FYP Report UNIKL MFI Tengku

POWER HAMMER
TENGKU MOHD HAFIZAN BIN TENGKU ZAHARI

50106118079
WAN MUHAMMAD IZZAT BIN WAN MAZIHAN
50106118042
NURUL AININ SOFIYA BT RUSDI
50106118005
RUSYDI FITRI BIN RUDZYLAN
50106118083
UNIVERSITI KUALA LUMPUR
JULY 2020
POWER HAMMER
TENGKU MOHD HAFIZAN BIN TENGKU ZAHARI

50106118079
WAN MUHAMMAD IZZAT BIN WAN MAZIHAN
50106118042
NURUL AININ SOFIYA BT RUSDI
50106118005
RUSYDI FITRI BIN RUDZYLAN
50106118083
Report Submitted to Fulfill the Partial Requirements For

the Diploma of Engineering Technology in Welding
Universiti Kuala Lumpur
JULY 2020
DECLARATION
I declare that this report is my original work and all references have been
cited adequately as required by the University.
Date : Signature : …………………………

Full Name :Nurul Ainin Sofiya Binti Rusdi
ID Number 50106118005

Full Name :Rusydi Fitri Bin RudzylaID
Number 50106118083

Full Name :Tengku Mohd Hafizan Bin
Tengku Zahari
ID Number 50106118079

Full Name :Wan Muhammad Izzat Bin
Wan Mazihan
ID Number 50106118042
APPROVAL PAGE
We have examined this report and verify that it meets the programmed and
university, requirement for the Diploma of Engineering Technology in Welding.

Supervisor : Mr. Abdul Aziz Bin Dawam
Official Stamp:

Co-Supervisor:
Official Stamp:
(Optional)
ACKNOWLEDGEMENT
We thank all of those who gave us the opportunity to complete this report for our
gratitude and appreciation. Special thanks to our project coordinator for the final year,
Mr. Abdul Aziz Bin Dawam, who helped us to organize our project, particularly when
writing this project, by encouraging suggestions and encouragement.
We would also like to acknowledge with much gratitude the crucial role played by Mr.
Mazlan, Technical and Operational Advisor of the Welding Workshop, who gave us
permission to use all the necessary machines and materials to complete the Handrail
project.
Last but not least, many thanks go to the members of the team, who have made every
attempt to accomplish the aims of successfully completing this mission, despite the
ups and downs together. We need to express our appreciation, who have helped us a
lot to successfully complete the project within a short timeline. We are working on this
project not only for marks, but also to increase our expertise. Thanks again to those
of you who helped us out.
TABLE OF CONTENTS
ACKNOWLEDGEMENT ...........................................................................................4
LIST OF TABLE ......................................................................................................10
LIST OF FIGURE ....................................................................................................11
ABSTRACT .............................................................................................................13
CHAPTER 1: INTRODUCTION.................................................................................1
1.1 Introduction ...................................................................................................... 2
1.1.1 Problem Statement ....................................................................................... 2
1.1.2 Objective ....................................................................................................... 2
1.1.3 Scope Of Work .............................................................................................. 3
1.1.4 Background Of The Project........................................................................... 3
1.1.5 Advantages Of The Product ......................................................................... 4
1.1.6 Project Design .............................................................................................. 4
1.1.7 Project Management ..................................................................................... 5
1.1.8 Planning And Scheduling ............................................................................. 5
1.1.9 Manufacturing Management ......................................................................... 6
1.2 Project Flow Chart ......................................................................................... 10
1.2.1 Management Team ..................................................................................... 11
1.2.2 Responsible Person .................................................................................... 13
1.2.3 Organization Chart……………………………………………………………….14
CHAPTER 2: LITERATURE REVIEW ....................................................................15
2.1 Introduction .................................................................................................... 15
2.1.1 Background Of The Project......................................................................... 15
2.1.2 Type Of Power Hammer ............................................................................. 16
2.1.3 Scenario Of Power Hammer ....................................................................... 17
2.1.4 Recent Research Of Power Hammer.......................................................... 18

CHAPTER 3: METHODOLOGY..............................................................................19
3.1 Introduction .................................................................................................... 19
3.1.1 Manufacturing ............................................................................................. 19
3.1.2 Manufacturing Process ............................................................................... 20
3.1.3 Costing ....................................................................................................... 20
3.1.4 Engineering Drawing (Assembly Drawing) ................................................. 25
3.1.5 Engineering Drawing (Bom & Exploded Drawing) ...................................... 31
3.1.6 Engineering Drawing (Weld Drawing) ........................................................ 37
3.1.7 Engineering Drawing (Weld Map & NDT Drawing) ..................................... 42
3.1.8 Engineering Drawing (Shop Drawing) ........................................................ 47
3.1.9 Engineering Drawing (Shop Drawing For Assembly Purpose) ................... 57
3.2.0 Engineering Drawing (Flat Pattern Drawing) .............................................. 59
3.2.1 Engineering Drawing (Squaring Drawing) .................................................. 60
3.2.2 Introduction To Quality Improvement .......................................................... 61
3.2.3 Innovation ................................................................................................... 61
3.2.4 First Critical Improvement (Shaft Holding Part)………………………………62
3.2.5 Second Critical Improvement (Shaft) .......................................................... 63
3.2.6 Third Critical Improvement (Pulley Locking Mechanism) ............................ 64
3.2.7 Fourth Critical Improvement (Hammer Holding Part) ................................. 66
3.2.8 Fifth Critical Improvement (Frame Material) ............................................... 67
3.2.9 Sixth Critical Improvement (Hammer Drill Fixture) ..................................... 67
3.3 Seventh Critical Improvement (Cam Assembly & Cam Lock)…………………71
3.3.1 Eight Critical Improvement (Dimmer & Paddle Switch) .............................. 73
3.3.2 Creativity .................................................................................................... 73
3.3.3 Example Of Finish Product (Milling,Turning & Laser cut) ........................... 74
3.3.4 Introduction Of Material .............................................................................. 75

3.3.5 Introduction Of Material Used ..................................................................... 75
3.3.6 Common Form Of ASTM A36 Steel ........................................................... 75
3.3.7 Application Of ASTM A36 Steel.................................................................. 76
3.3.8 Chemical Properties Of ASTM A36 Steel ................................................... 76
3.3.9 Mechanical Properties Of ASTM A36 Steel ................................................ 77
3.4 Welding Process Selection ............................................................................ 78
3.4.1 Advantage Of GMAW Process ................................................................... 78
3.4.2 Consumable Introduction ........................................................................... 79
3.4.3 Factor Determining Consumable ................................................................ 79
3.4.4 Introduction To ER70S-6 Filler Metal .......................................................... 79
3.4.5 Application Of ER70S-6 Filler Metal ........................................................... 80
3.4.6 Nominal Element Composition Of ER70S-6 Filler Metal ............................ 80
3.4.7 Typical Mechanical Properties Of ER70S-6 Filler Metal ............................. 81
3.4.8 Recommended Welding Parameters .......................................................... 82
3.4.9 Fabrication Process (Paperwork) ............................................................... 82
3.5 Fabrication Process (Selection Of Material And Its Form) ............................. 83
3.5.1 Fabrication Process (Drawing and Sketching)............................................ 83
3.5.2 Fabrication Process (Measuring and Marking) ........................................... 84
3.5.3 Fabrication Process (Cutting) ..................................................................... 84
3.5.4 Fabrication Process (Drilling)…………………………………………………..85
3.5.5 Fabrication Process (Welding) ................................................................... 86
3.5.6 Fabrication Process (Grinding) ................................................................... 87
3.5.7 Machine And Equipment Used (Shearing Machine) ................................... 88
3.5.8 Machine And Equipment Used (Metal Cut-Off Saw Grinder) ...................... 89
3.5.9 Machine And Equipment Used (Grinder)……………………………………...90
3.6 Machine And Equipment Used (GMAW Machine)…………………………......91

3.6.1 Machine And Equipment Used (Drilling Machine) ...................................... 92
3.6.2 Tool And Equipment (Caliper) .................................................................... 93
3.6.3 Tool And Equipment (Measuring Tape) ...................................................... 93
3.6.4 Tool And Equipment (L-Square) ................................................................. 93
3.6.5 Tool And Equipment (Ruler)…………………………………………………….94
3.6.6 Tool And Equipment (Mallet Hammer) ....................................................... 94
3.6.7 Tool And Equipment (Half Round File) ....................................................... 94
3.6.8 Tool And Equipment (Chipping Hammer)................................................... 95
3.6.9 Tool And Equipment (Wire Brush) .............................................................. 95
3.7 Tool And Equipment (Chalk)………………………………………………………95
3.7.1 Introduction To Safety ................................................................................ 96
3.7.2 Safety At The Workshop(Environment) ...................................................... 96
3.7.3 Safety At The Workshop(Machinery) .......................................................... 96
3.7.4 Safety At The Workshop(Equipment) ......................................................... 96
3.7.5 Introduction To Personal Protective Equipment………………………………97
3.7.6 Factor That Affecting Usage Of PPE .......................................................... 97
3.7.7 Personal Protectice Equipment (Head Shield) ........................................... 97
3.7.8 Personal Protectice Equipment (Safety Goggle) ........................................ 98
3.7.9 Personal Protectice Equipment (Glove) ...................................................... 98
3.8 Personal Protectice Equipment (Earmuff)………………………………………98
CHAPTER 4: RESULT AND DISCUSSION ............................................................99
4.1 Introduction .................................................................................................... 99
4.1.1 Process Of Testing ..................................................................................... 99
4.1.2 Introduction To Visual Inspection ................................................................ 99
4.1.3 Factor Affecting Quality Monitoring ........................................................... 100
4.1.4 Visual Inspection Criteria .......................................................................... 100

4.1.5 Visual Inspection Report (Joint 1)............................................................. 101
4.1.6 Visual Inspection Report (Joint 2) ............................................................. 102
4.1.7 Visual Inspection Report (Joint 3) ............................................................. 103
4.1.8 Visual Inspection Report (Joint 4)............................................................. 104
4.1.9 Introduction To Dye Penetrant Testing ..................................................... 105
4.2.0 Reference For Standard Practice ............................................................. 105
4.2.1 Personal Qualification For NDT ................................................................ 105
4.2.2 Chemical And Material Used .................................................................... 105
4.2.3 Procedure Qualification ............................................................................ 105
4.2.4 Acceptance Criteria .................................................................................. 106
4.2.5 Acceptance Standard ............................................................................... 106
4.2.6 Flow Chart Of Dye Penetrant Inspection .................................................. 107
4.2.7 Dye Penetrant Inspection Report (Joint 5) ............................................... 108
4.2.8 Dye Penetrant Inspection Report (Joint 6)…………………………………..109
4.2.9 Dye Penetrant Inspecstion Report (Joint 7)…………………………………110
4.3 Dye Penetrant Inspection Report (Joint 8)…………………………………….111
CHAPTER 5: CONCLUSION ................................................................................112
5.1 Conclusion ................................................................................................... 112
5.2 Suggestion ................................................................................................... 113
REFERENCE ........................................................................................................114
APPENDICES .......................................................................................................115
LIST OF TABLE
Table 1.1 Planning Schedule .......................................................................6
Table 1.2 Actual Schedule ..........................................................................7
Table 1.3 Production Flow Chart ................................................................8
Table 1.4 Production Flow Chart Explaination……………………………..…9
Table 1.5 Project Flow Chart………………………………………………..…10
Table 1.6 Costing .......................................................................................24
Table 1.7 Chemical Properties Of ASTM A36 ............................................76
Table 1.8 Typical Mechanical Properties ....................................................77
Table 1.9 Advantages And Disadvantages Of GMAW ...............................78
Table 2.0 Nominal Composition Of Filler Metal ..........................................80
Table 2.1 Typical Mechanical Properties Of Filler Metal .............................81
Table 2.2 Welding Parameter…………………………………………………..82

LIST OF FIGURE
Figure 1.1 Project Design .............................................................................4
Figure 1.2 Industrial Hammer Example ......................................................17
Figure 1.3 Old Design (Shaft Holding Part) ...............................................62
Figure 1.4 Weight Of Hammer And Cam (Old Vs New) ..............................63
Figure 1.5 Drive & Motor Pulley ..................................................................64
Figure 1.6 Locking Mechanism ...................................................................65
Figure 1.7 Hammer Holder .........................................................................66
Figure 1.8 Frame Material ..........................................................................67
Figure 1.9 Scanning Tutorial.......................................................................68
Figure 2.0 Hammer Drill Sketching .............................................................68
Figure 2.1 Clamp Location .........................................................................69
Figure 2.2 Location Of Block Jig .................................................................69
Figure 2.3 Jig Block & Clamp .....................................................................70
Figure 2.4 Cam Assembly & Cam Locking Mechanism ..............................71
Figure 2.5 Cam Housing .............................................................................72
Figure 2.6 Finish Product ...........................................................................74
Figure 2.7 Warehouse ................................................................................83
Figure 2.8 Cutting Process .........................................................................84
Figure 2.9 Drilling Process .........................................................................85
Figure 3.0 Welding .....................................................................................86
Figure 3.1 Grinding .....................................................................................87
Figure 3.2 Shearing Machine......................................................................88
Figure 3.3 Saw Grinder ..............................................................................89
Figure 3.4 Grinder ......................................................................................90
Figure 3.5 GMAW Machine ........................................................................91

Figure 3.6 Drilling Machine .........................................................................92
Figure 3.7 Caliper .......................................................................................93
Figure 3.8 Measuring Tape ........................................................................93
Figure 3.9 L Square ....................................................................................93
Figure 4.0 Ruler ..........................................................................................94
Figure 4.1 Mallet Hammer ..........................................................................94
Figure 4.2 Half Round File ..........................................................................94
Figure 4.3 Chipping Hammer......................................................................95
Figure 4.4 Wire Brush .................................................................................95
Figure 4.5 Chalk .........................................................................................95
Figure 4.6 Head Sheild ...............................................................................97
Figure 4.7 Safety Goggle ............................................................................98
Figure 4.8 Glove .........................................................................................98
Figure 4.9 Earmuff ......................................................................................98
Figure 5.0 Acceptance Criteria………………………………………………..100
Figure 5.1 Joint 1………………………………………………………………..101
Figure 5.2 Joint 2………………………………………………………………..102
Figure 5.3 Joint 3………………………………………………………………..103
Figure 5.4 Joint 4………………………………………………………………..104
Figure 5.5 Joint 5………………………………………………………………..108
Figure 5.6 Joint 6………………………………………………………………..109
Figure 5.7 Joint 7………………………………………………………………..110
Figure 5.8 Joint 8………………………………………………………………...111

ABSTRACT
Various types of machinery and devices have been used for various uses in many
fields, such as forging, hammering, slicing, etc. However the various problems, such
as low power supply, less workforce and even heavy labour, safety, etc., apply to the
operation which can be carried out either by means of an electric motor or by means
of manual means.
The purpose of this work is to build the smashing, forming and forging process that
are more reliable than manually. This machine executes hammering, shaping and
forging at the required speed, and this machine is Semi-automatic, which is powered
or regulated by the electric motor with the power of the current. This tool is based on
a mechanism that are worth to be made. This power hammer can be used in
manufacturing, domestic activities or small scale activities. It may be used with either
a thin metallic or a sturdy model or body.
CHAPTER 1: INTRODUCTION
1.1_Introduction
The acheivement of the final year task is to provide group of students of the final year
Diploma in Welding with understanding and skills for process planning and research
project execution. It is also to include the information, preparation and expertise
appropriate in the context of the project to identify and explain the steps taken, to show
the ability to coordinate and prepare for project execution and decision-making in
appropriate problem solving.
The aim of this project is to ensure a safe and precious hammering of work, such as
punching, filling, riveting and smiting, i.e. welding, etc. for all planned operating
conditions. The modeling, design and study of automated portable hammering
machines are explained in this article. A crucial aspect of the assembly process
is assumed by the programmed hammering machine (hammering process).
Hammering machine used in some part of the production of material from tool to center
point, automobile frame forming, metal molding and so on. Present innovations
associated with the metal squeezing machine and the shaping machine involved some
outstanding problems in terms of nail push, fitting components, shaping of metal and
breaking of separate issues.
Hammering is the most commonly used in mechanical activity as well as in

manufacturing operations.Power hammer is one of the new techniques suggested in
the development to accomplish instantaneous Hammering of precise repetition and
quick hammering.
Power hammer is one of the new techniques suggested in the development to

accomplish instantaneous Hammering of precise repetition and quick hammering.
It should also be user-friendly and secure, and the Laborer's Physical Work can be
used automatically. In the past, the labor used hammers to force nails, to attach
pieces, to tear apart, and more. It's going to be processed manually with more
1
effort and human capital involved in the process. But it is now possible to make
it easy to process by inventing automatic hammering. There are very obvious
advantages that the industry finds in the use of automated systems. These advantages
can be very beneficial in the longer term.
1.1.1_Problem Statement
While doing a hammering job, more energy will be needed to finish it. When physical
hammering is used the tasks can be performed, although it may take longer time to
complete. It really is challenging to really do manual hammering task for the production
and operation industry, as they may have various problems such as low power supply,
less workforce and also heavy labour. This automatic hammering will help them
overcome this dilemma. We therefore take this chance to use our knowledge and
experience to produce a power hammer to ensure that the process can be carried out
easily.
1.1.2_Objective
We had a group discussion with the teammates and the superiors. We suggested a
variety of initiatives and discussions. And eventually, we're selecting Power Hammer
as our graduation project. The goals of this project are as follows:
➢ To bring the hammering process smoother than normal

➢ Identify And implement the time needed for each operation
➢ Efficiency with the least strength of man.
➢ Low starting and operating costs
➢ As time required in the case of less useful mass production.
2
1.1.3_Scope of work
➢ Review of the literature on the design of the mechanism

➢ Modeling the mechanical component of the semi automated hammering
machine using CAD software using Autodesk Inventor Profesional.
➢ To Create an semi-automated hammering machine platform using the method
of welding, cutting, drilling, bending and machining such as milling and lathe
work.
➢ Producing the power hammer machine using the welding capabelity and
machining.
➢ Testing the design of joint and the fault for this future initiative.
1.1.4_Background of the project
Hammering yet is the most widely used im industrial yet required tons of our effort and
time so now we have a propensity to plan an semi automated hammering machine
that allows for semi automatic hammering anytime you need to use. The individual to
literally just need to install the work piece and start. This machine can be used for
semi automatic hammering because the DC motor consists of a pulley fixed to it which
is connected to the cam mechanism which will drive the hammer to forge the part.
The pulley is very efficient to transfer power and act as a medium to increase the
torque. This pulley is mounted on a shaft that act as connecting rod used to produce
lateral motion from the spinning shaft, by connecting the order end of the hammer to
the cam mechanism that has a mid-swing arrangement in order to achieve the
necessary hammer motion with an acceptable torque, we will use the appropriate
die where the work piece is mounted. The power hammer is a tool that can be used
for multipurpose operation either manually or semi automatically, mainly by
hammering a workpiece that can also be used for other purposes, such as punching
forging bending, etc.
3
1.1.5_Advantages of the machine
➢ Rapid Hammering.
➢ Speedy hammering operation.
➢ Very little effort physically.
➢ Multi-Operation.
➢ Maintenance is simplistic.
➢ Comparatively low costs.
➢ Ergonomically friendly.
➢ Effective repetition and impacts
1.1.6_Project Design
Figure 1.1 Project Design
4
1.1.7_Project Management
The project management schedule is a written framework that specifies how the
project is to be executed. It describes the scale, priorities, expenditure, timetable and
outcome of the project and is vital to keeping the work on schedule.
1.1.8_Planning & Scheduling
➢ Planning
Method of working that traditionaly organize the activities that are needed to
achieve the final goal. This task require development and management of a
plan. This method is a central property and traits for intelligent behaviour. This
process require critical suficient formulation and refinement of an approach
(strategy) to ensure its interact and support with other plans and as a result
incorporates the prediction of activities with the planning and preparation of
situations for how to tackle upcoming problem.
➢ Scheduling
The process, also known as the 'change model,' is a list of staff working in the
offices for a particular day, week or month. A schedule is required for any retail
shop or production facility's everyday operation. The planning process calls for
timetables. A daily optimum scheme combines workers' needs, obligations and
in some cases consumers.
A working day is usually a time schedule, meaning that the first day workers,
followed by the next job, are listed at the top.
Usually a weekly or monthly timetable of staff on the left or on the grid, with
days of a week at the top of the grid, is organized alphabetically. Usually, the
plan employs a repeated shift technique of alternating shifts. It is the chief that
draws the timetable most often. The Human Resources Officer or Scheduling
Specialist may be primarily responsible for the preparation of the strategy in
larger operations.
5
1.1.9_Manufacturing Management
➢ Planning Schedule
Activity/ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Week
Project
Planning
Design
Sketching
Material
Research
Material
Selection
Approval of
Supervisor
Actual
Measurement
Develop
Engineering
Drawing
Approval of
Material
Measuring &
Marking
Edge Preparation
Cutting
Welding
Installation
Inspection &
Painting
Report Writing
Presentation
Table 1.1 Planning Schedule

6
➢ Actual Schedule
Activity/ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Week
Project
Planning
Design
Sketching
Material
Research
Material
Selection
Approval of
Supervisor
Actual
Measurement
Develop Engineering
Drawing
Approval of
Material
Measuring &
Marking
Edge Preparation
Cutting
Welding
Installation
Inspection & Painting
Report Writing
Presentation
Table 1.2 Actual Schedule
7
➢ Production Flow Chart
Designing
Approval of Proposal
Measuring and Cutting
Joining and Welding Installation
Finishing
Table 1.3 Production Flow Chart
8
Drawn Conceptual idea are design using
Autodesk Inventor Profesional
Planning The main goals is to ensure that all operations run
constant & smooth without any heavt wastage at
the same time can be finished on time as plan.
Scope Create good quality and affordble machine,

Improve and improvise the existing ways in
fabricating the product.
Schedule
Schedule are construct and it is neceasary to
follow them
Risks • We take note of the value in terms of safety
and protection, such as providing personal
protective equipment at work, in order to
prevent any accident.
• We struggle to finish our project because of
COVID-19.
Resources • Using the material available in MFi

warehouse
• Rm250 each of 4 members (claimable)
Table 1.4 Production Flow Chart Explaination
9
1.2_Project Flow Chart
START
Define project with Inspection

supervisor
NO
Report writing
Does the
project is
approve FYP Presentation
YES
Review the END

design/articles/websites that
related to the project.
Designing
Proposal
Measuring & Cutting
Fabricate
Table 1.5 Project Flow Chart
10
1.2.1_Management Team
➢ Team Members
Name Tengku Mohd Hafizan Bin Tengku

Zahari
ID No. 50106118079
Contact No. 011-11421741
Name Nurul Ainin Sofiya Binti Rusdi

ID No. 50106118005
Contact No. 017-8222238
11
Name Rusydi Fitri Bin Rudzylan
ID No. 50106118083
Contact No. 017-8071043
Name Wan Muhammad Izzat Bin Wan Mazihan
ID No. 50106118042
Contact No. 017-3522001
12
1.2.2_Responsible Person
Name Mr. Abdul Aziz Bin Dawam
Department Fabrication & Joining
Position Project Supervisor / Final Year Project

Coordinator
Name Mohd Mazlan bin Hamedan
Department Fabrication & Joining
Position Technical & Practical Advisor
13
1.2.3_Organization Chart
Project Supervisor
Mr. Abdul Aziz bin Dawam
Designer
Tengku Mohd Hafizan bin Tengku
Zahari
Process Planner
Nurul Ainin Sofiya binti Rusdi
Fabricator
Rusydi Fitri bin Rudzylan
Inspection
Wan Muhammad Izzat bin Wan
Mazihan
14
CHAPTER 2: LITERATURE REVIEW
2.1_Introduction
This segment addresses the study created to be used as a primary point for the
revival of existing projects and processes. Various methods may be used to produce
a number of reference as a sources of information for the graduation project. This
study is carried out by on-going industry interventions, identifying emerging
vulnerabilities, challenges that are being addressed, related help hypotheses,
questionnaires and so on to find solutions to the problems raised:-
➢ Producing an insightful project concept

➢ Analyze to figure out all the problems that will emerge when you're doing the
task.
➢ Making special plans or find the right solution to the issues that occur during
the process.
➢ Consider the kinds of products or machinery that need to be used in the
development and production of projects.
➢ Could approximate the expense of the project.
➢ A security simulation methodology used for full or continuing work on
consumer protection.
➢ Choosing the right materials and specifications being used in this project in
order to achieve Power Hammer.
2.1.1_Background of the project
Hand tools research are long journey that require some timing. Variety of hand tools
are used in blacksmith work. This type of tool work very well when it is done by hand-
forging, but their use only enough only to minor forging. It is to really difficult to realize
that produce force of the strikes, no matter how strong one might attempt to do so by
hand smashing, might not have been sufficient to affect the correct plastic effect in
moderate also intense forging. Usually, more advance machine is used for this reason.
The strength falling die is determined by the summing weight of falling mention
component to the table die.
The hammer of 200 kg is a component that we called falling pieces that are weight at
200000 N. The heavier these components, and the higher the force it smash from
which they fall. The stronger the blast power the hammer is going to deliver. Power
15
hammers are widely found in a number of formsThese hammers are named in part for
their design, in part for their mode of operation. In addition to these, a considerable
number of forging presses and forging machines are used. These hammers and
instruments shall be addressed in more depth in the detail provided.
2.1.2_Type of Power Hammer
➢ Trips hammer
Trip hammers contain vertical reciprocat ram powered by toggle. The

connection is drive by a spinning shaft during peak of the hammer. Trips
hammer are built in sizes varying from 10kg until 210 kg. The frequency of the
stroke of both helve and trip hammers have a suddle ranges from 300 per
minute for small sizes to about 165 for large sizes.
➢ Helve hammers
Helve hammers are specificly designed for general engineering work,

where the size of the die stock is always modified. It form the basis of
a horizontal wooden helve, pivoted at one end and a hammer at the
other. An adjustable eccentric lifts the hammer, which hits a blow as it
falls. They are manufactured in sizes ranging from 5 kg to 200 kg.
➢ Level Spring-Hammer
Level spring hammers are a type of special hammer with a constant lift and a
continuous hammer that are equal with variable power of effect. It is increases
with increasing operation speed contribuite to the increases the number of
strokes per minute. It is powered by single rocking lever that operate on an
elastic rod. Rocking lever contain of a leaf spring such that elastic drive is made.
They suitable for shaping and flattening small forgings to produce a large
numbers of speciment. However their downside is the spring break quite
frequent and this is cause by vibrations during operation. This specific hammers
are produce with weight ram of 30 and 250 kg. Total of strokes produce is from
200 to 40 blows per 60 second.
16
➢ Pneumatic Hammer
The two-cylinder compressor cylinders and a ram cylinder are
mounted in this hammer. The compressor piston compresses air and
takes it to the ram cylinder, where the piston that is integral to the ram
delivers blows to the task. The reciprocation of the compression piston
is obtained from the crank drive, which is controlled by the engine from
the lower gear. The air circulating mechanism between the two
cylinders consists of rotary valves with alternate ports from which air
passes through the ram cylinder below and above the piston. This is
driving the ram up and down.
➢ Hydraulic Hammer
Instead of air oil, he used hammers. In comparison to pneumatic
hammers the hydraulic hammer costs are high. In high strength
applications, hydraulic hammer is used. This is less traffic. Less
noise.
2.1.3_Scenario of Power Hammer

Normally, commonly produced power hammers are expensive and may
cost a thousand of ringgits to get them out of the sight. Currently, the
available power hammers tend to be very heavy and occupy large space,
cause them to be unsuitable for smaller manufacturing operation. In fact,
currently available power hammers and extruders require more accurate,
updated machined die sets, which may be inoperative with other tools, in
order to provide adequate operating clearance. Also at end of the day the
currently available power hammers and extruders can be powered by
connection drives which have the ability to practically ruin the equipment if
sufficient die set-ups and clearances are not preserved.
Model:
Blachsmith Air Hammer C41- 55kg
Power Hammer
Price:
RM16518 RM22712
(US $4,000-5,500)
17
Figure 1.2 Indsutrial Hammer
RM 16518-RM 22712
2.1.4_Recent Research of power hammer
The present disclosure addresses a power hammer providing consumers
with a metal forming benefit correlated with powerfull machines at a lesser
price and a lower profile than currently available power hammer systems.
In particular, the power hammer configuration of the new technology

provides three-dimensional forming capabilities that are relevant in the
formation of unique metal items such as custom bikes and automotive
parts. A power hammer unit of the present disclosure could be produced
and measured in a model kit with readily available equipment to reduce
costs. Conversely, the power hammer unit of this disclosure can be
purchased in an assembled configuration.
In one aspect, the new power hammer assembly offers controlled forming
capability while remaining efficient in terms of performance, vibration and
compact size and acquisition expense. In some embodiments, the power
hammer assembly of the latest invention includes adjustment functions
that allow for the use of die sets in various configurations, such as the
height of the shank, the length of the shank or in addition, the die sets
produced for use with other machines. In some of the examples, the power
hammer arrangement of the latest invention may compose of a belts
transmission mechanism configured to slip in the case of a die disruption
during installation or service in order to protect the power hammer
assembly. In certain implementations, the power hammer arrangement of
the present invention demands a fine adjustment of the distance between
the upper and lower dies.
18
CHAPTER 3: METHODOLOGY
3.1_Introduction
This section will discuss the specifics of the flow of this project, which will be used to
create a hammer of force from the start to the end of the project. In this project, we
have to develop the product in order to make that it is the right product. We chose this
design because it can quickly help to minimize human energy when it is used. Another
phase, which is the production process, would be the best product. Before that it is
important to make a content collection. This is to choose the necessary material to be
used. The collection of materials is often accompanied by the feature of the
component.
3.1.1_Manufacturing
Manufacturing is the production of goods to be used or purchase by methods of

resources such as labor, machinery, biological and chemical refining or formulation.
The term may apply to a range of human practices, from craftsmanship to high-tech,
and is most commonly used in industrial manufacturing, in which raw methods are
extensively processed into finished products. Such finished products could be used
for the manufacturing of other more complicated goods such as cars, home appliances
or automobiles, or sold to wholesalers who in return, sell finished goods to suppliers
which then sell to end-users.
Industrial production occurs in a form of economic structure. In a free economy,

production is normally oriented towards the mass production of goods for sale to
consumers for gain. In a communitarian economy, industry is most commonly
regulated by the state to produce a centralized control economy.
19
3.1.2_Manufacturing Process
In order to develop a new product concept, certain procedures need to be
carried out without any complications before beginning the project. In addition,
the production process is often known as the method or technique in which
each implementation is performed out. Among the phases that we have
accomplished is:
➢ Costing
➢ Engineering Drawing
➢ Selection Of Materials
➢ Selection of Welding Process
3.1.3_Costing
In order to carry out the project manufacturing process, a selection of items
needs to be taken seriously in order to accelerate the method of delivery of the
material considered for the development of the proposed and completed
project. The following table includes a list of the specification materials needed
to complete this project.
20
S Total
i Price
No I Quantity z Price
t e (RM x
e (Pieces) (RM) Quantity)
m (Thickne
s
ss x
width x
length)
1 Mild steel Hollow ½ inch x ½ - -

Square inchx1.0mm
(t)
2 Mild Steel Hollow 3inch x - -
Square 3inch
x
3.0m
m(t)
3 Mild Steel Plate 8mm - -
4 Mild steel 1 inch x - -

rectangular tube 2inchx1.
0mm(t)
5 Hammer 30inch
1 RM42.01 RM42.01
Drill Bit 2 6.5mm RM5.80 RM11.60

6
Stainless Steel
M35
7 Drill Bit 2 5mm RM3.50 RM7.00
Stainless Steel
M35
8 1 23mm RM8.50 RM8.50
Dill Bit Stainless
Steel
9 2 11mm RM5.50 RM11.00
Drill Bit Stainless
Steel
10 1 RM7.56 RM7.56
Ellen Key
21
11 4 M10 x RM 1.70 RM6.80
M10 Hex Bolt 16mm~65mm
Hexagon Screw
M10
12 1 7x7x RM 14.66 RM14.66
Machine Key Flat 300mm
13 12 RM 7.40 RM88.80
L Angle Bracket
14 67 M6 RM 0.9 RM60.30
Flanged Hex Nut
15 3 M16 RM3.3 RM9.90
Flanged Hex Nut
16 8 M10 RM 1.00 RM8.00
Flanged Hex Nut
17 8 15mm RM 11.20 RM89.60
Set Screw
18 2 RM 7.50 RM15.00
Self Aligning
Pillow Block
Bearing
19 1 RM12.40 RM12.40
Pillow Set
Screw Block
Bearing
20 1 1kg RM17.90 RM17.90
Poly Putty Hitary
21 2 RM26.78 RM53.56
Aluminium
Pulley Belt
22 2 M6 x 10 RM4.20 RM8.40
Screw
Stainless
Steel
23 1 M5 x 12 RM4.20 RM4.20
Screw
Stainless
Steel
24 1 M4 x 16 RM4.20 RM4.20
Screw
Stainless
Steel
25 2 15mm x 1mL RM 31.20 RM62.40
Rod Stainless
Steel
22
26 2 160mm RM 5.11 RM10.22
Hexagon
Screw
27 6 M6 x 1.0, M6 RM1.10 RM6.60
Hexagon Socket x 40
Head Cap Screw
28 11 M6 x 1.0, M6 RM0.90 RM9.90
Hexagon Socket x 60
Head Cap Screw
29 25 M6 x 1.0,M6 x RM0.90 RM22.50
Hexagon Socket 20
Head Cap Screw
30 44 M6 x 1.0, M6 RM0.90 RM39.60
Hexagon x 25
Socket Head
Cap Screw
31 2 M6 x 1.0, M6 RM0.90 RM1.80
Hexagon x 16
Socket Head
Cap Screw
32 1 2.0mm RM24.10 RM24.10
Stainless Steel
Tension Spring
33 Ring Hook 1 14mm RM23.10 RM23.10
Extension
Coil Spring
34 Ring Hook 1 2.0mm Rm24.10 RM24.10
Extension
Coil Spring
35 17 M6 RM0.60 RM10.20
Flat Washer
36 3 3 ½’’ RM12.00 RM36.00
U Shape Hose
Paip Clip Muffler

37 1 2’’ RM4.90 RM4.90
U Shape Hose Paip
Clip Muffler
38 1 2-1/2’’ RM5.50 RM5.50
U Shape Hose Paip
Clip Muffler
23
39 2 4’’ RM13.80 RM27.60
U Shape Hose
Paip Clip Muffler

40 5 1-3/4’’ RM3.60 RM18.00
U Shape Hose
Paip Clip Muffler

41 6 M4 RM1.30 RM7.80
Hex Socket Head
Cap Thread Screw

42 1 RM50.0 RM50
Needle Roller
Bearing
43 1 RM26.42 RM26.42
Hand Taps Tap
and Die Set Kit

44 1 RM12.16 RM12.16
V Belt
45 4 M6 x 25mm RM1.50 RM6.00
Button Cap
Screw
46 6 M6 x 40 RM3.30 RM19.80
Button Head
Torx Screw
47 1 RM10.30 RM10.30
Paint
48 1 RM3.30 RM3.30
Paint Brush
49 1 RM7.77 RM7.77
Honda Original
Circlip External
50 1 RM25.00 RM25.00
Pedal Foot Switch
51 RM18.90 RM18.90
Arduino AC-AC
Regulator
52 1 RM103.46 RM103.46
Heavy Duty Drill
TOTAL RM 1090.82
Table 1.6 Costing

24
3.1.4_Engineering Drawing (Assembly Drawing)
25
26
27
28
29
30
3.1.5_Engineering Drawing (Bom & Exploded Drawing)
31
32
33
34
35
36
3.1.6_Engineering Drawing (Weld Drawing)
37
38
39
40
41
3.1.7_Engineering Drawing (Weld Map & NDT Drawing)
42
43
44
45
46
3.1.8_Engineering Drawing (Shop Drawing)
47
48
49
50
51
52
53
54
55
56
3.1.9_Engineering Drawing (Shop Drawing for Assembly Purpose)
57
58
3.2_Engineering Drawing (Flat Pattern Drawing)
59
3.2.1_Engineering Drawing (Squaring Drawing for Pre Material Removal)
60
3.2.2_Introduction to Quality Improvement
Quality Improvement is a traditional approach to analysis the performance by

having systematic efforts to improve it by any mean of reducing factor that
affecting the product. These models are revise to get the same thing which is
improvement. They are transforms by ongoing countless of effort to make
better performance.
i. In industry, quality efforts focus on topics related to product

failures or work-related accident.
ii. In administration, quality improvement is necessary to

increasing efficiency or reducing re-work.
iii. In medical practice, quality improvement is more focus toward

reducing medical errors and needless morbidity and mortality
3.2.3_Innovation
Generally, Innovation is divided into 3 group, it is product innovation, process

innovation and model innovation. For our case we mainly focus on product
innovation because our project is based on product that related to
engineering and technology. Innovation is necessary to improve an existing
product that could benefit to the user who uses and maintaining it. Innovation
of new product is usually base on technical specifications, quality
improvements that have been made to the product or the inclusion of new
function and component, materials of the product made of or desired
operating practicality into existing products. Beside that innovation can also
deduct the cost without changing the functionality, safety and comfort
product. The key innovation to this product its reliability. From our
observation previous design focus on more welded part primarily on drive
component and frame component. As we know drive component carry a load
of stress as the machine is use. Without proper precaution and risk measure
during the fabrication of the drive component, it will cause the machine to fail
as the machine is running.
61
3.2.4_First Critical Improvement (Shaft Holding Part)
The first critical improvement that we made is to change shaft holding part.
Below is the picture of shaft holding part old design and beside it, is the
picture of new design.
Figure 1.3 Old Design(Shaft Holding Part)
As you can see the previous design use cylindrical hollow and a thin plate as
a holder for the drive shaft that drive the hammer up and down and secondary
shaft that hold the hammer, preventing the hammer from slip while running, it
is welded together by mean of fillet weld and and is place to the wooden frame
by screwing the plate on it. As time past and the machine is used abusively.
The previous design is most likely to fail. This is cause by defect that occur in
weldment that is introduced to stress. Furthermore, the material used is mild
steel so it is prone to rust when expose moist carried out by oxygen. Lack of
suitable coating also contributed to failure. On the new design we use double
pillow block as medium to hold the shaft. This type of pillow block is primarily
made of aluminium and it is produced by casting. There is no defect we
encounter beside manufacture defect. But it is easily replaceable since there
is warranty on it. Further advantage of pillow block is, it included thrust ball
bearing as smoothing agent to constrain the shaft between another pillow
block. So, the driving component can function smooth and seamlessly. Beside
that pillow block come with locking mechanism, this will ensure the shaft in
location and prevent it from sliding as the machine running.
62
3.2.5_Second Critical Improvement (Shaft)
Second innovative improvement that we made is to change the diameter of the

driving shaft and secondary shaft. Previous design use 12.7 mm equivalent to
0.5 inch and new design we upgrade the shaft to 15 mm total diameter. The
material for the shaft remains the same which is chromoly steel. The reason
we increase the shaft diameter is because we suspect 12.7 mm shaft is prone
to bend when being use vigorously. Furthermore, old design shaft carried a
load of 54.92 N which is equivalent to 5.6 KG, this load is calculated from the
sum of hammer weight and hammer holder assembly. While new design carry
lot less load which is 52.96 N which is equivalent to 5.4 KG. With this much
reduction in weight, this ensure the shaft to be less susceptible to failure and
have_long_lasting_life.
Figure 1.4 Weight Of Hammer And Cam (Old Vs New)
63
3.2.6_Third Critical Improvement (Pulley Locking Mechanism)
Third innovative improvement that we made is upgrading existing pulley

locking mechanism. On previous design the pulley is held on shaft by using
external retaining ring, which is then place inside shaft groove with depth of
1.1mm. The pulley is lock with combination of rectangle feather key that place
inside the slot on the shaft. When the motor/drill hammer running the motor
pulley will drive/pull the hammer drill pulley and will drive the hammer, this will
cause tension to the hammer drill pulley. As a consequence, this combination
of locking will cause the pulley sliding outward if the retaining ring fail.
Figure 1.5 Drive & Motor Pulley
64
We analyse the problem with critical thinking and we came up with idea that
we called bush locking mechanism. Basically, it is a rectangular bush that we
drill with 15 mm drill bit in the centre and on every 1 side of the bush we drill 2
set of holes with 5.2 mm drill bit and all hole were threaded by tap drill m6x1.0.
All the hole that are threaded than are fill with set screw. This custom bush act
as stopper for the pulley from sliding outward, because the set crew that we
place in will hold the cylindrical surface of the shaft, with the help of retaining
ring that place in the end of the bush, this will produce more rigid locking
solution.
Figure 1.6 Locking Mechanism
65
3.2.7_Fourth Critical Improvement (Hammer Holding Part)
Forth improvement that we made is redesign hammer holding part, the

previous design of hammer holding part is consist of 1’’ diameter cylindrical
hollow and 1’’ square hollow, the square hollow is compress left and right to
ensure the hammer stick will fit inside it, then is place like diamond shape
below the cylindrical hollow and weld together by mean of butt joint. The
problem of previous design is lack of practicality in field of fabrication. We
improve this by placing the cylindrical hollow on the top of the square hollow
and welded together by mean of fillet weld. Then we drill 2 set of hole with
diameter of 6.6 mm on 3 side except top area, and we weld flange hex nut to
each of the hole we made. Then the hole was fill with socket headed screw M
6. This screw is important to ensure the hammer stick are in tight. This is to
ensure the strength of the joint is sufficient, improve fabrication practicality
beside improving the flexibility of the hammer stick to be aligned perfectly with
the back holder.
Figure 1.7 Hammer Holder
66
3.2.8_Fifth Critical Improvement (Frame Material)
Fifth improvement that we made is changing the material of the frame,

previous design frame use wood as frame material. As we know wood
is porous and it easily trap moist. From time to time moisture that trap
in porous capillary will decrease the strength of frame. Beside that our
machine deal vibration, especially on punch table, if the machine were
use abusively, this will cause failure to the punch table. Frame that we
build base on mild steel is more rigid solution to overcome this kind of
situation
Figure 1.8 Frame Material
3.2.9_Sixth Critical Improvement (Hammer Drill Fixture)
Sixth innovation that we made is redesigning hammer drill fixture, previous

design only uses one socket headed screw and hex flange nut as locking
mechanism. This is not quite good solution for long lasting use. When
maximum stress is held by the threaded and the nut, this is mechanism most
likely to break and fail. To ensure the hammer drill is hold in place, we pick
design element of jig and fixture and apply it to the previous concept. We
combine Jig block and clamp to ensure there is enough rigidity to hold the
hammer drill while in operation.
67
Figure 1.9 Scanning Tutorial
First step of inventing new fixture is by reverser engineering the physical model
of hammer drill. We separated the hammer drill casing and place the casing
on the printer. Then we scan the casing, after done scanning process we
export the output file to computer aided design software, then we trace the
image_by_using_line_command
Figure 2.0 Hammer Drill Sketching
After that we place the sketch that we have made and project the primary
sketch to the base of hammer drill. And start placing hole sketch
for clamp, outer diameter of flange nut sketch and sketching suitable location
for jig block
68
Figure 2.1 Clamp Location
Below is the location of jig block in sketch
Figure 2.2 Location Of Block Jig
After complete designing the base part of the hammer drill, we complete it by
assemble them with jig block and clamp, also weld in place on top of the foot
rail assembly
69
Figure 2.3 Jig Block & Clamp
70
3.3_Seventh Critical Improvement (Cam Assembly & Cam Lock)
The improvement that we made is improve the cam assembly and cam locking
mechanism. Previous design cam mechanism is hold by two cylindrical plate
that are place inside, welded together to the cam housing by mean of butt join.
And they use ball bearing without bearing housing and place inside the cam
housing to smooth the cam. For locking mechanism, the cam housing is
welded on both side below anvil cam bracket. This is not practical because the
area of joint is not flat and to obtain accuracy and make sure the cam housing
Is parallel to the centre of anvil cam bracket is quite challenging.
Figure 2.4 Cam Assembly & Cam Locking Mechanism
71
So, on the new design we upgrade the cam housing by combining the base for
locking clamp directly to the cam housing model. Then we place needle
bearing complete with bearing to ensure the seamless of the cam. For the cam
cover we use socket headed screw to seal the cam housing to make sure the
cam mechanism in place. We also make a stabilizer to ensure locking clamp
is hold in position while the machine working. All part that related to cam
assembly is fabricate by mean of computer numerical control. We partner with
GMI to produce the product base on requirement that we set; this is because
this is the key component to ensure the assembly is not failing.
Figure 2.5 Cam Housing
72
3.3.1_Eight Critical Improvement (Dimmer & Paddle Switch)
Our last improvement that we made is installing dimmer and paddle switch
together. This is been done by rewiring three component which is hammer drill,
dimmer and paddle switch. This improvement ensure the machine smoothness
with the ability to control desire speed. With the installation of paddle switch,
this react as emergency stopper beside the dimmer. This will help to save life
if machine gone wrong.
3.3.2_Creativity
Creativity is a broad skill that can be applied to all things. Creativity is a set of
lateral thinking tools that can be applied to any field. Creativity that our group
and our supervisor and co supervisor make the product become reality. That
give a new value for this product
73
3.3.3_Example of Finish Product (Milling,Turning & Laser cut)
Figure 2.6 Finish Product 74

3.3.4_Introduction_Of_Material
Every material can become an end product of its own or an unrefined raw
material. Materials are first mined or collected from the soil and separated into
shapes which can be quickly shipped and preserved and later refined into
semi-finished materials. These could be integrated into a modern cycle of
manufacturing and processing methods for the production of finished goods,
ready for sale, development and use.
Material is something composed of matter, comprising of one or even more

ingredients. Stone, concrete, nitrogen, water and air are types of materials.
Often the word "material" is used more specifically to refer to compounds by
certain mechanical properties that are used as components for processing or
manufacturing. Throughout this way, materials are the pieces used to create
anything more from buildings and sculpture and machines.
3.3.5_Introduction Of Material Used
ASTM A36 is indeed mild and hot-rolled steel most widely used. It has
excellent welding capabilities and is ideal for grinding, punching, tapping,
drilling and machining. The yield intensity of ASTM A36 is lower than those of
cold roll C1018, allowing ASTM A36 to fold more quickly than that of C1018.
Normally, greater diameters of the ASTM A36 were n’t produced as the hot roll
rounded of the C1018 are being used.
3.3.6_Common Form of ASTM A36 Steel
ASTM A36 is normally available in the following form:
➢ Bar of rectangle
➢ Place bar
➢ Circular bar
➢ Steel forms such as canals, angles, H-beams and I-beams.
75
3.3.7 Application of ASTM A36 Steel
The steel ASTM A36 has the following applications:
➢ It is used for the bolted, riveted or welded construction of bridges,

structures and oil rigs.
➢ It is used in the formation of drums, bins, bearing plates, fixtures, rings,
models, jigs, sprockets, cams, gears, base plates, forgings, ornamental
works, rods, braces, industrial and farm machines, frames, machine
parts.
➢ It can be used for various sections obtained by flame cutting, such as
parking garages, walkways, boat landing ramps and trenches.
3.3.8 Chemical Properties of ASTM A36 Steel
Element Content
Carbon, C 0.25 - 0.290 %
Copper, Cu 0.20 %
Iron, Fe 98.0 %
Manganese, Mn 1.03 %
Phosphorous, P 0.040 %
Silicon, Si 0.280 %
Sulfur, S 0.050 %
Table 1.7 Chemical Properties Of ASTM A36
76
3.3.9 Mechanical Properties of ASTM A36 Steel
Mechanical Metric Imperial

Properties
Tensile Strength, 400 - 550 MPa 58000 - 79800

Ultimate psi
Tensile Strength, 250 MPa 36300 psi

Yield
Elongation at Break 20.0 % 20.0 %

(in 200 mm)
Elongation at Break 23.0 % 23.0 %

(in 50 mm)
Modulus of Elasticity 200 GPa 29000 ksi
Bulk Modulus 140 GPa 20300 ksi

(typical for steel)
Poissons Ratio 0.260 0.260
Shear Modulus 79.3 GPa 11500 ksi
Table 1.8 Typical Mechanical Properties
77
3.4 _Welding Process Selection
For this power hammer project, we chose Gas Metal Arc Welding (GMAW)
welding processes. We choose these welding processes because of our raw
resources, which are plates and carbon steel which have lower thickness
which is 1.5mm to 4mm.
Gas Metal Arc Welding is generally referred to as Metal Inert Gas (MIG).
(MIG). gIt is a semi-automatic or automated welding process with constantly
fed consumable wire serving as both electrode and filler metal,runing along
with inert or semi-inert shielding gas running through the wire to protect the
welding area from surrounding atmosphere. Constant voltage, direct current
source is most widely seen for GMAW, but constant current alternating current
is often used.
With constantly fed filling electrodes, GMAW provides comparatively high

flexibility.
3.4.1_Advantage Of GMAW Process
Advantages Disadvantages
Higher welding speeds Higher initial setup cost
Higher maintenance cost due to

extra electronic components
Greater deposition rates
Less post welding cleaning The equipment is complex
Less skill factor required to Cannot be used in vertical or

operate overhead position because of
high input
The process is easily automated
Table 1.9 Advantages And Disadvantages Of GMAW

78
3.4.2_Consumable Introduction
When welding, using the right consumable material or filler material, it

maintains a tight connection between two metals. It was one of the four welding
elements, together with the metal welding, the heat source, and the air
shielding. As the material is heated to its melting point by being insulated from
the air, the consumable is applied to the region joined together to produce a
single piece of metal. The consumable part of arc welding itself is not only to
fill the seam, but also to regulate the flame of the electric arc.
3.4.3_Factor Determining Consumable
In general, the electrode or the filler wire should be selected on the basis of
the following factors:
➢ Basic metal properties

➢ Joint Position
➢ Joint form/type
➢ The quantity of welding required,
➢ The tightness of the joint fit-up
➢ Form of current available
3.4.4_Introduction to ER70S-6 Filler Metal
ER70S-6 is a competent, gentle, solid wire made from steel designed to deliver
higher solder and issues, free of heavy duty, high-speed operation, medium-
speed, slower-speed, short-arc applications. ER70S-6 has been developed for
the application in a variety of gas mixtures, including 100% CO2, 75/25 Ar/CO2
or 98/2 Ar/O2. Except in the most complicated applications, ER70S-6 offers a
smooth, stable arc with limited spreading spreader to produce a welding bead
that suits seamlessly and looks smoothly.
79
3.4.5_Application of ER70S-6 Filler Metal
Frame construction, automotive buggy, agricultural machinery, construction

equipment, pressure vessels component such as shell & manway, pipe
production, railway construction and maintenance, general manufacturing.
Commonly used for highly-speed automated and autonomous welding
systems and semi-automatic applications.
3.4.6_Nominal Element Composition of ER70S-6 Filler Metal
Elements Percentage of elements(%)
Carbon(C) 0.06-0.15
Silicon(Si) 0.80—1.15
Nickel(Ni) 0.15 max
Molybdenum 0.15 max
Copper(Cu) 0.50 max
Sulphur(s) 0.035 max
Chromium(Cr) 0.15 max
Iron(Fe) Balance
Manganese(Mn) 1.40-1.85
Phosphorus(P) 0.025 max
Vanadium 0.03 max
Others 0.50 max
Table 2.0 Nominal Composition Of Filler Metal
80
3.4.7_Typical Mechanical Properties of ER70S-6 Filler Metal
Shielding gas C02 75%Ar 25% 98%Ar 2% Co2
Co2
Tensile 80-85,000 85-90,000 85-90,000
strength(psi)
Yield 65-70,000 70-75,000 70-75,000
strength(psi)
Elongation% in 2 28.5% 28% 28%
Reduction of 55-70% 55-70% 55-70%
area
Charpy v notch 20-30% 25-35% 30-40%
ft lbs
Table 2.1 Typical Mechanical Properties Of Filler Metal
81
3.4.8_Recommended Welding Parameters
GMAW usually used reverse polarity or electrode positive spray transfer
Wire amps volts argon Wire feed
diameter ipm
0.023 85-170 23-27 25 360-620
0.030 135-230 24-28 25 390-670
0.035 165-300 24-28 30 360-520
0.045 200-375 24-30 30 210-390
1/16 275-500 24-32 40 150-360
3/32 300-600 24-33 50 75-125
Table 2.2 Welding Parameter

3.4.9_Fabrication Process (Paperwork)
Paperwork is mandatory in order to provide a clear overview of anything

associated with the project. In depth, the documentation will be one of the main
records to look out to any issues or changes that might be made in the future.
The documents issued by the appraisal officer must be in conformity with the
code and the standard.
82
3.5_Fabrication Process (Selection Of Material And Its Form)
We checked and analyzed the materials that need to be included in this project
to satisfy the requirements of our project. In contrast, we have chosen to make
effective use of mild steel to reach the maximum sense of financial quality, as
well as some welding can be carried out. Mild steel is ideal for welding and
general manufacturing applications. It is also easier to mold, drill, weld and cut
than some of the more delicate forms of steel.
Figure 2.7 Warehouse
3.5.1_Fabrication Process (Drawing and Sketching)
We first draw the concept before we construct this project. Sketching is an

effective method be used to help us discover the new ideas and solutions to
the design problem. It's a big challenge to 'freestyle' a complex idea out of mid-
air without sorting out the details. That's why sketching will continue to be an
important phase in the development. Afterwards, we handle the design using
computer aided design tools such as Autodesk Inventor Profesional and
Autodesk Autocad
83
3.5.2_Fabrication Process (Measuring and Marking)
a) Again after raw materials were selected from the factory, the residual
dirt and rust on the surfaces of the materials are eliminated by polishing
or brushing. Bring the raw materials to the workshop for the labeling of
the materials.
b) Material is mark according to the dimensions as defined in the
engineering drawing that have been accepted with the use of a chalk
stick or permanent marker in order to prevent non-visible
measurements
c) Marking is achieved with the help of measuring tape, ruler and the L-
ruler.
3.5.3_Fabrication Process (Cutting)
a) The designated materials will be shaped into their dimension with the
use of the milling, lathe, laser cut machine, shearing machine, cutter
and the sawing machine
b) During the operation of the machinery, precautions must be taken to
prevent any injuries that may occur
c) Hollow square frame is place on jig then will be slice by disc cutter
d) Ensure the marked region on the material is opposite to the disk.
e) Run the machine and cut the material perfectly.
f) Off the machine after finish using
g) Removed the by product from the fixture of the disc cutter
84
Figure 2.8 Cutting Process
3.5.4_Fabrication Process (Drilling)
a) Locational dimension of hole are measured on the origin axis of the

materials. Then it is necessary to marked precisely where the holes are
need to be drilled.
b) The right size of drill bit are selected for the suitableness for the
materials being drilled and the instrument being used.
c) Center punch with combination with hammer to make a slight mark on
the surfaces of the work-piece. This will keep the drills from
dislocation as they introduce to the surface of work piece.
d) The material was aligned to be concentrically with drill bit center
line and clamped to the fixture of the bench drill. Clamp fixture is apply
on the work piece to produce pressure that will hold the material from
wiggling during the drilling process.
e) Be sure that the size of the drill is matching with the outcome size.
f) Machine is turn on
g) The rotating drill was sunk into the material to ensure the drilling process
smooth, added coolant during the drilling process, It will helps lubricate
the hole,drill bit and the work piece. Coolant also provide longevity of
the drill bit because it ensure the drill bit from overheat produce by the
friction between the surface of the drill bit and the work piece
h) Machine is turn off after drilling process is done
i) Excess material is remove from work benc
j) Fluids and steel chips are cleaned up to ensure the area not mess
Figure 2.9 Drilling Process

85
3.5.5_Fabrication Process (Welding)
a) Firstly earth clamp is attach to worktable.

b) GTAW machine is switch on.
c) Gas Extractor is on.
d) Open the valve of the inert gas.
e) Set the regulator of the gas to 15-20 cfm.
f) Test the gas by using the gas button on machine to make sure the level
at the regulator is correct.
g) Use the current and voltage according to constructed WPS.
h) Adjust comfortability according to your situation.
i) Place the test base metal on worktable and start welding to get the feel.
j) Test welding again to fine tune the current and volt.
k) If the tune is satisfied start working on actual project.
l) If spatter and slag is present, remove them using chipping hammer.
m) After finish clean the workpiece using wire brush.
n) Turn off the gas valve and remove remaining gas in the system using
the gas button on the system.
o) Turn off the machine.
p) Turn off the gas extractor.
q) Work area is clean from the welding byproduct.
Figure 3.0 Welding 86

3.5.6_Fabrication Process (Grinding)
a) Equip yourself with personal protective equipment

b) Select suitable grinding disc that are suitable for the purpose, either use
for grinding or cutting, cause both of them have different on the way it
been used.
c) Plug the switch of the grinder and on the power source
d) Switch on the grinder
e) Grind the area that demand the need to be grind
f) Grind up to your desire and meet you expectation
g) Switch off the grinder
h) Clean the surrounding area
Figure 3.1 Grinding
87
3.5.7_Machine and Equipment Used (Shearing Machine)
Figure 3.2 Shearing Machine

Pre-Operational Safety Check
a) Bench shears must be tightly fastened to an bench stand.

b) Guards or protective equipment shall not be withdrawn nor modified
unless by an authorised individual for repair reasons.
c) Shearing tips must be preserved in excellent condition, free of distortion
as well as properly calibrated.
d) All operating sections must be properly lubricated as well as the blades
must clear from dust and debris.
e) Make sure that the hazard of fall or trip are present in the office and
walkways.
88
3.5.8_Machine and Equipment Used (Metal Cut-Off Saw Grinder)
Figure 3.3 Saw Grinder

Pre-operative safety checks
a) Identify and make sure that you are familiar with both machine
operations and function
b) Make sure that all guard are installed, safe and usable. Never work if
the guards are absent or defective.
c) Ensure that the saw is correctly mounted to the workbench by
bolts/clamps somewhere around the height of the hip.
d) Verify that the saw is run on an RCD protected circuit
e) Use abrasive cut disks for the right size of the arbor hole.
f) Analyse the cut-off disk for cracks and stones.
g) Make sure work areas and passageways to insure that no slip/trip
hazards are present
89
3.5.9_ Machine and Equipment Used (Grinder)
Figure 3.4 Grinder

Pre-operational safety checks
a) Make sure that both guards and safety shields are in place before
operating the grinder.
b) Make sure that the wheels does not contact the remainder of the job
and the distance between both the wheel and the rest does not exceed
1.5 mm.
c) Confirm that the disks are running perfectly and are not glazed or
loaded.
d) Identify and verify that you are comfortable with the function of the
ON/OFF starter.
e) Defective appliances shall not be used for work. Report directly to
responsible technician for any suspected machine.
90
3.6_ Machine and Equipment Used (GMAW Machine)
Figure 3.5 GMAW Machine

PRE-OPERATIONAL SAFETY CHECKS
a) Make sure that you are familiar with both system processes and
controls.
b) Ensure that work environment is sterile and free of grease, gasoline and
other combustible liquids.
c) Make sure the welding tools, work area and gloves dry to prevent
electrical shocks.
d) Verify that your gloves, your welding pistol and your work leads are in
good order.
e) Make sure that all users are secure from flashes by covering the curtain
to the welding bay or by erecting windows.
f) Begin the smoke extraction device until welding starts.
g) Ensure the job leads do not create a tripping threat.
OPERATIONAL SAFETY CHECKS

a) Ensure that the system is properly set up for current, voltage, wire feed
and gas flow.
b) Verify that the earth cables make solid contact with the workbench to
provide a strong electrical connection.
c) Please take caution to avoid flashes.
91
3.6.1_ Machine and Equipment Used (Drilling Machine)
Figure 3.6 Drilling Machine
PRE-OPERATIONAL SAFETY CHECKS
a) Discover and check that you are experienced with both system
processes and functions.
b) Make sure that all guard are mounted, safe and usable. Should not work
if the guards are absent or disabled.
c) Check the workspace and walkways to ensure that there are no slip/trip
risks.
d) Verify that the drill bit is in good order and safely installed.
e) Verify the coolant distribution system to allow adequate coolant flow.
OPERATIONAL SAFETY CHECKS
a) Keep the moving parts of the system visible.

b) Follow the necessary protocols for clamping. Keep overhangs as
minimal as possible and check the work - piece as stable as possible.
c) Adjust the right speed to accommodate the cutter diameter, the cutter
depth and the material.
92
3.6.2 Tool and Equipment (Caliper)
Figure 3.7 Caliper

Caliper is a form of measurement instruments that measures the distance
among 2 different sides of an object. Calipers are designed to measure
thicknesses and internal or external diameters which are unavailable to a
scale.
3.6.3_Tool and Equipment (Measuring Tape)
Figure 3.8 Measuring Tape

To measure distance with accurate measurement
3.6.4_Tool and Equipment (L-Square)
Figure 3.9 L Square

To direct the scribble when marking a line at a right angle to one edge of the
job.
93
3.6.5_Tool and Equipment (Ruler)
Figure 4.0 Ruler
Measure the distance and keep the dimensions in order for more
metalworking.
3.6.6_Tool and Equipment (Mallet Hammer)
Figure 4.1 Mallet Hammer
Repairing the body of a components and punching the center punch.
3.6.7_ Tool and Equipment (Half Round File)
Figure 4.2 Half Round File
To filling the curve between the surfaces.
94
3.6.8_ Tool and Equipment (Chipping Hammer)
Figure 4.3 Chipping Hammer
Act as a spatters remover due to welding
3.6.9_Tool and Equipment (Wire Brush)
Figure 4.4 Wire Brush

Act as cleaner of the welding metal from spatter and slag
3.7_Tool and Equipment (Chalk)
Figure 4.5 Chalk

Mark metal and steel with a transparent, wax-like mark.
95
3.7.1_Introduction to Safety
Security is the state of safety, the status of defense against physical, societal,
spiritual, environmental, political, mental, occupational, psychological,
educational or other effects of loss, injury, mistake, disaster, harm or some
other occurrence that may be deemed undesirable. Protection may also be
characterized as the management of known hazards in order to achieve an
appropriate degree of danger. This can take the form of protection against
exposure to material that causes health or economic damages. It can require
the safety of individuals or possessions.
Health is the most important factor in any sort of high risk of jobs. Safety at
work is required for the quality of work and when quality is high, efficiency often
improves indirectly by enhancing good work. Safety is the first concern in the
world of engineering when managing a project or other building.
3.7.2_Safety at the Workshop(Environment)
We should maintain that the workspace is free of all dirt and scrap material
that may pose harm and damage to the employee. For eg, gasoline, dirt, metal
dust and garbage.
3.7.3_Safety at the Workshop(Machinery)
Make sure that the machines are clean but also that the machine locations are
properly configured according to the 5S definition.
3.7.4_Safety at the Workshop(Equipment)
Before the operation, we must ensure that the protection equipment is in good
shape and complete.
96
3.7.5_Introduction to Personal Protective Equipment
Protective equipment also known as personal protective equipment worn to

limit exposure to dangers that inflict significant harm and sickness to the
employee. Accident is the result from contact with chemical, radiological,
physical, electrical, mechanical or other type of occupational hazards.
Personal protection gear also include products such as goggles, protective
goggles and footwear, earbuds or muffs, coveralls, or belts, jackets and full
body suits.
3.7.6_Factor that affecting usage of PPE
Factors that affecting the usage of personal protective equipment are:
a) Enforcment on the authority

b) Environment of the workplace
c) Management
d) Work factor
e) Knowledge
f) Budget to enforce
3.7.7_Personal Protectice Equipment (Head Shield)
Figure 4.6 Head Sheild

To protect face and eyer from hazard fumes and intense light during welding
97
3.7.8_Personal Protectice Equipment (Safety Goggle)
Figure 4.7 Safety Goggle

Protect eyes from dust and spark produce by grinding or polishing of metal
3.7.9_Personal Protectice Equipment (Glove)
Figure 4.8 Glove

Glove protect the hand from burr or sharp edges, also glove protect hand skin
from heat produce by welding, grinding or polishing.
3.8_Personal Protectice Equipment (Earmuff)
Figure 4.9 Earmuff

Prevent eardrum from intense and high frequency noise
98
CHAPTER 4: RESULT AND DISCUSSION
4.1_Introduction
As stated, it was found that the project produced requires a specification that
meets the specifications and expectations to produce the best performance.
Sum up, this project has been fruitful in the research process. Consequently, I
hope that this Power Hammer will be improved and innovated from period to
period as an example of making it light but strong so that it is easy to maneuver
around or incorporate artificial intelligence elements.
4.1.1_Process Of Testing
a) VI or Visual Inspection
b) DPI or Dye Penetrant Inspection
4.1.2_Introduction To Visual Inspection
Visual inspection or VI is reliable, flexible and required less technologically

advanced than any other non destructive technique. Because of this, it still has
a number of advantages across more high-tech methods. It is far more cost-
effective comparison to other techniques. That's because there is no need for
equipment that is required to conducting this type of inspection. Visual
inspection is also one of the easiest inspection techniques to be carried out
for multiple reason.
99
4.1.3_Factor Affecting Quality Monitoring
Well prepared QC can identify several signs of surface defect as a highlight for
upcoming problem. To preserve quality monitoring and assurance scheme,
the auditor shall check the work piece or specimen and ensure that:
• Welds are made according to the plans and make sure no welds are
incomplete.
• Weld is made accordance with guidance of approve welding procedure

specification
• Work piece shall be carried out in compliance with the standard.
4.1.4_Visual Inspection Criteria
100
Figure 5.0 Acceptance Criteria
4.1.5_Visual Inspection Report (Joint 1)
Figure 5.1 Joint 1 101

102
Figure 5.2 Joint 2
103
Figure 5.3 Joint 3
104
Figure 5.4 Joint 4
4.1.9_Introduction To Dye Penetrant Testing
DPI technique specified the identification of discontinuities open on the

surface, such as holes, seams, laps, cold shuts, lamination, by leakage or lack
of fusion in non-porous, metallic or non-metallic materials, by means of liquid
dye penetration tests
4.2.0_Reference For Standard Practice
ASTM E165: Standard Practice for Liquid Penetrant Inspection Method.
4.2.1_Personal Qualification For NDT
➢ Personnel performance NDT other than Visual shall bequalified in

conformance with the current edition of the America Society for
Nondestructive Testing recommended Practice NO-SNT- TC-1A
➢ NDT Level II or NDT Level I working under the NDT level II
4.2.2_Chemical And Material Used
➢ Non-fluorescent Penetrant are solvent removable penetrant dispensed

from pressurized aerosol can shall be used.
➢ Penetrant Remover are solvent remover dispensed from pressurized
aerosol can shall be used.
➢ Developer are non-aqueous wet developer from pressurized aerosol
can shall be used.
4.2.3_Procedure Qualification
Way to conducting Inspection and techniques are detailed in the technique

sheet and must be demonstrated and achieve satisfaction of the authorized
Inspector when it is required by the governing code.
105
4.2.4_Acceptance Criteria
4.2.5_Acceptance Standard
106
4.2.6_Flow Chart Of Dye Penetrant Inspection
107
4.2.7_Dye Penetrant Inspection Report (Joint 5)
Figure 5.5 Joint 5 108

4.2.8_Dye Penetrant Inspection Report (Joint 6)
109
Figure 5.6 Joint 6
4.2.9_Dye Penetrant Inspecstion Report (Joint 7)
110
Figure 5.7 Joint 7
4.3_Dye Penetrant Inspection Report (Joint 8)
111
Figure 5.8 Joint 8
CHAPTER 5: CONCLUSION
5.1_Final_Coclusion
From overall view of this final year project, the conclusions that can be made
are this project require extensive use of the knowledge obtain from semester
1 until semester 5. Students are encouraged to apply the knowledge that we
learn into the real work project. The subject also trains the student to use
critical thinking to improvise new improvement that are required to enhance
the longevity of the product. Beside that we also learn that proposal making is
real key area to find out the purpose of the project and what kind of product
and design should be produced, by implementing this kind of activity, this help
us to understand working nature. While project planning really helps us to
discipline and stay committed time to time to finish the product. Students also
are exposed with the real environment in planning a project, this help us to
plan maturely, because project planning is one of the keys to successful
product. Next this subject help us to train to be better and practice what we
have learned focus on part that related to welding area. This kind of project
also essentially improve our skills in using several software such as AutoCAD
and Inventor.
The time we built our project, COVID-19 get rage and force our university to
close, this prevent us from finishing our project according to schedule. So, we
prepare animation of the machine as side outcome. There are many obstacles
that face while doing animation. Because this area is not excessively
introduced to us in our study syllabus. This help us be self independent by
doing some research online, book reading by mean to complete this animation.
At last we successfully made our working machine animation.
Lastly, project management that we learn in welding management help us to

understand that managing are really requires the participation of all team
members. Project management also requires planning of time, work category
to be done as well as standard and specification of the material that need to
112
use. At last positive outcome that we can get by exposing to this project is it
taught us to be more punctual in working and the importance of teamwork.
A suggestion is basically an idea that someone proposes or discuss. Decision

process is divided by two either you can accept or reject that particular
suggestion. In life decision making is absolutes or optional for example when
someone gives an order like in the military service, it has to be enforced
despite on what time, condition and situation. On the other hand, a suggestion
is an idea that is optional.
5.1_Suggestion
Based on this project, we have attached some of our suggestion that can be
done at the project for other improvement.
a) Surface finish and coating
The surface finish of the frame is bare metal, which is prone to rust if expose
to normal environment. With little cleaning the surface finish of the frame can
be smoother and with the help of coating, the frame will have long lasting life
and are more resistant to rust
b) Burr and sharp edges
Most of the fabricated part have sharp edges and burr as a by-product of
cutting. By removing burr and sharp edges it will reduce the risk to fatal
accident, if our body part expose to unconditional circumstances.
113
114
APPENDICES
Welding Procedure 1
115
116
Welding Procedure 2
117
118
Proposal (Project Title)
Proposal (Brief)
119
Proposal (Design Sketch & Drawing)
Proposal (Costing)
120
Proposal (Organization Chart)
121

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FYP Report UNIKL MFI Tengku

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POWER HAMMER

TENGKU MOHD HAFIZAN BIN TENGKU ZAHARI

UNIVERSITI KUALA LUMPUR

TENGKU MOHD HAFIZAN BIN TENGKU ZAHARI

Report Submitted to Fulfill the Partial Requirements For

Date : Signature : …………………………

Date : Signature : …………………………

Date : Signature : …………………………

Date : Signature : …………………………

Date : Signature : …………………………

Date : Signature : …………………………

LIST OF TABLE ......................................................................................................10

LIST OF FIGURE ....................................................................................................11

1.1 Introduction ...................................................................................................... 2

1.1.1 Problem Statement ....................................................................................... 2

1.1.2 Objective ....................................................................................................... 2

1.1.3 Scope Of Work .............................................................................................. 3

1.1.4 Background Of The Project........................................................................... 3

1.1.5 Advantages Of The Product ......................................................................... 4

1.1.6 Project Design .............................................................................................. 4

1.1.7 Project Management ..................................................................................... 5

1.1.8 Planning And Scheduling ............................................................................. 5

1.1.9 Manufacturing Management ......................................................................... 6

1.2 Project Flow Chart ......................................................................................... 10

1.2.1 Management Team ..................................................................................... 11

1.2.2 Responsible Person .................................................................................... 13

1.2.3 Organization Chart……………………………………………………………….14

CHAPTER 2: LITERATURE REVIEW ....................................................................15

2.1 Introduction .................................................................................................... 15

2.1.1 Background Of The Project......................................................................... 15

2.1.2 Type Of Power Hammer ............................................................................. 16

2.1.3 Scenario Of Power Hammer ....................................................................... 17

2.1.4 Recent Research Of Power Hammer.......................................................... 18

3.1 Introduction .................................................................................................... 19

3.1.1 Manufacturing ............................................................................................. 19

3.1.2 Manufacturing Process ............................................................................... 20

3.1.3 Costing ....................................................................................................... 20

3.1.4 Engineering Drawing (Assembly Drawing) ................................................. 25

3.1.5 Engineering Drawing (Bom & Exploded Drawing) ...................................... 31

3.1.6 Engineering Drawing (Weld Drawing) ........................................................ 37

3.1.7 Engineering Drawing (Weld Map & NDT Drawing) ..................................... 42

3.1.8 Engineering Drawing (Shop Drawing) ........................................................ 47

3.1.9 Engineering Drawing (Shop Drawing For Assembly Purpose) ................... 57

3.2.0 Engineering Drawing (Flat Pattern Drawing) .............................................. 59

3.2.1 Engineering Drawing (Squaring Drawing) .................................................. 60

3.2.2 Introduction To Quality Improvement .......................................................... 61

3.2.3 Innovation ................................................................................................... 61

3.2.4 First Critical Improvement (Shaft Holding Part)………………………………62

3.2.5 Second Critical Improvement (Shaft) .......................................................... 63

3.2.6 Third Critical Improvement (Pulley Locking Mechanism) ............................ 64

3.2.7 Fourth Critical Improvement (Hammer Holding Part) ................................. 66

3.2.8 Fifth Critical Improvement (Frame Material) ............................................... 67

3.2.9 Sixth Critical Improvement (Hammer Drill Fixture) ..................................... 67

3.3 Seventh Critical Improvement (Cam Assembly & Cam Lock)…………………71

3.3.1 Eight Critical Improvement (Dimmer & Paddle Switch) .............................. 73

3.3.2 Creativity .................................................................................................... 73

3.3.3 Example Of Finish Product (Milling,Turning & Laser cut) ........................... 74

3.3.4 Introduction Of Material .............................................................................. 75

3.3.6 Common Form Of ASTM A36 Steel ........................................................... 75

3.3.7 Application Of ASTM A36 Steel.................................................................. 76

3.3.8 Chemical Properties Of ASTM A36 Steel ................................................... 76

3.3.9 Mechanical Properties Of ASTM A36 Steel ................................................ 77

3.4 Welding Process Selection ............................................................................ 78

3.4.1 Advantage Of GMAW Process ................................................................... 78

3.4.2 Consumable Introduction ........................................................................... 79

3.4.3 Factor Determining Consumable ................................................................ 79