Rapid sequence optimization of spot welds for improved geometrical quality using a novel stepwise algorithm

Joining sequence optimization is a combinatorial problem, requiring extensive computational time. The significance of determination of an optimal sequence for improved geometrical quality is substantial. Previously, genetic algorithms have been studied for defining the optimal sequence. However, these algorithms are highly dependent on the internal parameters, requiring additional computational analysis and thereby extended evaluation time. In this article, a novel robust stepwise algorithm is introduced to determine the optimal weld sequence. Application of the proposed algorithm leads to drastic time improvements for defining the optimal weld sequence of each assembly. Three industrial assemblies are evaluated. Comparison with the previously applied population-based optimization algorithms indicates that the optimization time can be reduced drastically with the proposed stepwise algorithm. The stepwise algorithm is intended to be applied in a geometry assurance digital twin, where the assembly parameters are being optimized for each individual assembly.