Question 1

(a) Describe briefly the principle of:

MIG Welding

MIG is mostly use when thicker sheets need to be welded. The consumable electrode is in the
form of a wire reel which is fed at a constant rate, through the feed rollers. The welding torch is
connected to the gas supply cylinder which provides the necessary inert gas. The electrode and
the work-piece are connected to the welding power supply. The power supplies are always of the
constant voltage type only. The current from the welding machine is changed by the rate of
feeding of the electrode wire. Normally DC arc welding machines are used for GMAW with
electrode positive. The electrode increases the metal deposition rate and also provides for a
stable arc and smooth electrode metal transfer. Also in the GMAW process, the filler metal is
transferred from the electrode to the joint. Depending on the current and voltage used for a given
electrode, the metal transfer is done in different ways.

Resistance welding

In resistance welding, the metal parts to be joined are heated by their resistance to the flow of an
electrical current. Usually this is the only source of heat, but a few of the welding operations
combine resistance heating with arc heating, and possibly with combustion of metal in the arc.
The process applies to practically all metals and most combinations of pure metals and alloys,
which have only a limited plastic range, are welded by heating the parts to fusion point. Also
some alloys may weld without fusion. In this case, the parts are heated to a plastic state at which
the applied pressure causes their crystalline structures to grow together. The welding of
dissimilar metals may be accomplished by melting both metals frequently only the metal with the
lower melting point is melted, and an alloy bond is formed at the surface of the solid metal. In
resistance welding processes no fluxes are employed, the filler metal is rarely used and the joints
are usually of the lap type.
Question 1B

Lap weld joint

Lap welding joints are used most often to joint two pieces with differing thicknesses together. A
Lap Joint is formed when 2 pieces are placed in an over lapping pattern on top of each other. Lap
joints are very common and are also applicable in plastic and wood. It is also used widely in
automation processes such as in tabling, temporary framing.

 The advantages of the lap joint are:

 They are easy to make

 Very string welds are obtained if double sided weld in made

But the main drawback is that sheets bearing heavy loads cannot bear one-sided weld.

Corner weld joint

The type of joint that is formed by placing the corner of two parts at a right angle to each other is
called a corner joint. As a result, an L shape is formed between the two parts that are being
joined. This is used on the outer edge of the sheet. Corner joints are used for sheet metal that is
used to attach pieces together or for welding light sheets of metal. Advantages of corner welds
are that strong welds can be produces and a variety of welds is possible. But the main
disadvantage is that there is an increased chance of wear and tear.

Tee weld joint

Tee welding joints are formed when two members intersect at a 90° angle which makes the edges
come together in the center of a plate or component. Tee Joints are considered a type of fillet
weld, and can also be made when a pipe or tube is welded onto a base plate. This type of weld is
mostly used is structural and machine applications, where the metal piece is attached to some
sort of a base.
The advantage is that no preparation is required for the T-joint. But the disadvantages are:

Extra attention and skill is needed to ensure effective penetration of the weld

Corrosion fatigue is common

Butt weld joint

A butt welding joint is also known as a square grove weld. It consists of two flat pieces that are
side by side parallel. Butt weld joints are used when working with pipes, valves, flanges and
fittings. It is a very affordable and easy option. But the disadvantages are that there is a need for
preparation of the edge before welding and also there is a high chance of porosity in the weld.

Question 1C:

Calculate the time taken to complete a 300 mm long cut on an aluminum plate using a 75 mm
diameter slab mill with 6 teeth?

𝑁 = (1000 × 100)/ (𝜋 × 75) = 424.41 𝑟𝑝𝑚

𝑓𝑚 = 0.6 × 424.41 × 6 = 1527.887

𝐶𝑢𝑡𝑡𝑖𝑛𝑔 𝑡𝑖𝑚𝑒 = (300 + 30) / (1527.887) = 0.21598 𝑚𝑖𝑛 = 12.95 s

Cutting time is equal to 12.95s

Question 2a

Facing

Facing is the process of removing metal from the end of a workpiece to produce a flat surface.
When a lathe cutting tool removes metal it applies considerable tangential force to the
workpiece. To safely perform a facing operation, the end of the workpiece must be positioned
close to the jaws of the chuck. The workpiece should not extend more than 2-3 times its diameter
from the chuck jaws unless a steady rest is used to support the free end.

Parting

Parting uses a blade-like cutting tool plunged directly into the workpiece to cut off the workpiece
at a specific length. It is normally used to remove the finished end of a workpiece from the bar
stock that is clamped in the chuck. Other uses include things such as cutting the head off a bolt.
Boring

In machining, boring is the process of enlarging a hole that has already been drilled (or cast) by
means of a single-point cutting tool (or of a boring head containing several such tools). Boring is
used to achieve greater accuracy of the diameter of a hole, and can be used to cut a tapered hole.

Drilling

Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in solid
materials. In the case of drilling on a lathe, the tool does not move, only the workpiece rotates.
The alignment between the headstock and tailstock of the lathe enables you to drill holes that are
precisely centered in a cylindrical piece of stock. Before you drill into the end of a workpiece
you should first face its end. The next step is to start the drill hole using a center drill.
Turning

Turning is the removal of metal from the outer diameter of a rotating cylindrical workpiece.
Turning is used to reduce the diameter of the workpiece, usually to a specified dimension, and to
produce a smooth finish on the metal. Often the workpiece will be turned so that adjacent
sections have different diameters.

Question 2B

Face milling

Facing on a milling machine is the process of cutting a flat surface perpendicular to the axes of
the milling cutter. This process removes the material by rotating the facing tool in the counter
clockwise direction as the table feeds the work piece across the cutter.

Side milling

Side milling is the operation of production of a flat vertical surface on the side of a work-piece
by using a side milling cutter. This process can be carried out on a horizontal milling machine.

Form milling

Form milling is the process of producing a surface having an irregular outline. A form milling
cutter is used to cut the required surface.

End milling
End milling is the process is of milling slots, flat surfaces, and profiles by end mills. End mills
cut the workpiece from end to end.

Gear cutting milling

This is the process of machining gears, after the worpiece is marked using the indexing process,
it is cut using the appropriate cutter to form the required teeth for the gear.
Question 2C:

5 factors affecting chip formation:

 Rake angle of the cutting tool

 Ductility of the material being cut
 Use of cutting fluid
 The sharpness of the tool
 Cutting speed of the tool

Question 2D:

Principle of ultrasonic testing;

Ultrasonic testing technology is based on the ability of high-frequency oscillations (about 20,000
Hz) to propagate into the metal and be reflected from surface scratches, voids, and other
discontinuities. The diagnostic wave enters into the tested material and if any crack or defects are
present, the wave will deviate, thus indicating a problem in the weld. The nature of the defect can
be recognized by graphical and parametric readings.
The procedure of the inspection:

 Remove all the paint and rust from welding seams and of the area on both sides.
 The transducer is moved zigzag along the weld and at the same time trying to turn around
its axis at 10-15 degrees.
 At occurrence of stable flaw signal move the transducer again and again. Find the
position, where the flaw signal will show its maximum.
 Make sure that the welding steam itself does not cause such reflection of the oscillations.
 The position of the defect should be recorded.
 As usual, weld seam inspection is carried out in one or two approaches.
 T-joints (90 degrees weld seams) are checked by echo method.

Question 3A:

(a) The specification of a grinding wheel is given as follows: 32A 40 L10 B

Give the interpretation of the underlined segments.

 32 – is the manufacturer s symbol indicating the exact nature of abrasive

 A – Type of abrasive used in this case, aluminum oxide
 40 – Grain size
 L – Grade of the wheel
 10 – structure of the wheel / spacing
 B – type of bond, in this case Retinoid (synthetic resin)

Question 3B:

Dressing operation is carried out when the grinding wheel need to be maintained. When the
sharpness of grinding wheel becomes dull because of glazing and loading, dulled grains and
chips are removed (crushed or fallen) with a proper dressing tool to make sharp cutting edges
and simultaneously, make recesses for chips by properly extruding to grain cutting edges. Thus,
these operations are for the dressing.

1. For the dressing process:

2. Clean the wheel of any dust or residues
3. Set up the dressing tool
4. Make sure the dressing tool bit is just shy of the surface of the grinding wheel
5. Start the grinding machine and move the dressing tool across the grinding wheel slowly
Question 3C;

Outline the main specifications that you deem important to suit the requirements of the
Workshop .
Firstly, the technical specification of the lathe
1. The swing over the machine
2. Swing over cross slide
3. Turning length
4. Width of the bed

Specification for the work spindle

1. The spindle diameter in front bearing
2. Spindle bore
3. Taper bore
4. Normal chuck diameter
5. Max. diameter of face plate and clamping disk

Specifications for the toolslide

1. Guide length of carriage
2. Graduation of longitudinal scale on hand wheel
3. Width of Cross-slide
4. Compound slide travel
5. Graduation of scale on compound slide spindle
6. Width of top slide
7. Stroke of quill
8. Diameter of centre sleeve
9. Taper socket
10. Scale graduation on centre sleeve
Specification for the drive
1. Number of speed ranges
2. Standartised metric threads
3. Coolant tank with complete pump capacity
Specification for the floor requirement of the machine
1. Length, width and height of machine
2. Sound pressure level according to ISO specification
3. Space available in the workshop
4. Orientation of the machine in the workshop

Question 4D;

The EDM, is a process where an electrical current is directed to pass between an electrode and a
workpiece that has been separated by a dielectric liquid, which acts as an electrical insulator.
Once a high enough voltage is applied, the dielectric fluid is ionized and it transforms into an
electrical conductor and erodes the workpiece by emitting spark discharge to shape it into the
desired form or final shape. This machining process is able to execute shaping processes with
high precision. The EDM is very useful when machining harder materials such as titanium or
tungsten carbide. But on main drawback is that it is a slow process compared to traditional
machining ways and thus is very inefficient when dealing with large scale projects.
Even though several EDM processes are specialized, industrial EDM processes are grouped in
three sub-processes; Sinker EDM (RAM), Wire EDM (Cheese Cutter), and Hole Drilling EDM
(Hole Popper). Each of the sub-processes of EDM provides a solution for machining applications
requiring high accuracy in metal shaping, cutting, and drilling, where conventional methods are
ineffective, difficult, or impossible.
EDM is mostly limited when it comes to large-scale projects, it is great for incredibly small
projects requiring one-off parts or limited volume production batches that require precision work
machining. For example, in the aerospace and automotive industries, EDM is used in the
development of small pieces in engines that are highly precise and advanced. Also, electrical
machining is used in the mold-making industry