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Construction Of Welding Machine
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CHAPTER THREE
3.0 GENERAL DESCRIPTION AND ITS WORKING PRINCIPLE
Regarding the design and fabrication of this project several information were gathered through consultation of previous journals text books and internet.
Definition: “welding is the process of joining together two pieces of metal so that bonding take place at their original boundary surface s. when two parts to be joined are melted together, heat or pressure or both is applied and with or without added metal for formation of metallic bond. Welding is a major technology in present day industry and has important effect and advantages in mechanical engineering construction and much more on modern industry.
The welding machine consists of component such as:-
• The Housing: this is the outer metal that cover up the remaining inside component. It is made of mild steel street of gauge which is powerful enough to carry the weight of the total machine
• The Transformer: this is the main component in the machine which can definitely be referred to as the welding machine. This is where the energy transformation takes place. It consists of stacked lamination transformer and the coils.
• Stack Lamination: this is the mechanical part of the transformer which allow for rigidity and stability in term of structure a medium for production of magnetic flux are required for the proper functioning of the machine and is a combination of I’s shape lamination which as far as the project is concerned is cut out of steel (mild steel). The bulk transformation of energy takes place here.
• The Former: this can be asbestos, thermosetting plastic or any other non conductive material that can withstand the maximum thermal dissipation of the transformer during operation. It is on these former the coils in the system are wound. This maybe hollow cubic in the shape cylindrical shape or any other shape depending on the cutting on the lamination is usually set into the former for optimum energy transformation in the electric field of the field coil (primary coil) into the output coil (secondary coil)
• The Coils: These are usually of two types depending on the power of the welding machine. The primary winding which is of hundred of turns and of very small “standard wire gauge†since it is used to with stand the high potential energy source. The other coil is know as the secondary coil of tens of turns of big thick “standard wire gaugeâ€. This is at low potential but generates a very high current in other to serve effectively the welding purpose.
• The Insulator: This is a street material of very high thermal ability stability and non conductive. It is used to separate the primary coil from the secondary coil from the lamination for the sake of safe operation
• The Fan: This is a device that help regulate the transformer engine temperature by pulling air through the transformer.
• The Insulated cables: These are of two types. One is smaller which is connected to the primary coil terminal. The insulated cable is sued for the purpose of connection to the (220 -240v) main electric supply which serves as the source of energy for the welding machine. The other insulated cable is capable enough to withstand very high current generated from the secondary coil terminal attached to these are electrode holder (welding tong) which hold the electrode used as a medium of welding and also ground clip which hold one of metal to be welded together in order to complete welding circuit
• The handle: These are iron rod which are bent and attached to the top main cover of the housing unit for the purpose of handling the welding machine.
3.1 WORKING PRINCIPLE OF THE WELDING MACHINE
The working principle is based mainly on the method of using the intense heat generated between the point of electrode attached to the holder from a cable that the metals to be welded get melted and melted metals when cool result in a binding of the metals. These metals are connected to the earth clip (ground cable) at the secondary coil side Electric arc is setup between electrodes and the work piece which coalesced the metals together.
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ABSRACT - [ Total Page(s): 1 ]ABSTRACT COMING SOON ... Continue reading---
CHAPTER ONE - [ Total Page(s): 2 ]CHAPTER ONE1.0 INTRODUCTIONIn 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 join ... Continue reading---
CHAPTER TWO - [ Total Page(s): 3 ]ii. OXIDIZING FLAMEOxidizing welding flame are produced hen slightly more than one volume of oxygen is mixed with one volume of acetylene. To obtained this type of flame, the flow of oxygen is then increased until the inner cone is shortened to about one tenth of it original length when the flame is properly adjusted, the inner cone is pointed and slightly purple. An oxidizing flame can also be recognized by it distinct hissing sound. The temperature of this flame is approximately 6300oF ( ... Continue reading---
CHAPTER FOUR - [ Total Page(s): 4 ]Where;K = constant (Boltzman constant in joules / kelvin)A= 200m x 4 = 800mmT2 = 3500CT1 = 3150CX = 50mmQ = k x 800mm 350 – 3150C 50mm Where K =8.617 x 10-5 J/kQ = 8.673 x 10-5 x 800mm (135 50mmQ =62044.46 J/K 4.1 WINDING DESIGNThe
basic of winding is to have number of turns being wounded around an
appropriate point of the core. Winding design in transformer
construction must be done perfectly and accura ... Continue reading---
CHAPTER FIVE - [ Total Page(s): 10 ]Now let assume a load having a power factor such that the secondary current is in phase with E2 the primary current must now have two component.1. I1 to maintain the useful flux2. I2 to neutralize the demagnetizing effect of the secondary current.Since the flux of each limb is link only with the winding by which it is produced, it is referred to as leakage flux and its responsible for reducing an e.m.f. of self inductance in the winding with which it is linked. The reluctance o ... Continue reading---
CHAPTER SIX - [ Total Page(s): 1 ]CHAPTER SIX6.0. CONCLUSION AND RECOMMENDATION6.1 CONCLUSION The project is a form of providing student with appreciable skills p4actically designed to expose or equip them with real working operation of machine and how they are being constructed and a better understanding of one’s own career goals and for the progress of the nation.The project seemed easy and simple but later on turn to be useful and interesting project for Engineering students. With all the proble ... Continue reading---
REFRENCES - [ Total Page(s): 1 ]REFERENCESFlood CR (1981) “Fabrication of welding and joining process†1st Edition, Butterworth and Co publisher limited London, P.P 21 – 25, 28 36- 37 and 39.Google: http://weldguru.com/welding-flamesFlood CR and parkin N. (1974) “craft practice “ 1st Edition pergamon press limited, New YorkDavies A.C (1984) “Welding science and technology†8th edition Cambridge Universities press. London Pg-42B.L. and A.K.Therage (1994 Textbook of Electri ... Continue reading---
