Se EXPERIMENT NO.: 03 TITLE:TO PREPARE MALE AND FEMALE JOINT. DATE OF BEGINNING DATE’OF FINISHING: SKETCH: TOOLS & EQUIPMENTS REQUIRED: 1. Bench Vice 7. Hand file 13. Vernier caliper 2. Hack saw 8 BallpeenHammer ._ 14. Surface Plate 3. Tri-square 9. Prick Punch(30° & 60°) 15. Angle Plate 4. Steel Rule 10. Centre Punch 16. Vernier Height Gauge 5. Flat file 11. Drilling Machine 17. Chisel 6. Square/Triangular file 12. Drill bit (Tolerance: +0.05mm) RAW MATERIALS REQUIRED: SEQUENCE OF OPERATIONS: 1. First study the sketch carefully 2. The dimension of the given workpiece is checked properly with the steel rule 3. Then the workpiece is clamped properly in the bench vice 4. Filing the adjacent sides of the workpiece by using flat file, Check whether the two sides are at right angles by using the tr-square Apply wet chulk as a marking media on the surface of the workpiece . The given dimensions are marked using the surface plate & the surface gauge by referring the two sides as base. Punch marks are put on the line marked using prick punch 60° & balkpin hammer . Cut & remove the excess material using hacksaw Using the flat chisel the unwanted material in the workpiece (female V) is removed 0. The corners of the stepped surfaces are filled by using a square or trianguiar file 1. Filing is continued until the required size and smooth surface of the workpiece is obtained. 12. The dimensional accuracy is checked by using vernier caliper while filing, 13. Finally the workpieces are smoothened, polished and the fitting is checked for the given dimensions, SAFETY PRECAUTIONS: 1. Use coolant while cutting with the hacksaw 2. Don’t use water or grease on the surface of the workpiece while filing RESULTS: Qn ageen sme WORKSHOP PRACTICE LAS et 5rr rr EXPERIMENT NO.: 04 TITLE: INTRODUCTION TO WELDING SHOP OBJECTIVES: To study about tools and equipments used in arc welding-and gas welding. THEORY: INTRODUCTION two similar or dissimilar metals by fusion It joins Welding is a process for joining e and with or without different metals/alloys, with or without the application of pressure the use of filler metal. The fusion of metal takes place by. means of heat, The heat may be generated: either from combustion of gases, electric arc, electric resistance or by chemical reaction. During some type of welding processes, pressure may also be employed, but this is not an essential requirement for all welding processes. ‘Welding provides a permanent joint but it normally affects the metallurgy of the components, The welding is widely used as a fabrication and repairing process in industries. Some of the typical applications of welding include the fabrication of ships, pressure vessels, automobile bodies, off-shore platform, bridges, welded pipes, sealing of nuclear fuel and explosives, etc. ARC WELDING: Arc welding is the welding process, in which heat is generated by an electric arc struck between an electrode and the work piece. Electric arc is luminous electrical discharge between two electrodes through ionized gas. f Electrode Holder Electrode / Lf cable a Z Weld 3 b oad a a Co 99 AC Cc Work \ . : \ . Welding Earthing machine == WORKSHOP PRACTICE LAB 16ARC WELDING EQUIPMENT: Any arc welding method is based on an ele 1. Arc welding power soyrce: Both direct current (DC) and alterneting current (AC) are used for electric arc welding, each having its particular applications. DC welding supply is usually obtained from generators driven by electric motor or if no electricity is available by internal combustion engines. For AC welding supply, transformers are predominantly used for almost all arc welding where mains electricity supply is available, They have to step Gown the usual supply voltage (200-400 volts) to the normal open circuit welding voltage (50-90 volts) 2. Welding cables: Welding cables are required for conduction of current from the power source through the electrode holder, the arc, the workpiece and back to the welding power source. These are insulated copper or aluminum cables, Cables are specified by their current carrying capacity, say 300 A, 400 A, etc. 3. Electrode holder: Electrode holder is used for holding the electrode manually and conducting current toit. These are usually matched to the size of the lead, which in tun maiched to the amperage output of the arc welder Electrode holders are available in sizes that range from 180 to 500 Amps. ctric circuit consisting of the following parts: 4, Welding Electrodes: An electrode is a piece of wire or a rod of a metal or alloy, with or without coatings. An arc is set up between electrode and workpiece. Welding electrodes are classified into following types- ‘ (1) Consumable Electrodes (@) Bare Electrodes (b) Coated Electrodes (2) Non-consumable Electrodes (@ Carbon or Graphite Electrodes (b) Tungsten Electrodes Consumable electrode is made of different metals and their alloys. The end of thiselectrode starts melting when arc is struck between the electrode and workpiece. Thusconsumable electrode itself acts as a filler metal. Bare electrodes consist of a metal or alloywire without any flux coating on them. Coated electrodes have flux coating which starismelting as scon asan electric arc is struck. This coating on melting = WORKSHOP PRACTICE LAE —_— {7™ performs many funetionslike prevention of joint from atmospheric contamination, arc stabilizers etc. r | 4 yf hit it materials like i ade up of high melting poin i Non-consumable electrodes are mi iP SD ee cl nay daring tro carbon,pure tungsten or alloy tungsten etc. These elect t welding. Butpractically, the electrode length goes on decreasing with the passage of time, because ofoxidation and vaporization of the electrode material during welding. The materials of nonconsumableelectrodes are usually copper coated carbon or graphite, pure tungsten, thoriatedor zirconiated tungsten. Solid extruded covering So Striaking end Core wire SG Bore end for gripping in electrode holder Point 5. Chipping hammer: Hiandlo Chipping Hammer is used to remove the slag by S x Ss striking. One end of the head is sharpened like a — cold chisel and the other, to a blunt, round point. 0! It is generally made of tool steel, Chis 6. Hand Screen: Hand screen used for protection of eyes and supervision of é) weld bead. J 7, Wire brush: Handle Wire brush is used to clean the surface to be weld. ee 8, Protective clothing: SEQ Operator wears the protective clothing such as apron to keep away the exposure of directheat to the body. . = WORKSHOP PRACTICE LAB 8 6=9. Welding table and cabin: It is made of steel plate and pipes. It is used for positioning the parts to be welded properly. Welding cabin is made-up by any suitable thermal resistance material, which can isolate the surrounding by the heat and light emitted during the welding process. A Suitable draught should also be provided for exhausting the gas produced during welding. 10. Hand gloves: y These are used [Link] the hands from electric shocks and hot spatters. PROCESS OF ARC WELDING: 1, Preparation of work: Before welding, the work pieces must be thoroughly cleaned of rust, scale and other foreign material. The piece for metal generally welded without beveling the edges, however, thick work piece should be beveled or veed out to ensure adequate penetration and fusion of all parts of the weld, But, in either case, the parts to be welded must be separated slightly to allow better penetration of the weld. Before commencing the welding process, the following must be considered a) Ensure that the welding cables are connected to proper power source. b) Set the electrode, as per the thickness of the plate to be welded. ©) Set the welding current, as per the size of the electrode to be used. 2. Striking an are: The following are the stages and methods of striking an are and running a bead a) Select an electrode of suitable kind and size for the work and set the welding current at a proper value : b) Fasten the ground clamp to either the work or welding table. ¢) Start or strike the are TYPES OF JOINTS: Welds are made at the junction of the various pieces that make up the weldment, The junctionsof parts, or joints, are defined as the location where two or more numbers are to be joined. Parts beingjoined to produce the weldment may be in the form of rolled plate, sheet, pipes, castings, forgings, orbillets. The five basic types of joints are listed below. m= WORKSHOP PRACTICE LAB —— 4ned in the same plane. This joint eae, members aligt A butt joint is used to join two 1k. A joint of this type may be isfrequently used in plate, sheet metal, and pipe wo! either square orgrooved. i Corner and tee joints are used to join two members located a Hight engi to each other. In cross section, the comer joint forms an L-shape, and ihe °S a t as the shapeof the letter T. Various joint designs of both types have uses In many types of metal structures. seco of metal A lap joint, as the name implies, is made by lapping one piece 0! metal over another. This is one of the strongest types of joints available. Lap joints are commonly used with torch brazing and spot welding applications. An edge joint is used to join the edges of two or more members lying in the same plane. While this type of joint has someapplications in plate work, it is more frequently used in sheet metal work. An edge joint should only beused for joining metals 1/4 inch or less in thickness that are not subjected to heavy loads. B. comer oT i Z E. EDGE aon Duar vont SAFE PRACTICE FOR ARC WELDING: Always weld in a well ventilated place. Fumes given off from welding are unpleasant and in some cases may be injurious, particularly from galvanized or zinc coated parts. 1. Do not weld around combustible or inflammable materials, where sparks may cause a fire. 2. Never weld containers, which have been used for storing gasoline, oil or similar materials, without first having them thoroughly cleaned. 3. Check the welding machine to make sure that it is properly grounded and that all leads properly insulated. 4, Never look at the arc with the naked eye. Th Always use a face shield while welding. me, Mme creat oven dou ayes severely 5, Prevent. welding cables from coming in contact wi Si grease. Avoid dragging the cables und sharp cone metal ‘wala gil, oF =m WORKSHOP PRACTICE LAE 0)——— 6, Ensure proper insulation of the cables and check for openings. 7. Always wear the safety hand gloves, apron and leather shoes. 8, Always turn off the machine when leaving the work. 9. Apply eye drops after welding is over for the day, to relieve the strain on the eyes. 10. While welding, stand on dry footing and keap the body insulated from the electrode, any other parts of the electrode holder and the work. GAS WELDING: GAS WELDING PROCESS: A fusion welding process which joins metals, Welling yeiding rod ; : ay, Wellin using the heat of combustion of an oxygen /eir ae ey and fuel gas (i.e. acetylene, hydrogen propane ‘4 or butane) mixture is usually referred as gas AQ \ \\ li 8 My Direction of welding. The flame thus produced melts and ote Le & wetting fuses together the edges of the parts to be SW” goer welded, generally with the addition of a filler ACA Ke LER metal. Operation of gas welding is shown in QWYAKS SESS Figure. The fuel gas generally employed is Molten weld Base — Solidified metal metal weld metal acetylene; however gases other than acetylene can also be used though with lower flame temperature. Oxy-acetylene flame is the most versatile and hottest of all ihe flames produced by the combination of oxygen and other fuel gases. Other gases such as Hydrogen, Propane, Butane, natural gas etc. may be used for some welding and brazing applications. OXY-ACETELENE GAS WELDING: In this process, acetylene is mixed with oxygen in correct Proportions in the welding torch and ignited. The flame resulting at the tip of the torch is sufficiently hot to melt and join the parent metal. The oxy-acetylene flame reaches a temperature of about 3300°C and thus can melt most of the ferrous and non-ferrous metals in common use. A filler metal rod or welding rod is generally added to the molten metal pool to build up the seam slightly for greater strength. TYPES OF WELDING FLAMES: !n oxy-acetylene welding, flame is the most important means to control the welding Joint and the welding process. There are three basic types of oxy-acetylene flames. 1. Neutral welding flame (Acetylene and oxygen in qual proportions). 2. Carburizing welding flamle (excess of acetylene) 3. Oxidizing welding flame (excess of oxygen). A WORKSHOP PRACTICE LAB <9y Neutral Welding Flame: A neutral flame results when qyrehr tip Inner cane Outlet envelepe approximately equal volumes of oxygen « and acetylene are mixed in the welding ¢——*—— torch and burnt at the torch tip. The t_--—- temperature of the neutral flame is of the Neutra! flame order of about 3260°C. It has a clear, well defined inner cone, indicating that the combustion is complete. The inner cone is light blue in color. It is surrounded by an outer flame envelope, produced by the combination of oxygen in the air and superheated carbon monoxide and hydrogen gases from the inner cone. This envelope is usually a much darker blue than the inner cone. A neutral flame is named so because it affects no chemical change on the molten mets! and, therefore will not oxidize or carourize the metal. The neutral flame is commonly used for the welding of mild steel, stainless steel, cast Iron, copper, and aluminium. Carburizing Welding Flame: The carburizing flame has excess of acetylene and can be recognized by oe acetylene feather, which exists between the QS == inner cone and the outer envelope. The Carburising flame outer flame envelope is longer than that of (Exeassive acotylone) the neutral flame and is usually much brighter in color. With iron and steel, carburizing flame produces very hard, brittle substance known as iron carbide. A reducing flame may be distinguished from carburizing flame by the fact that 2 carburizing flame contains more acetylene than 2 reducing flame. A reducing flame has an approximate temperature of 3038°C. It is used for welding with low alloy steel rods and for welding those metals, (e.g., non- ferrous) that do not tend to absorb carbon. This flame is very well used for welding high carbon steel. Feather Oxidising Welding flame: The oxidizing flame has an excess of oxygen over the acetylene. An oxidizing flame can be recognized by the small cone, Oxidizing flame which is shorter, much bluer in color and (Excessive oxygon) more pointed than that of the neutral flame. The otter flame envelope is much shorter and tends to fan out at the end, Such a flame makes a loud roaring sound. It is the = WORKSHOP PRACTICE LAB eehottest flame (temperature as high as 6300°F) produced by any oxy-fuel gas source. But the excess oxygen especially at high temperatures tends to combine with many metals to form hard, brittle, low strength oxides, It is not used in the welding of steel. GAS WELDING EQUIPMENTS: An arrangement of oxy acetylene welding set up is shown in the following figure. The basic tools and equipments used for oxy-acetylene welding are following: 1. Acotylene hose 9. Fusible plugs 17. Hand wheel 2 Adusting scrow 10. Oxygen hose 18. Bursting dise 3. Acatylene requlaior 41. Oxygen regulator 19. Acetylene vale 4. Regulator outlet pressure gauge 12. Regulator outlot pressure gauge 20. Oxygen valve 5. Cylinder pressure gauge 13. Cylindar pressure gauge 24. Welding torch [Link] wrencr 14. Cylindse cap 22° Torch tip T Acatylone cylinder valve 48. Oxygen cylinder valve 23. Flamo 8. Cylinder cap ‘ 16. Oxygen cylinder valve Oxy acetylene welding set up: Acetylene and oxygen gas is stored in compressed gas cylinders. These gas cylinders differ widely in capacity, design and colour code. However, in most of the countries, the standard size of these cylinders is 6 to 7 m3 and is painted black for oxygen and maroon for acetylene. An acetylene cylinder is filled with some absorptive material, which is saturated with a chemical solvent acetone. Acetone has the ability to absorb a large volume of acetylene and release it as the pressure falls, If large quantities of TS WORKSHOP PRACTICE LA5 73ite the gas uch cheaper to general gas at the Acetylene gas are being consumed, it is m' iene gas is gore, place of use with the nei of acetylene gas generators. Acetylene gi Generated by Carbide-to-water method. Oxygen gas cylinders are usually equipped with about 40 litres of oxygen a 5 Pressure of about 154 Kgifem® at 21°C. To provide against Ganacrously excessye._ Pressure, such as could occur if the cylinders were exposed ° fire, ver valve has a safety device to release the oxygen before there is any danger of rup' uring the cylinders. Fragile discs and fusible plugs are usually provided in the cylinders valves in Case it is subjected to danger. Gas pressure regulators: Gas pressure regulators are employed for regulating the supply of acetylene and oxygen gas from cylinders. A pressure regulator is connected between the cylinder and hose leading to welding torch. The cylinder and hose connections have left. handed threads on the acetylene regulator while these are right handed on the oxygen regulator. A pressure regulator is fitted with two pressure gauges, one for indication of the gas pressure in the cylinder and the other for indication of the reduced pressure et which the gas is going out. Torch tips: It is the portion of the welding epparatus through which the gases pass just prior to their ignition and burning. A great variety of interchangeable welding tips differing in size, shape and construction are available commercially. The tip sizes are identified by the diameter of the opening. The diameter of the tip opening used for welding depends upon the type of metal to be welded, Hose pipes: The hose pipes are used for the supply of gases from the Pressure regulators. The Most common method of hose Pipe fitting both oxygen and acetylene gas is the Teinforced rubber hose Pipe. Green is the standard color for oxygen hose, red for acetylene, and black hose for other industrially available welding gases, Welding torch: Figure shows the Construction of the welding torch. It is a tool for mixing oxygen and acetylene in Correct proportion and burning the mixture at the end of a tip. Gas = flow to the torch is controlled with \ the help of two needle valves in OM ing hana sine?! w= WORKSHOP PRACTICE LAB ee 24the handle of the torch. Goggles: These are fitted with colored lenses and are used to protect the eyes from harmful heat and ultraviolet and infrared rays. Gloves: These are required to protect the hands from any injury due to the heat of welding process. Spark-lighter: tis used for frequent igniting the welding torch, Filler rods: Gas welding can be done with or without using filer rod. When welding with the filler "od, it should be held at approximately 900 to the welding tip. Filler rods have the same or nearly the same chemical composition as the bese metal, Metallurgical Properties of the weld deposit can be controlled by the optimum choice of filler rod, Most of the filer rods for gas welding also contain deoxidizers to control the oxygen content of weld pool. ‘ Fluxes: Fluxes are used in gas welding to remove the oxide film and to maintain a clean surface, These ere usually employed for gas welding of aluminium, stainless steel, cast iron, brass andsilicon bronze. They are available in the market in the form of dry Powder, paste, or thick solutions SAFETY RECOMMENDATIONS FOR GAS. WELDING: Welding and Cutting of metals involve the application of intense heat to the objects being welded or cut. This intense heat in welding is obtained from the use of inflammable gases, (e.g. acetylene, hydrogen, etc.) or electricity. The beginner in the field of gas welding must go through and become familiar with these general safety fecommendations, which are given below. 4 2. Never hang a torch with its hose on regulators or cylinder valves. During working, if the welding tip becomes overheated it may be cooled by Plunging the torch into water; close the acetylene valve but leave a litle oxygen flowing. ~ . smm= WORKSHOP PRACTICE LAB —_orrect pressure regulators for a gas. Acetylene pressure 3. Always use the ct regulator should never be used with any other gas. 4, Do net move the cylinder by helding the pressure regulator and also handle pressure regulators carefully. 5. _Use pressure regulator only at pressures for which it is intended. 6. Open cylinder valves slowly to avoid straining the mechanism of pressur regulator. 7. Never use oil, grease or lubricant of any kind on regulator connections. 8. For repairs, calibrations and adjustments purposes, the pressure regulators should be sent to the supplier. 9. Do cracking before connecting pressure regulator to the gas cylinder. a 140. Never allow the hose to come into contact with oil or grease; these deteriorate the rubber and constitute a hazard with oxygen. CONCLUSION: We studied about arc welding and gas welding successfully. DO YOU KNOW? . Explain the vari NOOhOn> What is welding? How is it classified? jous types of joints commonly used in welding. How is gas welding performed? How is the flame adjusted? Give alist of equipments required in general for electric aro welding Explain the principle of arc-welding What safety precautions are associated with electric arc welding? Write short notes on: () Welding rods (il) Fluxes (jii) Gas flames (iv) Working of pressure regulators