3D numerical simulation of projection welding of square nuts to sheets

Abstract The challenge of developing a three-dimensional finite element computer program for electro-thermo-mechanical industrial modeling of resistance welding is presented, and the program is applied to the simulation of projection welding of square nuts to sheets. Results are compared with experimental observations and measurements produced by the authors with the aim and objective of assessing the accuracy, reliability and validity of the theoretical and numerical developments. The numerical developments include implementation of friction between deformable objects in the finite element flow formulation in order to model the frictional sliding between the square nut projections and the sheets during the welding process. It is proved that the implementation of friction increases the accuracy of the simulations, and the dynamic influence of friction on the process is explained.