TABLE OF
CONTENTS.
CHAPTER ONE
1.
INTRODUCTION
1.1 BREIEF HISTORY AND
HISTORICAL BACKGROUND
1.2 LITERATURE REVIEW
1.3 OBJECTIVES OF THE
PRESENT WORK
1.4 SCOPE OF ELECTRICC ARC
WELDING MACHINE
CHAPTER TWO
2.0 ANALYSIS OF ALTERNATE
METHOD OF WELDING AND
CHOICE OF BEST METHOD
2.1 ALTERNATIVES TO
ELECTRIC ARC WELDING MACHINE
2.1.1 JOINING PROCESS
2.1.2 GAS WELDING
CHAPTER THREE
3.0 GENERAL DESCRIPTION AND ITS WORKING
PRINCIPLE
3.1 WORKING
PRINCIPLE OF THE WELDING MACHINE
CHAPTER FOUR
4.0 DESIGN
CALCULATION
4.1 WINDING DESIGN
4.2 INSULATION PROCEDURE
4.3 POWER SOURCE
4.4 ELECTRODE TYPES
4.4.1 TYPES OF ELECTRODE AND THEIR USES
4.4.2 ELECTORDE STADARD GAUGE
CHAPTER FIVE
5.0 MATERIAL
SELECTION AND FABRICATION OF WELDING
MACHINE
5.1 FABRICATION OF WELDING
MACHINE
5.2 TRANSFORMER
5.2.1 WORKING PRINCIPLE OF
TRANSFORMER
5.3 USEFUL AND LEAKAGE
FLUXES IN A TRANSFORMER
5.4 METHODS OF REDUCING
LEAKAGE FLUX
5.5 TRANSFORMER
FABRICATION
5.4.1 TYPES
OF TRANSFORMER FABRICATION
5.5 COOLING
SYSTEM
5.6. METHOD
OF WLDING
5.7 FACTORS OF SUCCESSFUL
ARC WELDING
THE CORRECT LENGTH OF ARC
THE CORRECT SPEED OF TRAVEL
5.8 MAINTENANCE
5.9 THE SAFETY PRECAUTIONS
TESTING OF THE FABRICATED ELECTRIC
ARC WELDING
MACHINE
TESTING OF AN ELECTRIC ARC WELDING MACHINE
CHAPTER SIX
6.0. CONCLUSION AND
RECOMMENDATION
6.1 CONCLUSION
6.2 PROBLEMS ENCOUNTERED
AND RECOMMENDATION
REFERENCES
CHAPTER ONE
1.0 INTRODUCTION
In the past
with the necessary of metals it always seems impossible to join two metals
together with grooving riveting, this idea leads to alternative of finding a
lasting solution to the problem. This brought about the idea of a welding
machine with a well laminated core and coil wound together to form a high rated
transformer which is immersed in a can of oil.
Welding is the
most economical and efficient way to join metals permanently. It is the only
way of joining two or more pieces of metal permanently to make a single piece.
Welding is vital to our economy.
It is even said
that over (50%) of the gross nation product of the industries is related to
welding in one way or the other. Welding ranks high economy industrial process
and involve more science and variable than those involved in any other
industrial process.
The electrode
is either a rod that simply carried current between the tip of the tong and the
work, or a rod or wire that melts and supplies, fill metal to the joint.
The basic arc
welding circuit is an alternating current (A.C) or direct current (D.C) power
source connected by a “hot” cable to an electrode, when the electrode is
positioned close to the work piece, an arc is created across the gap between
the metal and the hot cable electrode. An ionized column of gas developed to
complete the circuit.
1.1 BREIEF HISTORY AND
HISTORICAL BACKGROUND
Arc
welding did not come into practice until much later. In 1802, “Vasily Petrov”
discovered the continuous electric Arc and subsequently proposed its possible
practical applications including welding. The French electrical inventor
“Auguste Demeritens” produced first carbon arc touch, patented in 1881, which
was successfully used for welding leading in the manufacturer of lead-acid
batteries. In 1881-1882 a Russian inventor “Nikolai Bernardo” created the
electric arc welding method for steel known as carbon arc welding, using carbon
electrode. (Lincoln Electric 1994), the procedure hand book of arc welding,
Cleceland Ohiho Lincoln Electric ISBN 99949-25-82-2. The advance in arc welding
contacted with the inventor of metal electrode in the late 19th
century by a Russian, “Nikolai Slavyanov” 1888 and an American, “C.L coffin”.
Around 1900 A.P strotimenger released in Britain a coated metal electrode which
gave more stable arc, in 1905 Russian scientist “Vladimir Mitevich” proposed
the usage of three phase electric arc for welding.
In
1919 the alternating current welding was invented by “C.J Hoslag” not become
popular for another decade. Competing welding process such as resistance
welding and oxy-fuel welding were developed during this especially the later,
faced stiff competition from arc welding especially after metal coving (known
as flux) for the electrode to stabilized the arc and shield the base material
from impurities continued to be developed.
The
arc welding was not common until during world war I, welding started to be used
in ship building in Great Brittan in place of riveted steel plates. The
Americans also became more of accepting of the new technology when the process
allowed them to repair their ships quickly after a German attack in the New
York Harbor at the beginning of the war. Even in the good old days, Nigeria
make use of forgoing whereby two pieces of metal are join together by heating
them to a high temperature ant then hammering them together (forge welding).
In
1919 the British ship builder “Cammel Laird” started construction of merchant
ship, the fillager, with entire welding hill, she was launched in 1921.
During
the following decade, further advanced allowed for the welding of reactive such
as aluminum and magnesium, this in conjunction with the development in
automatic welding, alternating current, flux fed a major expansion of arc
welding during the 1930’s and then during world war two after decades of
development, was finally perfected in 1941 and gas metal arc welding followed
in 1948, allowing for fast welding of non-ferrous material but required more
expensive shielding gases. Using a consumable electrode and a carbondioxide atmosphere
as shielding gas. It quickly becoming to most popular arc welding process , in
1957. The flux cored arc welding process debuted in which the self-shielded
wire automatic equipment, resulting in greatly increased welding speeds. In
that same year plastic arc welding was invented. Electro slag welding as
released in1958 and was followed by it cousin, electro-gas welding in 1961.
1.2 LITERATURE REVIEW
This write up
is fully based on the method and ways of carrying out welding work and
construction of the machine. Welding is a fabrication or sculptural process
that joins material usually metals or thermoplastics, by causing fusion, which
is distinct from the lower temperature metal. Joining techniques such as
brazing or soldering which do not melt the base metal. The value of welding as
a standard method of joining metal was not fully appreciated before world war
one, then because of the need for speed of production in every metal using and
metal fabrication industry, the order of welding processes came on their own.
During and after world war two, the new welding method were developed, which
further increased speed and facilitates the joining of the many special purpose
alloys that were developed during this period.
Limited in its
early application to small or less important parts, welding in the second half
of the 20th century was employed in fabrication too numerous to
mention, such as ship, locomotives, rail and cars. The petroleum industry is a
classic example. The cutting edge of the bit used to drill on wells consist of
a hard weld metal fused to backing transportation to and from refinery is via
all welded transport iron material.
Whenever a
piece of apparatus is intended to contain a liquid or gas, welding is the
logical method of fabrication. As such, it has almost completely replaced other
method. Welding as of course by no means of confined to wide application where
leak tightness is involved. In the conventional body on frame automobile, there
are some 8,000 to 10,000 resistance welds and up to 40ft of arc welding.
Building and
bridges can be erected y welding with a saving of (10%) to (20%) in the amount
of steel requires. The proportion of structures erected by welding was
increasing in the second half of the 20th century and trend appeared
likely to continue.
The processes
of welding may be divided into four processes
1.
Forge welding
2.
Arc welding
3.
Gas welding
4.
Resistance welding
Arc welding
will be expansiated on, in accordance to the title of the project.
1.3 OBJECTIVES OF THE
PRESENT WORK
1.
To find alternative replacement for
the imported models.
2.
To make it affordable at relatively
cheap price.
3.
To further understand the
fabrication or construction/working principle of the machine.
4.
To acquire basic understanding of
operating and welding of transformer.
1.4 SCOPE OF ELECTRICC ARC
WELDING MACHINE
The machine is designed to be
supplied with an input ranging from 220volt to 240 volt. A good weld must be
strong as parent metal. The scope of welding process in the modern industries
has taken a greater dimension more than the previous year. Today the science
and act of welding involves a wide range of process and procedure applicable to
materials of any thickness and shape. These may range from more a very thin
electronic component to a large machine and structure. The arc produces a
temperature of about 3600oc at the top armed melts part of the metal
being welded and part of electrode. This produces a pool of molten metal that
cools and solidifies behind electrode as it moved along the joint.
This electric arc welding machine is
a heavy duty machine which is capable of welding 12 gauges of electrodes while
in operation.
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