AbstractExport

This paper describes the specification and implementation of aggregate process planning methods for
complex welding operations. The methods are implemented as an aggregate process planning tool,
CAPABLE/Welding, which can be used to evaluate the manufacturability of complex fabrications at the
early stages of design. The first part of the paper discussed the aggregate product modelling methods,
which are object-oriented and feature-based. The aggregate product model provides the necessary
abstraction of design data to facilitate the assessment of early designs. A key planning requirement was
to utilise the aggregate product model by developing process knowledge capturing and optimisation
techniques so that production time and cost can be calculated for complex fabrications requiring many
welding operations and set-ups. CAPABLE/Welding is a tool usable directly by designers, as it does not
require specialist process knowledge. A range of generic welding process models has been developed
and the planning techniques are instantiated with regard to company specific production equipment and
factory layout. Alternative process and machine options are explored and the optimum production
method is found using a simulated annealing algorithm. This selects process types, equipment, finds the
best welding orientation, number of set-ups and finds the optimum processes and routes for minimum
product cost or lead time. The resulting plans are presented graphically via a hypertext browser. This
combines a graphic display of process time and cost distribution by feature with links to the relevant
process knowledge. The process planning procedure of a product is used in this paper to illustrate the
system functionality.

APPLICATIONS:

There are many different uses of spot welding machines.Some of the areas where it finds application are:

Automobile industry

Automotive manufacturing

Metal working

Shipbuilding

Fabrication

Casting
Tungsten Inert Gas (TIG) or Gas Tungsten Arc (GTA) weldingadminMay 26, 2015 Tungsten Inert Gas (TIG)
or Gas Tungsten Arc (GTA) welding2017-10-21T12:03:19+00:002 Comments

TIG Welding

Tungsten Inert Gas (TIG) or Gas Tungsten Arc (GTA) welding is the arc welding process in which arc is
generated between non consumable tungsten electrode and workpiece. The tungsten electrode and the
weld pool are shielded by an inert gas normally argon and helium. Figures show the principle of
tungsten inert gas welding process.

Fig.

Principle of TIG Welding

The tungsten arc process is being employed widely for the precision joining of critical components which
require controlled heat input. The small intense heat source provided by the tungsten arc is ideally
suited to the controlled melting of the material. Since the electrode is not consumed during the process,
as with the MIG or MMA welding processes, welding without filler material can be done without the
need for continual compromise between the heat input from the arc and the melting of the filler metal.
As the filler metal, when required, can be added directly to the weld pool from a separate wire feed
system or manually, all aspects of the process can be precisely and independently controlled i.e. the
degree of melting of the parent metal is determined by the welding current with respect to the welding
speed, whilst the degree of weld bead reinforcement is determined by the rate at which the filler wire is
added to the weld pool.

Fig.

Schematic Diagram of TIG Welding System

In TIG torch the electrode is extended beyond the shielding gas nozzle. The arc is ignited by high voltage,
high frequency (HF) pulses, or by touching the electrode to the workpiece and withdrawing to initiate
the arc at a preset level of current.

Selection of electrode composition and size is not completely independent and must be considered in
relation to the operating mode and the current level. Electrodes for DC welding are pure tungsten or
tungsten with 1 or 2% thoria, the thoria being added to improve electron emission which facilitates easy
arc ignition. In AC welding, where the electrode must operate at a higher temperature, a pure tungsten
or tungsten-zirconia electrode is preferred as the rate of tungsten loss is somewhat lesser than with
thoriated electrodes and the zirconia aids retention of the ‘balled’ tip.

Tungsten electrodes are commonly available from 0.5 mm to 6.4 mm diameter and 150 – 200 mm
length. The current carrying capacity of each size of electrode depends on whether it is connected to
negative or positive terminal of DC power source. AC is used only in case of welding of aluminum and
magnesium and their alloys.

he power source required to maintain the TIG arc has a drooping or constant current characteristic which
provides an essentially constant current output when the arc length is varied over several millimeters.
Hence, the natural variations in the arc length which occur in manual welding have little effect on
welding current. The capacity to limit the current to the set value is equally crucial when the electrode is
short circuited to the workpiece, otherwise excessively high current shall flow, damaging the electrode.
Open circuit voltage of power source ranges from 60 to 80 V.

Argon or helium may be used successfully for most applications, with the possible exception of the
welding of extremely thin material for which argon is essential. Argon generally provides an arc which
operates more smoothly and quietly, is handled more easily and is less penetrating than the arc obtained
by the use of helium. For these reasons argon is usually preferred for most applications, except where
the higher heat and penetration characteristic of helium is required for welding metals of high heat
conductivity in larger thicknesses. Aluminum and copper are metals of high heat conductivity and are
examples of the type of material for which helium is advantageous in welding relatively thick sections.

Pure argon can be used for welding of structural steels, low alloyed steels, stainless steels, aluminum,
copper, titanium and magnesium. Argon hydrogen mixture is used for welding of some grades of
stainless steels and nickel alloys. Pure helium may be used for aluminum and copper. Helium argon
mixtures may be used for low alloy steels, aluminum and copper.
TIG welding can be used in all positions. It is normally used for root pass(es) during welding of thick pipes
but is widely being used for welding of thin walled pipes and tubes. This process can be easily
mechanised i.e. movement of torch and feeding of filler wire, so it can be used for precision welding in
nuclear, aircraft, chemical, petroleum, automobile and space craft industries. Aircraft frames and its skin,
rocket body and engine casing are few examples where TIG welding is very popular.

DESIGN AND FABRICATION OF FILM FRAME BY GENEVA MECHANISM

ABSTRACT

Geneva drive or Maltese cross is a indexing mechanism that converts the continuous motion into
intermittent motion. By means of this mechanism the rotary motion of the driver wheel is converting
into intermittent rotary motion of sprocket. The film passed over the sprocket. Due to the intermittent
motion, the film advanced frame by frame in front of lens for 1/24th second in frequency of 48 Hz.

See Also : AUTO ROLL PUNCHING MACHINE USING GENEVA MECHANISM

GENEVA MECHANISM

In this mechanism, for every turn of the driver wheel A, the driven wheel B makes a quarter turn.
The pin, attached to driver wheel A, moves in the slots causing the motion of wheel B. The contact
between the lower parts of driver A with the corresponding hollow part of wheel B retains it in position
when the pin is out of the slot. Wheel A is cut away near the pin as shown, in order to provide clearance
for wheel B as it moves. If one of the slots is closed, A can make less than one revolution in either
direction before the pin strikes the closed slot and, stopping the motion.

Geneva Mechanism
Geneva Mechanism

Introduction To Geneva Mechanism:

Refer This:

Introduction

To Geneva Mechanism and Its Advantages/Disadvantages

COMPONENTS OF PROJECT:

DRIVER GEAR

The input is given manually by handle through this Driver gear. It’s a one type of continuous motion.

CAM & PIN

It’s main part of this mechanism. Because it converts The continuous rotary motion into intermittent
motion by guiding the Geneva cross along its circular path. Then it converts this motion as require for the
movement of film frame.

GENEVA GEAR OR MALTESE CROSS

It’s also take part as vital role in this mechanism. Because the rotary intermittent motion produced in this
part only. Ge-neva cross has 4 slots in it, pin goes into along circular movement of cam.

SHAFT

Shaft holds the all parts of mechanism by horizontally On its threaded portion. There are 2 shafts are
provided in this mechanism.

SPROCKET

It is provided for hold the film frame according to the rotary intermittent motion of the Geneva cross.
Pressure rollers also provided for perfect movement of film frame.

FILM FRAME

It’s the component which carries the picture on it and to slide on the sprockets regularly according to
the motion.

CONCLUSION

Geneva drive indexing mechanism converts the continuous motion of the driver wheel into
intermittent rotary motion of the sprocket. According to the film length, the cam wheel diameter was
chosen. Cam with pin arrangement integrated with Geneva drive. Input shaft having driver wheel at one
end and cam drive at the other end. Geneva drive and sprocket are mounted on the output shaft. By cam
with Geneva drive arrangement the continuous motion of the driver wheel converts into intermittent
motion of sprocket. Due to sprocket rotation the film advances frame by frame in front of the lens. Thus
the slide show of the film was obtained successfully.