Simulation of Variation in Assembly Forces Due to Variation in Spot Weld Position

Abstract

Resistance Spot Welding is frequently used for joining of sheet metal assemblies. Geometrical variation in parts to be joined, variation in fixtures and lack of repeatability in welding guns and robots, result in variation in spot weld position. Analysis of industrial scanning data showed deviations of spot weld positions of magnitudes up to 19 mm. This variation leads to variation in the initial gap between the parts to be joined and therefore, also to variation in the assembly force required to join the parts. In this paper, a simulation method for prediction of variation in assembly forces due to variation in spot weld position is presented.