Chapter 3: Literature review
Sr. No Name Research
1. Mohd Zaim Bin Din Experimental Study On Strength of Spot Welder
2. M. I. Khan, A. K. Pandey State of art in modern Resistance Spot Welding
3. Nachimani Charde Investigating spot weld growth on Austenitic stainless steel
4. Ali. Moarrefzadeh Study of Heat Affected Zone (HAZ) in
Resistance Welding Process
5. D. J. Radakovic Resistance Spot Weld Failure
Modes in Shear Tension Tests of Advanced
High-Strength Automotive Steels
3.1 Gap Identify:
In the above research papers we found that the resistance spot welding machine is very bulky, undergoes weld cycle which takes time that is, it does not join materials instantaneously, creates a larger heat zone which requires a longer time to cool and is susceptible to shear failure. It also does not weld at any angle, requires a proper foundation and is costly.
3.2 Objective:
To create a welding machine that:-
• Can Welding at any angle and any height
• Is flexible
• Is Less costly
• Compact in size
• Provide ease of operation to welder and
• Less weight.
• Is portable
• Does not require a rigid foundation.
Chapter 4: Design and modeling
4.1 Components of the equipment
• 17 gauge copper wire for primary winding
• Fiber glass coated aluminum for secondary windings
• Step down transformer
• Electrode
• Brass Electrode clamp
• Limit switches
• Stamping(Plates)
• Wooden casing
• Nut bolt
• Wire for main current supply
4.2 General equation used in spot welding
The shear strength of a single spot weld can be calculated as follows: τ = 2.6 • t • d • Rm
Where:
τ = shear strength, N t = sheet thickness, mm d = weld diameter, mm
Rm = tensile strength of the material, MPa
Electrodes indent at least slightly on the work piece surface. ...
... middle of paper ...
...oot operated and weighs nearly 200 kilos.
In this project we have removed the above said problems by creating a much simpler, lighter, portable, compact and flexible machine which is able to weld at any angle and can be easily operable by a less experienced worker with much ease and required accuracy.
The advantages of our equipment are as follows:-
• Welding at any angle, any height
• Provide flexibility
• Less costly
• Compact
• Provide ease of operation to welder and
• Less weight.
We conclude that our machine can be mass produced and can also be used for industrial purposes.
Chapter 8: References
1. Miller Hand book.
2. Welding technology by O.P. Khanna.
3. Ruukki Resistance welding manual.
4. Manufacturing Technology by P.N.RAO.
5. https://encrypted-tbn2.gstatic.com/images?q=tbn:ANd9GcRCMnoU86VE2WfmswJJNcQ6o_cOokYxVwUQaCR4AwlEJavqXa4_
6. Research Paper
scientific experiments (Go welding: history of welding 1). Conventional welding is most easily explained as arc welding processes. Some arc welding processes are TIG welding, Stick Welding(SMAW), and MIG welding. TIG stands for Tungsten Inert Gas welding this means that using tungsten as a electrode and an inert gas, which is usually argon, the weld is produced by creating an arc between the piece being welded and the tungsten electrode. SMAW or stick welding utilizes a stick electrode held in a clamp surrounded by a powdered substance to weld. Mig welding uses a machine that holds a wire feeder within it, the wire feeder feeds the wire electrode through a tube to a gun that slowly sends out the wire as well as a steady flow of inert gas. These and other processes classified as conventional welding processes are the best processes for welding jobs because they are more cost effective, more...
Welding is a very important job in today’s society. With new building designs, and bridges to every day metal products, welders are needed to do these tasks. Almost everything that you use every day has some sort of weld to it.
Gas metal arc welding, or most commonly referred to as MIG welding is a very common and sometimes preferred method of welding. Gas metal arc is personally one of the easiest and controllable welding types there is.
By Occupational Safety and Health Standards (OSHA) definition any operator of electric or gas welding and cutting equipment is called a "welder" and "welding operator". The standard 29 CFR 1910 Subpart Q which pertains to welding, cutting, and brazing. The standard consists of 5 parts, they include: 1910.251 Definitions, 1910.252 General requirements, 1910.253 Oxygen-fuel gas welding and cutting, 1910.254 Arc welding and cutting, 1910.255 Resistance welding. It is a rather diverse standard covering all aspects of industrial and commercial applications specializing in safety aspects, guidelines, and requirements as well as proper use and operating procedures.
Using manual welding, it is very tricky to achieve the utmost standards of quality and safety. This is mainly due to ce...
A welder fabricates, assembles, and deconstructs metal structures such as windmills, buildings, boats,etc. There are various types of equipment used in this profession that deconstruct and fabricates marvelous structures. Welders, welding rods, grinders, plasma cutters, shapers, and measuring tools all play a huge part in this hardworking profession. There are also multiple types of welding,(Arc welding, Electroslag welding, Flux-cored welding, Gas Metal Arc welding, Gas Tungsten-Arc welding, MIG welding, Plasma Arc welding, Shielded-Metal Arc welding, Submerged Arc welding, and TIG welding). Due to the certain type of work that welders do they the strength and skills to manage welding equipment. They also must be able to read and interpret
To begin with a welder uses equipment to apply heat to metal in order to create a permanent bond. In doing so, they weld metal parts, fill holes, and can even repair cracks in a brace. Because of its heavy duty strength, welds can be used to repair cars, ships, and even airplanes. Also, welds are used in the construction of buildings and bridges. Various tools are needed to perform proper welding techniques, for example, a person may need clamps, welding rods, a chipping hammer, a torch, glasses, a welding helmet, an apron or non flammable clothing to properly weld metal. In addition, a person may also need a specific type of welder for a certain occasions. For example if a person wants to weld aluminum a mig welder would be used along with argon and helium gases. Safety is always important for the welder. Welders are exposed to a variety of environments and situations that put their safety in jeopardy. They are at risk for cuts, bites, stings, and burns since they work outdoors. They are also exposed to gases, dust, fumes, and foul odors due to working in poorly ventilated areas. It is ev...
To make a decent weld, one has to have a steady hand, the proper safety equipment, and the welding tools must be set up to sometimes exacting specifications; unless you’re using explosives, then the specifications must always be exact.
Another type of welding is”Tig welding” which is when a electrode such as aluminum or tungsten that is melted with a strong torch or electrical arc. Another type of welding is “Mig welding” that is when you have a spool of wire and a inert gas such as argon or Co2 which acts as an insulator for the arc that is created in order to weld a bead. There are many more types of welding that you can learn when you are studying to become a welder or fabricator. When studing for welding you can and will learn about so much more stuff like oxy torch cutting and flux core welding which i hope many people will have the ability to at least try welding
Welders can use hand held welders or even robotic welders to produce welds. Both equally requiring a incredible amount of knowledge. They can also fill holes, produce structures and build custom parts for automotive race shops. Welders often work fulltime on shipyards, oil rigs, and pipelines or anywhere else where a specific job is needed. Welders are often required to interpret blueprints or sketches and weld accordingly to fulfill job duties. Arc welding is the most common type of welding today and is what most welders use. (bls) There are over 100 different welding processes that a welder can learn how to use however, Stick, Tig and Mig are the 3 most common used in the industry. These are used most to maintain equipment
GMAW (Gas Metal Arc Welding) is more economic; Springer reports that “ GMAW is an economic process because it has higher speeds and higher deposition rates than manual arc welding. There is also no need to constantly change electrodes” ( Page 11). GMAW has a higher speed, which means that you can get the job done faster. It also has high deposition rates which makes the weld look clean and smooth.” This method can be used for a high range of work, but it is not suited for repair work because of it’s weld quality” (Page 4). This process can be used for many variations of work including root welds, joints, T’s, butts, laps, and many more applications. Even though its used for many practices, it is not recommended to use this method for repair work because of the quality of the welds. “ It’s easy to use and it is inexpensive to afford now with 110v machines. But you cannot weld for a long time like a 220v machines would produce. Both have different duty cycles” (Parag. 7). M.I.G is something anyone can learn easily, it’s inexpensive to afford. 110v machines don't bring out the best power to weld, because these machines do not have a good duty cycle. Most people prefer 220v machines because they produce more work, even if they are more expensive. GMAW is the cheapest most reliable process for welding.
"Purchasing Your First Robotic Welding System | Lincoln Electric."Lincolnelectric. N.p., n.d. Web. 08 May 2014.
There is different types of rods and different types of ways to weld. You need a lot of training for it. There are many schools and colleges you can go to receive welding education. The most common welding processes are Gas Metal Arc Welding, Flux Core Arc Welding, Gas Tungsten Arc Welding and Shielded Metal Arc Welding. The easiest of these is the Gas Metal Arc Welding. Welding options are stick, flux core, tig, and mig. The pipeline tig and stick welds a lot more than the other .The pipeline use many types of techniques but, the most common on the pipeline is downhill root pass and the up hill pass. The median annual wage of welders, cutters, solderers, and brazers is
Welding is an art, science, and high paying career all in one. Welding is the most effective way to join two pieces of metal, it is the only way to join them so they act as one. Numerous things in our daily lives has been welded from coffeepots to skyscrapers. Welding can be done almost anywhere outdoors, indoors, underwater, and even space (“Welding Basics”). It is practically
?Automation Reduces Weld Spatter? Welding Design & Fabrication (Jun. 2001): 37 EBSCOhost. Online. Nov. 2002 .