IJSRST1737136 | Received : 01 Oct 2017 | Accepted : 15 Oct 2017 | September-October-2017 [(3) 7: 693-698] © 2017 IJSRST | Volume 3 | Issue 7 | Print ISSN: 2395-6011 | Online ISSN: 2395-602X Themed Section: Science and Technology 693 Study on Finite Element Analysis of Resistance Spot Welding to Study Nugget Formation Dr. R. Ramachandra Principal & Professor, Department of Mechanical Engineering, SKD Engineering College, Gooty, Andhra Pradesh, India ABSTRACT Resistance Spot Welding is being used inside the enterprise for sheet becoming a member of system in particular within the automobile and aerospace industry. The complicated behavior of this system must be analyzed to set the choicest parameters to get the choicest weld great. This paper affords the FEA simulation of the RSW procedure. It requires modelling of complex interactions among electrical, thermal, metallurgical and mechanical phenomena. A 2d axis symmetric FEM model has been evolved to examine the temporary thermal behaviors of technique the usage of ANSYS software and matched structural thermoelectric evaluation is done by means of the usage of superior coupled field detail PLANE223 to simulate the thermal characteristics of RSW technique. The targets of this evaluation is to understand physics of the system and to expand a predictive device lowering the range of experiments for the optimization of welding parameters. Keywords: RSW, Coupled Analysis, weld nugget, Temperature distribution I. INTRODUCTION Resistance welding is the maximum commonly used method for becoming a member of metallic sheets. An electro conductive touch surface is created among the work pieces with the aid of pressing them together. Watercooled electrodes made from alloyed copper are utilized in resistance welding. Electrodes convey a urgent pressure to the joint and direct the welding cutting-edge to the joint in the correct manner. After welding, the electrodes swiftly cool down the welded joint. Resistance spot welding is a complicated system in which coupled interactions exist among electric, thermal, mechanical, metallurgical phenomena and even floor behaviors. in the recent years, finite detail method has provided a effective device in reading these interactions and lots of related works have been carried out at the FEM modelling of RSW. Nied developed the primary FEA version for RSW technique, investigated the impact of the geometry of electrode on workpiece and anticipated the deformation and stresses as a function of temperature. Moreover, many researchers developed extra state-of-the-art FEA fashions that considered temperature established cloth properties, touch reputation, section changing and paired discipline effects into the simulation of RSW. To clear up the coupled hassle, iterative answer process is an regularlyfollowed approach. first of all the pressure subject and call status are received from the thermalmechanical analysis and then the temperature field is obtained from the completely coupled thermalelectrical analysis primarily based at the contact vicinity on the electrode workpiece interface and faying floor. The calculated temperature subject is then exceeded again to the thermalstructural analysis to update the stress discipline and speak to popularity. The goal of this paper is to expand a multi- coupled technique to analyse the thermal and mechanical behaviors of RSW technique, reduce the computing time with the minimal lack of accuracy and get more ok facts of the method. 1.1 Spot Welding Cycle Figure 1 indicates the spot welding system. The RSW process is composed of four levels as follows; a) Squeeze cycle time for the duration of which the upper electrode is introduced in contact