Abstract: The Arplas welding process is widely used in the automotive manufacturing field, particularly for exterior parts such as body panels and side frames, owing to its advantages of low welding energy, small heat-affected zone, and minimal mechanical deformation. However, due to the specificity of this process, welding quality is susceptible to influences from embossing, electrodes, sheet lapping, etc., making the process stability difficult to control. Therefore, based on the Bosch 7000 servo welding system and medium-frequency direct current welding gun, this paper establishes the embossment standard through boss height tracking experiments, and investigates the relationship between parameters and spattering using orthogonal experiments to determine the optimal parameter range for qualified quality. Additionally, the effects of electrode life and embossing process on welding quality and spattering are studied. A micro high-precision electrode dressing technology is proposed, which, combined with electrode detection and wear compensation, significantly improved the stability of the welding process, reduced spattering, effectively extended electrode life, and enhanced Arplas welding stability. The micro high-precision electrode dressing and boss cleaning technologies are of significant guiding importance for the optimization of the Arplas welding process.

Key words: Arplas welding; micro high-precision electrode dressing; electrode detection; electrode life

摘要： Arplas 焊接工艺因焊接能量低、热影响区小且机械变形小等优势，广泛应用在汽车制 造领域，特别是覆盖件、侧围等外观件中。由于其工艺的特殊性，焊接质量易受压凸、电极、 板材搭接等影响，焊接工艺稳定性难以控制。因此，文章基于博世 7000 伺服焊接系统及中频 直流焊枪，通过凸台高度跟踪实验确定凸台标准，利用正交试验探究参数与飞溅的关系，确 定了质量合格的最佳参数范围。同时，研究了电极寿命、冲凸工艺对焊接质量和飞溅的影响， 提出了电极微量高精度修磨技术，结合电极检测和损耗补偿，显著提高了焊接工艺的稳定性、 降低了飞溅现象，并有效延长了电极寿命，提高了 Arplas 焊接稳定性。电极微量高精度修磨 和凸台清洁技术对 Arplas 焊接工艺的优化具有重要的指导意义。

关键词: Arplas 焊接；微量高精度电极修磨；电极检测；电极寿命