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. 2021 Jun 3;14(11):3062.
doi: 10.3390/ma14113062.

Prediction Model of the Resulting Dimensions of Welded Stamped Parts

Milan Kadnár  1 , Peter Káčer  1 , Marta Harničárová  2   3 , Jan Valíček  2   3 , Mirek Gombár  4 , Milena Kušnerová  3 , František Tóth  1 , Marian Boržan  5 , Juraj Rusnák  1
Affiliations

Prediction Model of the Resulting Dimensions of Welded Stamped Parts

Milan Kadnár et al. Materials (Basel). .

Abstract

The combination of stamping and subsequent welding of components is an important area of the automotive industry. Stamping inaccuracies affect the final size of the stamping and the welded part. In this article, we deal with a specific component that is produced by such a procedure and is also a common part of the geometry of a car. We focused on the possibility of using a negative phenomenon-deformation during welding-on the partial elimination of inaccuracies arising during stamping. Based on the planned experiment, we created a prediction model for the selected part and its production, with the help of which it is possible to determine suitable welding parameters for a specific dimension of the stamping and the required monitored dimension of the welded part. The article also includes the results of additional experimental measurements verifying the accuracy of the model and prediction maps for practice.

Keywords: distortion; model; prediction; stamping; welding.

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Conflict of interest statement

The authors declare no conflict of interest.

Figures

Figure 1
Figure 1
Ishikawa diagram for the identification of the subassembly quality of a car [9].
Figure 2
Figure 2
Alignment corrections.
Figure 3
Figure 3
A welded part and the dimension to be examined.
Figure 4
Figure 4
Stamping procedure.
Figure 5
Figure 5
Location of welds and their order during welding.
Figure 6
Figure 6
Geometrical shape of weld joint with the monitored dimensions in quality inspection (α—toe angle; l1—leg length; l2—penetration; l3—gap width; l4—excess welding).
Figure 7
Figure 7
Weld cut: (a) Welding parameters I = 160 A, v = 70 cm·min−1; (b) welding parameters I = 200A, v = 50 cm·min−1.
Figure 8
Figure 8
The total deviation of the stamped component from the 3D model.
Figure 9
Figure 9
The total deviation of the welded part from the 3D model. Welding parameters (I = 190 A, v = 60 cm·min−1).
Figure 10
Figure 10
Defects when using incorrect welding parameters (I = 210 A, v = 80 cm·min−1).
Figure 11
Figure 11
Demonstration of the proposed experiment plan.
Figure 12
Figure 12
The influence of factor levels on the mean response Y value: (a) current I (A); (b) welding speed v (cm·min−1).
Figure 13
Figure 13
Influence of individual factors on the resulting Response Y.
Figure 14
Figure 14
Residue analysis: (a) Normal Q–Q Plot; (b) Box Plot; (c) Histogram; (d) Density.
Figure 14
Figure 14
Residue analysis: (a) Normal Q–Q Plot; (b) Box Plot; (c) Histogram; (d) Density.
Figure 15
Figure 15
Dependence of the welded arm length on the current and the welding speed for the dimension of the stamping Z = 315.80 mm.
Figure 16
Figure 16
The dependence of the welded arm resulting length on the current and the welding speed for the dimension of the stamping Z = 315.80 mm.
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