Welding Process

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Chapter 3: Literature review
Sr. No Name Research
1. Mohd Zaim Bin Din Experimental Study On Strength of Spot Welder
2. M. I. Khan, A. K. Pandey State of art in modern Resistance Spot Welding
3. Nachimani Charde Investigating spot weld growth on Austenitic stainless steel
4. Ali. Moarrefzadeh Study of Heat Affected Zone (HAZ) in
Resistance Welding Process
5. D. J. Radakovic Resistance Spot Weld Failure
Modes in Shear Tension Tests of Advanced
High-Strength Automotive Steels

3.1 Gap Identify:
In the above research papers we found that the resistance spot welding machine is very bulky, undergoes weld cycle which takes time that is, it does not join materials instantaneously, creates a larger heat zone which requires a longer time to cool and is susceptible to shear failure. It also does not weld at any angle, requires a proper foundation and is costly.
3.2 Objective:
To create a welding machine that:-
• Can Welding at any angle and any height
• Is flexible
• Is Less costly
• Compact in size
• Provide ease of operation to welder and
• Less weight.
• Is portable
• Does not require a rigid foundation.

Chapter 4: Design and modeling
4.1 Components of the equipment
• 17 gauge copper wire for primary winding
• Fiber glass coated aluminum for secondary windings
• Step down transformer
• Electrode
• Brass Electrode clamp
• Limit switches
• Stamping(Plates)
• Wooden casing
• Nut bolt
• Wire for main current supply
4.2 General equation used in spot welding
The shear strength of a single spot weld can be calculated as follows: τ = 2.6 • t • d • Rm
τ = shear strength, N t = sheet thickness, mm d = weld diameter, mm
Rm = tensile strength of the material, MPa
Electrodes indent at least slightly on the work piece surface. ...

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...oot operated and weighs nearly 200 kilos.
In this project we have removed the above said problems by creating a much simpler, lighter, portable, compact and flexible machine which is able to weld at any angle and can be easily operable by a less experienced worker with much ease and required accuracy.
The advantages of our equipment are as follows:-
• Welding at any angle, any height
• Provide flexibility
• Less costly
• Compact
• Provide ease of operation to welder and
• Less weight.

We conclude that our machine can be mass produced and can also be used for industrial purposes.

Chapter 8: References
1. Miller Hand book.
2. Welding technology by O.P. Khanna.
3. Ruukki Resistance welding manual.
4. Manufacturing Technology by P.N.RAO.
5. https://encrypted-tbn2.gstatic.com/images?q=tbn:ANd9GcRCMnoU86VE2WfmswJJNcQ6o_cOokYxVwUQaCR4AwlEJavqXa4_
6. Research Paper
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