镀锌钢板点焊电极寿命预测

采用连续点焊试验与数值模拟相结合的方法预测电极寿命,即利用镀锌钢板连续点焊试验得出电极端面直径随焊接点数增加的规律,并用ANSYS软件模拟不同电极端面直径下点焊区域温度场,得出对应的熔核直径.综合试验及模拟结果得出焊接点数与熔核直径的关系,在定义了保证焊点质量的临界熔核直径情况下,即可得出相应的临界电极端面直径和连续点焊可焊点数,从而预测电极寿命.结果表明,两种方法得出的熔核直径的误差不超过15%.此方法对实际生产过程中的电极修整及更换周期制定具有一定的指导作用.

Forecast of electrode life in spot welding of galvanized steel sheet

The electrode life is forecasted by comparing continuous spot welding experiment result with numerical simulation.The increasing rule of electrode diameter with the increase of the number of welding spots can be obtained by continuous spot welding of galvanized steel sheet,and the relative nugget diameter can be computed through ANSYS with different electrode tip diameters.So the relationship between the number of welding spots and nugget diameter can be defined by synthesizing the experiment and the simulation.Based on the definition of the critical nugget diameter,it is possible to forecast the electrode life.The result shows that the error between two methods is no more than 15%.So it can bring some meaningful effect to define the time for repairing and changing electrode in the practical production process.