimum by choosing optimum values for a set of design variables, including the weld spacing, weld diameter and overlap width. Keywords Finite Element Analysis, Optimum Design, Spot-Welded Joint, Weld-Bonded Joint, Lightweight Design 1. Introduction Spot welding is a quick welding process and can be easily adapted for automa- tion when combined with robots and control systems. The weld-bonded joining is a technology in which both adhesives and spot-welds are utilized to fasten metal sheets. Spot-welding and weld-bonding have been the conventional join- ing technologies for assembling metal sheets together for decades, notably for How to cite this paper: Zhang, S.Y. (2020) Nonlinear Finite Element Analysis and Op- timum Design of Spot-Welded Joints and Weld-Bonded Joints. Journal of Applied Ma- thematics and Physics, 8, 1715-1728. Received: July 20, 2020 Accepted: August 31, 2020 Published: September 3, 2020 Copyright © 2020 by author(s) and Scientific Research Publishing Inc. This work is licensed under the Creative Commons Attribution International License (CC BY 4.0). Open Access

Nonlinear Finite Element Analysis and Optimum Design of Spot-Welded Joints and Weld-Bonded Joints

Jun 04, 2023



Akhmad Fauzi
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