HYBRID SIMULATIONS FOR IN-LINE VISUALISATION OF WELDING STATE IN RESISTANCE SPOT WELDING

摘要

Hybrid simulation method is an advanced visualisation technique of directly invisible nugget formation process in welding and joining. The system consists of two parts: a sensing part of monitoring data during welding, and a numerical simulation part with the monitoring data as the input. Both part collaboratively work to predict the welding state history so that the simulated result outputs as visualised data of the invisible nugget formation process. It works as an in-line quality management system. This report introduces a result applied for this method to resistance spot welding. There are two types of hybrid simulation systems described. One is an ordinary type with grid mesh system that can output the temperature distribution in workpieces and electrode tips as well as current distribution etc. The other is a reduced high-speed system based on a reduced model developed with an integral form that can run as in-line real-time observer, but predicts only mean weld temperature and weld diameter. The sensing parts are the same for both systems. Both systems work well to visualise the invisible welding state.