Quantitative Study of Predicting the Effect of the Initial Gap on Mechanical Behavior in Resistance Spot Welding Based on L-BFGS-B.

The initial gap (IG) is frequently occurring in the process of resistance spot welding (RSW) for automotive body-in-white structures. It is an inevitable challenge that the RSW with IG can negatively impact the welding quality, subsequently reducing the structural integrity and safety of the vehicle. This research aims to study the influence of the IG on RSW mechanical behaviors based on the refined finite element model (FEM) of RSW with different IGs under tensile shear load.