Structural Seam Weld Optimization with Efficient Approach of DFSS

<div class="section abstract"><div class="htmlview paragraph">In automotive engineering, seam welds are frequently used to join or connect various parts of structures, frames, cradles, chassis, suspension components, and body. These welds usually form the weaker material link for durability and impact loads, which are measured by lab-controlled durability and crash tests, as well as real-world vehicle longevity. Consequently, designing robust welded components while optimizing for material performance is often prioritized as engineering challenge. The position, dimensions, material, manufacturing variation, and defects all affect the weld quality, stiffness, durability, impact, and crash performance. In this paper, the authors present best practices based on studies over many years, a rapid approach for optimizing welds, especially seam welds, by adopting Design For Six Sigma (DFSS) IDDOV (Identify, Define, Develop, Optimization, and Verification) discrete optimization approach. We will present the case testimony to show the approach throughout each phase of IDDOV. Three case studies are presented in this paper to demonstrate that the presented DFSS approach provides efficient, effective, and reliable practices to improve the robustness of weld designs over conventional design methodologies. This practice approach is scalable not just within the automotive industry but across other industries applying welded components.</div></div>