Grinding Machines and Types

The following types of grinders are included in this category.

1. Bench Grinder
These types of grinding machines are fixed on a workbench or table. Gear or pulley is fitted in it. For rotating the big-size gears or
pulley a handle is also fixed. It contains one or two grinding wheels. Edges of cutting tools can be made with this grinder.
Provision can be made to operate these with power also.
2. Hand Grinder
This grinder is also fixed on the workbench or table. There is a provision of moving the grinding wheels with a level as shown in
the figure.
3. Pedestal Grinder
Types of Grinding Machines – Pedestal Grinder
These types of grinding machines are operated with electric power. This is fitted on a pedestal frame separately on the ground. A
grinder wheel is fitted each on both sides of the shaft of the electric motor.
4. Portable Grinder
Portable Grinder and Flexible Grinder
This is a small grinder operated with electric power. It can be easily carried anywhere. Grinding can be done by holding it in
hand. It is used for cleaning heavy welding jobs.
5. Flexible Grinder
These types of grinding machines are shown in the figure. The electric motor in this grinder is fitted on such a basis that it can be
moved in any direction. A flexible shaft is fitted on the motor shaft with the help of a coupling. On one end of the shaft, a
grinding wheel and handle are provided. Large jobs can be easily grinded with this grinder.
6. Precision Grinder
In this type of grinder, a movable spindle is fitted in the grinding wheel. This spindle is fitted on a table along with its motor.
With this spindle, the grinding wheel can be turned in forward, backward, left, or right direction in running condition. Jobs of
excellent finish and accuracy are grinded with it. These grinders are of the following types:
 Welding helmet
A welding helmet is a type of personal protective equipment used in performing certain types of welding to protect the eyes, face,
and neck from flash burn, sparks, infrared and ultraviolet light, and intense heat.
• Principles of Operation
The SMAW process uses an electric circuit that
supports a welding arc to convert electric line
power or fuel into heat. The heat from the
welding arc is intense and extremely
concentrated. It immediately melts a portion of
the work piece and the end of the electrode.
Jan 4, 2018
• What is the core of SMAW?
It covers core competencies such as setting-up
welding equipment, preparing weld materials,
fitting up weld materials, welding carbon steel
plates and pipes using SMAW and repairing
welds. A person who has achieved this
Qualification is competent to be: SMAW Welder.
• What are the basic principles of welding?
Basic principles of welding. A weld can be defined
as a coalescence of metals produced by heating
to a suitable temperature with or without the
application of pressure, and with or without the
use of a filler material.
Weld defects, causes and Remedies:
• Preheat the metal as required.
• Provide proper cooling of the weld area.
• Use proper joint design.
• Remove impurities.
• Use appropriate metal.
• Make sure to weld a sufficient sectional area.
• Use proper welding speed and amperage current.
• To prevent crater cracks make sure that the crater
is properly filled.
Welding Processes: FCAW, GMAW, GTAW, SMAW,
SAW
In process industry there are many pipes which are
running across the plant transferring different fluid
from source to the destination. These pipes are
generally manufactured in a standard length of 6
meters or 12 meters so the pipes are joined together
to achieve the required routing. The most common
method of joining pipes is by welding two pipe spools
together.
The most common weld processes for welding of
piping are mentioned below with their
requirements:
• Flux Core-Arc Welding (FCAW)
• Gas Metal-Arc Welding (GMAW)
• Gas Tungsten-Arc Welding (GTAW)
• Shielded Metal-Arc Welding (SMAW)
• Submerged-Arc Welding (SAW)
• Filler Metals, Electrodes, Wire and Flux
ESSENTIALS FOR PROPER WELDING PROCEDURES
• Correct electrode size.
• Correct current.
• Correct arc length or voltage.
• Correct travel speed.
• Correct electrode angle.
The 5S concept consists of
Sort (seiri),
Set in Order (seiton),
Shine (seiso),
Standardise (seiketsu) and
Sustain (shitsuke).
One of the 5s elements is Straighten (seiton) where
the systemize workplace and worker discipline to
organize its work area become an important
factor to improve work efficiency.
5S refers to five steps – sort, set in order, shine,
standardize and sustain (also known as the 5
pillars of a visual workplace).
5S is a five-step methodology for creating a more
organized and productive workspace: Sort,
Straighten, Shine, Standardize, and Sustain. 5S
serves as a foundation for deploying more
advanced lean production tools and processes.
What Is the 5S Methodology?
Welding defects
Spatter – Spatter occurs
when metal particles from Weld spatter consists of small
the weld is stuck on the balls of molten metal that are
area adjacent to the weld created near the welding arc that
area. This defect is stick to the gas shroud of the
common in gas metal arc weld gun and block gas flow.
welding and it is Resulting problems include the
sometimes very hard to spatter sticking to work pieces
remove the particles. and/or tooling, injuries to
Causes of Spatter. Running workers, clean-up, porosity and
on very high amperage can loss of material.
cause spatter
Slag Inclusions are a common welding defect that
occurs when slag, a welding by-product, gets stuck
inside the weldment. This is an unfavorable condition
that creates performance issues down the line. In
most cases, it is a result of bad welding technique or
improper selection of components and parameters.
This defect primarily occurs in flux-based welding
techniques like Stick Welding and Flux-Cored Arc
Welding.
An Undercut in welding occurs when the weld puddle meets an
area of metal that has not melted. This happens more often
with non-ferrous metals. The flux we use when welding
stainless steel has a bad habit of creeping out in front of the
weld puddle and not melting. That is why, when the puddle
meets this unmelted flux, an undercut takes place.
Welding porosity is a welding defect that results from
unwanted gasses being trapped within the molten
weld puddle during solidification, which causes pockets
or pores on the surface or within the bead. Porosity
can occur on the surface of a weld or within the weld
bead.
Overlap. Overlap occurs when molten metal flows over
the surface of the base material and then cools without
fusing with the base material. A typical cause of overlap
is the supply of too much weld metal due to low welding
speed. Overlap in fillet welds is caused by the droop of
excessive molten metal due to gravity
Incomplete Penetration
There was too much space between the metal you're
welding together.
You're moving the bead too quickly, which doesn't
allow enough metal to be deposited in the joint.
You're using a too low amperage setting, which results
in the current not being strong enough to properly
melt the metal.
GMAW
• Chipping Hammer

Chipping hammers are designed with a pointed pick end on one

side and a flat end on the other side. They are used to chip
away the slag and bits of metal from your weld in case you
need to lay another bead on the same spot or a bead that is
going to overlap the first one. Otherwise, it is going to get
worked into your puddle and your bead. In addition to that, the
flat end of the hammer is used to remove the spatters from
alongside welds. The chipping hammer has to be carefully
swung and hit the weld to shatter the slag, without causing any
damage to the workpiece. Regardless of your welding type
(Stick, MIG, TIG), you’re going to use a chipping hammer a ton.
Use of hand tools in welding.
 MIG Welding Plier
Compared to every other plier, MIG pliers provide the users with a broad scope of functionality. As the name explains,
they are specially designed to help you with MIG welding. The outer section of the long needle nose allows you to
scrape out the splatter and junk from the inside of your cup on your MIG welding gun, and it can also help you to move
hot metal safely. The knurled section under the jaws helps you to get the contact tip started to spin and also reinstall it
easily. The plier is also equipped with a wire cutter section to trim your MIG wire at the proper stick out. In case the
outer cap on the gun gets tightly jammed when it heats and cools, the big knurled section over the handle helps you to
take it off. MIG pliers are going to be the handy small companions of your welding projects.
 Wire Brush
Another staple for a clean welding process is the wire brushes. Their objective is to remove the rust or heat
discoloration without damaging the base metal. The wire brushes are categorized under different groups considering
their application, such as wire wheel brushes, cup brushes, end brushes, and hand brushes. Wire wheel brushes are
used for interpass weld cleaning. Cup brushes are used to prepare large sized areas for the weld. End brushes offer
specifically cleaning hard-to-reach job sites like t-shape ones, and finally, the most common ones are hand brushes, used
for knocking off slags in small welds within few swipes. While purchasing a wire brush, it’s important to consider the size
you aim to clean and the roughness of the wires.
 26 ESSENTIAL WELDING TOOLS AND
EQUIPMENTS [PICTURES
As a beginner, you probably wonder how you can get started with the welding process. Welding can be a difficult task for beginners.
Performing a precise welding process requires skill, technique, and a lot of welding tools and equipments.
You may have heard that welding is quite expensive, but in reality, there are only a few essential welding tools and equipments that
you will use on a regular basis. In addition to basic tools, sometimes you need tools you haven’t heard of.
Therefore, we aim to introduce you to almost all welding tools that should not be missing from any welding workshop. We’ve covered
everything from security to basic equipment and essentials, you have everything you need here. So let’s look at the different
types of welding tools and equipments one by one.
Welding Tools
• The common welding tools used for gas welding purposes are as follows:
• Spanner
• Hammer
• Pliers
• Chisel
• Tongs
• Cylinder key
• Wire brush
• Clamps
• Angular grinder
• Spark lighter
• Try square
• Tip cleaner
• Files
• Centre punch
• Scale and weld-gauge
• Steel tape
 Why Welding is an Important Industry
The welding industry is not for everyone, as it is a very physically demanding and challenging job. However, it's a job that is essential
to a wide variety of products and infrastructures, and one that plays an important role in various aspects of everyday life.
Impact of the Welding Industry
• When we think about welding, we often don't realize how this industry impacts the world around us. Welding is an essential
component of many industries such as the automotive industry, the construction industry, the aviation industry, and more.
Without this form of metal work, so many things, including many buildings, gates, and fences, small kitchen appliances,
vehicles - and even space travel - would not exist.
The Future of the Welding Industry
According to American Welding Society President David McQuaid, by the year 2025, the U.S. will be faced with a shortage of
more than 400,000 welding professionals. While the issue of a shortage of welders has been known, the estimated extent of
the shortage seems to have increased significantly over the past few years.
 Why is Welding an Important Industry?

1. It’s Easy to Get Started

• To become a welder, you need no formal education, and at times, even experience. The more you understand, the better.
Nonetheless, it’s an excellent trade because you can begin from the bottom in a workshop and learn everything while on the job.
• If you’re raring, with a little help online, you can study how to weld at home. With sufficient practice, you can establish your business
from home.
2. There’s a Growing Demand for Welders
• Welders are needed all over the globe, and most places need more of them than are available. It makes welding an excellent trade
because, with a decent work ethic, you’ll never run short of job opportunities.
• Even if a Third World War comes, welders will carry on welding in a distinct field, while most of the other people would lose their
jobs and be forced to adjust to a new kind of job that supports their Armed Forces. It’s what happened during the Second World
War.
3. Climbing the Welding Ladder is Easy
• In the welding industry, it’s easy to advance. It’s because there’s an increased demand for welders, and with that comes more tasks.
With more work comes more chances if you’re career-propelled to reach a higher rank.
• For every group of welders, someone has to be there to control them. It implies that you can weld, and at the same time, manage a
team working on projects that have been assigned to you. However, it’s unusual for a person who has just come out of training to be
given workers to manage.
4. It Pays Handsomely
• Welding isn’t a fast scheme to get rich. Nevertheless, if you stick with it even for a brief period, you can earn well. Entry-level welders
earn a good amount every month, and with more experience, you get even more.
• Although welding itself pays quite well, the chances for numerous distinct welding positions due to high demand offer the
opportunity to earn more. The more you improve in welding, the more you’ll earn. The more welders under your management, the
more you’ll get.
5. Travel Opportunities
• Welding is the real deal if you would like to experience life in incomparable cultures and, at the same time, earn an income. Welding procedures are
similar around the globe, and there’s an increasing demand for competent welders in numerous countries. It facilitates getting jobs overseas.
• With many jobs, you’re required to stay abroad for a while. However, that’s an excellent way to tour a country and experience its way of life. If you
travel to a distinct country to widen your welding domain, then you’ll learn a lot more.
• Perhaps there are projects you work on overseas that you couldn’t have worked on in your native country.
6. Side Work
• If you would rather stay on-site and want to save more money, welding is an excellent trade if you want to earn some cash on the side.
• From fabricating your merchandise, operating a part-time welding service, to doing contract work during vacations, there are numerous options.
You can make more cash similar to your full-time job and more by just doing extra work.
7. You Can Easily Start your Business
• Just like how it’s easy to begin part-time work on the side, changing that into a full-time welding career will be much easier than establishing other
types of firms.
• You have the potential to establish a growing firm that offers you a huge salary and, at the same time, it gives other welders employment
opportunities. If you’re entrepreneurial, welding is an excellent choice.
8. Welding Work is Fun
• Apart from the numerous phenomenal chances when it comes to welding, it’s enjoyable. We love welding, and we understand that many other
welders relish it also.
• The difficulty of weaving a weld to form a potent and beautiful-looking part is rewarding. Furthermore, the satisfaction of altering a few metal parts
into an unbelievable project that appears excellent and is helpful for its particular purpose never seems to grow old.
9. Grow Your Skill Set
• Working in a workshop is rewarding, and there are numerous skills you’ll learn as you carry out your job every day. Working on private projects at
home or helping your friends is great.
• The mechanical aspect of the job of a welder also gives you useful skills that you can use to work on vehicles, doing tasks in your household and
property, and is advantageous in your hunting and fishing hobbies.
• Whatever you do, the practical expertise you learned in a workshop makes life outside the workshop more amusing and easier.
10. There’s Great Diversification in the Industry
• The welding industry is sundry. It’s because there are numerous distinct metals you’ll learn how to weld, and the project types appear to be infinite.
Several workshops may concentrate on a narrow area of manufacturing while others perform numerous different types.
• Generally, the range in the welding industry is gigantic. To experience a marvelous amount of diversity, you need to work for a couple of diverse
firms over a lifetime.
Complete the electrode characteristic
Label the grinder machine