Part B Micro Project Report

WELDING JOINTS.

1.0 Rationale:
Welded Joint is a permanent joint which is obtained by fusion of the edges of two parts to be
joined together using a filler material
Heat required for fusion of material may be obtained by burning of gas or by producing an
electric arc Pressure may or may not be applied during welding process Welding is extensively
used in fabrication work, repair work filling cracks, joining broken parts etc. For more details,
refer article.
Welded assembly results in lighter construction
Comparatively cheaper. Cost of welded assembly is lower than cost of bolted joints.
Design of welded assemblies can be easily and economically modified to meet the changing product
requirements
Welded joints are tight and leak proof as compared to other joints
When two parts are joined by threaded joints (ie screwed joints), holes are drilled in the parts to
accommodate bolts or screws These holes reduce the cross-sectional area of parts to be joined, which leads
to problem of stress concentration. There is no such problem in case of welded joints
Comparatively high strength. Please note that, strength of weld is more than strength of plates joined
Together. Machine components of complex shape can be easily welded. For example Circular steel pipes, noz
tapered pipes etc

2.0 Aim of the project

To study the concept related to Welding joints and principle of working Related to
industries

3.0 Course Outcomes:

1. Identity the various types of welding joints.
2. Determine the applications of welding joints
3. Determine the process of welding
4. Identify method of welding .

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4.0Literature Review

Welding is a material joining process in which two or more parts are coalesced at their
contacting surfaces by a suitable application of heat and/or pressure. Many welding
processes are accomplished by heat alone, with no pressure applied; others by a
combination of heat and pressure; and still others by pressure alone, with no external heat
supplied. In some welding processes, a filler material is also added to facilitate coalescence.
Among all welding process gas tungsten arc welding (GTAW) process is a very versatile, all-
position welding process that is widely used to join Ni-/Co-base alloys. TIG welding
developed during 1940 at the start of the Second World War. In GTAW, the heat for welding
is generated from an electric arc established between a non-consumable tungsten electrode
and the work-piece. GTAW can be performed manually or adapted to automatic equipment,
and can be used in production as well as repair welding situations. GTAW is most commonly
used to weld thin sections of stainless steel and nonferrous metals such as aluminum,
magnesium and copper alloys. The process grants the operator greater control over the weld
than competing processes such as shielded metal arc welding and gas metal arc welding,
allowing for stronger, higher quality welds. However, GTAW is comparatively more complex
and difficult to master, and furthermore, it is significantly slower than most other welding
techniques. In spite this, it has further more advantages over other types of welding
processes and welds almost all metals including dissimilar ones with a wide range of power
supplies.This survey presents a literature review on friction stir welding (FSW) with a special
focus on the dissimilar metal T-Joint. Friction stir welding is widely applied for similar and
dissimilar metal welding. In current scenario, FSW is widely applied for several industries
such as aerospace, automobile, reactors etc. FSW has an ability to weld dissimilar metals
having different melting points. The main advantages of FSW process are very eco-friendly
and produces less waste. Friction stir welded region have high strength, low distortion, no
melt related defects. The absence of filler materials and air eliminates filler induced defect,
and porosity. FSW technique is uses to produce T, lap and butt shaped welding and also used
in hollow pipes, pressure vessels etc. This review shows the types, application and testing of
T-joint welded by FSW process.
links :- http://www.ijste.org/articles/IJSTEV4I1024.pdf
https://shodhganga.inflibnet.ac.in/bitstream/10603/121775/11/11_chapter2.pdf

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5.0 Actual Methodology Followed :

1. First of all, we decided topic welding joints of subject Elements of machine design with
the help of faculty named Prof. S.V.Sagare
2. Then Tushar Niphade collected information with the help of reference
books.,Wikipedia.
3. Patil Vijay made some changes in that information .
4. We studied comparatively the Welding joints.
5. All this information , images are typed and inserted in the computer by Viresh Tidke.
6. With the help of project guide we inspected that project. Some mistakes were made
in that project.
7. Later those mistakes were solved properly, and we completed our project and prepare
report.
8. The total cost required for this project is Rs.100
9. The time required is 8 weeks approximately.

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Introduction on Welding joints

Welding is a common process for joining metals using a large variety of applications. Welding
occurs in several locations, from outdoors settings on rural farms and construction sites to
inside locations, such as factories and job shops. Welding processes are fairly simple to
understand, and basic techniques can be learned quickly. Welding is the joining of metals at
a molecular level. A weld is a homogeneous bond between two or more pieces of metal,
where the strength of the welded joint exceeds the strength of the base pieces of metal.
At the simplest level, welding involves the use of four components: the metals, a heat source,
filler metal, and some kind of shield from the air. The metals are heated to their melting point
while being shielded from the air, and then a filler metal is added to the heated area to
produce a single piece of metal. It can be performed with or without filler metal and with or
without pressure.
There are several types of welding that are used today. Gas Metal Arc Welding (GMAW) or
MIG, Gas Tungsten Arc Welding (GTAW) or TIG, Flux Core Arc Welding, and Stick Welding are
the most common found types in industrial environments.

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Types of Weld Joints

There are five common types of weld joints used in all types of welding: corner joints, edge
joints, lap joints, tee joints, and butt joints.

Corner Joint – When two pieces are perpendicular to each other and one piece’s edge
meets the end of the other piece’s surface, it is referred to as a corner joint. Common
corner joints are edge to edge, flush corner, and half overlap, each with their own benefits.

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Edge Joint – An edge joint is when two edges of weld pieces are adjacent and in parallel
planes with each other. The weld does not penetrate completely through the joint thickness
so it should not be used in high stress or pressure situations.

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Lap Joint – A lap joint in welding occurs when a bead is made on the surface of one
workpiece and the edge of the other piece. It should be performed with no gap between the
two pieces.

Tee Joint – The edge of one workpiece meeting the surface of the other workpiece with
material on both sides of the edge is called a tee joint.

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Butt Joints – When two workpieces are aligned on the same plane and joined by a weld
along their edges, it is called a butt joint. They are used where high strength is required
because they are reliable and can withstand stress better than any other type of weld.

Welding Symbols

Welding can be performed in thousands of combinations regarding position, welding type,

welding dimensions, and many other varying components of welding.
Due to its diverse nature and the precise needs of the industrial world, a complex collection
of symbols has been created to dictate exact weld details. This allows designers to precisely
indicate the type, style, and other details of a weld using a symbol on a print for the piece
being manufactured or otherwise altered.
The joint is the basis of reference for welding symbols. It has an arrow pointing to it and
connects to the reference line. Including the arrow, there are eight elements of a welding
symbol, explained below:

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Reference Line – The reference line is used to designate the type of weld, weld location, size
of the weld, extent of the weld, contour of the weld, and many other pieces of vital
information.

Arrow and Other Side – All welded joint symbols have an arrow and other side, which is
opposite the arrow side and used to indicate the location of the weld with respect to the joint.

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Weld Symbols – Weld symbols, as opposed to welding symbols, indicate the desired type of
weld.

Dimensions and Other Data – This information provides the details regarding the size of the
weld and any other data needed to find the proper weld size.

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Supplementary Symbols – Supplementary symbols give information on whether the weld is a
“weld all around” or a “field weld.” It also indicates the desired contour of the weld.

Finish Symbols – The finish symbol dictates how the weld should be shaped or ground after
the completion of the weld.

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Tail – The tail of the symbol is used to designate the process by which the metals will be
welded. It is also used to indicate the welding specifications, process, and other
supplementary information regarding the weld.

Specifications, Process, or Other Information – The process of the weld includes details such
as the type of filler rod, whether root chipping is required, and other pertinent data. There
are letter designations for each type of welding process that can be performed.

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Sleeve and Cotter Joint. This type of joint is used for light transmission of axial loads from one
rod to another rod. The ends of the two rods are forced into a sleeve. Two slots are provided
in the sleeve, and one slot each is provided in the rods to take one cotter each.

The slot considerably decreases the strength of the rod that is why the diameter of the rods
is increased for the length which comes inside the sleeve.

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2) Spigot and Socket Cotter Joint. This type of joint is used for round rods. The end of
one rod is forged in the shape of a socket and the other in the shape of a spigot. Slots are
provided in the spigot and socket ends to accommodate the cotter. The diameter of the
spigot end is increased to overcome the loss of strength due to the slot. To make the joint
rigid and perfectly tight, the slots are made slightly out of alignment, so that when the
cotters is driven in, it will tend to force the spigot and socket ends towards each other.

1) Gibb and Cotter Joint for Square Rods. This type of joint is used for joining two square
rods. One end of the rod is forged in the shape of a fork the other rod is pushed into
the fork. Slots are provided in the fork and the rod to accommodate
the gib and cotter while assembling the parts. The gib is inserted first so that the
straight surface touches the slot of the fork and then cotter is hammered into the rest
of the slot. Care should be taken that the tapered side of the gib and cotter should be
face to face with each other.

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 1.0 Failure of Cotter Joint

It consist of 3 elements: i. Socket ii. Spigot iii. Cotter Where, d= End diameter of rod d1=
Diameter of spigot/Inside diameter of socket d2= Diameter of spigot collar D1= Outer
diameter of socket D2= Diameter of socket collar C=Thickness of socket collar t1= Thickness
of spigot collar t= thickness of cotter b= Mean width of cotter a= Distance of end of slot to the
end of spigot P= Axial tensile/compressive force σt, σc , τ= Permissible tensile,

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Compressive, shear stress for the component material

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6.0 Outputs of the Micro Project:-

 Understood the various types of joints. And their working.

 Understood How to uses in day to day life.
 Information about proper Joints.

7.0 Skill developed / learning out:-

1) Increase in general knowledge.

2) Time management.
3) Better planning skill.
4) Increase efficiency of working

8.0 Application of this project:-

The construction of cotter joint, used to connect two rods subjected to tensile force P is
shown in the figure. When the cotter is inserted into the slot, the central portion of cotter
comes in contact with spigot and the spigot gets pushed into the socket till the collar of the
spigot comes in contact with the collar of socket. As shown in the figure, finally the cotter is
in contact with the spigot on one side having some clearance with the socket slot and is in
contact with the socket on the other side having some clearance with the spigot slot.
Clearance provided is generally 1.5 to 3 mm. Cotter gets locked because of the frictional
force of the contacting surfaces.
Advantages of Cotter Joint:
- Simple to design and manufacture.
- Simple to assemble and dismantle.
- Very high tightening force due to wedge action, which prevents loosening of parts in
service.

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