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Surrogate Model Development for Digital Experiments in Welding

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Development of a Quality Control System Using Modal Analysis to Evaluate a Multi-Point Projection Welding Process.

Maciej Karpiński^1,2, Paweł Sokołowski¹, Paweł Kustroń¹

¹Faculty of Mechanical Engineering, Wroclaw University of Science and Technology, Lukasiewicza 5, 50-371 Wroclaw, Poland.

Materials (Basel, Switzerland)

|October 26, 2024

Summary

Modal analysis effectively evaluates multi-point projection welding quality by detecting weld defects through resonant frequency shifts. This non-destructive method offers a new quality control approach for complex welding processes.

Keywords:

FEM modal analysis quality control resistance projection welding spectral analysis weld quality

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Area of Science:

Materials Science
Mechanical Engineering
Manufacturing Processes

Background:

Assessing multi-point projection welding quality is challenging due to simultaneous current flow through multiple points.
Existing methods lack effectiveness in real-time evaluation of the welding process course.
A novel quality control system is needed for multipoint welding.

Purpose of the Study:

To investigate the applicability of modal analysis for evaluating multi-point projection welding quality.
To determine the influence of weld defects on resonant frequencies of the welding station and sample.
To develop a quality control system based on modal analysis data.

Main Methods:

Modal analysis of the welding station and sample (including finite element method simulations).
Investigation of dynamic properties in the frequency domain.
Comparison with the dynamic resistance method for quality verification.

Main Results:

Modal analysis successfully identified the influence of weld defects on resonant frequency displacement.
The study demonstrated the correlation between weld quality and changes in dynamic properties.
Numerical and experimental modal analyses confirmed the findings.

Conclusions:

Modal analysis provides an effective, non-destructive method for assessing multi-point projection welding quality.
Resonant frequency shifts serve as reliable indicators of weld defects.
The developed approach offers a promising quality control strategy for complex welding operations.