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Abstract Spot welding of sheet metal is essential in various customers environment, are subjected to random amplitude
manufacturing sectors such as automobile, ship building, service loading, during its operating life.
aerospace, construction, refrigeration and air-condition. In this
According to Single there are three major fatigue life
paper the impact of sheet metal thickness and spot weld
diameter on the fatigue life of sheet metals is discussed. Three methods used in design and analysis. These three methods
different sheet thicknesses (1.5mm, 2 mm and 3 mm) and two are stress-life method, the strain-life method, and the linear-
different spot diameters (2.5 mm and 5 mm) were selected for elastic fracture mechanics (LEFM) method. The numerical
the study. The loads given during fatigue analysis were 35, 40, techniques based on the linear-elastic fracture mechanics
50, 70, 100 N respectively. Pro-E was used for designing the with input data from laboratory tests is often used to
specimen and Ansys was used for analysis of fatigue life. Finite establish fatigue failure criteria. The Strain Life approach is
Element Analysis was used for the study to determine the widely used at present. In this method strain can be directly
relationship between fatigue life on spot weld diameter and measured and has been shown to be an excellent quantity for
thickness of the sheet metal is discussed. It was found that for
characterizing low-cycle fatigue. Strain Life is typically
higher number of sheet thickness and spot diameters
respectively and respectively lower load, the number of cycles concerned with crack initiation, whereas Stress Life is
taken for the specimen to rupture was greater. In this case were concerned with total life and does not distinguish between
9.00E+06. initiation and propagation. Fracture Mechanics starts with an
assumed flaw of known size and determines the cracks
Index Term Spot welding, fatigue strength, sheet thickness, growth as is therefore sometimes referred to as Crack Life.
spot weld diameter. Fracture Mechanics is widely used to determine inspection
intervals.
1. INTRODUCTION In general, the fatigue process is characterized by three
Sheet metals are widely and extensively used in almost distinct regions [3]. Region I is associated with the growth of
every sector of manufacturing, production and construction. cracks at low stress intensity factor ranges and is commonly
Few of these include automobile, ship building, aircraft believed to account for a significant proportion of the fatigue
manufacturing and commercial purposes such as life of a component. Region II is the stable crack growth
construction, refrigeration and air-conditioning. In every of region and has been extensively studied for its technological
these manufacturing sectors the sheet metals are subjected to importance [4-17]. Rapid crack growth occurs in region III
spot welding for creating of joints. and this region is typically thought to account for a small
The parts fabricated by these sectors are subjected to fraction of the total life.
fatigue load. Mechanical failure of structures and In this paper the relationship between sheet metal
components is a serious concern in all types of industries. thickness and spot weld diameter on the fatigue life of a
Robert Stone [1] estimated that between 50 to 90 % of these welded sheet metal joint has been studied. Much research
failures are due to fatigue. According to him fatigue is work on welded sheet metal had been carried out by
defined as The process of progressive localized permanent researchers. The results based on mechanical properties,
structural change occurring in a material subjected to defects in joints, had been published in their papers. FEA on
conditions that produce fluctuating stresses and strains at welded joints and relationship with fatigues had also been
some point or points and that may culminate in cracks or analyzed and published. A few of those papers and their
complete fracture after a sufficient number of fluctuations. contents are shown below
Fatigue life is one of the most important properties when Alenius [18] have investigated Spot weldability of
designing such components. Fatigue damage has long been dissimilar metal joints between stainless steels and non
an important aspect of designing automotive and aeronautical stainless steels The aim was to determine the spot welding
components, and it has been extensively studied. The parameters for the dissimilar metal joints and to characterize
expected life of a product can be determined in the design the mechanical properties of the joints. Bin Zhou [19] has
stage itself by considering various factors such as static and presented a methodology for determining the cohesive
dynamic load, nature of working environment, nature of facture parameters associated with pull-out of spot welds.
weld joint, etc. A typical car or truck may have more Since failure of a spot weld by pull-out occurs by mixed-
than 2000 spot welds [2]. The majority of structural mode fracture of the base metal, the cohesive parameters for
components under actual working conditions, in the
60 Ts = 3 mm
35 138.5 1.00E+05
40
40 157.1 8.50E+04
20
50 214.9 2.00E+04
0
1.00E+04 8.10E+04 2.60E+05 8.00E+05 1.00E+06 70 311.17 7.50E+03
No. of Cycles 100 510.4 1.00E+03
Load (N)
Case 1 (sheet thickness of 2 mm)
60 Ts = 1.5 mm
40
Maximum No. of cycles to
Load 20
stress failure
(N) 0
(MPa) (N f) 1.00E+03 7.50E+03 2.00E+04 8.50E+04 1.00E+05
No. of Cycles
40 114.5 2.00E+05 4.2. For spot diameter of 5 mm with varying sheet thickness
50 176.2 8.00E+04 Analysis is carried out on the specimen for a spot diameter
of 5 mm with varying sheet thickness. Maximum stress and
70 241.2 1.50E+04 fatigue life values for a spot diameter of 5 mm with a sheet
thickness of 3 mm are shown in Table VI.
100 469.53 2.00E+03 TABLE VI
Case 1 (sheet thickness of 3 mm)
80 35 58.8 9.00E+06
Load (N)
60 Ts = 2 mm 40 65.56 5.00E+06
40
50 82.81 1.50E+06
20
70 99.74 5.00E+05
0
2.00E+03 1.50E+04 8.00E+04 2.00E+05 5.00E+05 100 169.5 7.60E+04
No. of Cycles
60 Ts = 3 mm 35 100.01 7.50E+05
40
40 101.9 3.00E+05
20
0 50 150.2 9.00E+04
7.60E+04 5.00E+05 1.50E+06 5.00E+06 9.00E+06
70 214.9 2.00E+04
No. of Cycles
40
35 78.92 2.00E+06 20
0
40 97.5 9.00E+05 1.50E+04 8.00E+04 3.00E+05 9.00E+05 2.00E+06
No. of Cycles
50 101.2 3.00E+05
Fig. 10. Case 3 (Sheet thickness of 1.5 mm)
1.00E+07
120 1.00E+06
No. of Cycles
100
1.00E+05 Ts = 3 mm
80
Load (N)
Ts = 2 m
60 Ts = 2 mm
1.00E+04 Ts = 1.5 mm
40
20 1.00E+03
0
1.00E+02
1.50E+04 8.00E+04 3.00E+05 9.00E+05 2.00E+06
35 40 50 70 100
No. of Cycles
Load (N)
Fig. 9. Case 2 (Sheet thickness of 2 mm)
Fig. 11. Effect of sheet thickness for spot diameter of 2.5 mm
A maximum stress and fatigue life value for a spot
diameter of 5mm with a sheet thickness of 1.5mm is shown
in Table VIII.
REFERENCES
[1] Robert Stone, Fatigue Life Estimates Using Goodman Diagrams
[2] M. M. Rahman; Rosli A. B., M. M. Noor, M. S. M. Sani, M. R.
M. Rejab, (2007) fatigue analysis of spot-welded joints using
finite element analysis approach, Regional Conference on
Engineering Mathematics, Mechanics, Manufacturing &
Architecture (EM3ARC).
[3] Shigley J E, Mischke C R and Budynas R G 2004 Mechanical
Engineering Design 7th ed. McGraw-Hill Companies, Inc., New
York, NY 10020.
[4] Molent L, Jones R, Barter S and Pitt S 2006 Int. J. Fatigue 28
175968
[5] Huang X and Moan T 2007 Int. J. Fatigue 29 591602
[6] Sansoz F and Ghonem H 2003 Mater. Sci. Eng. A356 8192
[7] Korda A, Miyashita Y, Mutoh Y and Sadasue T 2007 Int. J.
Fatigue 29 114048
[8] Ding J, Hall R F, Byrne J and Tong J 2007 Int. J. Fatigue
29 133949