DESIGN,DEVELOPMENT,OPTIMIZATION &ANALYSIS OF RESISTANCE SPOT WELDING

Resistance welding is fusion welding process in which a very high current & low voltage is passes through weld for shorter time. Due to this amperage heats the part due to the contact resistance and melts it. In this process pressure on to the joint has been maintained continuously & fused metal combine together. The sch. representation of the resistance welding process is shown in figure. The main requirement of the process is the low voltage and high current power supply. This is obtained by means of step down transformer with a provision to have different tapings on the primary side. The secondary winding's are connected to the electrodes, which are made of copper to reduce their electrical resistance. The time of electric supply needs to be closely controlled so that the heat released is just enough to melt the joint and the subsequent fusion takes place due to the force (forge welding on the joint). Force required can be provided either mechanically, hydraulically or pneumatically. This experimental study is based on an investigation of the effect and optimization of welding parameters. The combination of the optimum welding.The different parameters of welding process such as welding current, welding voltage, wire diameter s input parameters and welding time as output parameter is considered. Effective utilization of resources with efficient output is desirable. Thermal Analysis with heat flux provides firm base to the optimization parameters.