CHAPTER 1

INTRODUCTION

Welding is one of the most important methods of joining of two similar and
dissimilar metals with or without application of pressure. The welding process is
generally accepted as the preferred joining technique and is mostly chosen for
welding large metal structures such as bridges, automobiles, aircraft and ships due
to its joint strength, reliability, and low cost compared to other joining processes.
In the age of automation machine become an integral part of human being. By the
use of automation machine prove itself that it gives high production rate at good
quality than manual production rate. Due to continual increase in the need of high
production rates, accuracy and labour costs, automation have been adopted to the
welding technology. First automation applications started with mechanized,
automatic and semi-automated MIG-MAG systems as well as SAW. Robots have
been used in many industrial applications including welding technology in order to
increase efficiency, reduce overall costs, and increase productivity and product
quality as well safe working conditions.

1.1 Objective

The objective of the project is to design and fabricate a automatic dual

welding machine.

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 CHAPTER 2

LITERATURE SURVEY

Mithari Ranjeet et. al describe the welding positioner with auto indexing which is
very important for mass production industries related with circular welding.

Patil Kunal V. et. al describe a novel approach of MIG (Metal Inert Gas) Welding
as implemented in a control system based SPM at Gabriel which is the largest
manufacturer of shock absorbers in India. The function of the SPM is to weld a
knuckle bracket on the circular shaft of the shock absorber. It efficiently helps to
fully automate the process of welding. The paper provides the description of the
components implemented in the control system along with the flow of working of
various components.

Sateesh.R. et.al as described in the paper of fabrication of pneumatic double axis

welding machine. Two pneumatic cylinder and Solenoid valve are used . Cylinder
is for the forward and backward movement, it moves in both x and y axis. So, it is
called as double axis welding machine. Two pneumatic cylinders and solenoid
valve are provided. One cylinder is for the up and down movement and another
one for the rotary motion . The problems are with the automatic process, still in
their early design stages and difficult to use and program by regular operators. In
this project, these problems are discussed, and a system designed with the double
objective of welding applications and to assist industrial partners working with
welding setups is presented.

Seayon S. Dmello et.al Automatic welding allows creating and maintaining a

quality welding workflow, ensuring flexibility, high efficiency and high output
rates. The MIG welding machine has a relay switch to control ON/OFF operation
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of welding torch. The essential feature of the process is the small diameter
electrode wire, which is fed continuously into the arc from a coil. The base metal
used for welding is carbon steel. Through this report our effort will be to
completely eliminate human contact during welding which will no doubt be safer
but will also be more efficient. The machine is used to weld work pieces in flat
position since higher deposition rates are achieved in this position and is a
convenient approach.

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 CHAPTER 3

PROJECT DESCRIPTION

3.1 Components

1. DC MOTOR
2. BATTERY
3. FRAME
4. BEARING
5. SHAFT
6. METAL STRIP
7. WELDING HOLDER
8. SHEET METAL
9. RACK AND PINION
10.TWO WAY SWITCH

3.1.1 D.C Motor

The electrical motor is an instrument, which converts electrical energy into

mechanical energy. According to faraday’s law of Electromagnetic induction,
when a current carrying conductor is placed in a magnetic field, it experiences a
mechanical force whose direction is given by Fleming’s left hand rule.
Constructional a dc generator and a DC motor are identical. The same dc machine
can be used as a generator or as a motor. When a generator is in operation, it is
driven mechanically and develops a voltage. The voltage is capable of sending
current through the load resistance. While motor action a torque is developed

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 Figure 3.1 DC Motor

The torque can produce mechanical rotation. Motors are classified as series
wound, shunt wound motors.

Specification

• DC Motor capacity : 12V

• Un loading : 130rpm

• Loading : 90rpm

Principles of operation

The basic principle of Motor action lies in a sample sketch.

Figure 3.2 Principle of motor operation

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 The motor run’s according to the principle of Fleming’s left hand rule.
When a current carrying conductor is placed in a magnetic field is produced to
move the conductor away from the magnetic field. The conductor carrying current
to North and South poles is being removed.

In the above stated two conditions there is no movement of the conductors.

Whenever, a current carrying conductor is placed in a magnetic field. The field due
to the current in the conductor but opposes the main field below the conductor. As
a result the flux density below the conductor. It is found that a force acts on the
conductor to push the conductor downwards. If the current in the conductor is
reversed, the strengthening of the flux lines occurs below the conductor, and the
conductor will be pushed upwards

• In DC machines coils are wound on the armature core, which is supported

by the bearings, enhances rotation of the armature. The commentator
periodically reverses the direction of current flow through the armature.
Thus, the armature rotates continuously.
• An electric motor is all about magnets and magnetism: a motor uses magnets
to create motion. If you have ever played with magnets you know about the
fundamental law of all magnets: Opposites attract and likes repel.
• So, if you have 2 bar magnets with their ends marked north and south, then
the North end of one magnet will attract the South end of the other. On the
other hand, the North end of one magnet will repel the North end of the
other (and similarly south will repel south). Inside an electric motor these
attracting and repelling forces create rotational motion.
• In the diagram, below you can see two magnets in the motor, the armature
(or rotor) is an electromagnet, while the field magnet is a permanent magnet
(the field magnet could be an electromagnet as well, but in most small
motors it is not to save power).

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 Figure 3.3 Field coil
3.1.2 Battery
Batteries seem to be the only technically and economically available storage
means. Since both the photo-voltaic system and batteries are high in capital costs.
It is necessary that the overall system be optimized with respect to available energy
and local demand pattern. To be economically attractive the storage of solar
electricity requires a battery with a particular combination of properties

Figure 3.4 Battery

Construction of battery
Inside a lead-acid battery, the positive and negative electrodes consist of a
group of plates welded to a connecting strap. The plates are immersed in the
electrolyte, consisting of 8 parts of water to 3 parts of concentrated sulphuric acid.
Each plate is a grid or framework, made of a lead-antimony alloy.This construction
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enables the active material, which is lead oxide, to be pasted into the grid. In
manufacture of the cell, a forming charge produces the positive and negative
electrodes. In the forming process, the active material in the positive plate is
changed to lead peroxide (pbo₂). The negative electrode is spongy lead (pb).

Automobile batteries are usually shipped dry from the manufacturer. The
electrolyte is put in at the time of installation, and then the battery is charged to
from the plates. With maintenance-free batteries, little or no water need be added
in normal service. Some types are sealed, except for a pressure vent, without
provision for adding water.

Figure 3.5 Layout of Battery

3.1.3 Ball Bearing

A ball bearing is a type of rolling-element bearing that uses balls to maintain

the separation between the bearing races.

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 The purpose of a ball bearing is to reduce rotational friction and support
radial and axial loads. It achieves this by using at least three races to contain the
balls and transmit the loads through the balls. In most applications, one race is
stationary and the other is attached to the rotating assembly (e.g., a hub or shaft).
As one of the bearing races rotates it causes the balls to rotate as well. Because the
balls are rolling they have a much lower coefficient of friction than if two flat
surfaces were sliding against each other.

Ball bearings tend to have lower load capacity for their size than other kinds
of rolling-element bearings due to the smaller contact area between the balls and
races. However, they can tolerate some misalignment of the inner and outer races.

Figure 3.6 Ball Bearing

Specification

INNER DIAMETER :12mm

OUTER DIAMETER : 37mm

3.1.4 Shaft

Shaft is a common and important machine element. It is a rotating member,

in general, has a circular cross-section and is used to transmit power. The shaft
may be hollow or solid. The shaft is supported on bearings and it rotates a set of

9
gears or pulleys for the purpose of power transmission. The shaft is generally acted
upon by bending moment, torsion and axial force. Design of shaft primarily
involves in determining stresses at critical point in the shaft that is arising due to
aforementioned loading. Other two similar forms of a shaft are axle and spindle.
Axle is a non-rotating member used for supporting rotating wheels etc. and do not
transmit any torque. Spindle is simply defined as a short shaft. Typical sizes of
solid shaft that are available in the market are, Up to 25 mm 0.5 mm increments 25
to 50 mm 1.0 mm increments 50 to 100 mm 2.0 mm increments 100 to 200 mm 5.0
mm increments The ferrous, non-ferrous materials and non metals are used as shaft
material depending on the application.

Figure 3.7 Shaft

Specifications

Shaft diameter : 12mm

Material : Mild steel

Length : 26 inch

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3.1.5 Sheet Metal

Sheet metal is metal formed by an industrial process into thin, flat pieces. It
is one of the fundamental forms used in metalworking and it can be cut and bent
into a variety of shapes. Countless everyday objects are fabricated from sheet
metal. Thickness can vary significantly; extremely thin thicknesses are
considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are considered plate.

Sheet metal is available in flat pieces or coiled strips. The coils are formed
by running a continuous sheet of metal through a roll slitter.

There are many different metals that can be made into sheet metal, such
as aluminium, brass, copper, steel, tin, nickel and titanium.

Figure 3.8 Sheet Metal

Sheet metal is used to make the table.

Material - Mild steel

Size - 40 x 15cm

Thickness - 1mm

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3.1.6 Welding Holder

Welding is a fabrication or sculptural process that joins materials, usually

metals or thermoplastics, by causing fusion, which is distinct from lower
temperature metal-joining techniques such as brazing and soldering, which do
not melt the base metal. In addition to melting the base metal, a filler material is
typically added to the joint to form a pool of molten material (the weld pool) that
cools to form a joint that is usually stronger than the base material. Pressure may
also be used in conjunction with heat, or by itself, to produce a weld.

Figure 3.9 Welding Holder

3.1.7 Two Way Switch

Type: Reverse and forward condition.

Power supply: AC or DC.

A two way light switch is a simple single pole "changeover" switch with
three terminals. These are typically labelled COM, L1, and L2 (Some may label
the L1 and L2 positions as "1 Way" and "2 Way").

In one switch position the COM terminal is connected to L1. In the other
switch position it changes over so that COM is connected to L2. The design is a

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"break before make" type, such that the connection to the first terminal is
disconnected before the connection to the new one is made

Figure 3.10 Two way switch

Multiway switching is the interconnection of two or more electrical

switches to control an electrical load (often, but not always, lighting) from more
than one location. For example, this allows lighting in a hallway, stairwell or large
room to be controlled from multiple locations. While a "normal" light switch needs
to be only a single pole, single throw (SPST) switch, multiway switching requires
the use of switches that have one or more additional contacts and two or more
wires must be run between the switches. When the load is controlled from only
two points, single pole, double throw (SPDT) switches are used. Double pole,
double throw (DPDT) switches allow control from three or more locations.

3.1.8 Rack and Pinion

Rack and pinion animations rack and pinion is a type of linear actuator that
comprises a pair of gears which convert rotational motion into linear motion. The
circular pinion engages teeth on a linear “gear” bar–the rack. Rotational motion
applied to the pinion will cause the rack to move to the side, up to the limit of its
travel. For example, in a rack railway, the rotation of a pinion mounted on a
locomotive or a rail car engages a rack between the rails and pulls a train along a
steep slope.

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 Figure 3.11 Rack and Pinion

 A rack is a gear whose pitch diameter is infinite, resulting in a straight line

pitch circle.
 Involute of a very large base circle approaches a straight line.
 Used to convert rotary motion to straight line motion.
 Used in machine tools.

Specification

Material : Cast-iron

Outside diameter : 76mm

Circular pitch : 4.9mm

Tooth depth : 3.385mm

Module : 1.7mm

Pressure angle : 21

Pitch circle diameter : 77mm

Addendum : 1.5mm

Dedendum : 1.875mm
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 Circular tooth Thickness : 2.365mm

Fillet radius : 0.46mm

Clearance : 0.385mm

A rack and pinion is a type of linear actuator that comprises a pair of gears
which convert rotational motion into linear motion. A circular gear called “the
pinion” engages teeth on a linear “gear” bar called “the rack”; rotational motion
applied to the pinion causes the rack to move, thereby translating the rotational
motion of the pinion into the linear motion of the rack.

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 CHAPTER 4

DESIGN AND DRAWING

4.1 Design of Rack & Pinion

Power
P =

T =

T = 7.123×102 N-mm

4.2 Torque

Torque =

d3 =

diameter = 9.52mm

~ 10mm

To find torque

T =F×r

= 29.43× 0.039

T =1.14N-m

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4.3 Diameter of Pulley

Diameter of Smaller Pulley

D1 = 2.5 ds

D1 =1.5×10

d1 = 15mm

Diameter of Larger Pulley

D2 = 2.5 d1

D2 = 2.5×15

D2 = 37.5mm

4.4 Lift force of rack

T = Ft

Ft =

Ft = 379.89N

4.5 Mass of pinion

Ft = Mass ×gravity

m =

m = 38.72 kg

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4.6 Advantages

 Small in size.
 Cost is less compared others welding machine.
 Due to nature of portable it can be easily handled.
 Due to portable ability .it is easily handled
 Low cost intelligent robot

4.7 Applications

1. Automobile industry
2. Ship building
3. Fabrication
4. Manufacturing industry

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 CHAPTER 5
FABRICATION

5.1 Manufacturing Process

Manufacturing processes are the steps through which raw materials are
transformed into a final product. The manufacturing process begins with the
creation of the materials from which the design is made. These materials are then
modified through manufacturing processes to become the required part.
Manufacturing processes can include treating (such as heat treating or coating),
machining, or reshaping the material. The manufacturing process also includes
tests and checks for quality assurance during or after the manufacturing, and
planning the production process prior to manufacturing.

Sawing

Cold saws are saws that make use of a circular saw blade to cut through
various types of metal, including sheet metal. The name of the saw has to do with
the action that takes place during the cutting process, which manages to keep both
the metal and the blade from becoming too hot. A cold saw is powered with
electricity and is usually a stationary type of saw machine rather than a portable
type of saw.

Figure 5.1 Sawing cutting machine

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 The circular saw blades used with a cold saw are often constructed of high
speed steel. Steel blades of this type are resistant to wear even under daily usage.
The end result is that it is possible to complete a number of cutting projects before
there is a need to replace the blade. High speed steel blades are especially useful
when the saws are used for cutting through thicker sections of metal.

Welding

Welding is a process for joining similar metals. Welding joins metals by

melting and fusing 1, the base metals being joined and 2, the filler metal applied.
Welding employs pinpointed, localized heat input. Most welding involves ferrous-
based metals such as steel and stainless steel. Weld joints are usually stronger than
or as strong as the base metals being joined.

5.2 Welding Process

Several welding processes are based on heating with an electric arc, only a
few are considered here, starting with the oldest, simple arc welding, also known
as shielded metal arc welding (SMAW) or stick welding.

In this process an electrical machine (which may be DC or AC, but

nowadays is usually AC) supplies current to an electrode holder which carries an
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electrode which is normally coated with a mixture of chemicals or flux. An earth
cable connects the work piece to the welding machine to provide a return path for
the current. The weld is initiated by tapping ('striking') the tip of the electrode
against the work piece which initiates an electric arc. The high temperature
generated (about 6000oC) almost instantly produces a molten pool and the end of
the electrode continuously melts into this pool and forms the joint.

The operator needs to control the gap between the electrode tip and the
work piece while moving the electrode along the joint.

5.2 Bill of Materials

Table. No.5.1 Bill of Materials

S.No DESCIRPTION QTY MATERIAL

1 FRAME 1 MILD STEEL

2 SHAFT 1 MILD STEEL

3 METAL STRIP 1 MILD STEEL

4 SHEET METAL 1 MILD STEEL

5 RACK AND PINION 1 MILD STEEL

6 BEARING 3 STAINLESS STEEL

7 TWO WAY SWTICH 1 ELECTRICAL

8 D C MOTOR 1 ELECTRICAL

9 BATTERY 1 ELECTRICAL

10 WELDING HOLDER 2 BRASS

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5.3 COST ESTIMATION

Table. No. 5.2 Cost estimation

SL.NO DISCRIPTION COST (in Rs)

1 FRAME 1000
2 SHAFT 400

3 METAL STRIP 250

4 SHEET METAL 250

5 RACK AND PINION 500

6 BEARING 250

7 TWO WAY SWTICH 150

8 D C MOTOR 1000

9 BATTERY 1000

10 WELDING HOLDER 500

11 TOTAL 5300

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 CHAPTER 6

CONCLUSION

Automatic dual welding machine reduces operator fatigue considerably.

Because of this automation we achieved rise in production. At the same time there
is reduction in rejection which results increase in the profit directly. Hence, the
cost of project can be recovered within one and half month. Easy operation, as
table automatically Hence it is easy to operate as well as precise with noiseless
operation which leads to safety of operator. Auto stop feature, to start and end
process operation at precise positions with multiple indexer positions, enables to
make staggered welded joints. Compact, the entire drive assembly fitted below the
table itself, and the controls are placed on the front at ergonomic positions. This
system also required less amount of power, so it helps to achieve minimum power
consumption. Thus, we have developed a “AUTOMATIC DUAL WELDING
MACHINE” which helps to know how to achieve low cost automation. The
operating procedure of this system is very simple, so any person can operate. By
using more techniques, they can be modified and developed according to the
applications.

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REFERENCE:

1. Mithari Ranjeet, “Design of Multi-Axis Welding Positioner with Auto

Indexing”, International Journal of Innovations in Engineering and Technology
(IJIET), 2014, vol. 3.

2. Patil Kunal V., Gadade Balaji K., Raut Parag G., Gaikwad Suvarna K., Toke
Ganesh, “A Novel approach of MIG Welding using PLC”,International Journal of
Advanced Research in Electrical, 2014, vol. 3.

3. Sateesh.R, Sreenithi.R.M, Tamilmani.R,Tamil Selvan.V, Vasanthakumar.A

Fabrication of automatic pneumatic double axis welding machine, Vol - 4
Issue - 2 2018 IJARIIE ISSN(O) – 2395 4396

4. Seayon S. Dmello , Jebin Biju, Shashank S. Hegde, Anand V. Ganoo, Design

and fabrication of automated 2-axis welding machine, International Journal of
Mechanical Engineering and Technology (IJMET) ,Volume 8, Issue 3, March
2017, pp. 236 –244 A

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PHOTOGRAPH

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