TIG Welding Project ppt
-
Upload
ashok-kotthapalli -
Category
Documents
-
view
352 -
download
54
description
Transcript of TIG Welding Project ppt
![Page 1: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/1.jpg)
WELCOME
![Page 2: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/2.jpg)
![Page 3: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/3.jpg)
ABSTRACTThe present work aims to evaluate the effect of GAS
TUNGSTUN ARC WELDING process parameters on the quality of the weld bead.
Process parameters : Wire Diameter, Welding Current, Wire Feed Speed, Ratio of wire feed rate to travel speed & Plate Thickness.
The quality of the weld bead can be assessed by the bead characteristics such as Penetration, Reinforcement and Bead width. Experiments were conducted to study the effects of the WELDING process parameters using automatic GTAW machine and the results are tabulated and plotted. Also mathematical models are developed.
![Page 4: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/4.jpg)
INTRODUCTON The GTAW (Gas Tungsten Arc welding) process
is easily found in any industry whose products
requires metal joining in a large scale.
The quality of the welded material can be
evaluated by many characteristics, such as bead
geometric parameters (penetration, width and
height) and deposition efficiency (ratio of weight
of metal deposited to the weight of electrode
consumed).
![Page 5: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/5.jpg)
GTAW System setup
![Page 6: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/6.jpg)
Advantage of the GTAW Process
• Weld more kinds of metals and metal alloy.
– Stainless steel, nickel alloys, titanium, aluminum,
copper, brass
• Also can weld dissimilar metals to each other.
– Copper to brass
– Stainless steel to mild steel.
![Page 7: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/7.jpg)
Other Advantages
• Concentrated Arc– Pin point control of heat input to the work piece.– Narrow heat affected zone– This is where the base metal has undergone a
change due to the superheating of the arc and fast cooling rate.
• No Slag• No Sparks, Spatter or Noise• No Smoke or Fumes
![Page 8: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/8.jpg)
GTAW Disadvantages
• Low filler metal deposition rate.
• Arc Rays are brighter than normal welding.
• Need additional care to protect skin with
proper clothes and welding lens.
![Page 9: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/9.jpg)
STATISTICAL DESIGN OF EXPERIMENTS AND TAGUCHI
METHOD
![Page 10: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/10.jpg)
INTRODUCTION
Statistical designed experiments with 5 process
parameters (each at 3 levels) are conducted to study the effect
of these parameters on bead geometry. It is found from the
analysis of variance (ANOVA).
![Page 11: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/11.jpg)
The phases in design of experiments
![Page 12: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/12.jpg)
Importance of Taguchi Method
• Taguchi’s approach complements these two important areas.
1. Clearly defines a set of general design for factorial experiments that cover many applications.
2. Devised a standard method for analysis of the results.
![Page 13: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/13.jpg)
EXPERIMENTAL PROCEDURE
![Page 14: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/14.jpg)
• The aim of this project is to find the optimum
welding process parameters like welding
current, wire feed speed, welding speed, wire
diameter and plate thickness in a GTA welding
process.
![Page 15: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/15.jpg)
Automatic GTAW Machine
![Page 16: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/16.jpg)
Control Parameters & Its Levels
PARAMETERS UNITS NOTATIONFACTOR LEVELS
1 2 3
Current (X1) A I 140 160 180
Wire diameter (X2) mm D 1.2 1.4 1.6
Wire feed rate (X3) mm/min WFR 1500 2000 2500
Ratio of wire feed rate to
travel speed (X4)- WFR/TS 6 8 10
Pipe thickness (X5) mm PT 8 12 16
![Page 17: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/17.jpg)
Experimental Number
Current (A)
Wire Diameter (mm)
Wire Feed Rate (mm/min)
Ratio of wire feed rate to travel speed
Plate Thickness (mm)
E01 1 1 1 1 1
E02 1 2 2 2 2
E03 1 3 3 3 3
E04 2 1 1 2 2
E05 2 2 2 3 3
E06 2 3 3 1 1
E07 3 1 2 1 3
E08 3 2 3 2 1
E09 3 3 1 3 2
E10 1 1 3 3 2
E11 1 2 2 2 3
E12 1 3 1 1 1
E13 2 1 2 3 1
E14 2 2 3 1 2
E15 2 3 1 2 3
E16 3 1 3 2 3
E17 3 2 2 3 1
E18 3 3 1 1 2
![Page 18: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/18.jpg)
Bead Geometry
![Page 19: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/19.jpg)
To Calculate Bead parametersFiller metal being deposited using GTAW
machine and bead geometry was found by using microscopic examination.
1.Grinding & polishing2.Etching- Reagent (Picric acid)
NEOPHOT 2 Microscope is used for
Microscopic examination.
![Page 20: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/20.jpg)
NEOPHOT 2 Microscope
![Page 21: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/21.jpg)
Heat Input
J =
Where J is heat input in kj/mm V is welding voltage in volts I is Welding current in amps GTS is Gun travel speed in mm/min η is Arc Efficiency for GTAW (0.6)
![Page 22: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/22.jpg)
Wire Deposition Efficiency %
=
Where V1 =
V2 =
![Page 23: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/23.jpg)
RESULTS & DISCUSSIONS
![Page 24: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/24.jpg)
S. No.
D (mm)
I (Amp)
GTS (mm/min)
WFR (mm/min)
PT (mm)
Penetration (P) mm
Reinforcement ( R ) mm
Width (W) mm
Heat input (J) kJ/mm
Weld Bead Volume
(V1)mm3
Wire deposition
Volume (V2) mm3
Wire Deposition Efficiency
%
1 1 1 1 1 1 0.78 1.84 0.75 1.95 5.25 27.78 0.84
2 1 2 2 2 2 0.97 1.89 0.91 2.26 7.45 28.13 0.50
3 1 3 3 3 3 0.87 1.94 1.96 4.95 4.83 28.57 0.36
4 2 1 1 2 2 0.92 2.02 0.82 1.96 3.22 28.57 0.58
5 2 2 2 3 3 1.06 2.30 1.31 3.21 3.78 28.89 0.41
6 2 3 3 1 1 0.98 2.42 2.25 5.14 10.45 30.67 0.96
7 3 1 2 1 3 1.19 2.54 1.76 2.75 6.34 39.13 1.08
8 3 2 3 2 1 1.25 2.65 1.91 3.12 7.22 38.78 0.65
9 3 3 1 3 2 1.42 3.00 1.18 2.1 3.28 37.50 0.46
10 1 1 3 3 2 0.75 1.80 0.75 1.95 7.13 27.78 0.36
11 1 2 2 2 3 1.03 2.23 0.91 2.28 6.34 28.13 0.84
12 1 3 1 1 1 0.58 1.50 0.98 2.58 8.28 27.93 0.50
13 2 1 2 3 1 1.73 3.42 0.76 2.34 4.12 25.81 0.41
14 2 2 3 1 2 1.09 2.34 2.41 4.05 9.24 37.50 0.96
15 2 3 1 2 3 0.81 1.88 2.18 2.98 3.04 39.22 0.58
16 3 1 3 2 3 0.94 2.85 1.78 2.53 5.98 40.00 0.65
17 3 2 2 3 1 1.34 2.03 1.14 1.65 3.02 34.48 0.46
18 3 3 1 1 2 1.22 2.60 2.1 2.93 9.6 39.62 1.08
![Page 25: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/25.jpg)
effect of factor levels on depth of penetration in GTAW
A3 B3 C3 D1 E3
180160140
1.8
1.6
1.4
1.2
1.01.61.41.2 300020001000
1086
1.8
1.6
1.4
1.2
1.016128
A
Mean o
f M
eans
B C
D E
Main Effects Plot for MeansData Means
![Page 26: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/26.jpg)
effect of factor levels on reinforcement height in GTAW
A2 B3 C3 D1 E3
180160140
3.6
3.2
2.8
2.4
2.01.61.41.2 300020001000
1086
3.6
3.2
2.8
2.4
2.016128
A
Mean o
f M
eans
B C
D E
Main Effects Plot for MeansData Means
![Page 27: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/27.jpg)
effect of factor levels on bead width in GTAW
A1 B3 C3 D1 E2
180160140
8
7
6
5
4
1.61.41.2 300020001000
1086
8
7
6
5
4
16128
A
Mean o
f M
eans
B C
D E
Main Effects Plot for MeansData Means
![Page 28: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/28.jpg)
Mathematical Models• The multiple regression analysis resulted the following equations
Y = 10aX1bX2
cX3dX4
eX5f
• Penetration P = -- (5.1)
• Reinforcement R = -- (5.2)
• Width W = -- (5.3)
![Page 29: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/29.jpg)
Predicted value Vs Experimental value of penetration in GTAW
![Page 30: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/30.jpg)
Predicted depth of penetration at different wire feed rates in GTAW
(on 8 mm thick plate)
![Page 31: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/31.jpg)
Predicted depth of penetration at different wire feed rates in GTAW (on 12 mm thick plate)
![Page 32: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/32.jpg)
Predicted depth of penetration at different wire feed rates in GTAW (on 16 mm thick plate)
![Page 33: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/33.jpg)
Predicted value Vs Experimental value of reinforcement height in GTAW
![Page 34: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/34.jpg)
Predicted reinforcement at different wire feed rates in GTAW (on 8 mm thick plate)
![Page 35: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/35.jpg)
Predicted reinforcement at different wire feed rates in GTAW (on 12 mm thick plate)
![Page 36: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/36.jpg)
Predicted reinforcement at different wire feed rates in GTAW (on 16 mm thick plate)
![Page 37: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/37.jpg)
Predicted value Vs Experimental value of bead width in GTAW
![Page 38: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/38.jpg)
Predicted width at different wire feed rates in GTAW (on 8 mm thick plate)
![Page 39: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/39.jpg)
Predicted width at different wire feed rates in GTAW (on 12 mm thick plate)
![Page 40: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/40.jpg)
Predicted width at different wire feed rates in GTAW (on 16 mm thick plate)
![Page 41: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/41.jpg)
CONCLUSION • It is observed that penetration is increasing from 0.75mm to 2.25mm,
when the wire feed rate is increased from 1000mm/min to 3000mm/min. It is also observed that penetration is decreasing with decrease in the ratio of wire feed rate to travel speed.
• Reinforcement and bead width are following almost the same trend. Increase in 2.12mm in the case of reinforcement was obtained by increasing wire freed rate from 1000mm/min to 3000mm/min.
• With increase in plate thickness penetration and bead width were found to be decreasing. That may be due to requirement of high heat input.
• The effect of wire diameter was found to be insignificant compare to other input parameters considered.
• At high values of heat input micro cracks and discontinues bead formation was also observed.
![Page 42: TIG Welding Project ppt](https://reader034.fdocuments.us/reader034/viewer/2022042422/55cf9973550346d0339d7780/html5/thumbnails/42.jpg)
THANK YOU