Abstract—Designing and constructing resistance welding machines involves a combination of electrical design, machine structures, mechanisms and controls. The machines vary from simple mechanisms to exceptionally complicated units. Monitoring the condition of large upset welding machines in operating industries has attracted increasing interest in recent years owing to the need for decreasing the energy consumption on production machinery and for reducing the extent of secondary damage caused by failures. Upset Welding (UW) is a resistance welding process utilizing both heat and deformation to form a weld. A micro-setup would certainly reduce heat consumption and offer greater efficiency. In this paper an electro-mechanical micro upset welding setup is constructed following the fundamental principles of resistance welding. The chief electrical and mechanical components used are single phase ac transformer, welding arms or copper alloy electrodes, externally threaded steel shaft, frame, multimeter and control switches. After the construction of the micro welder, two thin sheets of mild steel are welded.

Index Terms—Upset welding, Electro-mechanical, Micro setup, Threaded shaft.

Cite: Gurjeet Singh and Nitin Arora, "Design and Development of Micro Upset Welding Setup," International Journal of Mechanical Engineering and Robotics Research, Vol. 2, No. 2, pp. 51-58, April 2013.