B1) 20 pts. The thickness of each of the two sheets to be resistance spot welded is 3.5 mm. It is desired to form a weld nugget that is 5.5 mm in diameter and 5.0 mm thick after 0.3 sec welding time. The unit melting energy for a certain sheet metal is 9.5 J/mm3 . The electrical resistance between the surfaces is 140 micro ohms, and only one third of the electrical energy generated will be used to form the weld nugget (the rest being dissipated), determine the minimum current level required.

Answer:

minimum current level required =  8975.95 amperes

Explanation:

Given data:

diameter = 5.5 mm

length = 5.0 mm

T = 0.3

unit melting energy = 9.5 j/mm^3

electrical resistance = 140 micro ohms

thickness of each of the two sheets = 3.5mm

Determine the minimum current level required

first we calculate the volume of the weld nugget

v = [tex]\frac{\pi }{4} * D^2 * l[/tex] = [tex]\frac{\pi }{4} * 5.5^2 * 5[/tex] = 118.73 mm^3

next calculate the required melting energy

= volume of weld nugget * unit melting energy

= 118.73 * 9.5 = 1127.94 joules

next find the actual required electric energy

= required melting energy / efficiency

= 1127 .94 / ( 1/3 )  = 3383.84 J

TO DETERMINE THE CURRENT LEVEL REQUIRED  use the relation below

electrical energy =  I^2 * R * T

3383.84 / R*T = I^2

3383.84 / (( 140 * 10^-6 ) * 0.3 ) = I^2

therefore  8975.95 = I ( current )

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