19564481 Cnc Machine Report

8/8/2019 19564481 Cnc Machine Report

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PORT DICKSON POLYTECHNIC

MECHANICAL ENGINEERING

DEPARTMENT

COURSE LECTURER: MR. HAFRIZALMAN

NAME REGISTRATION NUMBER

MOHAMAD SHOBRI BIN MAHADZAIR 06DEM08F2011

ROSNIN KHALID BIN ABDUL RAHMAN 06DEM08F2022

MOHD HAMDAN B. MOHAMED 06DEM08F2013

MUHAMAD HAZIQ BIN ZULKAFLIE 06DEM08F2012

TITLE CNC MACHINE

PROGRAMME & GROUP DEM 1 SEC 1

PRACTICAL DATE 10TH

AUGUST 2009 MARKS

SUBMIT DATE 24TH

AUGUST 2009

WORKSHOP REPORT

CNC MACHINE


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Contents PageOBJECTIVE 3

INTRODUCTION 4

EQUIPMENT 5 - 8

SECURITY APPARATUS 9

SAFETY RULES 10 -12

WELDING PROCEDURE 13 - 15

TYPES OF JOINT 16

PROJECT FIGURE 17DISCUSSION 18

CONCLUSION 19

REFERENCE 20


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OBJECTIVE

Learning how to use workshop equipmentsprecisely.

Learning how to usearc weldercorrectlyandsafely.

Observing the ways on how to welda metalbyusingarc welder.

To know how to preparea metalbefore weldingit.

To lathe severallines ona metalby using theright skills.

To control thevolume ofelectricityforweldingprecisely.

To know the ways on how to welda metalbyfollowing theright steps.


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INTRODUCTION

Thebasic principle ofarc weldinginvolvesheatingand melting ofbase metal usingelectricarc.

Theelectricarcis formed when thereis avoltagedifference

between the metalcoatingattheend oftheelectrodeand the surface ofthe

base metal.

Thearc will produce heat enough to melt thebase metaland theend oftheelectrode to form a

pool ofmolten metal.

The temperature ofthis process maybeas highas 3900C.

The pool ofmoltencompound will solidify toform

beads covered with alayerknownas slag.Thebead willform a strong permanent joint.


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EQUIPMENT

Welding Machine.y Speciallydesigned to supply suitableand strongenough current

foranarc welding work. Arc welding machinecanbe operated

by usingelectrical poweranddiesel orpetrolengine. Arcwelding machinein the workshop uses electrical power.

Transformerwill transfertheelectrical powerto therequired

voltageforarc welding.

Electrode holderandelectrodey Used to holdcurrent electrode while weldinga metal. Holder

must light, not easily hot and must becovered with good

insulatorto avoidelectrical shock.Electrodeis madeby orewire which has the samecontent with the welding metal.

Electricarcgenerates heat at least 5000

C and this resultedelectrodeand the metalbecome molten.

Welding Cabley Welding machineis connected to theelectrode holderandearth

plateby usingcable.Theconnectedcable must beflexibleenough so that it caneasily use. During welding process, current

willflow through this cable. Ifthecableis too long, thecurrentflow maydecrease.


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Welding Circuity This circuit shows that powersupplyis takenfrom the

workshop andconnected to welding machine.One ofthe power

sourceis connected to the holderandanotheris connected to theearth platevia welding metals.

Earth platey This deviceis used to connect theground wire to thebase ofthe

metal.Thereare two types ofearth plate which is called Clamp

typeandScrew type.

Cleanery In weldingcleaning process, we usechip hammerand wire

brush. Besides that, chisels and pliers arealso used to clean themetalafterwelding.


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ARC WELDING EQUIPMENT

The equipments used in arc welding are as the following below:

1.Transformer as a converter to adjust the welding voltage andcurrent.

2.Electrode holder is insulated and used to hold the electron.3.Electrode is a metal rod with a layer of coating which is used to

allow the flow of electric current to form the electric arc.

4.Earthing which connected to the base metal and the weldingmachine power supply to prevent electric shock.

5.Electrode cable is an electrical connection between the electrodeholder and power supply. The cable is insulated with rubber.

6.Cleaning tools are used to chip and clean the traces of metalspatters and slag produced on the surface of the welded metal.


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EQUIPMENTS

Electrode Holder

Wire Brush

Electrodes Tong

Earthing Cable

Chipping Hammer


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SECURITY APPARATUS

Safety Attire and Equipment

Safetyattireandequipment are used to protect and prevent awelderfrom injury when performingarc welding.Theequipmentand safetyattirerequiredareas thefollowing:

yFace shield protects the eyes and face from the effect of ultravioletrays and spatters while welding.

yLeather glove protects the hands from burns or scald.yLeather apron protects the body from heat and to protect the skin

from burns.

ySafety shoes are to protect the feet from arc spatters.

Safety MeasuresyWear the protective equipment such as face shield, gloves and

apron when performing welding.

yEnsure that the welding and earth cables are in good conditionand safe for use to prevent electrical shock.

yPerform welding away from inflammable materials.yPerform welding where the air circulation is good and

comfortable.


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SAFETY ATTIRE

Face sheld Leather gloves

Safety shoes Apron


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SAFETY RULES

WORKSHOP

ELECTRIC SHOCK CAN KILLy Make sureyou do not touch any segment orelectricequipment that

is switched on. Dont use thebrokendevices anddangerous. Make

sureyou wearthe suitable safetyboot.

SMOKE AND GASES CAN INFECT YOURHEALTHy Stayawayfrom the poisonous smokeandgases andavoidfrom

smellingit.

ARC SHINE CAN BURN EYE AND SKINy Make sureyou wearthefacecoverto protect ourfaceandeye

whendo thearc welding work.

WELDING COULD MAKE AN EXPLOSIONy Make sureyou wearthe safety shield while welding to avoidfrom

theburst.

HOTWORKPIECES COULD BURN YOURSKINy

Never touch the hot workpiece without using handgloves.


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PERSONy Avoidfrom gasping the poisonous fumes.y Explosion maycauseinjury.y The arc welding machine may easily explode if it is closed with

inflammablegoods.

y Dont touch the hot metalby using your hands instead of usingtongs.

y Thearc sparkmaycauseinjury to youreyes andbody.y Becareful of the wiringand theelectric sources which maycause

electrical shock. Make sure the tools areingoodcondition.

y Use the medicallotion to release the pain ofthe skinburnt.


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WELDING PROCEDURE

Arc Welding ProcedureProcedurey Clean the metal.y Place the plates close togetherwith sufficient gap for

welding.

y Select theappropriateelectrodeaccording to the joint type.y Adjust theelectriccurrent according to theelectrode size.y Scratch orknocktheelectrode tips onto the metal surface to

strike thearcanddo a tackweld to hold the joint.

y Weldalong the joint andfill the weldinggroovecompletely.

ySwitch offthe welding machine.

y Remove the slagfrom the weldingbead.


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BEADING AND BUTT JOINTB

eadingP

rocedure

i. Clean and mark the work piece surface to be welded.ii. Put the work piece on the working table and connect the

earth cable.

iii. Select the appropriate electrode and hold it with theelectrode holder.

iv. Adjust the current and voltage of the electrode.v. Knock or scratch the electrode to the surface of the electrode.

vi. Start beading in one direction following the mark.vii. Disconnect the electrode when beading is completed and

leave the work piece to cool.

viii. Remove slag on the work piece with a cleaning tool to inspectthe quality of the weld.


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Butt Joint Procedure

i. The method of butt welding is the same as (i) to (iv) of the beadingprocedure.

ii. Position the plates and leave sufficient gap for welding.iii. Tack weld at both end of the work piece to fix the position.iv. Weld along the surface of the work piece by filling the groove.v. Disconnect the electrode when butt welding is completed and

leave the work piece to cool.

vi. Remove slag on the object with a cleaning tool to inspect thequality of the butt weld.


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TYPES OF JOINT

1) Side Joint 2) Corner Joint

3) Paste Joint 4) T Joint

5) Sided Joint


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PROJECT FIGURE


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DISCUSSION

Make sureallequipments and tools areingoodcondition.Concernabout thelocationand thecondition ofthefirst aid

incaseifanyaccident occurs.

Scrape offrust andedge properly to avoidit from beingoxidized.

Ensure that electricvolumeis precisely used.

Do not let the metal melt so that thereis no hole on themetal.

Point the weldershooterstraightly on to the metal.

Do not touch the hot metalby hands nonetheless usea tongto moveit.Properprotection shouldbe wornat all times,

including protecting theeyes against glareandflying sparks.


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CONCLUSIONACCORDING TOTHISWELDING WORKSHOPREPORT, WE HAD LEARNT;

yHow to welda metalby usingarc weldingmachinepractically.

yHow to useinstruments in the workshopprecisely.

yHow to use theentire machines in theworkshop.

y How to learnabout the safety steps and the stepson how to welda metalby usingarc welding

machine.


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REFERENCES

y TECHNOLOGY BOOK MACHINE SHOP.IBRAHIM'S WRITER YOUNGCHE AND N.RAMUDARAM.EDITOR ROSNANI MAT JIHAN AND

NOREIDAH OTHMAN.HALL PUBLICATION LANGUAGE ANDLIBRARY

y KAMARRUDDIN BIN ISMAIL,AZMI BIN MOHD YASSIR AND RAMLIBIN ASUN.2003 BUKU PENGAJIAN KEJURUTERAAN MEKANIKAL

edited by ZAINAH BINTI MOHD.AZHAR AND NOR AZITA BINTI

UMAR. Dewan Bahasa And Pustaka's Publication Estuary Mud.

y www.google.image/arcwelding

19564481 Cnc Machine Report

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