Sunday, November 11, 2012 0 comments

Day - 3 , Manufacturing of Roll Cage

It's all about Grinding , Cutting and Welding..... 

Team Work :
Manufacturing of Roll cage : Subrat Sarkar, jayantraj
Welding : Parakh Kumar, manish kanwal
Grinding : All Team Members
Chop Saw

The day work started at 9:00am with cleaning the workshop, making proper alignment of roll-cage members, dimensioning using Solid Works ...

All about Grinding :

First of all Grinding machines is a machine tool use for making the surface of workpiece surface even and of high quality. However, there are some roughing applications in which grinding removals high volumes of metal quite rapidly. Thus grinding is a diverse field.
Types:
The most commonly used are
    1). Disc Grinder/ Angle Grinder / Side Grinder 
         Angle grinders can be powered by an electric motorpetrol engine or compressed air. The motor drives a      geared head at a right-angle on which is mounted an abrasive disc or a thinner cut-off disc, either of which can be replaced when worn. Angle grinders typically have an adjustable guard and a side-handle for two-handed operation. Certain angle grinders, depending on their speed range, can be used as sanders, employing a sanding disc with a backing pad or disc. The backing system is typically made of hard plastic, phenolic resin, or medium-hard rubber depending on the amount of flexibility desired.

Rotating abrasive Grinding wheel on a disc Grinder ( Courtsey: Sanjay Singh )


Angle Grinders give off a lot of sparks. This is a great hazard to the eyes



Safety goggles must be worn. Angle Grinders should never be used without their guard or handle attached, they are there as a necessary precaution for safety.


A typical Disc Grinder ( 1yr. old)


While grinding, if the soft metals get embedded in the inter-abrasive voids, it can be easily removed with the help of Dressing, i.e. the use of metal brush ..


Bench Grinder












The back side of Disc Grinder is provided with locking knob to help changing the discs ( Flap disc, Grinder Disc , Cutter Disc)



ALL ABOUT WELDING :For manufacturing of BAJA Vehicle this year , we are using Metal Inert Gas ( MIG) Welding also called as Gas Metal Arc Welding (GMAW) or Metal Active Gas Welding (MAG) . This is welding process in which an electric arc forms between a consumable wire electrode and the workpiece metal(s), which heats the workpiece metal(s), causing them to melt, and join. Along with the wire electrode, a shielding gas feeds through the welding gun, which shields the process from contaminants in the air. The process can be semi-automatic or automatic. A constant voltagedirect current power source is most commonly used with GMAW, but constant current systems, as well as alternating current, can be used. There are four primary methods of metal transfer in GMAW, called globular, short-circuiting, spray, and pulsed-spray, each of which has distinct properties and corresponding advantages and limitations.

Equipments :
To perform gas metal arc welding, the basic necessary equipment is a welding gun, a wire feed unit, a welding power supply, an electrode wire, and a shielding gas supply.
MAW torch nozzle cutaway image. (1) Torch handle, (2)Molded phenolic dielectric (shown in white) and threaded metal nut insert (yellow), (3) Shielding gas diffuser, (4)Contact tip, (5) Nozzle output face















 

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