Browse Publications Technical Papers 2018-28-0034

BIW Spot weld parameter standardization through parameter optimization across various sheet metal panel combinations 2018-28-0034

Body-in-white (BIW) is one of the critical aggregate of an automobile. Establishing the quality parameters during body manufacturing is essential to achieve robust BIW structure. Spot weld integrity and dimensional accuracy are the two major quality parameters of a BIW. Weld integrity plays an important role in achieving dimensional accuracy and structural stability. Various combinations of sheet metals are joined together to form a BIW structure. Spot weld parameter selection is one of the critical activity and needs to be programmed for the various combinations of sheet metals. Weld parameter for the various combinations are being calculated with the resistance of the joining sheet metals thicknesses. The calculated parameters are being validated with the coupon test (or) peel test and it requires several iterations to establish weld integrity of the different combinations and the selected parameters are getting registered in the weld controller. The conventional process consumes large quantity of weld coupons for destructive testing and also weld parameter of every combination is becoming unique. Maintaining the records of several unique weld parameter is a complicated activity and requires high rate of control for re-programing during weld gun maintenance and other trials. This study is focusing to address the issue in parameter selection for various combinations. Common material grades, thickness combinations, weld time and weld pulses are considered as major factors in the study. Standard parameters for the general combinations were identified through L27 Taguchi method and validated with the confirmation experiments. Selection of standard parameters ensures higher percentage of weld integrity & repeatability and also management of the weld programs become ease with limited parameters.


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