مهندسی ساخت و تولید ایران

مهندسی ساخت و تولید ایران

مقایسه مدل المان محدود کوپل الکتریکی-حرارتی-مکانیکی با چارچوب تحلیلی برای پیش‌بینی ابعاد دانه جوش و منطقه متأثر از حرارت در جوش نقطه‌ای فولاد S235 تحت اثر شار فرعی

نوع مقاله : مقاله پژوهشی

نویسندگان
گروه مهندسی مکانیک، دانشگاه ملی مهارت، تهران، ایران
10.22034/ijme.2026.579941.2171
چکیده
این مطالعه به اعتبارسنجی یک مدل المان محدود کوپل الکتریکی-حرارتی-مکانیکی می‌پردازد که به‌منظور شبیه‌سازی جوش‌کاری مقاومتی نقطه‌ای ورق‌های فولادی S235 توسعه یافته است. هدف اصلی، ارزیابی عملکرد این شبیه‌سازی در مقایسه با یک چارچوب تحلیلی اثبات‌شده برای پیش‌بینی دو ویژگی کلیدی جوش شامل قطر دانه جوش و حجم منطقه متأثر از حرارت است. مزیت اصلی این مدل المان محدود سه‌بعدی نسبت به چارچوب تحلیلی، توانایی شبیه‌سازی کامل عدم‌تقارن سه‌بعدی و تعاملات پیچیده چندفیزیکی ناشی از اثر شار فرعی است که مدل‌های تحلیلی متقارن قادر به پیش‌بینی مستقیم آن نیستند. پیش‌بینی‌های مدل تحت جریان‌ها و زمان‌های مختلف جوشکاری به‌صورت مورد بررسی قرار گرفت و کاربرد ویژه آن برای کمّی‌سازی اثر شار فرعی (انحراف جریان) به کار گرفته شده است؛ پدیده‌ای که در آن انحراف جریان از طریق دکمه جوش قبلی، کیفیت اتصال را تضعیف می‌کند. نتایج حاکی از تطابق قابل‌توجه میان روش عددی و تحلیلی بوده است، به‌طوری‌که قطر دکمه جوش و ابعاد منطقه متأثر از حرارت به‌ترتیب در محدوده 4- تا 4 درصد و 5- تا 5 درصد از مقادیر مرجع تحلیلی پیش‌بینی شده‌اند. مدل تأییدشده نشان داد که اثر شار فرعی می‌تواند در جریان‌های پایین‌تر (5/7 کیلوآمپر) اندازه دانه جوش را بیش از 25 درصد کاهش دهد و مهم‌تر آن‌که در شرایط مشابه، عدم‌تقارن جانبی قابل‌توجهی تا 40 درصد در منطقه متأثر از حرارت ایجاد می‌کند که مستقیماً ناشی از مسیر شار فرعی است. این همبستگی نزدیک، مدل المان محدود را به‌عنوان ابزاری قدرتمند و قابل‌اعتماد برای بهینه‌سازی پارامترهای جوشکاری و تحلیل تعاملات پیچیده چندفیزیکی در فرایندهای جوش نقطه‌ای اعتبار می‌بخشد.
کلیدواژه‌ها

عنوان مقاله English

A numerical-analytical comparative study of nugget and heat-affected zone formation in S235 spot welds using coupled FEM and theoretical framework with focus on shunting effect

نویسندگان English

Mehdi Jafari Vardanjani
Yaghoub Dadgar Asl
Department of Mechanical Engineering, Technical and Vocational University (TVU), Tehran, Iran
چکیده English

This study presents the comparison of a coupled electrical-thermal-mechanical finite element model developed to simulate resistance spot welding of S235 steel sheets. The primary objective is to benchmark the numerical simulation against a verified analytical framework for predicting two critical weld features: nugget diameter and heat-affected zone (HAZ) volume. The key advantage of the proposed 3D FEM model over the analytical framework lies in its ability to fully capture three-dimensional asymmetry and complex multi-physics interactions induced by the shunting effect, which cannot be directly predicted by simplified or axisymmetric analytical models. Model predictions were rigorously evaluated across various welding currents and durations, with a specific focus on quantifying the shunting effect (a phenomenon where current diversion through an existing weld nugget compromise subsequent joint quality). The results demonstrate excellent agreement between the numerical and analytical approaches, with predicted nugget diameters and HAZ dimensions deviating by less than ±4% and ±5% from theoretical benchmarks, respectively. The validated model quantifies that shunting can reduce nugget size by over 25% at lower currents (7.5 kA) and, more importantly, reveals a significant lateral HAZ asymmetry of up to 40% under identical conditions, directly attributable to the diverted current path. This strong correlation confirms the FEM model as a robust and reliable predictive tool for optimizing welding parameters and analyzing complex multi-physical interactions in spot welding processes.

کلیدواژه‌ها English

Resistance Spot Welding
Shunting Effect
Model Verification
Coupled Numerical Analysis
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