Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Textbook Question
Chapter 31, Problem 57SDP
Inspect the sheet-metal body of an automobile, and comment on the size and frequency of the spot welds applied. How would you go about estimating the number of welds in an automobile body?
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A welding operation is time-studied during which an operator was pace-rated as 120%. The operator took, on an average, 8 minutes for producing the weld-joint. If a total of 10% allowances are allowed for this operation. What is the expected standard production rate of the weld-joint in units per 8 hour day?
Assume that two 1.5-mm thick steel sheets are being spot welded at a current of 4000 A and current-flow time is 0.3 s. Using electrodes 5 mm in diameter, estimate the amount of heat generated and the amount of heat required to melt the weld nugget. Use an effective resistance of 350 un. Take u= 9,7 Joule/mm Which one of the following are correct? O
a. If the electrodes were 7 mm diameter, the amount of heat generated would decrease
b. The amount of heat generated by the equipment is between 1600 to 1700 Joules
c. The equipment has enough power to weld the steel sheets.
d. The equipment does not have enough power to weld the steel sheets
e. The amount of heat required is between 700 and 750 Joules
QUESTION 1
In an arc welding operation, a groove weld has a cross-sectional area=0.055 in² and is 24 in long. (Round your final answers to 1 decimal place)
(a) What quantity of heat (in Btu) is required to accomplish the weld, if the metal to be welded is aluminum?
Btu
(b) How much heat must be generated at the welding source, if the heat transfer factor = 90% and the melting factor = 60%?
H=
Btu
Chapter 31 Solutions
Manufacturing Engineering & Technology
Ch. 31 - Explain what is meant by solid-state welding.Ch. 31 - What is cold welding? Why is it so called?Ch. 31 - What is (a) a ferrule, (b) filled gold, and (c) a...Ch. 31 - What are faying surfaces in solid-state welding...Ch. 31 - What is the basic principle of (a) ultrasonic...Ch. 31 - Explain how the heat is generated in the...Ch. 31 - Prob. 7RQCh. 31 - Describe the principle of resistance-welding...Ch. 31 - Prob. 9RQCh. 31 - What type of products are suitable for stud...
Ch. 31 - Prob. 11RQCh. 31 - Prob. 12RQCh. 31 - Prob. 13RQCh. 31 - Describe how high-frequency butt welding operates.Ch. 31 - What materials are typically used in...Ch. 31 - Make a list of processes in this chapter,...Ch. 31 - Prob. 17QLPCh. 31 - Explain the reasons why the processes described in...Ch. 31 - Explain the similarities and differences between...Ch. 31 - Describe your observations concerning Figs....Ch. 31 - Would you be concerned about the size of weld...Ch. 31 - What advantages does friction welding have over...Ch. 31 - Prob. 23QLPCh. 31 - Prob. 24QLPCh. 31 - Discuss the factors that influence the strength of...Ch. 31 - What are the sources of heat for the...Ch. 31 - Can the roll-bonding process be applied to a...Ch. 31 - Prob. 28QLPCh. 31 - List and explain the factors involved in the...Ch. 31 - Give some of the reasons that spot welding is...Ch. 31 - Prob. 31QLPCh. 31 - Prob. 32QLPCh. 31 - Prob. 33QLPCh. 31 - Prob. 34QLPCh. 31 - Prob. 35QLPCh. 31 - Prob. 36QLPCh. 31 - Prob. 37QLPCh. 31 - Prob. 38QLPCh. 31 - Which processes in this chapter are not affected...Ch. 31 - Consider the situation where two round...Ch. 31 - Prob. 41QLPCh. 31 - The energy required in ultrasonic welding is found...Ch. 31 - Prob. 43QTPCh. 31 - Prob. 44QTPCh. 31 - Prob. 45QTPCh. 31 - Prob. 46SDPCh. 31 - Explain how you would fabricate the structures...Ch. 31 - Prob. 48SDPCh. 31 - Prob. 49SDPCh. 31 - Prob. 50SDPCh. 31 - Prob. 51SDPCh. 31 - Prob. 52SDPCh. 31 - Prob. 53SDPCh. 31 - Describe the methods you would use for removing...Ch. 31 - Prob. 55SDPCh. 31 - Prob. 56SDPCh. 31 - Inspect the sheet-metal body of an automobile,...Ch. 31 - Prob. 59SDPCh. 31 - Prob. 60SDPCh. 31 - Sketch the microstructure you would expect if a...
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- Your boss requests a recommendation on which process to use to weld the high strength structural steel rail tank cars hull section. You have this additional information: P-GMAW Productivity is substantially lower. However, you have welders already qualified to do manual p-GMAW welding. Labor is 80% of total cost HYPERFILLⓇ® Productivity gains are important, and the volume of the product is sufficient on the rail tank cars to justify capital investment. With confidence, you respond: Use process because .(Give process and short explanation for why you want to use that process)arrow_forwardCan you explain the difference between the two welded lines shown in figures (a) and (b)? Also, what are the characteristics of a good weld? b)arrow_forwardAn arc welding is performed to join two metal pieces. After the welding process, the product is subjected to fatigue test. Discuss which part of the weld joint will have high potential to experience fatigue failure.arrow_forward
- Example 27.2. A 100 mm x 10 mm plate is to be 150 mm x 10 mm by the fillet welding on three sides. The size of the weld is 6 mm. Find out the necessary over lap of the plate, for full strength of the joint. Take allowable tensile stress in plate equal to 150 N/mm and allowable stress in weld as 110 N/mm. welded to another platearrow_forwardCalculate the heat input during the arc welding process, if the voltage is 33 volts, current is 115 amperes, the length of the weld is 88mm and the time to complete the weld 34 secs.arrow_forwardTwo 3.5 mm thick metal (Um = 9.5 J/mm?) sheets are being joined using resistance spot welding. To achieve required strength, it is desired to form a weld nugget that is 5.5 mm in diameter and 4.0 mm thick. The weld duration will be set at 0.3 sec. If the electrical resistance between the surfaces is 140 microohms, and only onethird of the electrical energy generated will be used to form the weld nugget determine the current.arrow_forward
- What are some of the problems that oxygen can cause in welds?arrow_forwardWhy is it important to make small welds more accurately than large ones?arrow_forwardA gas tungsten arc welding operation is performed using a current of 250 A and an arc voltage of 20 V at a welding speed of 5 mm/s. Assuming that the arc efficiency is 70%, the net heat input per unit length of the weld will be kJ/mm (round off to one decimal place).arrow_forward
- Discuss the arc welding quality and type of defects involved? What are the inspection and testing methods available to check the quality of the weld joint?arrow_forwardA continuous fillet wild is used to weld two pieces of 7.0-mm-thick austenitic stainless steel plate in an arc-welding operation. The plates are joined at a 90° angle using an inside fillet corner joint. The velocity of the welding head is 6 mm/sec. Assume the cross section of the weld bead approximates a right angle isosceles triangle (a right triangle with the two legs and their corresponding angles equal) with a leg length of 4.5 mm. The length of the weld = 230 mm. The melting factor of the setup = 0.65, the heat transfer factor = 0.90, and the Tm for austenitic stainless steel = 1670°K. Determine (a) The amount of heat (in joules) required to melt the volume of metal in (b) The heat that , (c) The rate of heat generation required at the welding source to accomplish the weld this weld (filler metal plus base metal) must be generated at the heat sourcearrow_forwardA bracket to be welded into a steel channel using E-60 electrode 345 Mpa) Two welding sets are suggested as shown in Fig. (1)Based on maximum shear stress failure theory and safety factor of (2.5) (a) Find the weld size for each set. (b) Which set would you recommend A or B ?arrow_forward
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