PORT DICKSON

POLYTECHNIC
MECHANICAL
ENGINEERING
DEPARTMENT

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 MARKS
2009
TH
SUBMIT DATE 24 AUGUST
2009

COURSE LECTURER: MR. HAFRIZALMAN

All Rights Reserved © DEM2 S1 2009. Copyrights Protected. Page 1
 Contents Page
OBJECTIVE 3
INTRODUCTION 4
EQUIPMENT 5-8
SECURITY APPARATUS 9
SAFETY RULES 10 -12
WELDING PROCEDURE 13 - 15
TYPES OF JOINT 16
PROJECT FIGURE 17
DISCUSSION 18
CONCLUSION 19
REFERENCE 20

All Rights Reserved © DEM2 S1 2009. Copyrights Protected. Page 2

 OBJECTIVE

➢Learning how to use workshop equipments

precisely.
➢Learning how to use arc welder correctly and
safely.
➢Observing the ways on how to weld a metal by
using arc welder.
➢To know how to prepare a metal before welding
it.
➢To lathe several lines on a metal by using the
right skills.
➢ To control the volume of electricity for welding

precisely.
➢To know the ways on how to weld a metal by
following the right steps.

All Rights Reserved © DEM2 S1 2009. Copyrights Protected. Page 3

 INTRODUCTION
➢ The basic principle of arc welding involves
heating and melting of base metal using electric
arc.

➢The electric arc is formed when there is a

voltage difference between the metal coating at
the end of the electrode and the surface of the
base metal.

➢The arc will produce heat enough to melt the

base metal and the end of the electrode to form a
pool of molten metal.

➢The temperature of this process may be as high

as 3900°C.

➢The pool of molten compound will solidify to

form beads covered with a layer known as slag.
The bead will form a strong permanent joint.

All Rights Reserved © DEM2 S1 2009. Copyrights Protected. Page 4

 EQUIPMENT
➢ Welding Machine.

• Specially designed to supply suitable and strong enough current

for an arc welding work. Arc welding machine can be operated
by using electrical power and diesel or petrol engine. Arc
welding machine in the workshop uses electrical power.
Transformer will transfer the electrical power to the required
voltage for arc welding.

➢ Electrode holder and electrode

• Used to hold current electrode while welding a metal. Holder

must light, not easily hot and must be covered with good
insulator to avoid electrical shock. Electrode is made by ore
wire which has the same content with the welding metal.
Electric arc generates heat at least 5000°C and this resulted
electrode and the metal become molten.

➢ Welding Cable
• Welding machine is connected to the electrode holder and earth
plate by using cable. The connected cable must be flexible
enough so that it can easily use. During welding process,
current will flow through this cable. If the cable is too long, the
current flow may decrease.

All Rights Reserved © DEM2 S1 2009. Copyrights Protected. Page 5

 ➢ Welding Circuit
• This circuit shows that power supply is taken from the
workshop and connected to welding machine. One of the power
source is connected to the holder and another is connected to
the earth plate via welding metals.

➢ Earth plate

• This device is used to connect the ground wire to the base of

the metal. There are two types of earth plate which is called
Clamp type and Screw type.

➢ Cleaner

• In welding cleaning process, we use chip hammer and wire

brush. Besides that, chisels and pliers are also used to clean the
metal after welding.

All Rights Reserved © DEM2 S1 2009. Copyrights Protected. Page 6

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

1. Transformer as a converter to adjust the welding

voltage and current.

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

welding machine power supply to prevent electric
shock.

5. Electrode cable is an electrical connection between

the electrode holder and power supply. The cable is
insulated with rubber.

All Rights Reserved © DEM2 S1 2009. Copyrights Protected. Page 7

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

EQUIPMENTS

Electrode Holder

All Rights Reserved © DEM2 S1 2009. Copyrights Protected. Page 8

 Earthing
Cable

Chipping
Hammer

Wire Brush

All Rights Reserved © DEM2 S1 2009. Copyrights Protected. Page 9

 Electrodes Tong

SECURITY APPARATUS
 Safety Attire and Equipment

➢ Safety attire and equipment are used to protect and prevent a

welder from injury when performing arc welding. The equipment
and safety attire required are as the following:

• Face shield protects the eyes and face from the effect
of ultraviolet rays and spatters while welding.
• Leather glove protects the hands from burns or scald.
• Leather apron protects the body from heat and to
protect the skin from burns.
• Safety shoes are to protect the feet from arc spatters.

 Safety Measures

• Wear the protective

equipment such as face shield,
gloves and apron when performing welding.
All Rights Reserved © DEM2 S1 2009. Copyrights Protected. Page 10
 • Ensure that the welding and earth cables are in
good condition and safe for use to prevent electrical
shock.
• Perform welding away from inflammable materials.
• Perform welding where the air circulation is good
and comfortable.

SAFETY ATTIRE

Face sheld Leather gloves

All Rights Reserved © DEM2 S1 2009. Copyrights Protected. Page 11

 Safety shoes Apron

SAFETY RULES
 WORKSHOP

➢ ELECTRIC SHOCK CAN KILL

• Make sure you do not touch any segment or electric equipment
that is switched on. Don’t use the broken devices and dangerous.
Make sure you wear the suitable safety boot.

➢ SMOKE AND GASES CAN INFECT YOUR HEALTH

• Stay away from the poisonous smoke and gases and avoid from
smelling it.

➢ ARC SHINE CAN BURN EYE AND SKIN

All Rights Reserved © DEM2 S1 2009. Copyrights Protected. Page 12

 • Make sure you wear the face cover to protect our face and eye
when do the arc welding work.

➢ WELDING COULD MAKE AN EXPLOSION

• Make sure you wear the safety shield while welding to avoid from
the burst.

➢ HOT WORKPIECES COULD BURN YOUR SKIN

• Never touch the hot workpiece without using hand gloves.

 PERSON

• Avoid from gasping the poisonous fumes.

• Explosion may cause injury.

• The arc welding machine may easily explode if it is closed with

inflammable goods.

• Don’t touch the hot metal by using your hands instead of using
tongs.

All Rights Reserved © DEM2 S1 2009. Copyrights Protected. Page 13

 • The arc spark may cause injury to your eyes and body.

• Be careful of the wiring and the electric sources which may cause
electrical shock. Make sure the tools are in good condition.

• Use the medical lotion to release the pain of the skin burnt.

WELDING PROCEDURE
 Arc Welding Procedure

➢ Procedure

• Clean the metal.

• Place the plates close together with sufficient gap for

welding.
All Rights Reserved © DEM2 S1 2009. Copyrights Protected. Page 14
 • Select the appropriate electrode according to the joint type.

• Adjust the electric current according to the electrode size.

• Scratch or knock the electrode tips onto the metal surface

to strike the arc and do a tack weld to hold the joint.

• Weld along the joint and fill the welding groove

completely.

• Switch off the welding machine.

• Remove the slag from the welding bead.

 BEADING AND BUTT JOINT

Beading Procedure

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.

All Rights Reserved © DEM2 S1 2009. Copyrights Protected. Page 15

 iii.Select the appropriate electrode and hold it with
the electrode 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 inspect the quality of the weld.

 Butt Joint Procedure

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

of the beading procedure.

All Rights Reserved © DEM2 S1 2009. Copyrights Protected. Page 16

 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 the quality of the butt weld.

TYPES OF JOINT

All Rights Reserved © DEM2 S1 2009. Copyrights Protected. Page 17

1) Side Joint 2) Corner Joint

3) Paste Joint 4) T – Joint

5) Sided Joint

PROJECT FIGURE

All Rights Reserved © DEM2 S1 2009. Copyrights Protected. Page 18

 DISCUSSION
 Make sure all equipments and tools are in good condition.

 Concern about the location and the condition of the first aid
in case if any accident occurs.

 Scrape off rust and edge properly to avoid it from being

oxidized.

 Ensure that electric volume is precisely used.

 Do not let the metal melt so that there is no hole on the

metal.

 Point the welder shooter straightly on to the metal.

 Do not touch the hot metal by hands nonetheless use a tong

to move it. Proper protection should be worn at all times,
including protecting the eyes against glare and flying sparks.

All Rights Reserved © DEM2 S1 2009. Copyrights Protected. Page 19

 CONCLUSION
 ACCORDING TO THIS WELDING WORKSHOP
REPORT,WE HAD LEARNT;

• How to weld a metal by using arc welding

machine practically.

• How to use instruments in the workshop

precisely.
• How to use the entire machinesin the
workshop.
• How to learn about the safety steps and the steps
on how to weld a metal by using arc welding
machine.

All Rights Reserved © DEM2 S1 2009. Copyrights Protected. Page 20

 REFERENCES

• TECHNOLOGY BOOK MACHINE SHOP.IBRAHIM'S

WRITER YOUNG CHE AND N.RAMUDARAM.EDITOR
ROSNANI MAT JIHAN AND NOREIDAH OTHMAN.HALL
PUBLICATION LANGUAGE AND LIBRARY

• KAMARRUDDIN BIN ISMAIL,AZMI BIN MOHD YASSIR

AND RAMLI BIN 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.

• www.google.image/arcwelding

All Rights Reserved © DEM2 S1 2009. Copyrights Protected. Page 21