Equipment, tools, materials

Crank press with the nominal force of 630 kN 1

Die for die forging of gear billet 1

Dimension gage 5...6

Lead billets (11 mm in diameter and

15; 16.5; 17 mm in height 5...6 (of the each type)

The work must be executed as follows: Make acquaintance with design and operation of crank press and die. Study the safety precautions.

Develop draughts of the forgings. The articles to be manufactured of them are represented in Fig. 4.8. Stocks allowed for machining, biases and curvature radiuses would be given by an instructor.

Fig. 4.8. Draughts of the articles: a – gear; b – half-clench: c – lid; d – neck support; e – bushing

Determine volumes of the forgings and billets. Stamp 2…3 billets of calculated, lesser and greater volume.

Assess the character of filling up the finishing impression, surface quality of the forging and fin size. Make inferences.

Contents of the report. Describe briefly the essence of die forging process and forging's draught development procedure. Present the draught of finished product (article) and forging with all the necessary calculations.

Depict the kinematic scheme of crank press and explain its design.

Outline quality of the forging, degree of impression's filling up, fin size.

Make inferences.

5 Welding of metals

5.1 Manual electric arc welding

Purpose of the work: to become acquainted with electric arc welding processes, welding arc properties, design and operation of welding equipment, to become skilful at welding regimes determination and adjustment.

Theory. Welding is a process of permanent joints manufacture by setting up atomic bonds between working pieces while heating, deforming or heating and simultaneous deforming them. Local or general heating may be employed. Electric arc welding has found the most wide use due to its advantages over other welding processes: both high heat concentration and productivity, relative universality, various weld position in space, simple and inexpensive equipment, possibility to obtain stable and relatively high properties of weld metal.

The following kinds of electric arc welding are distinguished: alternating-current (a-c) and direct-current (d-c) welding; manual and automatic (machine) welding; unshielded arc, submerged arc and gas-shielded arc welding.

Electric arc with the temperature of 6000…8000 C in its core is the heating source in arc welding. Electric arc is a powerful stable arc discharge in ionized atmosphere of gases and metallic vapors. Arc distance ionization occurs at the instant of arc initiation and is sustained while arcing as a result of collisions between moving electrons (towards a cathode) and either gas molecules or metal vapor atoms. Electric properties of the arc are described by the static voltage-current characteristic, representing the dependence between voltage and current intensity (strength) at stable arcing instant. The main power source characteristic is considered to be its external characteristic – the relationship between output terminal voltage and current intensity in welding circuit. The intersection point of these two characteristics is supposed to accommodate the stable arcing (welding) (Fig. 5.1).

In arc welding transformers of ТД, ТС, СТШ, TCK types may be employed as a power source; in d-с welding – welding generators of ПСО, АСБ, АСД, CAM types and also rectifiers of ВД, BKC, BCC, ВДУ etc types. Welding current is adjusted by means of supply chokes (a-c welding) or variable resistances (d-c welding).

Manual arc welding is performed by an arc arcing between an electrode and working pieces. It is possible to use either non-consumable (of tungsten or graphite) or consumable electrodes – metallic rods (1.6…12 mm in diameter) coated with luting. Luting serves for stabilization of arcing, protecting of molten metal, deoxidizing an alloying it. Chemical content of electrode material has to match the content of a metal, which undergoes welding.

Fig. 5.1. Static voltage-current characteristic of a power source (1) and an arc (2) with different arc length l

Electrodes of 3…6 mm in diameter are mainly used in manual arc welding. Voltage is sustained within the range from 16 to 30 V, welding current intensity – 120…350 A.

Welding regime is completely characterized by welding current intensity I_W and electrode diameter d_e. The thickness of welding pieces determines the electrode diameter, the last determines the welding current intensity (approximately I_W = (40…60) d_e). Quantity of surfacing metal in welding is independent upon arc voltage. Therefore, voltage is not considered as welding characteristic.

Useful power N_u, W, released while arcing is determined by the formula:

N_u=I_wU_a

where I_w is welding current intensity, A;

U_a, is arc voltage, V.

Efficiency of welding transformer  is usually equal to 0.84…0.87. Hence, consumed power should be determined as follows:

N_c = N_u/

Equipment and materials

Power source for а-с (d-с) welding 1

Ammeter for welding current

intensity determination 1

Voltmeters for tapping off voltage at the

power source output terminals and on the arc 2

Welding electrodes of 338, 340 types 2…4

Welding pieces – plates of various

(4; 5; 6; 8 and 10 mm) thickness 2...4 (of the each dimension).

The work must be executed as follows. The electrode diameter, welding current intensity and welding rate should be determined as the function of the thickness of plates which undergo welding. Tap off the arc voltage U_a, welding current intensity I_w voltage during open-circuit test and, finally, current intensity in short circuit test. Refer presented above formulas to calculate useful power N_u, and consumed power n_c.

Plot the external voltage-current characteristic of the power source according to the available data.

Contents of the report. Characterize the arc welding process, its peculiarities and fields of application. Characterize the welding arc as a heating source.

Quote technical characteristic of the welding power source, plot its external voltage-current characteristic.

Calculate the consumed power and fill the following table 5.1.

5.1. Power calculations in welding

N° of the test	Voltage at input terminals of power source U1, V	Input current of power source I1, A	Consu- med power NC, W	Power source coef-ficient, 	Voltage in open circuit test U0C, V	Current density in short circuit test ISC, A	Voltage on the arc Ua, V	Welding current intensity, Ua, A	Useful power nu, W

In accordance with the data obtained in different tests plot the dependence between consumed power and thickness of welding plates.