Abstract:

Resistance spot welding is the main assembly process in body?in?white manufacturing. The number and layout of spot welds may have great effects on the dynamic and static stiffness of body?in?white， but these two effects are not always in the same direction. Therefore， in the optimization with concurrently improving both dynamic and static stiffness as the objective， an indicator， which can take into account both dynamic and static stiffness， is required， while ensuring the industrial robustness in production. In this paper， a decision?making indicator for spot weld optimization with consideration of both dynamic and static stiffness is proposed based on the strain energy of spot welds and adjacent elements. The indicator is then used to construct an efficient robustness analysis scheme， thus forming a multi?objective adaptive optimization method for spot?welds， enabling the realization of a spot?weld optimization process， with concurrent consideration of multiple performance indicators and robustness. Finally， the method is applied to the performance optimization and robustness analysis of the spot welds in the body?in?white of a light bus， with its effectiveness verified by tests.

Key words: spot?welds, robustness, adaptive optimization