Investigation of the parameters affecting the stud break in the welding process of the stud used in the assembly of passenger vehicles

In this thesis, the parameters affecting the break off the welded studs together with the sheet metal during assembly were investigated. Within the scope of study, the type of sheet material, sheet thickness and tightening value, which are the factors determined to affect the break off, were entered in the Minitab 18 program as two levels and a ten repetitive experiment design was made. According to the experimental design, the steel studs were welded on 0,7 mm and 1,2 mm thickness IF 210 and DP 600 sheets by arc stud welding method. The parts are tightened with 6 Nm and 4,5 Nm tightening torque values on the stud welded parts. The effect of the parameters on the amount of indentation rate was investigated by measuring the amount of indentation rate on the back surface of the sheet during tightening. In order to prevent the stud from tightening by tearing the sheet metal, it is aimed to minimize the indentation rate of the back surface of the sheet. According to the optimization made in Minitab 18, when the assembly part is tightened with 4,5 Nm to the stud welded to the 1,2 mm thick DP 600 sheet, the targeted minimum indentation will be seen on the back surface of the sheet. In this way, the studs used in the assembly of the parts will be prevented from break off by tearing the sheet metal during tightening.