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TITLE PAGE

ELECTRIC ARC WELDING MACHINE

BY

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EE/H2013/01430
DEPARTMENT OF ----
SCHOOL OF ---
INSTITUTE OF ---

DECEMBER,2018

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APPROVAL PAGE

This is to certify that the research work, "electric arc welding machine" by ---, Reg. No. EE/H2007/01430 submitted in partial fulfillment of the requirement award of a Higher National Diploma on --- has been approved.

By
---                                                     . ---
Supervisor                                                  Head of Department.
Signature……………….                           Signature……………….        

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External Invigilator

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DEDICATION
This project is dedicated to Almighty God for his protection, kindness, strength over my life throughout the period and also to my --- for his financial support and moral care towards me.Also to my mentor --- for her academic advice she often gives to me. May Almighty God shield them from the peril of this world and bless their entire endeavour Amen.

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ACKNOWLEDGEMENT

The successful completion of this project work could not have been a reality without the encouragement of my --- and other people. My immensely appreciation goes to my humble and able supervisor mr. --- for his kindness in supervising this project.
My warmest gratitude goes to my parents for their moral, spiritual and financial support throughout my study in this institution.
My appreciation goes to some of my lecturers among whom are Mr. ---, and Dr. ---. I also recognize the support of some of the staff of --- among whom are: The General Manager, Deputy General manager, the internal Auditor Mr. --- and the ---. Finally, my appreciation goes to my elder sister ---, my lovely friends mercy ---, ---, --- and many others who were quite helpful.

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This project is titled the designing and construction of an electric A.C arc welding machine. Electric Arc Welding Machine of 230/240 Volts and output voltage of 32volts. A core type step-down transformer and choke are essential as the voltage or the arc is 32v. The choke is necessary to displace the phase relationship of the voltage and current so that the heat of the arc may be maintained by ensuring that zero points of current and voltage are as far apart as possible. This welding machine is able to deliver a current 15Amps at voltage of 230 volts, the transformer is mounted on a rectangular metal frame and its enclosed by a case which has opening at a regular internal order to provide air for the cooling of the transformer. A double insulation technique is employed for better protection from electric shock and short circuit in the machine or when working in moist environment. An all-purpose electrode holder is connected across one or the output terminal of the transformer so that various size of electrode can be held properly. After the transformer had been constructed, the primary terminals were connected to source of supply. Then the secondary terminal was connected to the welding circuit, as a source of supply, with the aid of welding cable, by which one of the terminal was \connected to the ground clamp and the other to the electrode holder. A.C. Electric Arc Welding Machine uses alternating (AC) current, and consumable or non-consumable electrodes. The welding region is usually protected by some type of shielding gas, vapor, and/or slag. The aim of this work is to design and construct an electric welding arc that can be used to weld metals.

 

TABLE OF CONTENT
COVER PAGE
APPROVAL PAGE
DEDICATION
ACKNOWLEDGEMENT
TABLE OF CONTENT

1. INTRODUCTION
2. BREIEF HISTORY AND HISTORICAL BACKGROUND
3. LITERATURE REVIEW
4. OBJECTIVES OF THE PRESENT WORK
5. SCOPE OF ELECTRICC ARC WELDING MACHINE

1.5      purpose of the project
1.6      Limitation of the project
1.7      types of electric arc welding
1.8      application of the project
1.9      problems of the project
1.10   project organisation

CHAPTER TWO
2.0       ANALYSIS OF ALTERNATE METHOD OF WELDING AND CHOICE OF BEST METHOD
2.1       ALTERNATIVES TO ELECTRIC ARC WELDING MACHINE
2.1.1   JOINING PROCESS
2.1.2   GAS WELDING
2.1.3   SOLDERING
2.1.4   BRAZING
CHAPTER THREE
METHODOLOGY
3.0       GENERAL DESCRIPTION AND ITS WORKING PRINCIPLE
3.1       WORKING PRINCIPLE OF THE WELDING MACHINE
CHAPTER FOUR
4.0     DESIGN CALCULATION
4.1       WINDING DESIGN
4.2     INSULATION PROCEDURE
4.3     POWER SOURCE
4.4     ELECTRODE TYPES
4.4.1  TYPES OF ELECTRODE AND THEIR USES
4.4.2   ELECTORDE STADARD GAUGE
CHAPTER FIVE
5.0       MATERIAL SELECTION AND FABRICATION OF WELDING MACHINE
5.1       FABRICATION OF WELDING MACHINE
5.2       TRANSFORMER
5.2.1  WORKING PRINCIPLE OF TRANSFORMER
5.3       USEFUL AND LEAKAGE FLUXES IN A TRANSFORMER
5.4       METHODS OF REDUCING LEAKAGE FLUX
5.5     TRANSFORMER FABRICATION
5.6      METHOD OF WLDING
5.7     FACTORS OF SUCCESSFUL ARC WELDING
5.8     MAINTENANCE
5.9     THE SAFETY PRECAUTIONS

CHAPTER SIX
6.0     CONCLUSION AND RECOMMENDATION
6.1     CONCLUSION
6.2     PROBLEMS ENCOUNTERED AND RECOMMENDATION

 

CHAPTER ONE

• INTRODUCTION

In the past with the necessary of metals it always seems impossible to join two metals together with grooving riveting, this idea leads to alternative of finding a lasting solution to the problem. This brought about the idea of a welding machine with a well laminated core and coil wound together to form a high rated transformer which is immersed in a can of oil.
Welding is the most economical and efficient way to join metals permanently. It is the only way of joining two or more pieces of metal permanently to make a single piece. Welding is vital to our economy.
It is even said that over (50%) of the gross nation product of the industries is related to welding in one way or the other. Welding ranks high economy industrial process and involve more science and variable than those involved in any other industrial process.
The electrode is either a rod that simply carried current between the tip of the tong and the work, or a rod or wire that melts and supplies, fill metal to the joint.
The basic arc welding circuit is an alternating current (A.C) or direct current (D.C) power source connected by a “hot” cable to an electrode, when the electrode is positioned close to the work piece, an arc is created across the gap between the metal and the hot cable electrode. An ionized column of gas developed to complete the circuit.

1.1     BREIEF HISTORY AND HISTORICAL BACKGROUND
Arc welding did not come into practice until much later. In 1802, “Vasily Petrov” discovered the continuous electric Arc and subsequently proposed its possible practical applications including welding. The French electrical inventor “Auguste Demeritens” produced first carbon arc touch, patented in 1881, which was successfully used for welding leading in the manufacturer of lead-acid batteries. In 1881-1882 a Russian inventor “Nikolai Bernardo” created the electric arc welding method for steel known as carbon arc welding, using carbon electrode. (Lincoln Electric 1994), the procedure hand book of arc welding, Cleceland Ohiho Lincoln Electric ISBN 99949-25-82-2. The advance in arc welding contacted with the inventor of metal electrode in the late 19th century by a Russian, “Nikolai Slavyanov” 1888 and an American, “C.L coffin”. Around 1900 A.P strotimenger released in Britain a coated metal electrode which gave more stable arc, in 1905 Russian scientist “Vladimir Mitevich” proposed the usage of three phase electric arc for welding.
In 1919 the alternating current welding was invented by “C.J Hoslag” not become popular for another decade. Competing welding process such as resistance welding and oxy-fuel welding were developed during this especially the later, faced stiff competition from arc welding especially after metal coving (known as flux) for the electrode to stabilized the arc and shield the base material from impurities continued to be developed.
The arc welding was not common until during world war I, welding started to be used in ship building in Great Brittan in place of riveted steel plates. The Americans also became more of accepting of the new technology when the process allowed them to repair their ships quickly after a German attack in the New York Harbor at the beginning of the war. Even in the good old days, Nigeria make use of forgoing whereby two pieces of metal are join together by heating them to a high temperature ant then hammering them together (forge welding).
In 1919 the British ship builder “Cammel Laird” started construction of merchant ship, the fillager, with entire welding hill, she was launched in 1921.
During the following decade, further advanced allowed for the welding of reactive such as aluminum and magnesium, this in conjunction with the development in automatic welding, alternating current, flux fed a major expansion of arc welding during the 1930’s and then during world war two after decades of development, was finally perfected in 1941 and gas metal arc welding followed in 1948, allowing for fast welding of non-ferrous material but required more expensive shielding gases. Using a consumable electrode and a carbondioxide atmosphere as shielding gas. It quickly becoming to most popular arc welding process , in 1957. The flux cored arc welding process debuted in which the self-shielded wire automatic equipment, resulting in greatly increased welding speeds. In that same year plastic arc welding was invented. Electro slag welding as released in1958 and was followed by it cousin, electro-gas welding in 1961.

1.2     LITERATURE REVIEW
This write up is fully based on the method and ways of carrying out welding work and construction of the machine. Welding is a fabrication or sculptural process that joins material usually metals or thermoplastics, by causing fusion, which is distinct from the lower temperature metal. Joining techniques such as brazing or soldering which do not melt the base metal. The value of welding as a standard method of joining metal was not fully appreciated before world war one, then because of the need for speed of production in every metal using and metal fabrication industry, the order of welding processes came on their own. During and after world war two, the new welding method were developed, which further increased speed and facilitates the joining of the many special purpose alloys that were developed during this period.
Limited in its early application to small or less important parts, welding in the second half of the 20th century was employed in fabrication too numerous to mention, such as ship, locomotives, rail and cars. The petroleum industry is a classic example. The cutting edge of the bit used to drill on wells consist of a hard weld metal fused to backing transportation to and from refinery is via all welded transport iron material.
Whenever a piece of apparatus is intended to contain a liquid or gas, welding is the logical method of fabrication. As such, it has almost completely replaced other method. Welding as of course by no means of confined to wide application where leak tightness is involved. In the conventional body on frame automobile, there are some 8,000 to 10,000 resistance welds and up to 40ft of arc welding.
Building and bridges can be erected y welding with a saving of (10%) to (20%) in the amount of steel requires. The proportion of structures erected by welding was increasing in the second half of the 20th century and trend appeared likely to continue.
The processes of welding may be divided into four processes

• Forge welding
• Arc welding
• Gas welding
• Resistance welding

Arc welding will be expansiated on, in accordance to the title of the project.

1.3     OBJECTIVES OF THE PRESENT WORK

• To find alternative replacement replacement for the imported models.
• To make it affordable at relatively cheap price.
• To further understand the fabrication or construction/working principle of the machine.
• To acquire basic understanding of operating and welding of transformer.

1.4     SCOPE OF ELECTRICC ARC WELDING MACHINE
The machine is designed to be supplied with an input ranging from 220volt to 240 volt. A good weld must be strong as parent metal. The scope of welding process in the modern industries has taken a greater dimension more than the previous year. Today the science and act of welding involves a wide range of process and procedure applicable to materials of any thickness and shape. These may range from more a very thin electronic component to a large machine and structure. The arc produces a temperature of about 3600oc at the top armed melts part of the metal being welded and part of electrode. This produces a pool of molten metal that cools and solidifies behind electrode as it moved along the joint.
This electric arc welding machine is a heavy duty machine which is capable of welding 12 gauges of electrodes while in operation.

1.5                                   PURPOSE OF THE PROJECT

The purpose of his work is to design an electrical machine that uses a welding power supply to create an electric arc between an electrode and the base material to melt the metals at the welding point. They can use on alternating (AC) current, and consumable or non-consumable electrodes.

1.6                                           SIGNIFICANCE OF THE STUDY
a. AC Arc Welding Transformers are extensively used today in machine building and general purpose maintenance and fabrication work. Light medium and heavy structural work as a Power Source.
b. The safety advantages of switching to welding machine include reduced health hazards for workers. From limiting exposure to hazardous fumes to decreased risk of arc burn, arc welding machine help to save workers from a once dangerous job.
c. It has high welding efficiency and speed.
d. It provides better welding environment.
e. It gives consistent quality of weld.
f. It forms the strong bond in between the joined metals.
g. It has simple welding equipment.
h. Power source is not so expensive.
i. It is fast and reliable process.
j. Equipments can be used for multiple functions.
k. Welders can use standard domestic current.

1.7                                           LIMITATION OF THE PROJECT
1) Higher initial setup cost
2) Atmosphere surrounding the welding process has to be stable (hence the shielding gasses), therefore this process is limited to draught free conditions
3) Higher maintenance costs due to extra electronic components
4) The setting of plant variables requires a high skill level
5) Less efficient where high duty cycle requirements are necessary
6) Radiation effects are more severe

1.8                                               BENEFIT OF THE PROJECT
An arc welding machine uses a process which applies intense heat to metal at a joint, causing the metal to melt and intermix. Arc welding machine has several benefits, including improved weld consistency, decreased cycle times, and enhanced efficiency.

1.9                                          APPLICATION OF THE PROJECT
Arc welding utilizes an electric arc between an electrode and a metal base using either consumable or non consumable electrodes. This welding machine is commonly found in steel product and automobile manufacturing. Other applications include:
Construction: Arc Welding processes are a foundational aspect of all large-construction industries, ensuring strong, sustainable connections within buildings, bridges and other infrastructures.
Mechanical: For more rugged applications that involve thicker metal dimensions, arc welding provides the control and effectiveness necessary to firmly bond heavier pieces together. In the automotive industry, arc welds bond heat shields, exhaust systems and hydraulic lines to the chassis. Metal furniture pieces like office desks, file cabinets and shelving units are often welded. Heating, ventilation and air conditioning units are usually constructed using welding processes.
Equipment: Most, if not all, of today’s industries rely on properly functioning equipment, and welding processes are vital to the success of those machines.
Farm equipment: In agriculture, farm machines that plow, plant, seed and harvest are fundamental to the country’s food supply. Those machines are welded throughout their frames and processes. On the chassis, the cab frame, fenders and brackets are formed by welds. Motor structure and electrical functions are fused, as are the features of specialized tools such as threshers and spreaders. These machineries can be welded using arc welding machine
Lawn and garden: Lawn mowers, trimmers, power saws and other garden equipment have long lives due to the strength of their welded frames. Other metal garden features enhance the enjoyment of outdoor life, such as barbecue grills, enclosures, seating and watering systems.
Highway equipment: Maintenance of safe and passable roads also depends on secure welds. Manhole cover plates and the sewer and utility systems that frequently run under roads are also usually constructed with welding processes.
Institutional equipment: Hospitals, medical facilities, schools and homes all rely on well-functioning appliances to keep food warm or cold, run accurate testing operations and clean clothing or dishes. Virtually every appliance in use today was constructed at least in part with a arc welding process.

1.10                                              PROBLEM OF THE PROJECT
High skilled operator is required to do arc welding and also heavy to carry because of the iron cores and copper wires.

1.11                                        PROJECT WORK ORGANISATION
The various stages involved in the development of this project have been properly put into five chapters to enhance comprehensive and concise reading. In this project thesis, the project is organized sequentially as follows:
Chapter one of this work is on the introduction to the study. In this chapter, the background, significance, objective, purpose,  limitation and problem of the study were discussed.
Chapter two is on literature review of this study. In this chapter, all the literature pertaining to this work was reviewed.
Chapter three is on design methodology. In this chapter all the method involved during the design and construction were discussed.
Chapter four is on testing analysis. All testing that result accurate functionality was analyzed.
Chapter five is on conclusion, recommendation and references.

 

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CHAPTER TWO: The chapter one of this work has been displayed above. The complete chapter two of "electric arc welding machine" is also available. Order full work to download. Chapter two of "electric arc welding machine" consists of the literature review. In this chapter all the related work on "electric arc welding machine" was reviewed.

CHAPTER THREE: The complete chapter three of "electric arc welding machine" is available. Order full work to download. Chapter three of "electric arc welding machine" consists of the methodology. In this chapter all the method used in carrying out this work was discussed.

CHAPTER FOUR: The complete chapter four of "electric arc welding machine" is available. Order full work to download. Chapter four of "electric arc welding machine" consists of all the test conducted during the work and the result gotten after the whole work

CHAPTER FIVE: The complete chapter five of design and construction of a "electric arc welding machine" is available. Order full work to download. Chapter five of "electric arc welding machine" consist of conclusion, recommendation and references.

 

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