Cnc Machine Report
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PORT DICKSON POLYTECHNIC MECHANICAL ENGINEERING DEPARTMENT
NAME MOHAMAD SHOBRI BIN MAHADZAIR ROSNIN KHALID BIN ABDUL RAHMAN MOHD HAMDAN B. MOHAMED MUHAMAD HAZIQ BIN ZULKAFLIE TITLE PROGRAMME & GROUP PRACTICAL DATE SUBMIT DATE
REGISTRATION NUMBER 06DEM08F2011 06DEM08F2022 06DEM08F2013 06DEM08F2012 CNC MACHINE DEM 1 SEC 1
10TH AUGUST 2009 TH 24 AUGUST 2009
MARKS
COURSE LECTURER: MR. HAFRIZALMAN All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 1
Contents
Page
OBJECTIVE
3 4 5-8 9 10 -12 13 - 15 16 17 18 19 20
INTRODUCTION EQUIPMENT SECURITY APPARATUS SAFETY RULES WELDING PROCEDURE TYPES OF JOINT PROJECT FIGURE DISCUSSION CONCLUSION REFERENCE
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 2
OBJECTIVE ➢Learning how to use workshop equipments precisely. ➢Learning how to use arc welder correctly and safely. ➢Observing the ways on how to weld a metal by using arc welder. ➢To know how to prepare a metal before welding it. ➢To lathe several lines on a metal by using the right skills. ➢ To control the volume of electricity for welding precisely. ➢To know the ways on how to weld a metal by following the right steps.
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 3
INTRODUCTION ➢
The basic principle of arc welding involves heating and melting of base metal using electric arc.
➢The electric arc is formed when there is a voltage difference between the metal coating at the end of the electrode and the surface of the base metal. ➢The arc will produce heat enough to melt the base metal and the end of the electrode to form a pool of molten metal. ➢The temperature of this process may be as high as 3900°C. ➢The pool of molten compound will solidify to form beads covered with a layer known as slag. The bead will form a strong permanent joint.
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 4
EQUIPMENT ➢
Welding Machine. •
Specially designed to supply suitable and strong enough current for an arc welding work. Arc welding machine can be operated by using electrical power and diesel or petrol engine. Arc welding machine in the workshop uses electrical power. Transformer will transfer the electrical power to the required voltage for arc welding.
➢ Electrode holder and electrode •
Used to hold current electrode while welding a metal. Holder must light, not easily hot and must be covered with good insulator to avoid electrical shock. Electrode is made by ore wire which has the same content with the welding metal. Electric arc generates heat at least 5000°C and this resulted electrode and the metal become molten.
➢ Welding Cable •
Welding machine is connected to the electrode holder and earth plate by using cable. The connected cable must be flexible enough so that it can easily use. During welding process, current will flow through this cable. If the cable is too long, the current flow may decrease.
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 5
➢
Welding Circuit •
This circuit shows that power supply is taken from the workshop and connected to welding machine. One of the power source is connected to the holder and another is connected to the earth plate via welding metals.
➢ Earth plate •
This device is used to connect the ground wire to the base of the metal. There are two types of earth plate which is called Clamp type and Screw type.
➢ Cleaner •
In welding cleaning process, we use chip hammer and wire brush. Besides that, chisels and pliers are also used to clean the metal after welding.
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 6
ARC WELDING EQUIPMENT The equipments used in arc welding are as the following below:
1.
Transformer as a converter to adjust the welding voltage and current.
2. Electrode holder is insulated and used to hold the electron. 3. Electrode is a metal rod with a layer of coating which is used to allow the flow of electric current to form the electric arc. 4.
Earthing which connected to the base metal and the welding machine power supply to prevent electric shock.
5. Electrode cable is an electrical connection between the electrode holder and power supply. The cable is insulated with rubber. All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 7
6. Cleaning tools are used to chip and clean the traces of metal spatters and slag produced on the surface of the welded metal.
EQUIPMENTS
Electrode Holder
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 8
Cable
Earthing
Chipping Hammer
Wire Brush All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 9
Electrodes
Tong
SECURITY APPARATUS Safety Attire and Equipment ➢
Safety attire and equipment are used to protect and prevent a welder from injury when performing arc welding. The equipment and safety attire required are as the following:
Face shield protects the eyes and face from the effect of ultraviolet rays and spatters while welding. • Leather glove protects the hands from burns or scald. • Leather apron protects the body from heat and to protect the skin from burns. • Safety shoes are to protect the feet from arc spatters. •
Safety Measures • Wear the protective equipment such as face shield, gloves and apron when performing welding. All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 10
Ensure that the welding and earth cables are in good condition and safe for use to prevent electrical shock. • Perform welding away from inflammable materials. • Perform welding where the air circulation is good and comfortable. •
SAFETY ATTIRE
Face sheld
Leather gloves
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 11
Safety shoes
Apron
SAFETY RULES WORKSHOP ➢ ELECTRIC SHOCK CAN KILL • Make sure you do not touch any segment or electric equipment that is switched on. Don’t use the broken devices and dangerous. Make sure you wear the suitable safety boot. ➢ •
SMOKE AND GASES CAN INFECT YOUR HEALTH Stay away from the poisonous smoke and gases and avoid from smelling it.
➢ ARC SHINE CAN BURN EYE AND SKIN All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 12
• Make sure you wear the face cover to protect our face and eye when do the arc welding work. ➢ WELDING COULD MAKE AN EXPLOSION • Make sure you wear the safety shield while welding to avoid from the burst.
➢ HOT WORKPIECES COULD BURN YOUR SKIN • Never touch the hot workpiece without using hand gloves.
PERSON • Avoid from gasping the poisonous fumes. • Explosion may cause injury. • The arc welding machine may easily explode if it is closed with inflammable goods. •
Don’t touch the hot metal by using your hands instead of using tongs.
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 13
• The arc spark may cause injury to your eyes and body. •
Be careful of the wiring and the electric sources which may cause electrical shock. Make sure the tools are in good condition.
• Use the medical lotion to release the pain of the skin burnt.
WELDING PROCEDURE Arc Welding Procedure ➢ Procedure •
Clean the metal.
•
Place the plates close together with sufficient gap for welding.
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 14
• Select the appropriate electrode according to the joint type. • Adjust the electric current according to the electrode size. •
Scratch or knock the electrode tips onto the metal surface to strike the arc and do a tack weld to hold the joint.
• Weld along the joint and fill the welding groove completely. • Switch off the welding machine. • Remove the slag from the welding bead.
BEADING AND BUTT JOINT Beading Procedure i.Clean and mark the work piece surface to be welded. ii.Put
the work piece on the working table and connect the earth cable.
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 15
iii.Select the appropriate electrode and hold it with the electrode holder. iv.Adjust
the current and voltage of the electrode.
v.Knock or scratch the electrode to the surface of the electrode. vi.Start beading in one direction following the mark. vii.Disconnect the electrode when beading is completed and leave the work piece to cool. viii.Remove slag on the work piece with a cleaning tool to inspect the quality of the weld.
Butt Joint Procedure
i.The method of butt welding is the same as (i) to (iv) of the beading procedure.
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 16
ii.Position the plates and leave sufficient gap for welding. iii.Tack weld at both end of the work piece to fix the position. iv.Weld along the surface of the work piece by filling the groove. v.Disconnect the electrode when butt welding is completed and leave the work piece to cool. vi.Remove slag on the object with a cleaning tool to inspect the quality of the butt weld.
TYPES OF JOINT All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 17
1) Side Joint
2) Corner Joint
3) Paste Joint
4) T – Joint
5) Sided Joint
PROJECT FIGURE All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 18
DISCUSSION Make sure all equipments and tools are in good condition. Concern about the location and the condition of the first aid in case if any accident occurs. Scrape off rust and edge properly to avoid it from being oxidized.
Ensure that electric volume is precisely used.
Do not let the metal melt so that there is no hole on the metal. Point the welder shooter straightly on to the metal.
Do not touch the hot metal by hands nonetheless use a tong to move it. Proper protection should be worn at all times, including protecting the eyes against glare and flying sparks.
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 19
CONCLUSION
ACCORDING TO THIS WELDING WORKSHOP REPORT,WE HAD LEARNT; •
How to weld a metal by using arc welding machine practically.
•
How to use instruments in the workshop
•
precisely. How to use the entire machinesin the
•
workshop. How to learn about the safety steps and the steps on how to weld a metal by using arc welding machine.
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 20
REFERENCES • TECHNOLOGY BOOK MACHINE SHOP.IBRAHIM'S WRITER YOUNG CHE AND N.RAMUDARAM.EDITOR ROSNANI MAT JIHAN AND NOREIDAH OTHMAN.HALL PUBLICATION LANGUAGE AND LIBRARY •
KAMARRUDDIN BIN ISMAIL,AZMI BIN MOHD YASSIR AND RAMLI BIN ASUN.2003 BUKU PENGAJIAN KEJURUTERAAN MEKANIKAL edited by ZAINAH BINTI MOHD.AZHAR AND NOR AZITA BINTI UMAR. Dewan Bahasa And Pustaka's Publication Estuary Mud.
•
www.google.image/arcwelding
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 21
NAME MOHAMAD SHOBRI BIN MAHADZAIR ROSNIN KHALID BIN ABDUL RAHMAN MOHD HAMDAN B. MOHAMED MUHAMAD HAZIQ BIN ZULKAFLIE TITLE PROGRAMME & GROUP PRACTICAL DATE SUBMIT DATE
REGISTRATION NUMBER 06DEM08F2011 06DEM08F2022 06DEM08F2013 06DEM08F2012 CNC MACHINE DEM 1 SEC 1
10TH AUGUST 2009 TH 24 AUGUST 2009
MARKS
COURSE LECTURER: MR. HAFRIZALMAN All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 1
Contents
Page
OBJECTIVE
3 4 5-8 9 10 -12 13 - 15 16 17 18 19 20
INTRODUCTION EQUIPMENT SECURITY APPARATUS SAFETY RULES WELDING PROCEDURE TYPES OF JOINT PROJECT FIGURE DISCUSSION CONCLUSION REFERENCE
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 2
OBJECTIVE ➢Learning how to use workshop equipments precisely. ➢Learning how to use arc welder correctly and safely. ➢Observing the ways on how to weld a metal by using arc welder. ➢To know how to prepare a metal before welding it. ➢To lathe several lines on a metal by using the right skills. ➢ To control the volume of electricity for welding precisely. ➢To know the ways on how to weld a metal by following the right steps.
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 3
INTRODUCTION ➢
The basic principle of arc welding involves heating and melting of base metal using electric arc.
➢The electric arc is formed when there is a voltage difference between the metal coating at the end of the electrode and the surface of the base metal. ➢The arc will produce heat enough to melt the base metal and the end of the electrode to form a pool of molten metal. ➢The temperature of this process may be as high as 3900°C. ➢The pool of molten compound will solidify to form beads covered with a layer known as slag. The bead will form a strong permanent joint.
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 4
EQUIPMENT ➢
Welding Machine. •
Specially designed to supply suitable and strong enough current for an arc welding work. Arc welding machine can be operated by using electrical power and diesel or petrol engine. Arc welding machine in the workshop uses electrical power. Transformer will transfer the electrical power to the required voltage for arc welding.
➢ Electrode holder and electrode •
Used to hold current electrode while welding a metal. Holder must light, not easily hot and must be covered with good insulator to avoid electrical shock. Electrode is made by ore wire which has the same content with the welding metal. Electric arc generates heat at least 5000°C and this resulted electrode and the metal become molten.
➢ Welding Cable •
Welding machine is connected to the electrode holder and earth plate by using cable. The connected cable must be flexible enough so that it can easily use. During welding process, current will flow through this cable. If the cable is too long, the current flow may decrease.
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 5
➢
Welding Circuit •
This circuit shows that power supply is taken from the workshop and connected to welding machine. One of the power source is connected to the holder and another is connected to the earth plate via welding metals.
➢ Earth plate •
This device is used to connect the ground wire to the base of the metal. There are two types of earth plate which is called Clamp type and Screw type.
➢ Cleaner •
In welding cleaning process, we use chip hammer and wire brush. Besides that, chisels and pliers are also used to clean the metal after welding.
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 6
ARC WELDING EQUIPMENT The equipments used in arc welding are as the following below:
1.
Transformer as a converter to adjust the welding voltage and current.
2. Electrode holder is insulated and used to hold the electron. 3. Electrode is a metal rod with a layer of coating which is used to allow the flow of electric current to form the electric arc. 4.
Earthing which connected to the base metal and the welding machine power supply to prevent electric shock.
5. Electrode cable is an electrical connection between the electrode holder and power supply. The cable is insulated with rubber. All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 7
6. Cleaning tools are used to chip and clean the traces of metal spatters and slag produced on the surface of the welded metal.
EQUIPMENTS
Electrode Holder
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 8
Cable
Earthing
Chipping Hammer
Wire Brush All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 9
Electrodes
Tong
SECURITY APPARATUS Safety Attire and Equipment ➢
Safety attire and equipment are used to protect and prevent a welder from injury when performing arc welding. The equipment and safety attire required are as the following:
Face shield protects the eyes and face from the effect of ultraviolet rays and spatters while welding. • Leather glove protects the hands from burns or scald. • Leather apron protects the body from heat and to protect the skin from burns. • Safety shoes are to protect the feet from arc spatters. •
Safety Measures • Wear the protective equipment such as face shield, gloves and apron when performing welding. All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 10
Ensure that the welding and earth cables are in good condition and safe for use to prevent electrical shock. • Perform welding away from inflammable materials. • Perform welding where the air circulation is good and comfortable. •
SAFETY ATTIRE
Face sheld
Leather gloves
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 11
Safety shoes
Apron
SAFETY RULES WORKSHOP ➢ ELECTRIC SHOCK CAN KILL • Make sure you do not touch any segment or electric equipment that is switched on. Don’t use the broken devices and dangerous. Make sure you wear the suitable safety boot. ➢ •
SMOKE AND GASES CAN INFECT YOUR HEALTH Stay away from the poisonous smoke and gases and avoid from smelling it.
➢ ARC SHINE CAN BURN EYE AND SKIN All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 12
• Make sure you wear the face cover to protect our face and eye when do the arc welding work. ➢ WELDING COULD MAKE AN EXPLOSION • Make sure you wear the safety shield while welding to avoid from the burst.
➢ HOT WORKPIECES COULD BURN YOUR SKIN • Never touch the hot workpiece without using hand gloves.
PERSON • Avoid from gasping the poisonous fumes. • Explosion may cause injury. • The arc welding machine may easily explode if it is closed with inflammable goods. •
Don’t touch the hot metal by using your hands instead of using tongs.
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 13
• The arc spark may cause injury to your eyes and body. •
Be careful of the wiring and the electric sources which may cause electrical shock. Make sure the tools are in good condition.
• Use the medical lotion to release the pain of the skin burnt.
WELDING PROCEDURE Arc Welding Procedure ➢ Procedure •
Clean the metal.
•
Place the plates close together with sufficient gap for welding.
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 14
• Select the appropriate electrode according to the joint type. • Adjust the electric current according to the electrode size. •
Scratch or knock the electrode tips onto the metal surface to strike the arc and do a tack weld to hold the joint.
• Weld along the joint and fill the welding groove completely. • Switch off the welding machine. • Remove the slag from the welding bead.
BEADING AND BUTT JOINT Beading Procedure i.Clean and mark the work piece surface to be welded. ii.Put
the work piece on the working table and connect the earth cable.
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 15
iii.Select the appropriate electrode and hold it with the electrode holder. iv.Adjust
the current and voltage of the electrode.
v.Knock or scratch the electrode to the surface of the electrode. vi.Start beading in one direction following the mark. vii.Disconnect the electrode when beading is completed and leave the work piece to cool. viii.Remove slag on the work piece with a cleaning tool to inspect the quality of the weld.
Butt Joint Procedure
i.The method of butt welding is the same as (i) to (iv) of the beading procedure.
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 16
ii.Position the plates and leave sufficient gap for welding. iii.Tack weld at both end of the work piece to fix the position. iv.Weld along the surface of the work piece by filling the groove. v.Disconnect the electrode when butt welding is completed and leave the work piece to cool. vi.Remove slag on the object with a cleaning tool to inspect the quality of the butt weld.
TYPES OF JOINT All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 17
1) Side Joint
2) Corner Joint
3) Paste Joint
4) T – Joint
5) Sided Joint
PROJECT FIGURE All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 18
DISCUSSION Make sure all equipments and tools are in good condition. Concern about the location and the condition of the first aid in case if any accident occurs. Scrape off rust and edge properly to avoid it from being oxidized.
Ensure that electric volume is precisely used.
Do not let the metal melt so that there is no hole on the metal. Point the welder shooter straightly on to the metal.
Do not touch the hot metal by hands nonetheless use a tong to move it. Proper protection should be worn at all times, including protecting the eyes against glare and flying sparks.
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 19
CONCLUSION
ACCORDING TO THIS WELDING WORKSHOP REPORT,WE HAD LEARNT; •
How to weld a metal by using arc welding machine practically.
•
How to use instruments in the workshop
•
precisely. How to use the entire machinesin the
•
workshop. How to learn about the safety steps and the steps on how to weld a metal by using arc welding machine.
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 20
REFERENCES • TECHNOLOGY BOOK MACHINE SHOP.IBRAHIM'S WRITER YOUNG CHE AND N.RAMUDARAM.EDITOR ROSNANI MAT JIHAN AND NOREIDAH OTHMAN.HALL PUBLICATION LANGUAGE AND LIBRARY •
KAMARRUDDIN BIN ISMAIL,AZMI BIN MOHD YASSIR AND RAMLI BIN ASUN.2003 BUKU PENGAJIAN KEJURUTERAAN MEKANIKAL edited by ZAINAH BINTI MOHD.AZHAR AND NOR AZITA BINTI UMAR. Dewan Bahasa And Pustaka's Publication Estuary Mud.
•
www.google.image/arcwelding
All Rights Reserved © DEM2 S1 2009. Copyrights Protected.
Page 21
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