1. Material properties data (for each material of workpiece, coating, electrode, rivet, die)
- Material name
- Material type or grade, tempering status, aging conditions etc.
- Chemical composition with percentage of each element
- Mechanical properties, incl. yield strength, tensile strength, elongation at break, n-value
- Physical properties, incl. resistivity, thermal conductivity, heat capacity, mass density
2. Geometric dimensions of Workpieces (or sheets)
- Geometry and Dimensions of each workpiece (e.g. thickness of each sheet)
- Thickness of surface coating, if any
3. Geometric dimensions of Electrodes, Rivets, Dies
- Geometry and dimensions of electrodes especially the tip face diameter and curvature
- Water cooling of electrodes (water temperature and flowing rate), if and Geometry and dimensions of rivets and dies for mechanical joining
4. Welding/ Joining setup (illustrated with technical drawing)
- Positioning of the workpieces and electrodes in resistance welding
- Positioning of the workpieces, rivet and die in mechanical joining
- Loading direction of the force, and mechanical fixture or supporting tools
5. Characteristics of welding machine/gun, Joining machine
- Type of electrical power source (AC, DC or CD)
- Type of mechanical loading system (pneumatic, hydraulic, spring, servo etc.)
- Maximum secondary current (kA) and power (kVA)
- Maximum mechanical loading capacity (kN)
6. Welding/joining process parameters
- For resistance welding: Weld current, number of pulses, Weld time, Weld force.
- For mechanical joining: Velocity of punch movement, maximum loading force
- Any other special features or limitations
7. Welding/Joining problem to be analyzed
- Description of the existing welding problem
- Expectations from the simulation