UDP Final Report

PORTABLE SEAM AND SPOT WELDING MACHINE
A PROJECT REPORT
ON
PORTABLE SEAM AND SPOT WELDING MACHINE
Submitted by
Sr No. Name Enrollment no
1 Parmar Ashwin S. 130670119005

2 Nandanwar Mayur K. 130670119050
3 Mehta Yash K. 130670119542
4 Rakhunde Dipak G. 130670119590
UNDER THE GUIDANCE OF

Prof. Rupal Tank
In Fulfilment for the award of the degree of

BACHELOR OF ENGINEERING
In
MECHANICAL ENGINEERING
SAL INSTITUTE OF TECHNOLOGY AND ENGINEERING

RESEARCH AHMEDABAD
Gujarat Technological University, Ahmedabad
April, 2017
SAL Institute of Technology & Engineering Research
Mechanical department
April 2017
Certificate
This is to certify that the dissertation entitled PORTABLE SEAM AND SPOT WELDING
MACHINE has been carried out by Mehta Yash, Rakhunde Dipak, Nandanwar Mayur,
Parmar Ashwin under fulfillment of the degree of Bachelor of Engineering in Mechanical
Engineering (8th Semester) of Gujarat Technological University, Ahmadabad during the
academic year 2016-17.
Place: Ahmadabad
Date:
Internal Guide Head of Department External Guide
i
Acknowledgement
First and foremost let us grateful to almighty God. Our deepest regards and
greatest admiration remain to my parents, & family, who has taught me how to
walk on an untrodden path in the quest of knowledge.
We would like to thank our Institute Sal Institute of Technology &
Engineering Research and also Gujarat Technological University for
providing us an opportunity to apply theatrical knowledge through the project.
As an essential part of training in Industry in Engineering.
We sincerely convey our gratitude to our guide Rupal Tank, Associate
Professor, Mechanical Engineering Department, and Prof. Darshit K. Nayak
Assistant Professor, Mechanical Engineering Department, SALITER,
Ahmedabad who made us believe in our self and guided us through the whole
process of dissertation writing. He has never failed to help us to get a grasp on
the subject. We sure that this dissertation would not have been possible without
his support, understanding and encouragement.
We sincerely thank, Prof. S.M. BHATT, Head of Mechanical Engineering
Department, who helped us in pointing the need of the project, suggestions and
encouragement during the Project.
ii
Abstract
Manufacturing engineering in general has experienced an increased

demand of process planning in order to optimize process to reduce costs,
environmental impact and increase time efficiency. Resistance welding is a
common and large-scale joining method in several manufacturing industries
indicating significant potentials of efficient process planning.
Generally resistance welding machine requires a lot of space heavy,
restrained by height in this project we have then to overcome the above
problems recreating the design.
We trying to create a simple, lighter, portable, compact, flexible and
economically machine which will be able to weld any type of weld like spot,
tack, overlap, continuous welding.
Generally this different type of welding required two different welding
machines which require more space and experience worker for operate the
machine.
We studied various research paper and concluded that two different
machine are expensive and so more requirement so decided that to make
combine single welding machine to fulfilled the all the requirements.
The goal of this project is to establish new knowledge for updated and
improved process planning of resistance welding in industrial applications.
The goal is expressed by required two different welding machines for
different joining welding application can be done by portable combine seam and
spot welding machine.
For developing this machine we used solid works software for designing,
modelling and finite element analysis To make working model based on the
design.
iv
Table of Contents
I Certificates i
II Acknowledgement ii
III Abstract iv
IV Table of contents 5
V List of Figures 8
VI List of Tables 9
VII List of Notations and Abbreviations 10
Chapter-1 INTRODUCTION 11-16
1.1 Introduction of welding 11
1.2 Types of Welding Process 12
1.3 RESISTANCE WELDING 13
1.4 RESISTANCE SPOT WELDING 13
1.4.1 Application of spot welding 13
1.5 RESISTANCE SEAM WELDING 14
1.5.1 Application of seam welding 15
Chapter-2 LITREATURE REVIEW 17-20
2.1 Literature review 17
Chapter-3 DESIGN AND MODELLING 21-28
3.1 RESISTANCE WELDING PARAMETERS 21
3.1.1 Heat generation 21
3.1.2 Materials for electrode and work piece 21
3.1.3. Welding cycle 21
3.2 Component requirement for Portable seam and 22
spot welding machine
3.3 3D modelling of seam and spot welding machine. 23
v
Chapter-4 FEA ANALYSIS 28
4.1 FINITE ELEMENT ANALYSIS OF 28
STRUCTURE
Chapter-5 TRANSFORMERS 29-33
5.1. INTRODUCTION 29
5.2 COMPONENTS OF TRANSFORMERS 29
5.3 PROCESS FOR MAKING OF TRANSFORMER 30
Chapter-6 PROTOTYPE 31
6.1 circuit diagram 31
6.1.1 BILL OF MATERIAL 33
6.2 COST OF EQUIPMENT 34
Chapter-7 COMPARISON 34
Chapter-8 CONCLUSION 36
REFRENCES 37
vi
List of Figure
Fig 1.1 Types of welding 2
Fig 1.2 Resistance spot welding set up 4
Fig 1.3(a) Principle of seam welding process 5
Fig.1.3(b) Seam welding process set up 5
Fig.3.1 Types of spot electrode 11
Fig.3.3 Sequence of Steps in Welding Cycle 11
Fig.3.3 Base plate
Fig.3.4 Base column 35
Fig.3.5 Rectangular and square column
Fig. 3.6 Circular plate 36
Fig 3.7 Hollow pipe 41
Fig 3.8 Spring 42
Fig 3.9 Nut and bolt 42
Fig 3.10 Copper electrode 43
Fig.3.11 Transformer
Fig 3.12 Welding wire 48
Fig 3.13 Seam wheel 48
Fig 3.14 Voltage regulator 49
Fig.3.15 Limit switch 52
Fig.4.1 Structure 53
Fig 4.2 Mesh 55
Fig 4.3 Von misses stress 55
Fig 4.4 Displacement 61
Fig 4.5 Equivalent strain 61
Fig 5.1 Stamping 27
Fig 5.2 Primary coil 28
Fig 5.3 Secondary coil 28
Fig 5.4 Insulating paper 28
Fig 5.5 Stamping 29
Fig.6.1 Circuit diagram 31
Fig. 6.2 Prototypes 32
Fig.7.1 Spot welding machine 34
Fig.7.2 Seam welding machine 34

Fig.7.3 Portable spot and seam welding machine 35
vii
List of Table
Table 4.1 Model information 21

Table 4.2 Study property 22
Table 4.3 Units 22
Table 4.4 Material Properties 22
Table 4.5 Loads and Fixtures 23
Table 4.6 Mesh information 24
Table 4.7 Resultant forces 24
Table 5.1 Voltage information 29
Table 6.1 Bill of materials 33
Table 6.2 Cost of equipment 33
Table 7.1 Comparison 34
viii
List of Notations and Abbreviations
H heat
Welding current required
R Resistance
T Time of current flow in second
K Heat losses
V Voltage
ix
Portable seam and spot welding machine I.D. 79224
CHAPTER-1
INTRODUCTION
1.1 Introduction of welding

Welding is defined as a localized coalescence of metal, wherein coalescence is
obtained by heating to suitable temperature, with or without application of pressure,
filler material. The filler metal has a melting point equal to the base of the metals.
Welding is a process for joining two similar or dissimilar metals by fusion. It joins
different metals/alloys, with or without the application of pressure and with or without
the use of filler metal.
The fusion of metal takes place by means of heat. The heat may be generated either
from combustion of gases, electric arc, electric resistance or by chemical reaction.
Welding provides a permanent joint but it normally affects the metallurgy of the
components. It is therefore usually accompanied by post weld heat treatment for most
of the critical components.
The welding is widely used as a fabrication and repairing process in industries.
Some of the typical applications of welding include the fabrication of ships, pressure
vessels, automobile bodies, off-shore platform, bridges, welded pipes, sealing of
nuclear fuel and explosives, etc.
In common words:-
Welding is a process of joining different materials.
There are about 35 welding and brazing processes and several soldering methods used
by industry today
.
1
1.2 Types of Welding Process
Welding
Pressure Fusion
welding Welding
Resistance
Cold pressure Friction
pressure
welding welding
welding
Induction Conduction
pressure pressure
welding welding
Projection Resistance Flash butt

Spot welding Seam welding
welding butt welding welding
Fig 1.1 types of welding
Unlike normal welding processes which use consumable electrodes, resistance spot
welding machine does not use consumable electrode.
In general, welding a lot of heat is generated which causes the electrode to melt and
form a Weldment however in spot welding and seam welding only a weld nugget is
formed.
2
1.3 RESISTANCE WELDING

Resistance welding processes are pressure welding processes in which heavy current
is passed for short time through the area of interface of metals to be joined.
These processes differ from other welding processes in the respect that no fluxes are
used, and filler metal rarely used.
In resistance welding the metal parts to be joined are heated by their resistance to the
flow of an electrical current.
Usually this is the only source of heat, but a few of the welding operations combine
resistance heating with arc heating, and possibly with combustion of metal in the arc.
The process applies to practically all metals and most combinations of pure metals
and those alloys, which have only a limited plastic range, are welded by heating the
parts to fusion.
In resistance welding processes, no fluxes are employed, the filler metal is rarely used
and the joints are usually of the lap type. The amount of heat generated in the
workpiece
depend on the following factors:
1) Magnitude of the current,
2) Resistance of the current conducting path
Mathematically,
H = Heat
= Welding Current Squared
R = Resistance
T = time of current flow in second
1.4 RESISTANCE SPOT WELDING

In resistance spot welding, two or more sheets of metal are held between electrodes
through which welding current is supplied for a definite time and also force is exerted
on work pieces
3
Fig 1.2 Resistance spot welding set up

In this process overlapping sheets are joined by local fusion at one or more spots, by the
concentration of current flowing between two electrodes.
This is the most widely used resistance welding process.
A typical resistance spot welding machine is shown in Fig.1.1. It essentially consists of
two electrodes, out of which one is fixed. The other electrode is fixed to a rocker arm (to
provide mechanical advantage) for transmitting the mechanical force from a pneumatic
cylinder. This is the simplest type of arrangement. The other possibility is that of a
pneumatic or hydraulic cylinder being directly connected to the electrode without any
rocker arm. Here the electrode holders and the pneumatic pressurizing system are present
in the form of a portable assembly which is taken to the place, where the spot is to be
made.
The electric current, compressed air and the cooling water needed for the electrodes is
supplied through cables and hoses from the main welding machine to the portable unit. In
spot welding, a satisfactory weld is obtained when a proper current density is maintained.
The current density depends on the contact area between the electrode and the work-
piece. With the continuous use, if the tip becomes upset and- the contact area increases,
the current density will be lowered and consequently the weld is obtained over a large
area.
1.4.1 Application of spot welding

It has applications in automobile and aircraft industries
The attachment of braces, brackets, pads or clips to formed sheet-metal parts such as
cases, covers or trays is another application of spot welding.
4
Spot welding of two 12.5 mm thick steel plates has been done satisfactorily as a
replacement for riveting.
Many assemblies of two or more sheet metal stampings that do not require gas tight or
liquid tight joints can be more economically joined by spot welding than by mechanical
methods.
Containers and boxes frequently are spot welded.
1.5 RESISTANCE SEAM WELDING

It is a continuous type of spot welding wherein spot welds overlap each other to the
desired extent. In this process coalescence at the faying surfaces is produced by the heat
obtained from the resistance to electric current (flow) through the work pieces held
together under pressure by circular electrodes.
The resulting weld is a series of overlapping resistance-spots welds made progressively
along a joint by rotating the circular electrodes. The principle of seam welding is shown
in Fig. 1.2(a) and resistance seam welding process set up is shown in Fig. 1.2(b).
The seam welding is similar to spot welding, except that circular rolling electrodes are
used to produce a continuous air-tight seam of overlapping welds. Overlapping
continuous spot welds seams are produced by the rotating electrodes and a regularly
interrupted current.
Fig 1.3(a) Principle of seam welding process Fig 1.3(b) seam welding process set up
Fig 1.4 types of seam welding

5
1.5.1 Application of seam welding

1) It is used for making leak proof joints in fuel tanks of automobiles.
2) Except for copper and high copper alloys, most other metals can be seam welded.
3) It is also used for making flange welds for use in watertight tanks.
6
CHAPTER-2
LITERATURE REVIEW
The review of literature involves the systematic identification, location, and analysis of
documents containing information related to the research problem. In this chapter
literature review is carried out in the following areas.
1) Resistance welding
2) Failure analysis of Seam welding and spot welding
1. Study on effect of electrode force on resistance spot welding process

By Kang Zhou and Lilong Cai 2014.
In this paper describe about effect of electrode force on resistance spot welding process.
As one of the most important parameter during the process, the electrode force can
influence the process in different aspects. According to theoretical analysis, large
electrode force may easily induce surface expulsion. Also, it can decrease the overall
dynamic resistance values and postpone the time when first melting point appears, as
well as enlarge the duration between times when first melting point and peak value
appear. However, the overall nugget diameter may be smaller and its growth terminates
earlier than when smaller electrode force is applied. Also, in future work, the detailed
mechanism of electrode force during the welding process can be further explored. The
integrated model combining the welding current, welding time and material
characteristics will be established for actual welding operation[1].
2. Parametric studies and finite element analysis of welded steel in resistance spot
welding process.
By Kishore, N. Sreenu. S, Ramachandran, N, Allesu. K 2014
In this paper describe about finite element analysis of weld steel in spot welding
process. Due to the contact resistance to current flow, the temperature rises
from resistance heating. When temperature reaches the desired fusing
temperature, a molten is formed, the current is shut off after a designated time
to allow the nugget to cool down and solidification of the weld spot occurs under
pressure. It is proposed to study the effect of various parameter on nugget
dimensions and strength of the weld joint in RSW and concentrating on different
7
material and thickness to get good weld joint at low cost and compared with
analytical part done in ansys[2].
3. Experimental analysis of leakages in seam welding by controlling seam welding

parameters.
By Avishi Gupta, Dr. K.M. Moeed 2015
In this paper describe about effect of different welding parameter like heat %,
cool time, type of pass, weld time, sheet thickness, and electrode force on the
leakage percentage of seam welding in transformer radiator. The seam welding is
one of the most popular welding techniques used in industries for leak proof
welding joints. The input parameters in seam welding plays a significant role in
deciding the weld quality, strength, cost and speed. Most of the times
manufacturer faces a problem to select optimum process parameters for a good
quality weld. In order to analyse leakage percentage, experimental work has
been performed[3].
4. Study of Heat affected zone in resistance welding process

By Ali. Moarrefzadeh 2012.
In this paper, the resistance welding is studied and steel temperature field is
gained in this process. The thermal effect of resistance welding that specially
depends on the electrical and temperature field of it in workpiece, is the main
key of analysis and optimization of this process. This paper reports the
determination of optimum welding conditions for butt joints of steel alloys sheet
using resistance welding. Numerical simulation of welding process in simple
method and by ansys software for gaining the temperature field of workpiece,
the effect of parameter variation on temperature field and process optimization
for different cases are done. The influence of the welding parameter for each
mode on the dimensions and shape of the weld and on their ferrite contents is
investigated [4].
8
5. New design of resistance spot welding machine for quality control.

By K.I. JOHNSON, AND J, C, NEEDHAM 1972
In this paper describe about effect of electrode load on the growth of the weld
nugget in resistance spot welding has been investigated for 0.9 mm and 1.6 mm
mild steel sheet using a specially constructed low inertia, rigid experimental
machine. It has been shown that spot welding can be made tolerant to variations
in welding current and time by automatically controlling the electrode load as a
function of the weld expansion. A compatible monitor system for weld quality
assurance is also described which utilizes the increase in load for the restrained
head system to confirm that a nugget has been established [5].
2.1 Objectives
To create a Portable 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.
9
CHAPTER-3
DESIGN AND MODELING
3.1 RESISTANCE WELDING PARAMETERS
1. Heat generation
A modification of Ohms Law may be made when watts and heat are considered
synonymous. When current is passed through a conductor the electrical resistance of
the conductor to current flow will cause heat to be generated. The basic formula for
heat generation may be stated[6].
(3.1)
H = Heat
R = Resistance
The key fact is, although current value is the same in all parts of the electrical circuit,
the resistance values may vary considerably at different points in the circuit. The heat
generated is directly proportional to the resistance at any point in the circuit [6].
2. Materials for electrode and work piece
The physical metallurgy of the materials to be welded determines the application of
the resistance welding process variables.
In general, there are two categories of metals to be welded Conductive (such as
aluminium, copper, silver and gold), and Resistive (steel, nickel, inconel, titanium,
tungsten, molybdenum) With a third, small, middle ground category occupied
primarily by brass.
The rule of opposites applies to matching electrodes to workpieces to be welded.
The general rule (with a few exceptions such as aluminium and beryllium copper) is
to utilize conductive electrodes against resistive parts and resistive electrodes against
conductive parts [6].
By extension, when welding dissimilar materials, the upper and lower (or anode and
cathode) electrodes must be of different materials to each other in order to apply the
rule of opposites.
10
Fig 3.1 types of spot electrode
3. Welding cycle
The welding time cycle is a series of discrete time events as shown in Figure3.1
Fig 3.2 Sequence of Steps in Welding Cycle

Squeeze Time
During the squeeze time, the welding electrodes are moved together and the force is
applied from the pressure chamber. The pressure will force the work pieces together
to build up the necessary resistance for the welding process. If there is less squeeze
time, the welding current will start flowing before the work pieces are tightly joined
together. This will cause overheating, spatter, electrode wear and, eventually, a
defective weld.
Heat or weld Time
The weld time is the time during which a set amount of current flows through the
work pieces. If this time is large, expulsion will take place, which means that the
11
molten metal is expelled from the welding nugget as a shower of sparks. On the other
hand, if this time is less cold weld is obtained, or sometimes no welding nugget is
formed [7].
Hold time
This is the time after the application of the current, pressure is applied so that the
work pieces are held tightly together to form a welding nugget [7].
Off time
During this time the pressure is released and the electrodes are separated for the
next spot weld [7].
Welding time
Resistance welding depends on the resistance of the base metal and the amount of
current flowing to produce the heat necessary to make the spot weld. Another
important factor is time. In most cases, several thousand amperes are used in making
the spot weld. Such amperage values, flowing through a relatively high resistance,
will create a lot of heat in a short time [7].With the addition of the time element, the
formula is completed as follows:
... (3.2)
H = Heat
R = Resistance
T = Time
K = Heat losses
4. Pressure
The effect of pressure on the resistance Welding should be carefully considered. The
primary purpose of pressure is to hold the parts to be welded in intimate contact at the
joint interface. This action assures consistent electrical resistance and conductivity at
the point of weld.
12
5. Electrode tips
Copper is the base metal normally used for resistance spot welding tongs and tips.
The purpose of the electrode tips is to conduct the welding current to the work piece,
to be the focal point of the pressure applied to the weld joint, and to conduct heat from
the work surface. The tips must maintain their integrity of shape and characteristics of
thermal and electrical conductivity under working conditions. Electrode tips are made
of copper alloys and other materials [7].
6. Welding Force
The pressure exerted by the tongs and the electrode tips on the work piece has a great
effect on the amount of weld current that flows through the joint. The greater the
pressure, the higher the welding current value will be, within the capacity of the
resistance spot welding machine. Setting pressure is relatively easy.
3.2 Component requirement for Portable seam and spot welding machine.
1. Base Plate
13
Fig 3.3base plate

We use mm mild steel plate for base
2. Wheels
Fig 3.4 base wheel

We use 4 base wheel for easy to move machine one place to another place
3. Square and Rectangular column
14
Fig 3.5 Rectangular & Square column
We use rectangular and square column for structure which material is mild steel
which is less cost and high strength.
Dimension of rectangular column is mm. and for square column
mm.
4. Circular plate
Fig 3.6 circular plate
15
In this project, we use mild steel circular plate which has 2 mm thickness. It is used to
fix copper electrode.
5. Hollow pipe
Fig 3.7 hollow pipe
6. Compression spring
16
Fig 3.8 spring

In this project, we use spring to applied pressure of upper electrode.
7. Nut and bolt
Fig 3.9 nut & bolts

8. Copper electrode
17
Fig 3.10 Copper electrode

We use two copper electrodes for spot welding which has 16mm diameter and 150
mm equal Hight.
9. Transformers
Fig 3.11 transformers

10. Wire for main current supply
Fig 3.12 welding wire
18
11. Seam Wheel
Fig 3.13 seam wheel

We use seam wheel for seam welding. We use copper wheel which has two different
dimension upper wheel has a 130-mm diameter and lower wheel has 76-mm diameter
both wheel has same thickness around 7mm.
12. Voltage regulator
Fig 3.14 voltage regulator
19
13. Limit switch
Fig 3.15 Limit switch
3.3 3D modelling of seam and spot welding machine.
Fig 3.14 3d model of seam and spot welding machine.

20
CHAPTER-4
FINITE ELEMENT ANALYSIS
4.1 FINITE ELEMENT ANALYSIS OF STRUCTURE
Model Information
Model name: Part1 Structure

Fig 4.1 structure
Solid Bodies
Document Name and Treated As Volumetric Properties Document Path/Date
Reference Modified
Combine3 Solid Body Mass:25.835 kg F:\document\udp\3D
Volume:0.00327025 m^3 MODEL\welding
Density:7900 kg/m^3 machine\Part1
Weight:253.183 N Structure.SLDPRT
Mar 06 21:50:44 2017
Table no 4.1 model information
Study Properties
Study name Static 3
Analysis type Static
Mesh type Solid Mesh
Thermal Effect: On
Thermal option Include temperature loads
Zero strain temperature 298 Kelvin
Include fluid pressure effects from Off
SOLIDWORKS Flow Simulation
Solver type FFEPlus
Inplane Effect: Off
21
Soft Spring: Off

Inertial Relief: Off
Incompatible bonding options Automatic
Large displacement Off
Compute free body forces On
Friction Off
Use Adaptive Method: Off
Result folder SOLIDWORKS document (F:\document\udp\3D
MODEL\welding machine)
Table no 4.2 study properties
Units
Unit system: SI (MKS)
Length/Displacement Mm
Temperature Kelvin
Angular velocity Rad/sec
Pressure/Stress N/m^2
Table no 4.3 units
Material Properties
Model Reference Properties Components
Name: AISI 1020 SolidBody
Model type: Linear Elastic 1(Combine3)(Part1
Isotropic Structure)
Default failure Unknown
criterion:
Yield strength: 3.51571e+008
N/m^2
Tensile strength: 4.20507e+008
N/m^2
Elastic modulus: 2e+011 N/m^2
Poisson's ratio: 0.29
Mass density: 7900 kg/m^3
Shear modulus: 7.7e+010 N/m^2
Thermal expansion 1.5e-005 /Kelvin
coefficient:
Table no 4.4 material properties
22
Loads and Fixtures

Fixture name Fixture Image Fixture Details
Fixed-1 Entities: 1 face(s)
Type: Fixed Geometry
Resultant Forces
Components X Y Z Resultant
Reaction force(N) 86.3372 594775 -646.294 594775
Reaction Moment 0 0 0 0
(N.m)
Load name Load Image Load Details

Pressure-1 Entities: 1 face(s)
Type: Normal to
selected face
Value: 35
Units: N/mm^2 (MPa)
Phase Angle: 0
Units: deg
Table no 4.5 load and fixtures
23
Mesh information Details

Total Nodes 48272
Total Elements 24877
Maximum Aspect Ratio 76.393
% of elements with Aspect Ratio < 3 29
% of elements with Aspect Ratio > 10 11.8
% of distorted elements(Jacobian) 0
Time to complete mesh (hh; mm;ss): 00:00:22
Computer name: AKASH
Table no 4.6 mesh information
Mesh Quality Plots
Name Type Min Max

Mesh Quality1 Aspect Ratio 1.1036 76.3935
Element: 21097 Element: 10901
Fig 4.2 mesh
Resultant Forces
Reaction forces
Selection set Units Sum X Sum Y Sum Z Resultant
Entire Model N 86.3372 594775 -646.294 594775
Reaction Moments
Selection set Units Sum X Sum Y Sum Z Resultant
Entire Model N.m 0 0 0 0
Table no 4.7 Resultant force
24
Study Results
Name Type Min Max
Stress1 VON: von Mises 176.691 N/m^2 1.17646e+011 N/m^2
Stress Node: 20411 Node: 10198
Fig 4.3 Von Mises stress
Name Type Min Max

Displacement1 URES: Resultant 0 mm 2875.75 mm
Displacement Node: 227 Node: 288
Fig 4.4 displacement
Name Type Min Max

Strain1 ESTRN: Equivalent Strain 7.59299e-010 0.479498
25
Element: 18543 Element: 18161
Fig 4.5 Equivalent strain
26
CHAPTER-5
TRANSFORMERS
5.1 INTRODUCTION
A transformer is a static device consisting of a winding, or two or more coupled
windings, with or without a magnetic core, for inducing mutual coupling between
circuits.
Transformers are exclusively used in electric power systems to transfer power by
electromagnetic induction between circuits at the same frequency, usually with
changed values of voltage and current.
In this project, we use single phase transformers. A single-phase two-winding
transformer is nothing more than a primary and a secondary winding wound around
the same magnetic core. Single-phase two-winding transformers can be used in either
single-phase circuits or polyphase circuits. A polyphase two-winding transformer
contains a number of sets of primary and secondary windings. Each set wound around
a separate magnetic core leg.
5.2 COMPONENTS OF TRANSFORMERS
1. 16 number F type stamping of MS sheet. Around 8-12 kg of stamping is required for
transformer.
Fig 5.1 stamping
27
2. Copper wire of 18 gauge
Fig 5.2 primary coil Fig 5.3 secondary coil
3. Insulating paper
Fig 5.4 Insulating paper

4. Plastic cap having numbers
5. Wooden bobbin
6. Cotton tape
5.3 PROCESS FOR MAKING OF TRANSFORMER
For Primary winding
First of all, we select a bobbin of required dimension, then we fix this bobbin on the
winding machine.
After that the copper wire is wound around this bobbin which is fixed on the machine.
The machine rotates the bobbin.
An automatic counting machine is fixed on the other end which counts the number of
times the bobbin rotates.
After the first turn we put an insulating paper so that the copper wire does not touch
other layer and the process is repeated.
28
Tapping comes out for following number of term:

1) 1st Tapping at 0-115 turns
2) 2nd Tapping at 115-130 turns
3) 3rd Tapping at 130-150 turns
4) 4th Tapping at 150-170 turns
Taping is used for varying power. The single wire at end of n number of turns is
doubled and is tapped by a plastic cap. For a particular set of tapped wire an
insulating tape is wound, which represents the number of wires.
Voltage calculation for primary and secondary coil.
No. of tapping No. of turns o/p voltage
1 170 5.2
2 150 5.8
3 130 6.8
4 115 7.7
Table no 5.1 Voltage calculation

Calculation for primary coil: -
7.5757575 (core area) ( )
Fig 5.5 stamping

Calculation for secondary coil: -
0.7014 ( ) on secondary coil
If we need 6 V o/p = 4.2 turn required on secondary coil
29
For Secondary winding

After the 4th taping, the coated copper strip is wounded 4 times over the layer of
copper wires.
An insulating paper is provided between primary and secondary winding.
After the 4rd turn of the copper strip, the bobbin is removed from the winding
machine. The windings are placed over a wooden bobbin and hammered against it to
get required shape. After wooden bobbin is removed, the windings are covered with
the insulating tape.
Two F type stampings are selected and inserted between the insulated windings, and
then another two F type stampings are inserted between the windings in reversed
manner and fixed in between. The process is repeated until the gap of wooden bobbin
is filled with stampings.
The gap is filled after which the stampings are inserted in a correct manner so as to
create a perfect alignment around the coil. The stampings are joined together with nut
and bolts.
After nut and bolts are fixed the transformer is ready.
30
CHAPTER-6
PROTOTYPE
6.1 circuit diagram
Fig 6.1 circuit diagram
31
FIG 6.2 Prototypes
32
6.1 BILL OF MATERIAL
Item No. Part Name Description Qty.

1 Base Plate MS 1
2 Rectangular Column MS 2
3 Square Column MS 3
4 Circular Plate MS 3
5 Hollow Pipe MS 1
6 Compressed Spring MS 1
7 Spot electrode Copper 2
8 Seam Roller Copper 2
9 Insulator fiber 1
Table no 6.1 bill of materials
6.2 COST OF EQUIPMENTS
Sr no. Materials Rupees

1 Copper wire 690
2 Sheet Metal 410
3 Rectangular column 400
4 Stamping 650
5 spring 40
6 Copper Electrode 350
7 Seam Roller 1000
8 Controller 500
9 Accessories 160
10 Welding wire 600
11 Brass 190
Total 4990
Table no 6.2 cost of equipment
33
CHAPTER-7
COMPARISON
Fig 7.1 spot welding machine Fig 7.2 seam welding machine
General equipment Our equipment

Complex design Simple Design
Foundation required Foundation not required
Difficult handling Easy handling
Experienced worker Less skilled worker
Stationary equipment Portable equipment
Occupies more floor area Very less area occupied
deferent machine require as per all application to be perform
application
costly Economic
Heavy weight(more than 200kg) Light in weight(15 kg)
Table 7.1 comparison
34
Fig 7.3 portable seam and spot welding machine
35
CHAPTER-8
CONCLUSION
This project provides a low cost portable spot and seam welding machine in comparison to
present resistance spot and seam welding machine which is costly, occupies larger floor
area, of complex design, can only be used by an experienced worker. The present
equipment is rigid; foot operated and weighs nearly above 200 kilos.
In this project we have removed the above said problems by creating a much simpler,
lighter, portable, compact, flexible and combine seam and spot both can be done in one
machine which is able to weld and can be easily operable by a less experienced worker with
much ease and required accuracy.
The advantages of our equipment are as

follows:-
Provide flexibility
Less costly
Compact
Provide ease of operation to welder and
Less weight.
Combine of seam and spot welding machine
We conclude that our machine can be mass produced and can also be
m u l t i p u r p o s e used for industrial purposes.
36
REFERENCES
[1] Kang Zhou and Lilong Cai Study on effect of electrode force on resistance
spot welding process 2014
[2] Kishore, N. Sreenu. S, Ramachandran, N, Allesu. K Parametric studies and
finite element analysis of welded steel in resistance spot welding process 2014
[3] Avishi Gupta, Dr. K.M. Moeed Experimental analysis of leakages in seam
welding by controlling seam welding parameters 2015
[4] Ali. Moarrefzadeh Study of Heat affected zone in resistance welding process
2012
[5] K.I. JOHNSON, AND J, C, NEEDHAM New design of resistance spot

welding machine for quality control 1972
[6] Welding technology by O.P. Khanna

[7] Manufacturing technology by Rajender Singh
37

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PORTABLE SEAM AND SPOT WELDING MACHINE

PORTABLE SEAM AND SPOT WELDING MACHINE

Sr No. Name Enrollment no

1 Parmar Ashwin S. 130670119005

UNDER THE GUIDANCE OF

In Fulfilment for the award of the degree of

SAL INSTITUTE OF TECHNOLOGY AND ENGINEERING

Internal Guide Head of Department External Guide

Manufacturing engineering in general has experienced an increased

Fig.6.1 Circuit diagram 31

Fig. 6.2 Prototypes 32

Fig.7.1 Spot welding machine 34

Fig.7.2 Seam welding machine 34

Table 4.1 Model information 21

1.1 Introduction of welding

1.2 Types of Welding Process

Projection Resistance Flash butt

Fig 1.1 types of welding

1.3 RESISTANCE WELDING

1.4 RESISTANCE SPOT WELDING

Fig 1.2 Resistance spot welding set up

1.4.1 Application of spot welding

1.5 RESISTANCE SEAM WELDING

Fig 1.4 types of seam welding

1.5.1 Application of seam welding

1. Study on effect of electrode force on resistance spot welding process

3. Experimental analysis of leakages in seam welding by controlling seam welding

4. Study of Heat affected zone in resistance welding process

5. New design of resistance spot welding machine for quality control.

= Welding Current Squared

Fig 3.1 types of spot electrode

Fig 3.2 Sequence of Steps in Welding Cycle

= Welding Current Squared

Fig 3.3base plate

Fig 3.4 base wheel

Fig 3.5 Rectangular & Square column

Fig 3.6 circular plate

Fig 3.7 hollow pipe

Fig 3.8 spring

Fig 3.9 nut & bolts

Fig 3.10 Copper electrode

Fig 3.11 transformers

Fig 3.12 welding wire

11. Seam Wheel

Fig 3.13 seam wheel

Fig 3.14 voltage regulator

13. Limit switch

Fig 3.15 Limit switch

3.3 3D modelling of seam and spot welding machine.

Fig 3.14 3d model of seam and spot welding machine.

4.1 FINITE ELEMENT ANALYSIS OF STRUCTURE

Model name: Part1 Structure

Table no 4.1 model information

Soft Spring: Off

Loads and Fixtures

Load name Load Image Load Details

Mesh information Details

Name Type Min Max

Fig 4.2 mesh

Fig 4.3 Von Mises stress

Name Type Min Max

Fig 4.4 displacement