FINAL YEAR PROJECT REPORT (14, times new roman, center, caps)

ON (12, times new roman, center, bold, caps)

DESIGN AND FABRICATION OF SPOT WELDING MACHINE (14pt)

(AUG 2014 DEC 2014) (12, times new roman, center, caps)

SUBMITTED FOR (12, times new roman, center, caps)

THE PARTIAL FULFILMENT OF THE AWARD OF
THE DEGREE OF
B.TECH (MECHANICAL & AUTOMATION ENGINEERING) (12, times roman, center, caps)

Prepared by: (12, times new roman, center, bold, caps)

SAJAL MATHUR
NISHANT VIRMANI
CHETAN PRATAP
SHRUTI CHAUHAN
PAWAN KUMAR

082/BTechMAE/ASET/03
04/LE/BTechMAE/ASET/04
01/LE/BTechMAE/ASET/04
009/BTechMAE/ASET/03
057/BTechMAE/ASET/03

UNDER THE SUPERVISION OF

MR. PANKAJ SINGH

AMITY SCHOOL OF ENGINEERING & TECHNOLOGY (14pt)

BIJWASAN, NEW DELHI-110061 (12, times new roman, center, caps)

Affiliated to (12, times new roman, center)

GURU GOBIND SINGH INDRAPRASTHA UNIVERSITY (14, bold, times roman, center)
SECTOR 16 C DWARKA, NEW DELHI -110075
DEPARTMENT OF MECHANICAL & AUTOMATION ENGINEERING

ACKNOWLEDGEMENT

Final year (7TH Semester) project is an indispensable part of any engineering curriculum. It
provides the students with an opportunity to gain experience on the practical application of their
technical knowledge.
We express our gratitude to Prof. B.P.Singh, Senior Director, Amity school of Engineering &
Technology Dr. (Prof) Rekha Agrawal, Director, Amity school of Engineering & Technology,
Mr. Manander Singh, HOD, Department of Mechanical and Automation Engineering and all the
faculty members at Amity School of Engineering and Technology (ASET) who have helped us
at every juncture of our project. We have no doubt that this project has helped us gain much
practical knowledge and the experience has been unique.
We would like to thank Mr. Pankaj Singh, Assistant Professor, Department of Mechanical and
Automation Engineering for giving us this opportunity to work under his guidance on this
project. His technical help and goal oriented approach has been unique and a stepping stone
towards the successful completion of our project.
We would also like to thank Mr.Aditya K.Singh, Lab Superintendent, Mr. B.S. Mehta ,Mr.
Satendra Singh and Shushil Singh lab. Attendant of the Mechanical Lab at ASET for
guiding us and helping us on many occasions during the design and manufacturing of our
project.

CERTIFICATE

This is to certify that the Final year Project entitled, Design & Fabrication of Spot Welding
Machine has been submitted to the Department of Mechanical & Automation Engineering of
Amity School of Engineering & Technology, New Delhi, by Nishant Virmani, Sajal Mathur,
Chetan Pratap, Shruti Chauhan and Pawan Kumar for partial fulfillment of the award of
degree, Bachelor of Technology in Mechanical & Automation Engineering. The work is a record
of genuine work carried out by them under our guidance and supervision and fulfills all
requirements for the submission of the thesis, which has required standard.
The matter embodied in this dissertation has not been submitted in part or full to any other
university or institute for the award of any degree or diploma.

Mr. Pankaj Singh

Mr. Manander Singh

Project Guide

H.O.D

Department of MAE

Department of MAE

ABSTRACT
Design and Fabrication of a Spot Welding Machine

Sheet metal stampings have now replaced many components which were earlier cast or machined.
Material economy & the resultant reduction in weight & cost , high productivity, use of unskilled
labour, & a high degree of possible precision have rendered press work indispensable for many
mass produced goods such as electronic appliances, steel furniture, utensils & vehicles. The entire
top of the car can be finished to size from a single metal sheet.

Sophisticated sheet components need to be welded together to perform various functions. The most
common type of method used is the Resistance Welding and Spot Welding is one of this method.

Our project is to design and fabricate a spot welding machine so as to weld various metal sheets of
gauges varying from 26 *gauge (0.457mm) to 38 *gauge (0.1524mm). It utilizes a simple
mechanism to create a spot or a nugget between the two sheets to be welded. The sheets to be
welded are held in between the two electrodes and pressure is applied at the point of weld. Current
of the value ranging from 4000-10000 Ampere passes through it and a lot of heat is generated due
to the resistance offered by the workpiece.

Experimental work includes the study of variations of quality of the weld with the variation in
current, time and the thickness of the sheets.

*Single gauge is equivalent to 7.62mm.

CONTENTS
1.

GENERAL INTRODUCTION
1.1
1.2
1.3

1.4

Introduction
Types of Welding
Resistance Welding
1.3.1 Spot Welding
1.3.2 Principle
1.3.3 Factors Affecting Spot Welding
Surface Conditions
1.4.1 Materials for welding
1.4.2 Summary
Applications

1.5

2. EXPERIMENTAL SETUP
2.1.
2.2.

2.3.

Introduction
Mechanical Components
2.2.1 Frame arrangement
2.2.2 Lever arrangement
2.2.3 Electrodes and Tongs
Electrical Components
2.3.1 Transformer
2.3.2
Electrical connections

3.

7
7
8
9
9
10
11
12
14
14
15
.15
.15
.15
.17
.18
.19
.20
.23

DESIGNING
3.1.

Frame design
3.1.1 Column under buckling
3.1.2
Beams under deflection
3.1.3
Bolts under shearing
Electrode design
Lever design

3.2
3.3
4.

24
.....24
.24
.26
.27
27
28

FABRICATION
4.1.
4.2.
4.3.

5.

Frame
Lever
Tongs and Electrodes

EXPERIMENTAL WORK

32
..32
..33
.34

35

6.

CONCLUSION AND LIMITATION

43

7.

FUTURE SCOPE FOR IMPROVEMENT

44

REFERENCES

45

APPENDIX A : AUTOCAD DRAWINGS

46

APPENDIX B : WELDED SAMPLES

50