A shape optimization study for tool design in resistance welding

The purpose of this study is to apply shape optimization tools for design of resistance welding electrodes. The numerical simulation of the welding process has been performed by a simplified FEM model implemented in COMSOL. The design process is formulated as an optimization problem where the objective is to prolong the life-time of the electrodes. Welding parameters like current, time and electrode shape parameters are selected to be the design variables while constraints are chosen to ensure a high quality of the welding. Surrogate models based on a Kriging approximation has been used in order to simplify the calculation of shape sensitivities and to generate a generic tool that can be interfaced with other simulation tools. An example numerical study shows the potential of applying optimal design techniques in this area.