The paper deals with the designing of mechanism, which
can weld the silencer shells of sheet metal in a linear motion with an improved degree of fineness and are relatively less cumbersome than traditional welding process. The technical constraint that has to be considered while designing and developing the mechanism was to achieve the stability, linear and uniform speed of welding torch and uniform weld thickness for quality product. The details of testing on various silencer shells are given in paper. In near future variable
frequency drive (VFD) can be installed for its full atomization.
The paper deals with the designing of mechanism, which
can weld the silencer shells of sheet metal in a linear motion with an improved degree of fineness and are relatively less cumbersome than traditional welding process. The technical constraint that has to be considered while designing and developing the mechanism was to achieve the stability, linear and uniform speed of welding torch and uniform weld thickness for quality product. The details of testing on various silencer shells are given in paper. In near future variable
frequency drive (VFD) can be installed for its full atomization.
The paper deals with the designing of mechanism, which
can weld the silencer shells of sheet metal in a linear motion with an improved degree of fineness and are relatively less cumbersome than traditional welding process. The technical constraint that has to be considered while designing and developing the mechanism was to achieve the stability, linear and uniform speed of welding torch and uniform weld thickness for quality product. The details of testing on various silencer shells are given in paper. In near future variable
frequency drive (VFD) can be installed for its full atomization.
Automation in Sheet Metal Tig Welding Process: A Case Study Author: Roshan W.Ttulankar Author: Suraj S. Dehankar Student Student Department Of Mechanical Engg. Department Of Mechanical Engg. J.D.I.E.T. Yavatmal, India J.D.I.E.T. Yavatmal, India
Abstract- The paper deals with the designing of mechanism, which can weld the silencer shells of sheet metal in a linear motion with an improved degree of fineness and are relatively less cumbersome than traditional welding process. The technical constraint that has to be considered while designing and developing the mechanism was to achieve the stability, linear and uniform speed of welding torch and uniform weld thickness for quality product. The details of testing on various silencer shells are given in paper. In near future variable frequency drive (VFD) can be installed for its full atomization. Keyword: TIG Welding, VFD. I. INTRODUCTION Unlike other developed countries, we are still lagging behind in advancement of machineries. Instead of utilizing automated machines, we are quite habitual of the traditional methods of production. On the other hand, developed countries are more focused to bring automation in every sector of production. This has immensely helped them in reducing production time, wastage of material, etc. Automation provides accuracy, quality as well as requires less time and man power. Despite of losses in old methods of manufacturing and hazards associated with them, small scale industries do not prefer automated machines or special purpose machines for specific work. Most of the work in production is done manually. Manpower is involved in the process instead of the machine as it is unaffordable for small scale industries. It is needed to enhance the old machineries by automating themin order to get more benefits. Whereas the arena is somewhat different in large scale industries, they generally buy too costly special purpose machines for TIG welding. But in the long run it would again turnout to be an expensive affair as regards maintenance, repair or replacement of any of the machine parts. This creates the need for an indigenously made automatic TIG welding mechanism which would minimize direct exposure of welder to hazardous fumes and bright light of arc. Also minimize the time consumption for TIG welding, thus overcoming the drawbacks in the present manual welding process. In manual TIG welding process the production rate is less & due to the non-uniformity in the linear motion, the accuracy and quality of welding gets adversely affected. But in case of this mechanism, the motion is uniformwhile welding & it helps to avoid the pits and bulges forming due to an-uniformity in the movement of welders hand.
II. TIG WELDING TIG welding (Tungsten inert gas welding) is also called as gas Tungsten Arc Welding (GTAW) uses a non consumable electrode and a separate filler metal with an inert shielding gas.[5] This is the termused by welding engineers on blueprints, and in welding procedures. When TIG was introduced around the 1940s it used to be referred to as HeliArc because the shielding gas used was helium.[6] It is no longer called HeliArc because in most cases the shielding gas used is Argon. It is an arc welding process that uses a non-consumable tungsten electrode to produce the weld.[4] Some welds, which International Journal of Engineering Trends and Technology (IJETT) - Volume4 Issue7- July 2013
ISSN: 2231-5381 http://www.ijettjournal.org Page 3079 join thin materials, (known as autogenous or fusion welds) can be accomplished without filler metal; most notably edge, corner, and butt joints. The weld area is protected from atmospheric contamination by an inert shielding gas (argon or helium). A constant-current welding power supply produces energy which is conducted across the arc through a column of highly ionized gas and metal vapour known as plasma.[1,2&3]
Fig.1 Setup of TIG Welding. Manual GTAW is often considered the most difficult of all the welding processes commonly used in industry. Because the welder must maintain a short arc length, great care and skill are required to prevent contact between the electrode and the work piece. TIG welding is most commonly used to weld thin sections of stainless steel and non-ferrous metals such as aluminium, magnesium, and copper alloys. The process grants the operator greater control over the weld than competing processes such as shielded metal arc welding and gas metal arc welding, allowing for stronger, higher quality welds. However, GTAW is comparatively more complex and difficult to master as it requires greater welder dexterity than MIG or stick welding and furthermore, it is significantly slower than most other welding techniques. A related process, plasma arc welding, uses a slightly different welding torch to create a more focused welding arc and as a result is often automated.[3] Weld Discontinuities: Undercutting, Tungsten inclusions, Porosity, Weld metal cracks, Heat affected zone cracks. TIG Welding Problems: Erratic arc, Excessive electrode consumption, Oxidized weld deposit, Arc wandering, Porosity, Difficult arc starting.[1] TIG Welding Benefits :i. Superior quality welds. ii. Welds can be made with or without filler metal. iii. Precise control of welding variables (heat). iv. Free of spatter. v. Low distortion.[2] III. THE NECESSITY OF AUTOMATION The TIG welding process is carried out for welding the shells of cylindrical and conical shape which are made by metal sheet of 1.2 & 1.5 mmthickness. previously this work was done manually. The reasons which were discussed are as follows, Adverse effect on Health of welding gun operator due to amount of Tungsten fumes produced in welding process; Non -Uniformity of the weld due to shaking of hand while moving of torch. safety of the operator;. The available SPM in the market is very costly, small scale industries doesnt afford this SPM. International Journal of Engineering Trends and Technology (IJETT) - Volume4 Issue7- July 2013
IV. DESIGN OF COMPONENT Design of belt: Centre distance=3.5diameter of larger pulley [12] =3.510 =35 inch Length of belt=L=2C+ (D2+D1) 2 + (D2-D1) 2 4C L=89inch Design of pulley: Size of larger pulley 10inch Size of smaller pulley 2.5inch Calculation for pulley D1 D2 = N2 N1 [10] 2 D2 = 300 1425
D2=10 inch Design of lead screw Overall Length : 35inches Length of threaded portion : 25 inches Calculation of lead screw P=180 watt T= P W = P60 2 N
= 18060 21425
=4.47 N-m T= 1 16 d 3
=42 Mpa (Given) [12]
d =8.7 mm By considering Bending Moment When torch is at center position then, M= wL 4 = 29.81660 4
International Journal of Engineering Trends and Technology (IJETT) - Volume4 Issue7- July 2013
T e =5519.14 N-mm. T e = 1 16 d 3 d=8.74mm. V. WORKING The TIG welding machine should be in off condition before starting an operation. Torch should be kept on either side of the mechanism. Silencer shell which is to be weld is then kept on the magnetic fixture. The distance is adjusted between sheet shell surface and tip of tungsten electrode by slight adjustment of nuts provided on the bolt attached to the fixtures. Also edge line is matched by moving the pointers over it. This given arrangement provides the scope to fixture to move in both X & Y direction. Current, voltage and Argon gas flow is checked and adjusted themall to the required value. TIG welding machine is switched ON. Then the supply is given to the motor, motor starts rotating and torch starts welding automatically as soon as electrode come in front of metal sheet cylinder surface and electrode. The welding was held continuously till the shell ends. After completion of welding in this forward stroke motor was stopped and shell was replaced by new un-weld shell and motor allowed to start rotating in reverse direction. In the same way that shell also welded and same procedure is repeated for other shells for welding. In this the reverse-forward motion and stopping of the torch is controlled by the R/F switch.
Fig.4 Mechanism I. PERFORMANCE ANALYSIS The percentage of quality achieved is considered on the basis of proportion of fine welded length as to total length welded Table 1 For sheet thickness =1.2mm(Conical Shell) No of trials Length(mm) By Manual By Mechanism Time (sec) Quality % Time(sec) Quality % 1 610 35 76 % 33 92 % 2 610 36 75 % 34 94 % 3 610 34 80 % 33 92 % 4 610 37 73 % 33 95 % 5 610 36 75 % 33 94 % 6 610 35 77 % 33 93 % 7 610 36 74 % 34 93 % 8 610 34 80 % 33 92 % 9 610 37 76 % 33 95 % 10 610 36 79 % 33 94 % International Journal of Engineering Trends and Technology (IJETT) - Volume4 Issue7- July 2013
Table 3 For sheet thickness =1.5mm(Cylindrical Shell)
Table 2 For sheet thickness =1.2mm(Cylindrical Shell)
Table 4 For sheet thickness =1.5mm(Conical Shell)
II. CONCLUSION The mechanismreported in this study can weld silencer shells for variety of popular bikes like Splendor, CT-100, CD- Dawn, Passion, Pulsar, Discover, etc. A lead screw is used to convert rotational motion into uniform linear motion. TIG welding torch is mounted on the lead screw nut. The lead screw is coupled to an induction motor with V-belt. R/F switch helps in reversal of the direction of movement. From the table of performance analysis, It observed that the silencer shell welded using this mechanismdiscussed in this study are better in quality and required less time than manual welding. Thus the mechanism offers an efficient and less expensive alternative for the TIG welding process and also reduces the human involvement thereby reducing the health hazard and safety hazard.
REFERANCES [1] Modern Welding Technology-Howard B. Cary & Scott C. HelzerPublisher Pearson/Prentice Hall 2005. [2] Welding Principles & Application Larry J effus Publisher Cengage Learning, 1997. [3] Gas Tungsten Arc Welding WilliamH. Minnick Publisher Goodheart- Willcox Co.,1995. [4] Kuang-Hung Tseng, Ko-J ui Chuang Application of iron based powder in tungsten inert gas welding Powder Technology 228 (2012) 3646. [5] Ahmed Khalid Hussain, Abdul Lateef, Mohd J aved, Pramesh. T Influence of welding speed on tensile strength of welded joint in TIG welding process Iinternational J ournal of Applied Engineering Research, Dindigul volume 1, No 3, 2010.
[6] S. P. Gadewar, Experimental investigations of weld characteristics for a single pass TIG welding with SS304, International J ournal of Engineering Science and Technology Vol. 2(8), 2010, 3676-3686.
[7] Kripa K. Varanasi, Samir A. Nafeh The dynamics of lead screw , J ournal of Dynamic Systems, Measurement, and Control vol. 126, 388-396, 2004. [8] Gerbert, B.G., Force and Slip Behavior in V-Belt Drives, ActaPolytechnica Scandinavica, Mech. Engrg. Series, Helsinki (67) (1972). [9] Pundaleek. B. H., Manish G. Rathi, Vijay Kumar M. G. Speed Control of Induction Motor IJ CSNS International J ournal of Computer Science and Network Security, VOL.10 No.10, October 2010 [10] Machine design By- Khurmi & Gupta , S. Chand publications [11] Production Engg. By P.C. Sharma, S. Chand publications [12] Datahand book By- B.D. Shiwalkar. [13] Theory of Machine By-Khurmi& Gupta, S. Chand publications.
Optimization of MIG and TIG Welding Parameter To Increase The Tensile Strength, Using Various Destructive, Non Destructive Test and Finet Element Analysis PDF