Assessing Electrode Characteristics in Continuous Resistance Spot Welding of BH 340 Steel Based on Dynamic Resistance
The aim of this investigation is to offer a data-based scheme for predicting electrode wear in resistance spot welding. One of the major factors affecting the mechanical properties of spot welds and the variation in weld quality is electrode wear and alloying. In this study, Rogowski coils and twist...
| Main Authors: | , , , , , |
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-12-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/7/6/218 |
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| author | Dawei Zhao Nikita Vdonin Mikhail Slobodyan Sergei Butsykin Alexey Kiselev Anton Gordynets |
| author_facet | Dawei Zhao Nikita Vdonin Mikhail Slobodyan Sergei Butsykin Alexey Kiselev Anton Gordynets |
| author_sort | Dawei Zhao |
| collection | DOAJ |
| description | The aim of this investigation is to offer a data-based scheme for predicting electrode wear in resistance spot welding. One of the major factors affecting the mechanical properties of spot welds and the variation in weld quality is electrode wear and alloying. In this study, Rogowski coils and twisted pairs attached to the top and bottom electrodes were used to obtain the welding current and the voltage between the electrodes in the welding process, thereby calculating the dynamic resistance value during the welding process. The electrode tip diameter was obtained from the pressure exerted by the upper and lower electrodes on the carbon paper when the current was cut off and was regarded as an indicator of electrode wear. By continuously welding 0.5 mm thick BH 340 steel plates until the electrode failed, the dynamic resistance signal was recorded in real time. Simultaneously, the electrode diameter after every several welds was also recorded. On this basis, the correlation between electrode tip diameter and dynamic resistance is studied. In order to quantitatively study the mapping relationship between dynamic resistance and electrode wear, 10 characteristic values were extracted from the dynamic resistance, and the stepwise regression method was used to obtain the regression formula between the characteristic values and the electrode tip diameter. Using new data to verify the effectiveness of the regression model, the acquired results display that the maximum error between the predicted value of the electrode tip diameter and the measured value obtained by the regression equation with the interactive quadratic term is 0.3 mm, and the corresponding relative error is 7.69%. When welding with a new pair of electrodes, the maximum absolute error was 0.72 mm, and the relative error of the model prediction is within 20% according to the linear regression model with interaction terms. This indicates that this regression model is barely satisfactory for monitoring electrode condition. |
| first_indexed | 2024-03-08T20:38:23Z |
| format | Article |
| id | doaj.art-e4befd8b42544879a436c574e77c8972 |
| institution | Directory Open Access Journal |
| issn | 2504-4494 |
| language | English |
| last_indexed | 2024-03-08T20:38:23Z |
| publishDate | 2023-12-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj.art-e4befd8b42544879a436c574e77c89722023-12-22T14:18:26ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942023-12-017621810.3390/jmmp7060218Assessing Electrode Characteristics in Continuous Resistance Spot Welding of BH 340 Steel Based on Dynamic ResistanceDawei Zhao0Nikita Vdonin1Mikhail Slobodyan2Sergei Butsykin3Alexey Kiselev4Anton Gordynets5Department of Welding Engineering, South Ural State University, 454080 Chelyabinsk, RussiaDepartment of Welding Engineering, South Ural State University, 454080 Chelyabinsk, RussiaTomsk Scientific Center of the Siberian Branch of the Russian Academy of Sciences, 10/4 Academichesky Avenue, 634055 Tomsk, RussiaSchool of Advanced Manufacturing Technologies, Tomsk Polytechnic University, 634050 Tomsk, RussiaSchool of Advanced Manufacturing Technologies, Tomsk Polytechnic University, 634050 Tomsk, RussiaSchool of Advanced Manufacturing Technologies, Tomsk Polytechnic University, 634050 Tomsk, RussiaThe aim of this investigation is to offer a data-based scheme for predicting electrode wear in resistance spot welding. One of the major factors affecting the mechanical properties of spot welds and the variation in weld quality is electrode wear and alloying. In this study, Rogowski coils and twisted pairs attached to the top and bottom electrodes were used to obtain the welding current and the voltage between the electrodes in the welding process, thereby calculating the dynamic resistance value during the welding process. The electrode tip diameter was obtained from the pressure exerted by the upper and lower electrodes on the carbon paper when the current was cut off and was regarded as an indicator of electrode wear. By continuously welding 0.5 mm thick BH 340 steel plates until the electrode failed, the dynamic resistance signal was recorded in real time. Simultaneously, the electrode diameter after every several welds was also recorded. On this basis, the correlation between electrode tip diameter and dynamic resistance is studied. In order to quantitatively study the mapping relationship between dynamic resistance and electrode wear, 10 characteristic values were extracted from the dynamic resistance, and the stepwise regression method was used to obtain the regression formula between the characteristic values and the electrode tip diameter. Using new data to verify the effectiveness of the regression model, the acquired results display that the maximum error between the predicted value of the electrode tip diameter and the measured value obtained by the regression equation with the interactive quadratic term is 0.3 mm, and the corresponding relative error is 7.69%. When welding with a new pair of electrodes, the maximum absolute error was 0.72 mm, and the relative error of the model prediction is within 20% according to the linear regression model with interaction terms. This indicates that this regression model is barely satisfactory for monitoring electrode condition.https://www.mdpi.com/2504-4494/7/6/218resistance spot weldingelectrode weardynamic resistanceregression modelelectrode tip diameter |
| spellingShingle | Dawei Zhao Nikita Vdonin Mikhail Slobodyan Sergei Butsykin Alexey Kiselev Anton Gordynets Assessing Electrode Characteristics in Continuous Resistance Spot Welding of BH 340 Steel Based on Dynamic Resistance Journal of Manufacturing and Materials Processing resistance spot welding electrode wear dynamic resistance regression model electrode tip diameter |
| title | Assessing Electrode Characteristics in Continuous Resistance Spot Welding of BH 340 Steel Based on Dynamic Resistance |
| title_full | Assessing Electrode Characteristics in Continuous Resistance Spot Welding of BH 340 Steel Based on Dynamic Resistance |
| title_fullStr | Assessing Electrode Characteristics in Continuous Resistance Spot Welding of BH 340 Steel Based on Dynamic Resistance |
| title_full_unstemmed | Assessing Electrode Characteristics in Continuous Resistance Spot Welding of BH 340 Steel Based on Dynamic Resistance |
| title_short | Assessing Electrode Characteristics in Continuous Resistance Spot Welding of BH 340 Steel Based on Dynamic Resistance |
| title_sort | assessing electrode characteristics in continuous resistance spot welding of bh 340 steel based on dynamic resistance |
| topic | resistance spot welding electrode wear dynamic resistance regression model electrode tip diameter |
| url | https://www.mdpi.com/2504-4494/7/6/218 |
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