汽车车身用铝合金电阻点焊接头疲劳分析数据

通过疲劳试验采集具有不同板厚匹配、焊点直径、几何构型的样品疲劳数据，辅助以疲劳失效分析、有限元计算等分析手段，构建具有普适性的铝合金电阻点焊疲劳寿命预测模型，该模型可根据铝板厚度、焊点直径等输入参数，快速计算出焊点的疲劳寿命，用于汽车白车身焊接结构耐久性设计和评估。（1）数据采集：设计铝合金电阻点焊样品几何尺寸，以及疲劳试试验测试方法，利用MTS疲劳试验机开展疲劳试验采集原始数据。（2）数据处理：将采集到的疲劳数据进行进一步分析，根据试验载荷计算得到施加在焊点出的拉力和弯矩，建立有限元模型，计算该载荷下的焊点应力响应；再计算换算薄膜应力和换算弯曲应力两个应力分量构建含待定参数的等效应力公式：换算薄膜拉力=循环最大载荷*COS(循环最大载荷*(上层板厚+下层板厚)*60/(2*70000*(25.4/12)*(上层板厚^3+下层板厚^3)))；换算弯曲应力=循环最大载荷*(1/(1+(下层板厚/上层板厚)^3))*(下层板厚+上层板厚)/2；最后得到疲劳寿命预测模型。（3）应用场景：铝合金电阻点焊是轻量化汽车最常采用的连接技术之一，其疲劳寿命预测是白车身耐久性设计和评价的必备工具。通过疲劳试验获得具有不同板厚匹配、焊点直径、几何构型的样品疲劳数据，辅助以疲劳失效分析、有限元计算等分析手段，构建了具有普适性的铝合金电阻点焊疲劳寿命预测模型，该模型可根据铝板厚度、焊点直径等输入参数，快速计算出焊点的疲劳寿命，用于汽车白车身焊接结构耐久性设计和评估。

Fatigue data of specimens with different sheet thickness matches, spot weld diameters and geometric configurations were collected via fatigue tests. Assisted by analytical methods such as fatigue failure analysis and finite element calculation, a universal fatigue life prediction model for aluminum alloy resistance spot welding was established. This model can quickly calculate the fatigue life of spot welds based on input parameters including aluminum sheet thickness and spot weld diameter, and is used for durability design and evaluation of automotive body-in-white (BIW) welded structures.

(1) Data Collection: The geometric dimensions of aluminum alloy resistance spot welding specimens and the fatigue test methodology were designed. Fatigue tests were conducted using an MTS fatigue testing machine to collect raw experimental data.

(2) Data Processing: The collected fatigue data was further analyzed. The tensile force and bending moment applied at the spot weld were calculated based on the test loads. A finite element model (FEM) was established to calculate the stress response of the spot weld under these loads. Then two stress components, equivalent film stress and equivalent bending stress, were calculated to construct an equivalent stress formula with undetermined parameters:
Equivalent film stress = Cyclic maximum load × cos(Cyclic maximum load × (Upper sheet thickness + Lower sheet thickness) × 60 / (2 × 70000 × (25.4/12) × (Upper sheet thickness^3 + Lower sheet thickness^3)))
Equivalent bending stress = Cyclic maximum load × (1 / (1 + (Lower sheet thickness / Upper sheet thickness)^3)) × (Lower sheet thickness + Upper sheet thickness) / 2
Finally, the fatigue life prediction model was obtained.

(3) Application Scenarios: Aluminum alloy resistance spot welding is one of the most commonly used joining technologies for lightweight automobiles, and its fatigue life prediction is an indispensable tool for durability design and evaluation of body-in-white structures. Fatigue data of specimens with different sheet thickness matches, spot weld diameters and geometric configurations were obtained through fatigue tests. Assisted by analytical methods such as fatigue failure analysis and finite element calculation, a universal fatigue life prediction model for aluminum alloy resistance spot welding was established. This model can quickly calculate the fatigue life of spot welds based on input parameters including aluminum sheet thickness and spot weld diameter, and is used for durability design and evaluation of automotive body-in-white welded structures.

搜集汇总

数据集介绍

特点

该数据集包含679条汽车车身用铝合金电阻点焊接头的疲劳分析数据，涵盖板厚、焊点直径、循环载荷等12个关键参数，用于构建疲劳寿命预测模型，支持汽车白车身焊接结构的设计和评估。数据来源于企业，按需更新，已通过存证公证。