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The major
industrial sectors applying resistance welding are listed
below.
SORPAS®
is tailor-made welding software for simulation and optimization of resistance welding processes. It has been commercialized
since 2000 and now applied by many companies in various industrial
sectors all over the world. It supports research and development, weldability evaluation, welding process parameter optimization, production line building and planning, as well as maintenance in resistance welding including spot
welding and projection welding etc.
Below are some examples for industrial applications of the software. Welding process simulation:
Welding process parameter optimization: With the Enterprise Edition , several functions for automated simulations have been developed to support welding process parameter optimization. It is possible to run fully automated procedures to generate the weld growth curves and the weldability lobes.
This is a weld growth curve
generated automatically with SORPAS® for spot
welding of 1 mm mild steel sheets in the range of weld current from
2 kA to 16 kA. The software has automatically identified the working
range with green color points indicating the good spot welds, the
red color points indicating splashes and the black color points
indicating no weld. This is a weldability lobe generated automatically
with SORPAS®
for spot welding of 1 mm mild steel sheets
with two welding process parameters (weld current and time) referring
to ISO 14327:2004. Three reference weld nugget diameters (minimum, maximum and
nominal) are indicated. It is also possible to generate the weldability lobe with weld
current and force. After each
simulation, SORPAS®
will generate a Report of Simulation for documentation. Below is a typical report for a spot welding simulation. In the upper part, it shows the initial welding conditions including
material combinations, geometry of electrodes and workpieces as well as the
welding process parameter settings. In the lower part, it shows the main
simulation results with a selected process parameter curve, the final
temperature distribution with the weld nugget dimension in each workpiece.
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