Soldagem por resistência elétrica para uso acadêmico

Abstract

The process of electrical resistance welding, invented by Elihu Thomson, is one of the main methods for welding metal sheets in various industrial sectors. Therefore, it is essential that future professionals have both theoretical and practical knowledge of this methodology. It has been noted that the IFBA, Jequié campus lacks equipment for practical teaching of this method. This study proposes the development of a project for an electrical resistance welding machine for academic use, through three-dimensional modeling, intended to permanently join small thickness metal pieces. The calculations and modeling of the equipment were mostly developed to use components available at the Institute, aiming to reuse materials, reduce costs, and create a sustainable project. The equipment will be operated by an electric pedal, moving the actuator that brings the faces of the pieces to be welded together and releases a short-circuit current to fuse the region. It includes movement mechanisms, electric actuation, automatic control, and safety modules to ensure proper operation/maintenance. The detailed project includes three dimensional modeling, technical drawings of the mechanical system parts, electrical and control diagramming, as well as a material list. Mechanical simulations were performed to ensure that the equipment can withstand the mechanical stresses of the welding process, aiming to achieve efficiency standards comparable to industrial equipment. Finally, the study will significantly contribute to the practical training of students and serve as a reference for the subsequent development of a prototype, serving not only as a means of practical learning but also as an innovative one.