A PROJECT REPORT ON

“DESIGN AND FABRICATION OF SEAM WELDING MACHINE”

Submitted by

Guided by
In Fulfilment for the award of the degree
of
BACHELOR OF ENGINEERING
in

Gujarat Technological University, Ahmedabad

 ABSTRACT

The aim of the project is to design a resistance seam welding machine; resistance seam welding
is a process that produces a weld at the faying surfaces of two similar metals. The seam may be
a butt joint or an overlap joint and is usually an automated process. It differs from butt welding
in that butt welding typically welds the entire joint at once and seam welding forms the weld
progressively, starting at one end. Like spot welding, seam welding relies on two electrodes,
usually made from copper, to apply pressure and current. The electrodes are disc shaped and
rotate as the material passes between them. This allows the electrodes to stay in constant contact
with the material to make long continuous welds. The electrodes may also move or assist the
movement of the material.

A transformer supplies energy to the weld joint in the form of low voltage, high current AC
power. The joint of the work piece has high electrical resistance relative to the rest of the circuit
and is heated to its melting point by the current. The semi-molten surfaces are pressed together
by the welding pressure that creates a fusion bond, resulting in a uniformly welded structure.
Most seam welders use water cooling through the electrode, transformer and controller
assemblies due to the heat generated. Seam welding produces an extremely durable weld
because the joint is forged due to the heat and pressure applied. A properly welded joint formed
by resistance welding is typically stronger than the material from which it is formed.
Team Id: 23699 INTRODUCTION

INDEX
ABSTRACT ............................................................................................................................................................. 2

CHAPTER-1 INTRODUCTION ................................................................................................................................. 5

1.1 General Outline:....................................................................................................................... 5
1.2 Problem Definition: .................................................................................................................. 8
1.3 Introduction: ............................................................................................................................ 8
1.4 Working Principle: .................................................................................................................... 9
1.5 Types of seam welding: .......................................................................................................... 11
1.6 Advantages: ........................................................................................................................... 14
1.7 Limitations: ............................................................................................................................ 14
1.8 Applications: .......................................................................................................................... 14

CHAPTER-2 LITERATURE SURVEY ........................................................................................................................ 15

2.1 Literature Survey on “PARAMETRIC OPTIMIZATION OF SEAM WELDED AISI 1015 MILD
STEELFOR NUGGET WIDTH” ..................................................................................................... 15
2.2 Literature Survey on “A STUDY OF DIFFERENT PARAMETERS OF THE SEAM WELDING PROCESS
FOR REDUCING WELDING CURRENT” ....................................................................................... 17
2.3 Literature on “EXPERIMENTAL ANALYSIS OF LEAKAGES IN SEAM WELDING BY CONTROLLING
SEAM WELDING PARAMETERS” ................................................................................................ 18

CHAPTER-3 OJECTIVE OF WORK AND WORK PLAN.............................................................................................. 19

3.1 Objectives of Work: ................................................................................................................ 19

3.2 Work Plan: ............................................................................................................................. 20
3.3 Market Survey: ....................................................................................................................... 22

CHAPTER-4 DESIGN AND MODELLING ................................................................................................................. 23

4.1 Sketches on Papers:.......................................................................................................... 23
4.2 Designing in Parametric Software:..................................................................................... 23

CHAPTER-5 TECHNICAL OVERVIEW ..................................................................................................................... 27

5.1 Working: .............................................................................................................................. 27

5.2 Operation of Seam Welding: ................................................................................................. 28

5.3 Important aspects of Seam Welding: ...................................................................................... 30

CHAPTER-6 COST ESTIMATION............................................................................................................................ 31

6.1 Bill of Materials:..................................................................................................................... 31

CHAPTER-7 CONCLUSION AND FUTURE SCOPE ................................................................................................... 32

7.1 Conclusion:........................................................................................................................... 32
7.2 Future Scope: ....................................................................................................................... 32

REFERENCES........................................................................................................................................................ 33
Team Id: 23699 INTRODUCTION

FIGURES
1.1 Conventional wide wheel seam welding ............................................................................................ 5
1.2 Different types of weld nuggets in seam welding .............................................................................. 7
1.3 Resistance Seam Welding ................................................................................................................. 9
1.4 Working ......................................................................................................................................... 10
1.5 Wide wheel seam ............................................................................................................................ 11
1.6 Narrow weld seam .......................................................................................................................... 12
1.7 Consumable wire seam ................................................................................................................... 12
1.8 Mesh seam welding ........................................................................................................................ 13
1.9 Foil butt seam welding .................................................................................................................... 13
3.1 Work Plan ...................................................................................................................................... 20
4.1 2D Drawing of model ..................................................................................................................... 24
4.2 Base Table ...................................................................................................................................... 24
4.3 Work-piece holding mechanism ...................................................................................................... 25
4.4 Roller ............................................................................................................................................. 25
4.5 Gear ............................................................................................................................................... 26
5.1 Working ......................................................................................................................................... 27
5.2 Seam Welding Setup....................................................................................................................... 28
5.3 Operation of Seam Welding ............................................................................................................ 29

TABLES
Table 2.1 Literature Review - I ............................................................................................................. 16
Table 2.2 Literature Review - II ............................................................................................................ 17
Table 2.3 Literature review - III ............................................................................................................ 18
Table 4.1 Designed Parts ...................................................................................................................... 23
Table 6.1 Bill of Materials .................................................................................................................... 31
Team Id: 23699 INTRODUCTION

CHAPTER-1 INTRODUCTION
1.1 General Outline:
The seam welding process is an adaptation of resistance spot welding and
involves making a series of overlapping spot welds by means of rotating copper alloy
wheel electrodes to form a continuous leak tight joint. The electrodes are not opened
between spots. The electrode wheels apply a constant force to the work pieces and rotate
at a controlled speed. The welding current is normally pulsed to give a series of discrete
spots, but may be continuous for certain high speed applications where gaps could
otherwise occur between individual spots. Seam welding equipment is normally fixed
and the components being welded are manipulated between the wheels. The process may
be automated; see below.

1.1 Conventional wide wheel seam welding

Resistance seam welding is a process that produces a weld at the faying surfaces
of two similar metals. The seam may be a butt joint or an overlap joint and is usually an
automated process. It differs from butt welding in that butt welding typically welds the
entire joint at once and seam welding forms the weld progressively, starting at one end.
Like spot welding, seam welding relies on two electrodes, usually made from copper, to
apply pressure and current. The electrodes are often disc shaped and rotate as the
material passes between them. This allows the electrodes to stay in constant contact with
the material to make long continuous welds. The electrodes may also move or assist the
movement of the material.
Team Id: 23699 INTRODUCTION

A transformer supplies energy to the weld joint in the form of low voltage, high
current AC power. The joint of the work piece has high electrical resistance relative to
the rest of the circuit and is heated to its melting point by the current. The semi-molten
surfaces are pressed together by the welding pressure that creates a fusion bond,
resulting in a uniformly welded structure. Most seam welders use water cooling through
the electrode, transformer and controller assemblies due to the heat generated.

Seam welding produces an extremely durable weld because the joint is forged
due to the heat and pressure applied. A properly welded joint formed by resistance
welding can easily be stronger than the material from which it is formed.

A common use of seam welding is during the manufacture of round or

rectangular steel tubing. Seam welding has been used to manufacture steel beverage cans
but is no longer used for this as modern beverage cans are seamless aluminum.

There are two modes for seam welding: Intermittent and continuous. In
intermittent seam welding, the wheels advance to the desired position and stop to make
each weld. This process continues until the desired length of the weld is reached. In
continuous seam welding, the wheels continue to roll as each weld is made.

Resistance seam welding is a simple process that uses one or two wheels to apply
pressure to the surface of two or more layers of conductive material. As the wheels roll,
electric energy is applied using a capacitive discharge, high frequency, or line frequency
weld controller in precise amounts to form a joint between the faying surfaces of the
material. The resistance seam weld process is a fast, reliable and low cost way to join
many materials. Like most joining methods, it competes with other technologies like
laser and TIG welding. This article explores the joint types and the common
configurations to used form seam welds on small scale parts.

Whether the seam weld is longitudinal, circular, or a unique planar contour, the
weld nugget is formed in one of three ways:

a) Roll spot

b) Overlapping spot

c) Continuous seam
Team Id: 23699 INTRODUCTION

The roll spot type occurs when there are distinct separations between the nuggets
as the roller walks across the surface. If the weld schedule is fired at a constant repetition
rate, the cross‐section result looks like that shown in Figure

1.2 Different types of weld nuggets in seam welding

Obviously, if one maintains the linear velocity, but increases the firing rate, the
spots will get closer and closer together until they overlap. This is called overlap spot
welding and creates a hermetic (i.e. leak tight) joint between the materials as depicted in
Figure. The overlap spot weld technique is very effective at joining thin materials (i.e. <
0.015” thick) without burn through. Continuous seam welding occurs when a constant
stream of energy is applied to the rollers. This results in a joint like that in Figure 1(c).
Regardless of the type used, the electrodes are not opened between spots which results in
a high speed joining process.

Typical linear velocities for small scale resistance seam welding range from 0.2
to 1.0 in/sec and depend on the material type, part thickness, and weld schedule (one or
two pulse) used. The roller forces usually range from 5 to 75 lbs for thin materials, about
5 to 10 times that for a comparable pointed spot weld electrode using the same material
thickness. The higher force is due to the additional surface area of the roller when
compared to a straight electrode tip.
Team Id: 23699 INTRODUCTION

1.2 Problem Definition:

Seam welding produces an extremely durable weld because the joint is forged
due to the heat and pressure applied. A properly welded joint formed by resistance
welding is typically stronger than the material from which it is formed. Resistance seam
welding has a wide range of applications.

So, we took our project title as “DESIGN AND DEVELOPMENT OF SEAM

WELDING MACHINE.” This machine will be having low cost and low maintenance so
every industrialist can afford it.

1.3 Introduction:
Resistance seam welding (RSW) is a resistance welding process which produces
coalescence at the faying surfaces the heat obtained from resistance to electric current
through the work parts held together under pressure by electrodes or a type of continuous
weld made between or upon overlapping metal parts. The resulting weld is a series of
overlapping resistance spot welds made progressively along a joint by rotating the
electrodes. Resistance seam welding is another variation on resistance spot welding. In
resistance seam welding, the welding electrodes are motor driven wheels rather than
stationary caps. This results in a “rolling” resistance weld or seam weld. There are two
modes for seam welding: Intermittent and continuous. In intermittent seam welding, the
wheels advance to the desired position and stop to make each weld. This process
continues until the desired length of the weld is reached. In continuous seam welding,
the wheels continue to roll as each weld is made.
Team Id: 23699 INTRODUCTION

1.3 Resistance Seam Welding

1.4 Working Principle:

Seam welding is the one type of resistance welding and also another modification
of spot welding. The basic chief difference of spot weld and seam weld is that the
formation of electrode. They are usually power driven and rotate whilst gripping the
work. The current is supplied through the rotatable wheel and melt the metal. The edges
of the two sheets must be overlap, so that the welding heat can be developed in joining
interface of the sheet metal. The large manufacturing of cylindrical container, drum,
pipe, etc. is best suited by these types of welding.

When the body is being performed into a tube, the overlapping edge made in
united piece which is called longitudinal welding and the end position fitted of assembly
work welding is called circumferential welding.
Team Id: 23699 INTRODUCTION

The use of seam welding is mainly designated for the thin sheet metal; the sheet
metal often welded which should not exceed 1/8 inch. The welding speed may vary with
the sheet gauge. The special machines are employed for the faster welding speed. In the
bellow diagram the basic principle of seam welding is shown.

1.4 Working

Generally two types of seam welding machines found 1) Circumferential Seam

Welding Machine 2) Longitudinal Seam Welding Machine. They are called because of
the types of welding joint performance. Although the Universal Seam Welding Machine
can perform both operation. By the changing of electrode assembly the circumferential
welding can be converted into longitudinal welding.

In the seam welding operation, the sheets to be welded are properly overlapped
and positioned between the both rollers. The clamp may be provided for the holding
properly and applying the pressure. A current is provided through rollers to the material
contact with them. The sufficient heat is produced and material reached in plastic stage.
The welding operation is done by pressure applied with both rollers and applied current.
Team Id: 23699 INTRODUCTION

Another important factor is roller cooling efficient. The huge amount of heat is
developed through the rollers, so its required sufficient cooling system, which is increase
the life of roller electrodes. The removal of heat from region of the work the special type
roller is used. Which is cooling system is provided. After a short period of use the edges
of the electrodes require trimming, the trimming operating cannot be obtained by filling
operation. The trimming or re-shaping operation of copper alloy electrode properly can
be done with lathe machining. Another process to reshaping the electrode fit into the
roller machine, which have plus point is no material loss happened. The self trimming
device is widely used which is which keeps the edge of electrode constantly good
condition.

1.5 Types of seam welding:

 Wide wheel seam
 Narrow wheel seam
 Consumable wire seam welding
 Mash seam welding
 Foil butt seam welding

Wide wheel seam:

• Wheel contact width normally 5√ t mm flat (where t is single sheet thickness in mm).

• General purpose welding (domestic radiators up to about 6 m/min).

1.5 Wide wheel seam

Team Id: 23699 INTRODUCTION

Narrow wheel seam

• Wheel contact shape typically 6mm radius.

• Knurl drive on wheel edge with contact surface continuously planished.

• Controls electrode contamination when welding coated steels, such as for vehicle fuel
tanks.

1.6 Narrow weld seam

Consumable wire seam welding

• Shaped, consumable copper wire fed between the wheels and sheets to be joined to
give consistent clean contact.

• Used for welding coated steels such as tin cans and vehicle fuel tanks.

1.7 Consumable wire seam

Team Id: 23699 INTRODUCTION

Mash seam welding

• Narrow overlap of sheet edges, which are partly crushed together during welding.

• High speed welding of tin cans and drums (0.2mm tinplate up to 100m/min).

• Wide wheel or consumable wire processes used.

1.8 Mesh seam welding

Foil butt seam welding

• Foil welded on to each side of the butted edges of the sheets to be joined.

• Typically 4mm wide stainless steel foil used to preserve corrosion resistance on coated
steel.

• Virtually flush finish with no crevice and used to produce wide panels.

1.9 Foil butt seam welding

Team Id: 23699 INTRODUCTION

1.6 Advantages:
 Efficient energy use, with little pollution
 Fast processing times
 Easily automated
 No required filler materials
 Economical
 Adaptable to a variety of electrically conductive materials
 Ability to produce leak-tight welds
 Can be performed by unskilled operators
 For certain high strength aluminium alloys, it is practically the only process
applicable
 Low fumes

1.7 Limitations:
 Limited by component shape and wheel access
 Initial equipment costs
 Lower tensile and fatigue strengths
 Thickness of welded sheets is limited - up to 1/4” (6 mm)

1.8 Applications:
Resistance seam welding has a wide range of applications such as:

 Manufacturing of round or rectangular steel tubing

 It can be used to fabricate liquid or gas tight sheet metal vessels such as gasoline
tanks, automobile mufflers and heat exchangers.
 Manufacturing of steel beverages cans
 Manufacturing of steel fuel tanks for motor vehicles
 Production of seam welded pipes and tubing (Butt seam weld)
 Manufacturing of steel drums and domestic radiators
Team Id: 23699 OJECTIVE OF WORK AND WORK PLAN

CHAPTER-2 LITERATURE SURVEY

2.1 Literature Survey on “PARAMETRIC OPTIMIZATION OF SEAM

WELDED AISI 1015 MILD STEELFOR NUGGET WIDTH”

TITLE AUTHOR PUBLICATION CONCLUSION

YEAR

Resistance welding is one of most

widely used welding technique in
sheet metal manufacturing
industries. It is method of joining
two faying surfaces of metal
“Parametric sheets. The three variants of
Optimization Resistance welding are spot, seam
of Seam G. S. Gaikwad, May 2017 and projection welding. Response
Welded AISI K. H. Inamdar variables like nugget width and
1015 Mild tensile strength are major quality
Steel for factors that plays vital role in
Nugget seam welding process. The
Width” objective of this paper was to
investigate effect of process
parameters on nugget width for
seam welded AISI 1015 low
carbon steel. The study
parameters considered in the
experiments are welding current,
electrode pressure, welding time.
Taguchi’s experimental design
Team Id: 23699 OJECTIVE OF WORK AND WORK PLAN

has been used for optimization to

determine optimum process
parameters. An orthogonal array
of L9 was used for the
experimental design and Nugget
width was investigated for each
experimental run. ANOVA and
signal to noise ratio (S/N) were
used to find the significant effect
of process parameters on nugget
width and optimized condition for
process parameters. The result
showed that welding current
found to be most significant factor
contributes 78.36 % and welding
time was the least significant
factor contributing 6.60 %.

Table 2.1 Literature Review - I

Team Id: 23699 OJECTIVE OF WORK AND WORK PLAN

2.2 Literature Survey on “A STUDY OF DIFFERENT PARAMETERS

OF THE SEAM WELDING PROCESS FOR REDUCING WELDING
CURRENT”

TITLE AUTHOR PUBLICATION CONCLUSION

YEAR

Resistance seam welding process uses

the heat generated from the resistance to
the flow of current. This heat is used to
“A Study
obtain the weld. Seam welding process
of
requires continuous flow of current.
Different
Hence, large current consumption is one
Parameter
of the drawbacks of this process. In this
Shaikh Ozair,
s of the
June 2018 paper we study various parameters that
Dr.N.H.
Seam
affect the welding current. The
Deshpande
Welding
experimentation work was carried out at
Process
Viraj Engineering Company located in
for
Satara. The company manufactures
Reducing
storage tanks. Different parameters of
Welding
the seam welding process are studied
Current”
and ways to reduce the current
consumption of the seam welding
machine is given in this paper. The
objective of this project is to reduce the
power consumption of the company by
limiting the current usage of the seam
welding machines used in the company.

Table 2.2 Literature Review - II

Team Id: 23699 OJECTIVE OF WORK AND WORK PLAN

2.3 Literature on “EXPERIMENTAL ANALYSIS OF LEAKAGES IN

SEAM WELDING BY CONTROLLING SEAM WELDING
PARAMETERS”

TITLE AUTHOR PUBLICATION CONCLUSION

YEAR
.
The seam welding is one of the most
popular welding techniques used in
industries for leak proof welding
joints. This basically uses a non-
consumable welding electrode in the
form of wheel. The input parameters
“Experimental in seam welding play a significant
Analysis of Avishi role in deciding the weld quality,
Leakages in Gupta, April 2015 strength, cost and speed. Most of the
Seam Welding Dr. K. M. times manufacturer faces a problem
by Controlling Moeed to select optimum process parameter
Seam Welding for a good quality weld. This paper
Parameters” will present the 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. These all
parameter have different effect on
welding leakage. In order to analyze
leakage percentage, experimental
work has been performed.

Table 2.3 Literature review - III

Team Id: 23699 OJECTIVE OF WORK AND WORK PLAN

CHAPTER-3 OJECTIVE OF WORK AND WORK PLAN

3.1 Objectives of Work:

 Prepare a requirement document to reach expectations of project and to come up with
functionalities which are needed to be implemented.
 Documentation of expected output for various aspects with accepted margin error was
also documented.
 To design overall system based on workflow requirements.
 Discussion with the project guide and Head of Department on ways to improve the
design and to optimize performance.
 Choosing suitable components and methods based on the configurations availability
and requirements.
 Testing and remedies.
 Recommendations
Team Id: 23699 OJECTIVE OF WORK AND WORK PLAN

3.2 Work Plan:

 This is simple work plan that covers our work of project for current semester.

selection of Detailed Analysis/

topic Design Simulation

Compare
identificatio with Material
n of need Standard Purchase
Materials

Constructio
problem Market
n of final
statement Survey
Model

Design in Report
Rough
Parametric Generation
Design
Software

3.1 Work Plan

Team Id: 23699 OJECTIVE OF WORK AND WORK PLAN

The whole work-plan of the project is to be completed as per the decided timeline below.

SEMESTER – 7

 JULY

 Study of research papers related to our project

 Industry visits regarding to our project

 AUGUST

 Decide materials to be used in our project

 Find approx. costing for the project

 SEPTEMBER

 Develop design drawings / make basic rough Sketch.

 OCTOBER

 Modeling in Solidworks Parametric Software.

SEMESTER – 8

 Fabricate/manufacture final working model of the project as per the

requirement.
Team Id: 23699 OJECTIVE OF WORK AND WORK PLAN

3.3 Market Survey:

For making the best product which will satisfy the customers need and overcome
the problems arriving in the existing product the market survey is necessary, so in order
to make convenient product we took a market survey through the various resources such
as visiting the various industry, we referred various article, books, magazine, newspapers
related to our field of invention and we found many problems arising in our field.

We also take survey on local factories and there we observed that the quality of
very hard work by workers. Their traditional work of using big machine makes them
busy whole day and require lots of energy.

After analyzing all the things, we come to our conclusion to make a product that
overcomes all the problems and difficulties present with conventional methods and we
are inspired to make the “Design and Development of Seam Welding Machine” which is
more convenient and more economical.
Team Id: 23699 DESIGN AND MODELLING

CHAPTER-4 DESIGN AND MODELLING

4.1 Sketches on Papers:

For better understanding of different parts of our project first we made sketches
on paper so we can understand different components of our project and get idea to how
we will make project model.

4.2 Designing in Parametric Software:

For final product designing we made 3D model in SOLIDWORKS Software, in
which we made different individual components and finally we made assembly of
different components.

For manufacturing of any machine, it requires to firstly making individual parts

with desired shape and dimensions containing in whole machine and then we need to
assemble every individual parts with each other to make final machine.

Here, different view of parts and the materials with dimensions of the parts are
shown for manufacture / machining them in workshop. They are as follows:

Sr. No. Part Name

1 2D Drawing of model
2 Base Table
3 Work-piece holding mechanism
4 Roller
5 Gear
6 Final Assembly

Table 4.1 Designed Parts

Team Id: 23699 DESIGN AND MODELLING

4.1 2D Drawing of model

4.2 Base Table

Team Id: 23699 DESIGN AND MODELLING

4.3 Work-piece holding mechanism

4.4 Roller
Team Id: 23699 DESIGN AND MODELLING

4.5 Gear

4.6 Final Assembly

Team Id: 23699 TECHNICAL OVERVIEW

CHAPTER-5 TECHNICAL OVERVIEW

5.1 Working:
The method used in effect is a continuous spot welding process in which current
is regulated by the timer of the machine. Seam welding consists of a continuous weld on
two overlapping pieces of sheet metal that are held together under pressure between two
circular electrodes. Coalescence is produced by heat obtained from the resistance tow
flow of current that passes through the overlapping sheets. In high-speed seam welding
using contiguous current, the frequency of the current acts as an interrupter.

5.1 Working
The heat at the electrode contact surfaces is kept to a minimum by the use of
copper alloy electrodes and is dissipated by flooding the electrodes and weld area with
water. Heat generated at the interface by contact resistance is increased by decreasing the
electrode force. Another variable that influences the magnitude of the heat is the weld
time, which in seam welding is controlled by the speed of rotation of the electrodes. The
amount of heat generated is decreased with an increase in welding speed.
Team Id: 23699 TECHNICAL OVERVIEW

5.2 Operation of Seam Welding:

The two work pieces to be joined are cleaned to remove dirt, grease and other
oxides either chemically or mechanically to obtain a sound weld. The work pieces are
overlapped and placed firmly between two wheels shaped copper alloy electrodes, which
in turn are connected to a secondary circuit of a step-down transformer. The electrode
wheels are driven mechanically in opposite directions with the work pieces passing
between them, while at the same time the pressure on the joint is maintained. The overlap
of the work piece with its comparatively high electrical resistance is intensely heated by
the current.

5.2 Seam Welding Setup

Welding current is passed in series of pulses at proper intervals through the

bearing of the roller electrodes wheels. With each positive or negative current half-wave
the parts are heated to a semi-molten condition, especially at the current peaks. As the
current passes through the electrodes, to the work piece, heat is generated in the air gap at
the point of contact (spot) of the two work pieces. This is heat melts the work pieces
locally at the contact point to form a spot weld.
Team Id: 23699 TECHNICAL OVERVIEW

5.3 Operation of Seam Welding

Under the pressure of continuously rotating electrodes and the current flowing
through them, a series of overlapping spot welds are made progressively along the joint.
The semi-molten overlap surfaces are pressed together by the welding pressure which
causes them to bond together into a uniformly welded structure after cooling. Thus work
pieces to be joined are passed through the space between the two discs, and under
pressure applied by the discs and current flowing through them, a continuous weld is
formed. The weld area is flooded with water to keep the electrode wheels cool during
welding. Most seam welded technologies use water cooling through the weld roller
assemblies due to the intense heat generated. But overall Seam welding enables high
welding speeds to be obtained compared with many other techniques, but can be limited
by component shape and wheel access.
Team Id: 23699 TECHNICAL OVERVIEW

5.3 Important aspects of Seam Welding:

Important Issues:

The main issues concerning seam welding are in weld quality control and welding
speeds.

 High speed welding of coated steels is of particular importance in manufacture of tin

cans. Specialist consumable wire seam welding machines are used. Quality monitors
have been developed for these applications and welding speeds up to about 100m/min
are possible. Steels with alternative coatings to tin, for canning applications, present
difficulties due to their high surface resistance.
 Weld quality is controlled mainly by tight process control together with periodic
testing of samples. Factors such as material and pressing quality, and alignment of the
electrodes to the material, are critical to achieve high speed, quality welding, for
example in coated steels for fuel tanks.

Risks:

 There are some limitations on material weldability but attention to correct setting up
and good process control can solve most production problems. The main hazards are:
 (i) the risk of crushing fingers or hands; and
 (ii) Burns or eye damage from splash metal. Little fume is produced but may need
attention when welding coated steels or when oils or organic materials are present.
Team Id: 23699 CONCLUSION AND FUTURE SCOPE

CHAPTER-6 COST ESTIMATION

6.1 Bill of Materials:

SR.NO PART NAME COST QUANTITY TOTAL COST

1 Gears 550 2 1100

2 Rods 150 3 450

3 Handle 300 1 300

4 Frame 2000 1 2000

5 Workpiece Holder 1500 1 1500

6 Feed For Welding 800 3 2400

7 Wheels 1200 2 2400

8 Other Material 900 - 900

9 Fabrication Cost 1750 - 1750

Total Cost ₹ 13,400/-

Table 6.1 Bill of Materials

Team Id: 23699 CONCLUSION AND FUTURE SCOPE

CHAPTER-7 CONCLUSION AND FUTURE SCOPE

7.1 Conclusion:
After completing the project, we can conclude that our project is simple in
construction and compact in size for use. Manufacturing of machine is easy and cost of
the machine is less. As one can see, a micro resistance seam welder is a flexible machine
that is well suited to fabricating various small scale components. It offers a cost effective
and high throughput joining method that often provides a reliable alternative to TIG and
laser welding.

7.2 Future Scope:

Some of future developments that may be considered for the seam welding
machine are as follows:
 To achieve more flexibility
 To reduce maintenance cost as well as manufacturing cost
 To provide guaranteed consistent part welded under optimal conditions
 To make machine more smart and compact
 Modifications/enhancements to be made considering factors like energy
consumption, life span, and recyclability. This will ensure that the developed
system is beneficial not just technically, but also provides a demonstrable return
on investment within a reasonable period of time, and has no negative
environmental effects.
Team Id: 23699 REFERENCES

REFERENCES

 https://www.google.co.in/search?q=components+used+in+seam+welding&source=lnms
&tbm=isch&sa=X&ved=0ahUKEwjLxevBnPHcAhXJOY8KHZLFAqsQ_AUICigB&bi
w=1920&bih=943#imgrc=IdDubZdbay0yyM
 http://www.yourarticlelibrary.com/welding/resistance-welding/resistance-welding-spot-
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