lecture 10 tool design for joining processes
DESCRIPTION
Tool DesignTRANSCRIPT
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ITCD – 301-001
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Types of joining processes
• Physical•Application of heat•Application of pressure•Both heat and pressure
•Mechanical•Does not involve changes in composition•Edges remain distinct
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Tooling in joining
• Hold the parts in correct relationship•Assist and control the joining process•Mechanically or physically•Alignment of workpieces•Physical joining requires tooling•High temperature makes manual positioning impractical•Tooling for hot processes should withstand heat and accelerate or retard flow of heat•Hot fixtures should have thermal expansion coefficient so that it remains functional
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Welding Fixtures
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Distortion
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Distortion based on material type
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Fixture design objectives
•Hold the part in the best position•Providing proper heat control of the weld zone•Provide suitable clamping to reduce distortion•Providing channels and outlets for welding atmosphere•Providing access for the welding process•Providing for ease of operation, part loading and unloading
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Other factors
•Cost of fixture•Size of the production run and rates•Adaptability of available welding equipment•Complexity of the weld•Quality required in the weldment•Welding process to be used• Conditions of welding•Dimensional tolerances•Materials to be welded•Part-surface finish requirements•Coefficient of thermal expansion and thermal conductivity of workpiece and tool
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Gravity type fixture gas welding fixture
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Gas welding fixture
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Factors for gas welding fixtures
•Part print tolerances•Material heat resistance•Heat-transfer qualities•Fixture rigidity required to ensure workpiece alignment accuracy•Prevent rapid heat dissipation from the weld area•Cast Iron, carbon steel and stainless steel
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Arc welding fixtures
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Arc welding fixtures
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Design considerations in arc welding
•Exert enough force to prevent or minimize part misalignment•Too much restraint leads to weld cracking due to residual stresses•Promote heat dissipation from the weld line•Support the molten weld, govern the weld contour•Protect the root of the weld from the atmosphere
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Resistance Welding
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Spot welding
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Spot weld assembly
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Flash butt welding
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Typical standard electrodes
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Design considerations
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Clamp installation
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Laser welding
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Nesting fixture
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Soldering machine with nesting fixture
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Nesting for brazing
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Bolts and studs
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Single-thread nut
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Stamped nut
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Riveting
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References
Fundamentals of tool design, fifth edition, Society of Manufacturing Engineers
Donaldson, and Lecain, Tool Design, McGraw Hill
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Questions?