Subject of this diploma thesis is manufacturing of the guiding rail HB 02150 made of metal sheets and used for table slide rail in drawer system. This thesis was made in cooperation with Hettich ČR Company which is producer of furniture hardware. Theses contains theoretical part which explains matters of cutting and bending technology. Marginally will be mentioned matters of spot welding. Practical part contains explanation of production of guiding rail, lay-out of bending roll and cutting tools. In this work there is also described solution of problem with wastrels caused by faulty welding of metal sheets and the draft of welding fixture which solves this problem. Economical and technical summary of this manufacturing process is the last part of this thesis.

Spot welding of 1.4307 material of 1+1 mm thickness is tuned out excellently by the enterprise ROSTEX – at the changes only of the welding current it was managed to approach the value of thickness achieved by enterprise ROSTEX. At the welding of 1.4307 material of 2+2 mm thickness it was managed to achieve more strength under welding parameters: Fs = 5500N, Is = 8,964 kA, ts = 10 Per. Spot welding of 1.0330 material revealed a possibility in proceeding with welding current increasing which could stand for the weld strength increasing (not necessarily) – a limit where material could splash was not achieved. The soft mode welding is not convenient for up-to date spot welding because the material is extremely affected by heat at the long welding time, it also leads to huge thermal losses, thermal effect and distortion of electrodes (electrodes life diminishing). Soft mode welding is not expedient even economically. In accordance with economic comparison, see chart 27, page 64 – for instance welding of 1.4307 material with 1+1 mm thickness at 1000 welds there is difference of 644 Czech crowns between the hard and the soft mode welding in benefit to the hard mode.

In dieser Arbeit werden vier Wege aufgezeigt die Gebrauchsdauer von Elektroden zu verbessern. Der erste Weg besteht darin die tatsächlich verfügbare Standmenge zu nutzen, soweit es statische Fräszyklen ermöglichen. Vom aktuellen Orientierungswert, welcher bei 120 Punktschweißverbindungen für eine Standmenge liegt, lassen sich auf diesem Weg 70% an Elektroden beim Schweißen feuerverzinkter Stahlbleche einsparen. Auf dem zweiten Weg wird nachgewiesen, dass die Standard-CuCr1Zr-Legierung verbessert werden kann. Bereits mit geringsten Gefüge-Modifikationen lassen sich ein gutmütigeres Verschleißverhalten, eine größere Standmenge und ein charakteristischeres Standmengenende erzielen. Der dritte Weg beleuchtet dispersionsgehärtete Elektrodenkappen. Solche sind nicht neu, aber wurden in den 2000er Jahren weiterentwickelt. Ihr nun verfügbares Potential erlaubt gegenüber der ersten Betrachtung einen bis zu 95% verringerten Elektroden-Bedarf an feuerverzinkten Blechen. Abschließend formuliert der vierte Weg eine zukunftsweisende Möglichkeit die Standmenge dynamisch der real verfügbaren Standmenge anzupassen. Dieser Ansatz erlaubt einerseits Haftpflichtrisiken an mathematisches Vorgehen zu überantworten und andererseits das Werkstoffpotential vollständig zu nutzen. Da Streubreiten der realen Standmengengrenzen bei bis zu 40% liegen, ist eine entsprechende Einsparung an Kupfer erreichbar. In der vorliegenden Arbeit wird dazu der Ansatz verfolgt den Punktdurchmesser aus typischen Prozessgrößen mittels Data Mining zu bestimmen. Das fertigungsnahe Qualitätsband von +/-10% Punktdurchmesser kann basierend auf einem mathematisch transparenten Modell mit über 93% Wahrscheinlichkeit korrekt berechnet werden.

Es wird ein Überblick über die Bedeutung des Übergangswiderstandes beim Pressschweißen, sowie dessen physikalische Ursachen gegeben. Ausgewählte etablierte und neuere Ansätze der mathematischen Beschreibung des Übergangswiderstandes und deren Charakteristika werden dargestellt und charakterisiert. Im Vergleich wird der empirische Ansatz des KMK-Modells des Übergangswiderstandes dargestellt und dessen Implementierung in das FEM- Programmsystem erläutert. Ein Anwendungsbeispiel belegt die Qualität der mit dem Modell durchführbaren Simulationen, und zeigt daraus resultierende vertiefte Bewertungsmöglichkeiten des Schweißvorganges auf.

Increased understanding of improving the weld-bonding process is essential in order for the automotive industry to constantly develop their designs and production processes for the energy-efficient vehicles of the future. The joining method of weld-bonding, a hybrid method of adhesive joining and resistance spot welding, has introduced new challenges in the manufacturing and design of auto bodies. At the same time as adhesives are more incorporated in the joint configurations’, continuous development and implementation of ultra-high-strength steels, the complexity of the weld-bonding process increases. This thesis presents new approaches of parameter set-up and testing methods for weld-bonded joints. Aiming to displace the adhesive from the welding zone new parameters are tested by producing 1-D weld lobes that are analyzed in a screening matrix to find the factor with greatest effect on the weldability. Laser displacement measurement is a new method used to measure the amount of adhesive present in the joint during the welding cycle. The amount of adhesive plays an important role in the process and the intention is to get an assessment of how different thicknesses affect the weldability. The results showed that the different parameters have different influential behavior depending on the sheet thickness of the welded material. From the main effect screening, cap type has the greatest influence on the weld current range followed by the addition of an extra pre-pulse. The measured amount of adhesive present immediately before the weld pulse is very small. An interesting observation is that samples showing the largest increase in weld current range, compared to the corresponding reference were the samples which had most adhesive present in the contact area. The study showed that there are new parameters that improve the weldability of a weld-bonded joint that can be utilized using existing welding equipment. Finally, the study has shown that many possibilities exists to continue exploit within the field of weld-bonding, to be able to further utilize the effectiveness of weld-bonded joints in future lightweight autobody design. / Ökad förståelse och förbättring av weld-bonding processen (limpunktsvetsning) är väsentligt för att fordonsindustrin ska kunna fortsätta utveckla sina konstruktioner och tillverkningsprocesser för framtidens energieffektiva fordon. Fogningsmetoden weld-bonding, en hybridmetod av limning och punktsvetsning, har tillfört nya utmaningar i tillverkningen och konstruktionen av fordonskarosser. Samtidigt som limfogar används i allt större utsträckning så sker ständig utveckling och tillförande av ultrahöghållfast stål i karosserna som ytterligare påverkar weld-bonding processens komplexitet. Det här examensarbetet introducerar nya sätt att konfigurera processparametrarna och testmetoderna för weld-bondförband. Målet att tränga bort så mycket lim som möjligt från fogen med hjälp av de nya processparametrarna, testas genom att ta fram svetslober som analyseras i ett parameterkartläggande flerfaktorförsök för att hitta de faktorer som har störst inverkan på svetsbarheten. Avståndsmätning med laser är en ny metod som används för att mäta mängden lim som finns i fogen under svetscykeln. Mängden lim har en betydande roll i processen och målsättningen är att få en uppskattning om hur olika limtjocklekar påverkar svetsbarheten. Resultatet visar att olika parametrar har olika inverkan på processens beteende beroende på vilken materialtjocklek som svetsas. Parameterkartläggande flerfaktorförsöket visar att de faktorer som har störst inverkan på svetsfönstrets storlek är elektrodhätta följt av tillförandet av en extra förpuls. Den uppmätta limtjockleken i fogen precis före huvudsvetspulsen är väldigt liten. En intressant observation är att svetsproverna som påvisade den största ökningen av svetsfönstrets storlek, jämfört med referensproverna utan lim, var de prover som hade mest lim kvar i kontaktytan innan svetspulsen. Arbetet i uppsatsen visar att det finns nya svetsparametrar som ökar svetsbarheten hos weld-bondingfogar och som kan tillämpas i existerande svetsutrustningar. Slutligen har arbetet visat att det existerar många möjligheter att fortsätta utveckla weld-bondingprocessen ytterligare för att fortsättningsvis utnyttja fogens effektivitet i framtidens konstruktion av lätta fordonskarosser.

<p>The dissertation offers a Multiphysics perspective in analyzing emerging metallurgical techniques. Heat transfer, structural deformation, and fluid flow associate with one another in phase-changing materials processing methods. To comprehensively analyze these aspects for an optimized final product, the authors have proposed a numerical mathematical model describing the thermal and geometric progression of the binary alloy casting process. The model is further executed in COMSOL Multiphysics, adapted in two metal manufacturing applications, resistance spot welding (RSW) and binder jet printing (BJP). </p><p>Resistance spot welding is a well-adapted metal sheeting joining technique with comparably limited modeling and simulating research. The heat transfer module and geometric deformation module are applied to the simulation of RSW to discuss the thermal gradient development of the welding zone. The model was further calculated and verified through a case study with Python. </p><p>BJP is a rapidly developing additive manufacturing method. The novel 3D printing technique brings challenges in post-processing geometric control and material selection limitations. Multiphysics simulation serves as an excellent tool in process parameters analysis and quality control. This dissertation focuses on the sintering process of BJP of binary alloy powders. Melting and solidification mathematical models were implemented in COMSOL, where the sintering shrinkage rate could be calculated. The shrinkage rate was further verified through experimental analysis of binder jet printed samples. </p><p>Microstructural analysis on sintered binder jet printed parts was performed to assess the validity of BJP to substitute the die casting method for manufacturing of valvebody. Sintering shrinkage and metallurgical analysis have been performed on the green and sintered BJP samples. After sintering, the final part achieved 98% density, and the integrity of the designed channels was preserved. The shrinkage analysis has indicated the effect of printing orientation and sintering orientation on the geometry and metallurgy of the final products. Microstructure analysis on the cross-sections of the sintered products also indicates the various defects induced from biner jet 3D printing. </p><p>The research aims to provide a systematic rheology analysis of the phase transformation process of binary alloys. The dissertation has connected the physical, mathematical modeling with 15 </p><p><br></p><p>simulative modeling through the rheological evaluation of phase-changing manufacturing techniques. The connections were conclusively verified through empirical studies, including case assessment and experimentation. The research aims to offer universally applicable models that can be applied to phase-changing metal processing techniques. </p>

Spot friction welding (SFW) was performed on ultra high strength steel (UHSS) steel sheet commonly used in automobile manufacturing. Alloys studied included DP780, DP780EG, DP980, and DF140T sheet steel of varying thickness from 1.2 mm to 1.4 mm. Welding was accomplished using a PCBN standard tool. Weld strengths were then compared to a proposed AWS standard. Initial hardness readings were taken in cross sectioned samples. Grain structure in a SFW is presented. Resistance spot welds were created in three steels. This study focuses on the strength of SFW joints as compared to traditional resistance spot welding (RSW) in welding like materials to one another. Cycle times of SFW were also evaluated and compared to production rate cycle times of RSW.

The purpose of this study was to generate a greater understanding of how the shunt distance affects the shunting phenomena which occurs when working with resistance spot welding (RSW). Shunting affects the quality of the weld and the goal of the study was to create guidelines for RSW to minimize its impact on the weld quality. In order to minimize waste from production and to reduce the welding time there is need for understanding of what the shunt effect depends on. To evaluate what impact the shunt distance will have on the weld, two different experiments were performed. In the first experiment, a one-dimensional welding lobe was manufactured for various materials and the current range was compared over three different shunt distances. The second experiment consisted of welding with a constant current on different shunt distances to investigate how this would impact the second weld performed in the welding sequence. A range of different steel grades and sheet thicknesses was used in the experiments to further explore what impact different material properties will have on the shunt effect. The result showed that the shunt distance has little impact on the acceptable weld-current range, with minor deviations. However, the shunt distance will affect the size of the shunted weld, which decreases as the shunt distance is reduced. Overall, the data collected in this study is not expansive enough to make guidelines that could be implemented in today´s industry. The phenomena of shunting require more data to fully be understood. / Syftet med denna studie var att skapa en större förståelse för hur shuntavståndet påverkar det shunt-fenomen som uppstår när man arbetar med punktsvetsning (RSW). Shuntning påverkar svetsens kvalitet och målet var att skapa riktlinjer för arbete med RSW för att minimera shunt-effektens påverkan på svetsen. I syfte att kunna minimera spill i produktionen samt att minska svetstiden krävs det förståelse av vad shunt effekten beror på. För att utvärdera vilken påverkan shuntavståndet kommer att ha på svetsen utfördes två olika experiment. I det första experimentet skapades en endimensionell svetslob för varje material och det genererade strömintervallet jämfördes över tre olika shuntavstånd. Det andra experimentet bestod av svetsning med en lika stor ström vid olika shuntavstånd för att undersöka hur detta skulle påverka den andra svetsen. En rad olika stålsorter och plåttjocklekar användes för att ytterligare se vilken påverkan dessa faktorer kom att ha på shunteffekten. Resultatet visade att shuntavståndet hade liten inverkan på det acceptabla svetsströmintervallet, med mindre avvikelser. Emellertid påverkar shuntavståndet storleken på den shuntade svetsen genom att storleken minskar när shuntavståndet minskas. Sammantaget räcker inte de uppgifter som samlats in i denna studie för att skapa riktlinjer som skulle kunna implementeras i dagens industri, utan det krävs mer data för att fullständigt kartlägga shunteffekten.

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