The Splash Control Study Of Relay Resistance Welding

Relay is an important automatic control component, which is the electronic information industry support and related to future international competition, comprehensive national strength and military strength as the important strategic component. Because the input and output part of the relay extensive use of high conductivity of copper alloy materials, and are thin-walled components, so resistance spot welding has been widely used. However, as the copper alloy not only has the high thermal conductivity and conductive properties but also sensitive to the change of welding parameters, resulting in the poor welding quality, so the research mechanism of resistance spot welding process is the foundation and the key to solve these problems.While, the process is not visible in the formation process of resistance spot welding, and the welding is instantaneous. This characteristics have brought great difficulties to the experimental study of resistance spot welding. Therefore, this paper use the numerical simulation. Through the simulation to represent the welding process, research the mechanism of copper alloy spot welding nugget formation. In this paper analysis of the process of copper alloy spot welding mechanical, electrical, thermal coupled behavior, to provide theoretical basis for address the quality of resistance spot welding of aluminum alloy in the relay.Based on Marc finite element analysis software, we set up the three-dimensional model of mechanical, thermal, electrical coupling behavior in the nugget formation process of tin-bronze resistance spot welding. Through the numerical simulation, we reveal the contact pressure's variation law in the squeeze stage of copper alloy spot welding. Analysis the influence of the pressure change on the electrode to pre-press behavior. Describes the welding temperature field variation law at different time and get the nugget formation mechanism of copper alloy spot welding process.Furthermore the reliability of relay always considered as the most important selection criteria of conventional and high-performance components, while the extra material in the relays is an important influence factor for their reliability. In this paper, we analysis the relationship between nugget growth velocity and growth velocity of the plastic area by the numerical simulation results,thus control the splash effectively in spot welding process, and ensuring the reliability of the relay.In this paper, we also set up the general spot welding models for the dissimilar thickness workment, and carry out dynamic simulation for general spot welding, various diameters electrodes and hard parameter of resistance spot welding process respectively. Through the analysis of the characteristics of nugget formation of the three models, we conclude that the last two models are more effective for preventing the nugget deviation of dissimilar thickness plate.