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Projection Design & Equipment

Projection Design & Equipment. Projection Equipment. Learning Activities View Slides; Read Notes, Listen to lecture Do on-line workbook. Lesson Objectives When you finish this lesson you will understand: Equipment requirements necessary for successful projection welding. Keywords

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Projection Design & Equipment

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  1. Projection Design & Equipment

  2. Projection Equipment • Learning Activities • View Slides; • Read Notes, • Listen to lecture • Do on-line workbook • Lesson Objectives • When you finish this lesson you will understand: • Equipment requirements necessary for successful projection welding Keywords Projection Weld Electrodes, Low Inertia Electrode Holders, Projection Punch and Die Set

  3. 5.0 Equipment Requirements 1.5.1 Electrodes and Electrode Holders Describe the design of electrodes and electrode holders, and its significance Describe the design of die assemblies and its significance 1.5.2 Die Assemblies

  4. Types of Electrodes • Large flat electrodes, often made from bar stock • Not recommended on weldments which are distorted from the projection forming operation • Advisable when welding a few projections in a localized area • A series of local contact surfaces made by relieving a bar between projections or by brazing inserts of hard copper alloy to the bar • Tend to equalize the total current and force in spite of distortion or tolerance of the weldment • Recommended as best for all projection welding, and especially in those applications involving four or more projections. • Composite type electrodes

  5. Type of Electrodes Flat Type Electrode Composite Type Electrode Localized Contact Type Electrode Brazed Joint h Electrode Electrode Copper W Insert Shear Burr Electrode Electrode h W [Reference: Resistance Welding Manual, p.3-12, RWMA] Relief

  6. Spring-Loaded Low Inertia Electrode Holders [Reference: Resistance Welding Manual, p.3-10, RWMA]

  7. Grease-Equalized Electrode Holders [Reference: Resistance Welding Manual, p.3-10, RWMA]

  8. Hydraulically Operated Press Welder [Reference: Resistance Welding Manual, p.3-11, RWMA]

  9. Low Inertia Welding Head Relaxed Diaphragm Compressed Diaphragm Partially Compressed Diaphragm Air Inlet Welding- Current Switch (Open) Welding- Current Switch (Closed) Welding- Current Switch (Closed) Welding Head Outer Shaft Air Inlet Piston Cylinder Spring (Under Initial Compression) Partially Compressed Spring Fully Compressed Spring Inner Shaft Upper Electrode Workpieces Workpieces Workpieces Lower Electrode (a) Welding head in open position (b) Welding head in position for squeezing and heating projection (c) Welding head at instant of projection collapse and start of nugget formation [Reference: Metals Handbook Volume 6, p.503-524, ASM]

  10. Punch and Die Set Design for Mild Steel Sheet Punch Insert A Punch Plug Fit Die B C 1/4 1-3/8 1-3/8 A 1/4 F Die Insert B B H Plug Fit [Reference: Recommended practice for resistance welding, AWS Document C1.1-66, AWS, 1966]

  11. Punch Shapes Used for Various Thicknesses (a) (c) (b) (d) [Reference: Resistance Welding Manual, p.3-3, RWMA]

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