Simulation of nugget formation process in multi-points projection welding and its application

Firstly,the thermo-electric coupling ANSYS model of multi-points projection welding is built up and the results reveal that the current has an apparent diversion phenomenon at different projection points. Due to the combined effects of temperature and pressure,the values of current density in the middle of contact points between the upper and lower workpieces are maximal and decrease distinctly on both sides. Then the thermal and electrical behavior of the metal corrugated plate packing with 0.17 mm thickness 304 stainless steel is quantitatively analyzed in the process of projection welding. Meanwhile,the temperature field in the nugget formation process has been obtained. The sizes of nugget obtained by numerical simulation are in good agreement with the measured results. Therefore,this method provides a theoretical basis for the design and optimization of the parameters in multi-point projection welding process.