Abstract: An axisymmetric finite element electro-thermo-mechanical model for resistance spot welding process is introduced. A simulation method of the interaction of electrical, thermal and mechanical factors is presented. A calculation method of contact resistance is provided. The influence of the electrical and mechanical parameters of welding machine, the temperature dependent material properties and verious cooling boundary condition on welding process is also taken into account in the model. Experimental verification shows that the model prediction agrees well with the practical. The model provides an useful theorious tool for the analysis of resistance spot welding process.

Key words: Finite element, Numerical model, Resistance spot welding