Optimizing the placement of weld points in assemblies using the finite element method.
Numerical simulation, spotweld, Optimization
The automotive industry has always been extremely competitive, and the recent increase in foreign brands in the market has contributed to this even further. Faced with this, engineers are directing their efforts towards finding ways to reduce the cost and production time of new vehicles and thus gain an advantage over competitors in this dispute. One possible way to achieve this goal is to create a method that defines the best position for the thousands of weld points used in the manufacture of an automobile. With this in mind, a topological optimization method was developed using the finite element method to define the best distribution of weld points applied between the flanges of two joined plates, subject to previously defined constraints. First, topological optimizations were performed based on four distinct boundary conditions, subject to volume reductions of 70% and 85% each. Subsequently, the distribution found was reproduced in a model for structural analysis, and the difference in stiffness between it and another model using the same number of weld points, but distributed equally along the flange, was compared for each load case. Finally, it was possible to see that some loads were more sensitive to the distribution of weld points and that the correct distribution of points can improve the stiffness of the structure. In the end, a functional method for defining the distribution of weld points is obtained, but it needs adjustments to be applied in more complex cases and to present even better results.