A Intro

Semi-automatic welding machine equipment 2016
1.INTRODUCTION
1 M.G.I.T.E.R.,NAVSARI
1.1 Basic Introduction

Welding is a fabrication process that joints, usually metals or thermoplastics by causing
fusion. For making better of welding technology, one must produce accurate welding equipment.
In recent year automated welding process is used the advantage of this automated welding
process are increased the productivity, improved weld quality. However, an automated welding
process may not be best for every application and cost for automated welding process is also high.
Although manually welding process is time consuming and lower accurate. To produce better quality
weld and accuracy we must consider semi-automatic welding which decreases production time and
increases better weld.
But we must consider welding types for this semi-automatic welding equipment. Following
are the various types of welding:
Fig.1.1.1 Classification of welding
1.2 Types of Welding (Based on Degree of automation)
Welding can be done as following:
Manual Welding: - Movement of welding gun is controlled by hand. This may be called hand-held
welding.
 Field of Application :-
 Maintenance and repair industries
 Naval Industry
 Construction of steel structures
 Pipelines
 Welds any position
 Advantage :-
 Equipment Cheap, Versatile, Simple and Portable
 Weld any position
 Disadvantage :-
 Irregular weld
 Chances of hazards
Semi-automatic welding: - Uses a gun that is connected to a manipulator of some kind (not
Hand-held ). An operator has to constantly set and adjust controls that move the manipulator.
Fully Automatic Welding: - Uses equipment which welds without the constant adjusting of
Controls by a welder or an operator. On some equipment, automatic sensing devices control the
Correct gun alignment in a weld joint.
1.3 Working Principle of MIG
As shown in fig. the electrode in this process is in the form of coil and continuously fed
towards the work during the process. At the same time inert gas (e.g. argon, helium, ) is passed
around electrode from the same torch. Inert gas usually argon, helium, or a suitable mixture of these
is used to prevent the atmosphere from contacting the molten metal and HAZ. When gas is supplied,
it gets ionized and an arc is initiated in between electrode and work piece. Heat is therefore produced.
Electrode melts due to the heat and molten filler metal falls on the heated joint.
Fig.1.3.1 Working Condition of Work piece
Fig.1.3.2 Working Principle of MIG welding
1.4 Basic Equipment for a Semi-automatic welding Setup

(For General MIG Semi-automatic setup)
Welding Power Source:- provides welding power.
Wire Feeders (Constant Speed And Voltage-Sensing ) :- controls supply of wire to welding gun.
Constant Speed Feeder - Used only with a constant voltage (CV) power source. This type of
feeder has a control cable that will connect to the power source. The control cable supplies power to
the feeder and allows the capability of remote voltage control with certain power source/feeder
combinations. The wire feed speed (WFS) is set on the feeder and will always be constant for a given
preset value.
Welding Gun - delivers electrode wire and shielding gas to the weld puddle
Shielding Gas Cylinder - provides a supply of shielding gas to the arc.
Fig.1.4.1 Basic MIG welding setup
2.LITERATURE REVIEW
2.1 Background research

To understand the challenges of designing a welding fixture, background research must
be consider.
G. Haragopal, P V R Ravindra Reddy and J V Subrahmanyam presented a method to

design process parameters that optimize the mechanical properties of weld specimen for aluminum
alloy (Al-65032), used for construction of aerospace wings. The process parameters considered for
the study were gas pressure, current, groove angle and pre-heat temperature. Process parameters were
assigned for each experiment. The experiments were conducted using the L9 orthogonal array.
Optimal process parameter combination was obtained. Along with this, identification of the
parameters which were influencing the most was also done. This was accomplished using the S/N
analysis, mean response analysis and ANOVA. Mechanical properties obtained for three samples of
each run were obtained. Signal to noise ratio for each quality (S/N) ratio for each quality
characteristic was calculated, significant parameters were identified and optimum input parameter for
each quality characteristic were predicted from S/N values and mean response. Analysis of variance
(ANOVA) ascertained significant parameters identified through S/N analysis. A confirmation test
was conducted at optimum conditions to ensure correctness of analysis [1].
Omar Bataineh, Omar Barqawi was identified and optimized the main factors that have
significant effect on weld joint strength through factorial design experiments. Welding experiments
were carried out using MIG Welding process and An ER1100 filler wire with 1.2 mm in diameter was
used as a consumable electrode. The shielding gas used was 100% pure Argon. Test specimens were
composed of two pieces each, and each piece was 100 mm × 50 mm × 8 mm in size and made of 1070
aluminum alloy.
Fig.2.1.1 Joint geometry for the welding specimen
The factors that were studied are arc voltage, filler feed rate, gas flow rate, specimen edge
angle and preheat temperature. Results of factorial design experiments and the analysis of variance
(ANOVA) showed that arc voltage and filler feed rate are the only significant factors of the five.
Optimal settings of arc voltage and filler feed rate were reached using regression analysis at 24 V and
7 in/s, respectively, at which the mean weld strength is maximum [2].
Izzatul Aini Ibrahim, Syarul ashraf mohamat, Amalina.amir,et. al performed experiments
in the effects of different parameters on welding penetration, micro structural and hardness
measurement was measured in mild steel that having the 6mm thickness of the base metal by using
the robotic gas metal arc welding. The variable parameters are arc voltage, welding current and
welding speed. The penetration, microstructure and hardness were measured for each specimen after
the welding process and the effect it was studied. As a result, it obvious that increasing the parameter
value of welding current increased the value of depth of penetration. Other than that, arc voltage and
welding speed is another factor that influenced the value of depth of penetration. In these experiments
use 100 % shielding gas and wire electrode is ER70S 6 with 1.2 diameter nozzle to work distance
is 12mm and only one pass on weld plate. In Figure ,The effect of welding current on penetration was
present in welding speed as constant as 20 cm/min and the value of penetration was increased by
increasing the value of welding current 90, 150 and 210 A. The highest penetration is 2.98 mm at 22
V and 210 A. Welding speed as constant as 40 cm/min and the value of penetration was increased by
increasing the value of welding current 90, 150 and 210 A. The highest penetration is 3.26 mm at 22
V and 210 A. The change in the value depth of penetration is similar at voltage of 26V and 30V. The
welding speed as constant as 60 cm/min and the value of penetration was increased by increasing the
value of welding current 90, 150 and 210 A. The highest penetration is 2.79 mm at 26 V and 210 A.
The changes in gas metal arc welding parameters are influenced the effect of the
microstructure of weld metal. The increased welding current, welding speed and arc voltage the grain
size of microstructure also different from one point to another point.
Fig.2.1.2 Penetration vs. Welding Current & Voltage
So by these experiments we can conclude that depth of penetration increased by increasing the value
of welding current. Welding current is a factor that will determine the penetration. Penetration also
influences by the factors from welding speed and arc voltage. The grain boundaries of
microstructures changes from bigger size to smallest size when the variable welding parameters
changed [3].
2.2 Effect of process parameter on bead geometry
Voltage :-
The height decreases with increase in voltage but the reverse is true with the width and
dilution. Increasing the arc voltage makes the bead wider; the height is reduced because the
same volume of weld metal is involved. Greatest effect of individual parameter on bead
width was of arc voltage.
Fig.2.2.1 Effect of Voltage on bead width
Current:-
Increase in current gives rise to enhanced line power per unit length of the weld bead and
higher current density, causing larger volume of the base material to melt and hence, deeper
penetration. As current increases the temperature, the heat content of the droplets also
increases, which results in more heat being transferred to the base material.
Increase in current also increases momentum of the droplets, which on striking the weld pool
causes a deeper penetration. An increase in welding current, with other variables remaining
constant, results in increased depth of penetration, increased deposition rate and increased
weld bead size and shape at a given cross-section.
Fig.2.2.2 Effect of Current on bead width
Welding speed:-
Welding speed is not showing any significant effect on penetration. At any current, bead
width is inversely proportional to the welding speed. With high welding speed, the excess
weld metal builds up due to rapid cooling of the weld pool edges and results in increase of
height and simultaneously width decreases. Decrease in height could be due to the fact that
weld pool size is affected by cooling rate, which decreases with increasing the welding
current or by decreasing the travel speed. Thus at higher welding speed, size of the weld pool
and metal deposition rate will decrease i.e. width, and height will decrease.
Fig.2.2.3 Effect of welding speed on bead width
3. WORKING
METHODOLOGY
3.1 ACTUAL SET-UP
Fig 3.1.0 Actual Set-up
3.2 WORKING METHODOLOGY

1. Arrange the welding torch on the torch plate.
2. Mount the work piece on the work plate where the welding is to be
done.
3. Manually adjust the air gap between the work piece and the welding
torch as per the requirement of the process.
4. Operate the handle and perform the initial run.
5. Move the work piece in forward and reverse direction as per the
requirement with the help of handle.
6. Unload the work piece from the worktable.
3.3 EXPERIMENTAL WORK
JUNE JULY AUG SEP OCT NOV JAN FEB MARCH

Topic  
Selection
Literature  
Review
Group  
Registration
PPR  
submission
Designing   
Component   
searching
and
purchasing
Fabrication 
Business 
Model
Canvas
Patent 
Drafting
Exercise
4. DESIGN AND
MODELING
4.1 DESIGN PROCESS
Design Formation
Design Formation for Semi-automatic welding process were carried out to discuss the benefits of
each design. Alternatives for semi-automatic welding process were worked on. Analysis of each
design for all the parts carried out by calculations of various loads in working conditions.
Design Selection and Creation

Design of parts is carried out by considering safety against various static and other loads.
Calculations for failure safety were carried out by various formulas where some of the
loads were assumed according to application areas of equipment.
Final Design
Final Design of project is formulated and modified according to changes and modifications in
assembly. The main focus of design on the easiness with which fixture can locate and hold
welding torch.
4.2 DESIGN OF BED/BASE

Bed is important in all the machine tool, because it’s providing support to all other component of
machine. Here we assume material of bed is grey cast iron (FG200) IS: 210 – 1993 because, FG 200
has,
 Easily cast
 Better vibration absorption capacity.
 Good compressive strength.
 Fewer prices.
Check bed in bending,

We know that bending stress
Where, σ = bending stress of material (N / mm²)
Mb = maximum bending moment (N – mm)
Z = section of modulus (mm³)
Fig.4.2.1 Design of bed
Z= b /6
Z=500× /6
Z=3×
Load acting on the bed is shown in Figure
Fig.4.2.2 Load distribution diagram
Taking Moment @A (Assume clockwise direction as Positive)
M@A=0
0 = (98.1×200) + (69.62×300) + (19.62×800) + (69.62×1300) – (RB×1400)
0 = 146708 – (RB×1400)
RB = 104.781 N
Now,
RA – RB = 98.1 + 69.62 + 19.62 + 69.62
RA = 152.169 N
Here,
M@p = – (104.781×1200) + (69.62×1100) + (19.62×600) + (69.62×100)

= – 30433.2 N mm (CCW)
M@q = – (104.791×1100) + (69.62×1000) + (19.62×500)

= – 35840.1 N mm (CCW)
M@r = – (104.791×600) + (69.62×500)

= – 28064.6 N mm (CCW)
M@s = – (104.791×100)
= – 10479.1 N mm (CCW)
Maximum Bending Moment occurs at point q;
= N/
= 11.94 N/
Here, <
(Where, = 160 N/mm2)
Hence Design is safe.
Calculation for bending moment diagram

B =0
B = (69.62×100) + (19.62×600) + (69.62×1100) – (104.791×1200)

= – 30433.2 Nmm
= – 30.4332 Nm
B = (19.62×500) + (69.62×1000) – (104.791×1100)

= – 35840.1 Nmm
= – 35.8401 Nm
B = (69.62×500) – (104.791×600)
= – 28064.6 Nmm
= –28.0646 Nm
B = – (104.791×100)
= – 10479.1 Nmm
= –10.4791 Nm
B =0
Calculation for shear force diagram
@A = 152.169 N
= 152.169 N
@p = 152.169 – 98.1
= 54.069 N
= 54.069 N
@q = 54.069 – 69.62
= –15.551 N
= –15.551 N
@r = –15.551–19.62
= –35.717 N
= –35.717N
@s = –35.71–69.62
= –104.791 N
= –104.791 N
@B = –104.791 + 104.791
=0N
Fig.4.2.3 shear force diagram of bed
Fig.4.2.4 bending moment diagram of bed
4.3 DESIGN OF LEAD SCREW

Function of lead screw in this fixture is same as in Lathe, on lead screw work table is mounted with
nut &lead screw is connected with motor. So when lead screw moves axially then work table also
moves axially.
Material of lead screw is 30 C 8 (IS : 1570 – 1978) [2] because, 30 C 8 steel have a high strength &
wear resistance properties.
Fig.4.3.1 Load distribution on lead screw
Here,
= 0.6
= 0.6× 300
Now ,
Where, = Bending Stress, N/
M = Maximum bending moment, N-mm
I = moment of inertia for circular cross-section,
y = distance from the neutral axis, mm
=( )
d = 11.225 mm
Here, d = 16mm is taken, considering the standard steel shaft and safety.
Fig.4.3.2 Projection of lead screw
4.4 BEARING SELECTION
According to design of lead screw, Diameter of end of lead screw is 12mm. Suitable
bearing for this diameter (considering load) is 6001.
Calculation of bearing capacity
d=12mm (bore diameter) n=300rpm

Fa=0N(Axial Load) Fr=40N(Radial Load)
Ka=1.2(Load Factor) V=1(Rotation Factor)
X=1(Radial Factor) Y=0(Thrust Factor)
Pe=Equivalent Fact
Fig 4.4.1 Cross section of bearing 6001
= (X V +Y )
= (1x1x40+0) x 1.2 Lh10

= 481
L10= Lh10 × 60 × n × 10-6

L10=8000 × 60 × n × 10-6
= 144 million revolution
Now, using load-life relationship
L10 =
144=
C=251.6 N
C=0.2516 kN
C< Dynamic Capacity (5.07kN)
Since the Dynamic Load rating (C) is less than the Basic dynamic capacity of the bearing 6001,
selected bearing is safe under working conditions.
4.5 DESIGN OF SIDE PLATE
In this fixture side plate give support to the lead screw. Side plate only gives support ,so stress
not induces in this component. In the side plate bearing fitted that provides smooth motion to lead
screw. Material for this part is 7C4 (IS: 1762 – 1974). Select this material because, this part not
required high strength & it’s cheap.
Fig.4.5.1 Projection of side plate
4.6 AUXILIARY PARTS
4.6.1 TORCH HOLDING PLATE
This parts useful to hold the torch of MIG welding . This part only carries torch weight. Torch
material is 7C4. Because high strength not required & it’s very cheap.
Fig.4.6.1 Projection of torch holding plate
4.6.2 SLOT PLATE
This part is used to hold the torch holding plate. This part only carries torch and torch plate
weight. Material is 7C4 because high strength not required & it’s very cheap.
Fig.4.6.2 Projection of slot plate
4.7 ASSEMBLY AND MATERIAL SELECTION
Fig.4.7.0 Views of Assembly
SR NO. PART NAME MATERIAL QUANTITY

1 BASE FG-200 1
2 WORK TABLE 7C4 1
3 SLOT PLATE 7C4 2
4 HANDLE - 1
5 SIDE PLATE 7C4 2
6 LEAD SCREW 30C8 1
7 TORCH HOLDING PLATE 7C4 1
8 SUPPORT ROD 7C4 2
(All models are created and assembled by using Inventor professional 2015)
4.8 BED
4.8.0 Modeling of Bed
4.9 LEAD SCREW
4.9.0 Modeling of Lead Screw
4.10 SIDE PLATE
4.10.0 Modeling of Side Plate
4.11 SLOT PLATE
4.11.0 Modeling of Slot Plate
4.12 TORCH HOLDING PLATE
4.12.0 Modeling of Torch holding plate
4.13 SUPPORT ROD
4.13.0 Modeling of Support Rod
4.14 FINAL ASSEMBLY
Fig 4.14.0 Semi-automatic welding equipment
4.15 ANALYSIS OF BED
(Analysis of Bed using Inventor professional 2015 )
Fig 4.15.0 Inventory analysis of Bed
5. RESULT AND
DISCUSSION
5.1 OBSERVATION
The Objective of this Fixture is to reduce the time required for welding and increase the
accuracy. After performing this operation the result obtains are as follows:
Table 1: Observation Table
SR NO. PLATE PLATE MANUAL FIXTURE TIME

THICKNESS (mm) LENGTH WELDING WELDING DIFFERENCE
(mm) TIME(Sec) TIME (Sec) (Sec)
1 6 25 97 66 31
2 8 25 126 81 45
3 10 25 153 102 51
4 12 25 183 123 60
5.2 COST
Table 2: COST
SR COMPONENT COST (Rs.)

NO.
1 MS Sheet (Bed, Side & Slot plate, Torch holding plate) 2700
2 Bearing (2 Piece) 440
3 Lead screw 700
4 Support Road (2 piece) 280
5 Nuts and Bolts 200
6 Labour cost 500
7 Total Cost 4820
6. CONCLUSION
6. CONCLUSION
We have designed a semi-automatic welding equipment in this project using empirical formulas of
design for selected materials under required working condition. And it is concluded the equipment is
well safe for desired condition .
REFERENCES
REFERENCE
BOOKS
1. Bhandari, V.B. Design of Machine Elements, TATA McGraw- HILL Companies.

2. PSG Design data book.
3. Parmar, R.S., Welding Processes and Technology, Khanna Publishers, New Delhi,
2010.
4. Machine Design by R.S. Khurmi, J.K. Gupta. S.Chand Publications-2008.
PDF
1. REVIEW ON OPTIMIZATION OF MIG WELDING PARAMETER by www.ijemr.net

2. LEAD SCREWS & NUTS by www.pic-design.com
3. AUTOMATION SOLUTIONS by Kjellberg finsterwalde
4. ENGINEERING MATERIALS AND THEIR PROPERTIES by novinmech.com
APPENDIX

A Intro

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Semi-automatic welding machine equipment 2016

1.1 Basic Introduction

Fig.1.1.1 Classification of welding

1.2 Types of Welding (Based on Degree of automation)

Welding can be done as following:

1.3 Working Principle of MIG

Fig.1.3.1 Working Condition of Work piece

Fig.1.3.2 Working Principle of MIG welding

1.4 Basic Equipment for a Semi-automatic welding Setup

Welding Power Source:- provides welding power.

Shielding Gas Cylinder - provides a supply of shielding gas to the arc.

Fig.1.4.1 Basic MIG welding setup

2.1 Background research

G. Haragopal, P V R Ravindra Reddy and J V Subrahmanyam presented a method to

Fig.2.1.1 Joint geometry for the welding specimen

Fig.2.1.2 Penetration vs. Welding Current & Voltage

2.2 Effect of process parameter on bead geometry

Fig.2.2.1 Effect of Voltage on bead width

Fig.2.2.2 Effect of Current on bead width

Fig.2.2.3 Effect of welding speed on bead width

3.1 ACTUAL SET-UP

Fig 3.1.0 Actual Set-up

3.2 WORKING METHODOLOGY

4. Operate the handle and perform the initial run.

6. Unload the work piece from the worktable.

3.3 EXPERIMENTAL WORK

JUNE JULY AUG SEP OCT NOV JAN FEB MARCH

4.1 DESIGN PROCESS

Design Selection and Creation

4.2 DESIGN OF BED/BASE

Check bed in bending,

Fig.4.2.1 Design of bed

Load acting on the bed is shown in Figure

Fig.4.2.2 Load distribution diagram

Taking Moment @A (Assume clockwise direction as Positive)

0 = (98.1×200) + (69.62×300) + (19.62×800) + (69.62×1300) – (RB×1400)

RA – RB = 98.1 + 69.62 + 19.62 + 69.62

M@p = – (104.781×1200) + (69.62×1100) + (19.62×600) + (69.62×100)

M@q = – (104.791×1100) + (69.62×1000) + (19.62×500)

M@r = – (104.791×600) + (69.62×500)

Maximum Bending Moment occurs at point q;

(Where, = 160 N/mm2)

Hence Design is safe.

Calculation for bending moment diagram

B = (69.62×100) + (19.62×600) + (69.62×1100) – (104.791×1200)

B = (19.62×500) + (69.62×1000) – (104.791×1100)

Calculation for shear force diagram

Fig.4.2.3 shear force diagram of bed

Fig.4.2.4 bending moment diagram of bed

4.3 DESIGN OF LEAD SCREW

Fig.4.3.1 Load distribution on lead screw

Where, = Bending Stress, N/

M = Maximum bending moment, N-mm

I = moment of inertia for circular cross-section,

Fig.4.3.2 Projection of lead screw

4.4 BEARING SELECTION

Calculation of bearing capacity

d=12mm (bore diameter) n=300rpm

Fig 4.4.1 Cross section of bearing 6001

= (1x1x40+0) x 1.2 Lh10

L10= Lh10 × 60 × n × 10-6

C< Dynamic Capacity (5.07kN)

4.5 DESIGN OF SIDE PLATE