Key

Q NO 1 Write a brief note on Electric resistance welding? (50 Marks)

Answer: -

ELECTRIC RESISTANCE WELDING

Electric resistance welding, either spot welding or seam welding, is typically used to
join thin sheet metal components during the manufacturing process.
SPOT WELDING
Two copper electrodes are held in the jaws of the spot-welding machine, and the
material to be welded is clamped between them. Pressure is applied to hold the electrodes
tightly together and electrical current flows this pressure is held after the current stops flowing
long enough for the metal to solidify. The amount of current, pressure, and dwell time are all
carefully controlled and matched to the type of material and the thickness to produce the
correct spot welds.
SEAM WELDING
Rather than having to release the electrodes and move the material to form a series
of spot welds, a seam welding machine is used to manufacture fuel tanks and other
components where a continuous weld is needed. Two copper wheels replace the bar-shaped
electrodes. The metal to be welded is moved between them, and electric pulses create spots
of molten metal that overlap to form the continuous seam.
Q NO 2 Write a brief note on squaring shear and explain its distinct operation?
(20+30 Marks)
SQUARING SHEAR

The squaring shear provides the airframe technician with a convenient means of
cutting and squaring sheet metal. Available as a manual, hydraulic, or pneumatic model, this
shear consists of a stationary lower blade attached to a bed and a movable upper blade
attached to a crosshead.

Two squaring fences, consisting of thick strips of metal used for squaring metal
sheets, are placed on the bed. One squaring fence is placed on the right side and one on the
left to form a 90° angle with the blades. A scale graduated in fractions of an inch is scribed
on the bed for ease in placement.

To make a cut with a foot shear, move the upper blade down by placing the foot on
the treadle and pushing downward. Once the metal is cut and foot pressure removed, a
spring raises the blade and treadle. Hydraulic or pneumatic models utilize remote foot pedals
to ensure operator safety. The squaring shear performs three distinctly different operations:

1. Cutting to a line
2. Squaring
3. Multiple cutting to a specific size

CUTTING TO A LINE

When cutting to a line, place the sheet on the bed of the shears in front of the cutting
blade with the cutting line even with the cutting edge of the bed. To cut the sheet with a foot
shear, step on the treadle while holding the sheet securely in place.

SQUARING

Squaring requires several steps. First, one end of the sheet is squared with an edge
(the squaring fence is usually used on the edge). Then, the remaining edges are squared by
holding one squared end of the sheet against the squaring fence and making the cut, one
edge at a time, until all edges have been squared.

MULTIPLE CUTTING

When several pieces must be cut to the same dimensions, use the backstop, located
on the back of the cutting edge on most squaring shears. The supporting rods are graduated
in fractions of an inch and the gauge bar may be set at any point on the rods. Set the gauge
bar the desired distance from the cutting blade of the shears and push each piece to be cut
against the gauge bar. All the pieces can then be cut to the same dimensions without
measuring and marking each one separately.