DESIGN AND DEVELOPMENT OF SUBMERGED ARC WELDING (SAW) SYSTEM: PROCESS OPTIMIZATION AND PERFORMANCE ANALYSIS

The design, modeling, analysis, and development of an ARC welding head is crucial for enhancing welding efficiency, precision, and durability in industrial applications. This study focuses on the systematic approach to developing a high-performance ARC welding head, integrating advanced engineering principles and computational techniques. The design phase involves selecting suitable materials and structural configurations to ensure optimal thermal and mechanical stability. The modeling process employs CAD software to create a detailed 3D representation of the welding head, enabling precise modifications before fabrication. Finite Element Analysis (FEA) is used to evaluate thermal distribution, stress concentrations, and overall performance under real-world conditions. The developed prototype undergoes experimental validation, ensuring its efficiency, reliability, and suitability for various welding applications. This research contributes to advancements in automated welding technology, improving productivity, cost-effectiveness, and welding quality in manufacturing industries