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Isuzu manufacturing plant started in April 2016 in Sri City,Tada,
Andhra Pradesh.
Spread over 107 acres.
There are four departments in this plant:
1. Press shop
2. Body Shop
3. Paint shop
4. Tcf
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P.3
Press shop
-In press shop the GI metal sheet is moulded into the required shape of
the car profile.
-The sheet metal is punctured by the dice and makes it required design and
dimensions
Body Shop
-In body Shop the molded sheet parts are joined by welding and make it as one
profile that is cab
Paint Shop
-The cabs are received from body Shop to paint shop
-PT&ED processes are done to the cab.
-Next the cab is moved to the sealer line.
-Then top coat processes are done to the cab.
-Next it goes into the final line and gets checked
TCF
-In the tcf the cab and the chassis are assembled.
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Definition of Resistance Welding :
Resistance welding is a fusion welding process in which
combination of metals is produced at the faying surfaces by the
heat generated at the joint by the resistance of the work to the flow
of electricity.
Force is applied before, during, and after the application of current
to prevent arcing at the work piece.
Melting occurs at the faying surfaces during welding.
Resistance welding depends on three factors:
– Time of current flow (T).
– Resistance of the conductor (R)
– Amperage (I).
Heat generation is expressed as
Q = I2R T, Q = Heat generated.
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Servo robotic guns
integrated trans
guns
portable guns
robotic guns
fixture guns
Types of spot welding guns :
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P.9
Hanger
Trigger switch
Trigger cable
Aid cable
Fitting
Arm (yoke)
Moving
piston
Shank
Adaptor
Cylinder Retract lever
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P.10
Cap tip shanks
adaptors
One piece Cap tip holders Insert electrodes
Consumable parts
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The Four Steps of Spot Welding
The process of resistance spot welding is made of four steps as shown.
1. Squeeze
2. Weld
3. Hold
4. Off
The time for all these steps are expressed in cycles where one cycle is
equal to 1/50th of a second (if a 50Hz A/C source is used)
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Application of Spot welding
1. Spot welding vast application in automobile and aircraft industries. such
as for Body Shell, Fuel tank etc.
2. The attachment of braces, brackets, pads or clips to formed sheet metal
parts such as cases, covers, bases or trays is another application of spot
welding.
3. Now a days , spot welding is considered as replacement of riveting.
4. The attachment of braces, brackets, pads or clips to formed sheet metal
parts such as cases, covers, bases or trays is another application of spot
welding.
1. Low cost .
2. High speed of welding.
3. Dependability.
4. More general elimination of warping or distortion of parts.
5. High uniformity of products .
6. No edge preparation is needed.
Advantages
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P.13
Destructive Test
Weld Control
Teardown
Non destructive Test
Coupon Test Complete Body shell
Ultrasonic testing
Visual checking Pry bar checking
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P.15
• Shunt effects
• Welding splashes
ø
6 ø
9
• Electrode wear
• Changes in kind and thickness of coating
• Switch between 2 and 3 sheets welding
operations
• Adhesive between the sheets
• Drop and increase in electrode force
Weld disturbance
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Issue – Profile
weld
Profile weld leads to
Spatter and porous
welds
Correct weld
location
Why Profile Weld Leads To Spatters and Porous Welds?
The Panel point at the curvature area / Profile area cannot be
squeezed to required level to complete efficient welding
process.
Action Required
To be Avoid Profile
Weld Through
training & Providing
Gun Guide.
Profile weld
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This type of poor spots will not Acceptable.
Samples For Poor Angle / Alignment
