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FAKULTI TEKNOLOGI KEJURUTERAAN

MEKANIKAL & PEMBUATAN


UNIVERSITI TEKNIKAL MALAYSIA MELAKA

MANUFACTURING PRACTICES

BMMP 1303 SEMESTER 2 SESI 2018/2019

ARC WELDING MACHINE LAB REPORT

NAME OF GROUP 1. MUHAMMAD ISMANAJMI BIN ROZI B091810258


MEMBERS &
MATRIX NUMBER 2.

3.

4.

5.

6.

YEAR & PROGRAM 1BMMH S1/2

SUBMISSION DATE 2019

NAME OF INSTRUCTOR 1. EN KHAIRUL AZRI BIN AZLAN

2.

EXAMINER’S COMMENT VERIFICATION STAMP

TOTAL MARKS: / 100


TABLE OF CONTENTS

ITEM PAGE

1. OBJECTIVES
3

2. INTRODUCTION
3

3. THEORY
3

4. SAFETY EQUIPMENT
4-5

5. TOOL USED
6-7

6. PROCEDURE
8-9

7. RESULT & DISCUSSION


9-10

8. CONCLUSION
10

9. REFERENCES
11

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1.0 OBJECTIVES

At the end of the practical activity, will be able to:


1. Apply safety procedures while working in the workshop.
2. Familiarize the arc welding machine features, handling and operating the machine.
3. Combine the two plate by using arc welding machine based on technical drawing.
4. To study how to setup AC machine.

2.0 INTRODUCTION

Welding is a common process for joining metals using a large variety of applications. The
metals are heated to their melting point while being shielded from the air, and then a filler metal
is added to the heated area to produce a single piece of metal. There are several types of welding
that are used today. Gas Metal Arc Welding (GMAW) or MIG, Gas Tungsten Arc Welding
(GTAW) or TIG, Flux Core Arc Welding, and Stick Welding are the most common found types
in industrial environments.

3.0 THEORY
Arc welding is a welding process that is used to join metal to metal by using electricity
to create enough heat to melt metal, and the melted metals when cool result in a binding of the
metals. It is a type of welding that uses a welding power supply to create an electric arc between
a metal stick ("electrode") and the base material to melt the metals at the point of contact. Arc
welders can use either direct (DC) or alternating (AC) current, and consumable or non-
consumable electrodes.
The welding area is usually protected by some type of shielding gas, vapor, or slag.
Arc welding processes may be manual, semi-automatic, or fully automated. First developed in
the late part of the 19th century, arc welding became commercially important in shipbuilding
during the Second World War. Today it remains an important process for the fabrication of
steel structures and vehicles.

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4.0 SAFETY EQUIPMENTS

EQUIPMENTS FUNCTION

1. HEAD SHIELD - protective eyewear that usually enclose


or protect .To the area surrounding the
eye in order to prevent particulates,
water or chemicals from striking the
eyes.

- Most welding helmets include a


window covered with a filter called a
lens shade, through which the welder
can see to work. In most helmets, the
window may be made of tinted glass,
tinted plastic, or a variable-density
filter made from a pair of polarized
lenses.

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2. Jacket
- To protect the body like a piece
personal protective equipment (PPE).

- To protects regular clothing that are


worn underneath.

3. Apron

- it protects you and your clothing from


hot metal and slag and that is
generated while welding, grinding or
using a cutting torch.

4. Glove

- It can protect you from electric shock,


flames, hot parts, sharp or flying metal,
and arc rays.

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5.0 TOOL USED

TOOL USED FUNCTIONS

1. Arc welding machine


- The device that supplies the high
current at relatively low voltage needed
for welding arcs. The voltage-current
relationship needs to conform to a
certain set of rules for it to be a pleasant
device to use.

2. Electrode - It is used to conduct current through a


workpiece to fuse two pieces together

3. Earth clamp (Holder) - To ensure that the metal enclosure of


the welding machine and ground is at
the same potential.

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4. Brush
- A wire brush is used for cleaning the
welding surface, removal of slag, rust
etc. The brush has stainless steel
bristles.

- When working on stainless steel, a


brush with stainless steel bristles and
chipping hammer made of stainless steel
must always be used.

5. Hammer
- A chipping hammer is a tool used to
remove welding slag from a weld and
welding spatter from alongside welds.

- Used by carefully swinging and hitting


the weld to shatter the slag.

6. Electro Holder

- It is a clamping device for holding the


electrode securely in any position.

- The welding cable attaches to the holder


through the hollow insulated handle.

- The design of the electrode holder


permits quick and easy electrode
exchange

7. Playar
- It used for clamp the piece plate to hold
it.
- To prevent lifting by hand during wait
the hot plate.

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Fig 2 shielded Metal Arc Welding Equipment

6.0 PROCEDURES

6.1 Each student will be given 2 pieces of metal.

6.2 Make sure you have put on all necessary PPEs before switching ON the welding set.

6.3 Set Voltage(V) and Amps(A) to the desired settings.

6.4 Try start to weld and familiarize with the right welding position, direction and distance.

6.5 Perform either butt joint using provided electrode (refer Fig 6.1).

6.6 Complete the final welding bead which is the one to be evaluated.

6.7 Clean work piece after finish and submit your welding project.

Fig 6.1

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Task 1: joint the two plate

7.0 RESULT

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8.0 DISCUSSION

1. What mean by MS in electrode ?

- MS is Malaysia standard.

2. How much the voltage for standard arc welding ?

- 80 V

3. What will happen if move slow in welding ?

- It will cause the size of alignment become large.

4. How many content in rod ?

- Steel
- China clay
- Rotile

5. Why the alignment become error ?

- It because of lack of experience and need more practical.

6. How to prevent alignment become error ?

- Constant the slow movement and make a correct handle the electrode holder with 60°
from surface of metal.

9.0 CONCLUSION

At these practical, we learn about how to joining the plat iron use the Arc and Gas
Welding. Other than that we also have been teach by our lecturer how to adjust the volume of
the electric. Besides that, Our lecture always remain us to stay alert in safety while doing a
work before and after finish the pratcice. Conclusion is, I want to thanks to lecturer and my
friend during learning of arc and gas welding. However,these practical i will never ever
forget because these talent is bring us to learn a new thing’s in my studying at these
workshop.

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10.0 REFERENCES
1.http://www.google.com/search?newwindow=welding+gas+arc workshop & oq = welding +
gas + workshop.

2. J Hu, HL Tsai - International Journal of Heat and Mass Transfer, 2007 - Elsevier

3 TJ Bliss - US Patent App. 05/566,937, 1977 - Google Patents

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LAB 3: ARC WELDING (REPORT RUBRIC)
Student 1: .Muhammad Ismanajmi Bin Rozi Matrix No.: B091810258

Course/ Section: 1 BMMH 1/2

Topic in report Evaluation Scores

Correct measurement to 2
A. Product decimal places (15%)
Dimension
(20%) Work piece picture attached
(5%)

Correct processes arranged in


correct manner (10%)
B. Manufacturing
Cutting Tools Use (10%)
Sheet (35%)
Sketch and Process Parameters
included (15%)

Comprehensive Discussion.
C. Discussion
Includes safety
(15%)
precautions/PPE (15%)

D. Conclusion Comprehensive conclusion


(10%) (10%)

Student 1 Student 2
Ability to operate machine and
E. General
equipment’s (10%)
Conducts

(10%) Attitude, behavior,


involvement with others (10%)

Total Score ____/ 100 ____/ 100

Overall Report Mark / 5% / 5%

Instructor Signature: Date:

…………………………………………… ………………………..

Name:

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