Design and Fabrication of 90 Degree Welding Clamp [PDF]

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DESIGN AND FABRICATION OF 90 DEGREE WELDING CLAMP PROJECT REPORT



Design And Fabrication Of 90 Degree Welding Clamp submitted by: • AFSAL MOHAMED KANI.M



(922318114004)



• DHIVAKARAN.M



(922318114304)



• ASHVANTH.P



(922318114010)



• RENGARAJAN.S



(922318114037) in partial fulfilment for the award of the degree of BACHELOR OF ENGINEERING IN MECHANICAL ENGINEERING



UNIVERSITY COLLEGE OF ENGINEERING DINDIGUL-624622 ANNA UNIVERSITY : CHENNAI 600025 JULY 2021



ACKNOWLEGEMENT We extremely thanlfull to our Head Of The Department of Mechanical Engineering DR.K.LINGADURAI M.E.,M.B.A., Ph.D professor department of mechanical engineering university college of engineering Dindigul for his valuable ideas in our project work. we express our sincere thanks to our project coordinator M.R DR.P.C.MUKESH KUMAR ,M.E, Ph.D., Assistant professor Department of Mechanical Engineering University College Of Engineering Dindigul for his valuable ideas in our project work. we are thanlful to our project guide D.R.V.S.CHANDRA SEKHAR Assistant professor Department Of Mechanical Engineering University College Of Engineering Dindigul for his unflinching support and valuable guidance to our project work. Last but not least we thankfull beloved parents,teaching staffs of our department for their moral support



TABLE OF CONTENTS • INTRODUCTION 1.WHAT ARE WELDING CLAMPS 1.OBJECTIVES 2.WHY WE USE WELDING CLAMPS 3.What qualities should you look for in a welding clamp 2.IMPORTANT FACTORS (A) Material (B) Clamp build (C) Padding (D) Jaw gap (e) Correct alignment 3.Material Characteristics 1.Conductivity 2.Corrosion Resistance 3.Hardness 4.Strength



4. DIMENSIONS OF 90 Degree WELDING CLAMP 5. DESIGN AND FABRICATION OF 90 DEGREE WELDING CLAMP CAD/CAM DESIGN OF 90 DEGREE WELDING CLAMP 6.CLEARANCES OF 90 DEGREE WELDING CLAMP 7. 3D VEIWS OF 90 DEGREE WELDING CLAMP 8.ASSEMBLY OF WELDING CLAMP 9.FABRICATION OF 90 DEGREE WELDING CLAMP MAKING OF WELDING CLAMPS MATERIALS NEEDED BUILDING OF CLAMP 10. SELECTION OF CLAMP 11.CLAMP CUSHIONS REDUCE ABRASIONS 12.THE COST OF WELDING CLAMPS 13. PROJECT OUTPUT 14.REFERENCES



INTRODUCTION : Here we are design and fabricating the 90 DEGREE WELDING CLAMP;Welding is a fabrication process that joins materials, usually metals or thermoplastics, by using high heat to melt the parts together and allowing them to cool, causing fusion. Welding is distinct from lower temperature metal-joining techniques such as brazing and soldering, which do not melt the base metal. In addition to melting the base metal, a filler material is typically added to the joint to form a pool of molten material (the weld pool) that cools to form a joint that, based on weld configuration (butt, full penetration, fillet, etc.), can be stronger than the base material (parent metal). Pressure may also be used in conjunction with heat or by itself to produce a weld. Welding also requires a form of shield to protect the filler metals or melted metals from being contaminated or oxidized.



1.WHAT ARE WELDING CLAMPS? Welding clamps are metal sheet or leg holders that temporarily hold two pieces of materials together tightly. This makes it easier for welders to run the arc and weld the pieces together without worrying about movements in the sheets.



The clamps enable you to weld pieces together in a tight alignment. They’re particularly useful for working with large sheets and metal frames that are difficult to hold together just by hand. But this doesn’t mean they are only good for larger shields. Butt welding clamps are also great for connecting and welding smaller pieces of metal together. They allow you to create precise joints at difficult angles where the metal pieces must be held fixed when the arc is run over them.



OBJECTIVES: • Fast and easy clamping/holding of components at 90° for welding • Fast, cost effective clamping of components rigid at 90° angles • Ideal for weld preparation, metalworking,fabrication and assembly of large components • For jigging on sheets, pipes and tubes • 2 magnetic faces provide 90° clamping



• Angular tolerance: +/- 0.05/100mm The Right Angle Clamp makes projects with 90° joints faster and easier than ever by giving you the helping hand you need to hold the parts in position as you drive in the screws. Just slip the pin on the Right Angle Clamp into a pocket hole, close the clamp, and it draws the mating pieces tightly together



You may need to hold two or more in position. That can become quite expensive if you need four right angle clamps. That's what makes this right-angle clamp from HORUSDY such an attractive buy. With its inexpensive price tag, you can afford to buy multiple clamps.



2.WHY WE USE WELDING CLAMPS : Sometimes you will need to hold two pieces of metals together to create the perfect weld. Since you will need to hold the welding gun as well and have two hands only to put all this together, it can be very difficult to achieve this task.



• The welding clamps can be very handy (no puns intended) to achieve this task. The will hold the metal sheets securely in place and allow you to weld the joints from any angle. • These clamps can also be used to create corners with different angles and make welds both inside and outside the joint. Clamps allow you to create a variety of different angles, based precisely on your welding blueprint.



3.What qualities should you look for in a welding clamp? • If you are looking to buy a welding clamp for your business, you should be aware of the things you need to check. Just like other welding tools, the real value of a welding clamp depends on two main factors. 1.How important is the clamp for your projects? 2.How precisely does it get the job done? • These two will determine the necessity for buying the welding clamp. Other important factors to look for include the following. • Ground clamp material, cross-sectional area, contact geometry, contact pressure, and travel distance all matter when it comes to delivering quality welds.



IMPORTANT FACTORS: (A) Material: Most modern welding clamps are made of stainless steel or cast iron. Stainless steel is obviously better as it is generally rust proof. Iron clamps can begin to rust but they are usually cheaper. If you are willing to spend a good amount, go with a stainless steel clamp. On the other hand, if you will only use the clamp occasionally on specific projects, the iron cast clamp could also do the trick. (B) Clamp build:



If you are aware of the process for manufacturing the clamp, it can give you important details about its quality. For example, find out if it was forged or pieced together. Forged clamps are sturdier but prone to breaking while clamps made with replaceable parts last longer. This information is usually written on the label and easy to find.



(C) Padding: Some advanced clamps have a soft material or rubber pads on the parts that secure metal sheets together. The padding prevents scratches and abrasions on the metal sheets and legs. This is useful if you are creating something that will not be painted and the scratches might look bad. Clamps with padding generally cost more. However, if you are working on a precise project that requires better attention to aesthetics, you may want to buy this specific type of clamp. (D) Jaw gap: The jaw distance identifies the maximum thickness that can be held between the clamp teeth. If you are working with thicker metal sheets, you will need a clamp with greater jaw gap. These clamps are generally bigger in size. If your sheets are less than an inch in thickness, you can go with smaller clamps. If the material width varies, it is better to get multiple clamps with different jaw gaps. You probably don’t want to find yourself in a situation where you can’t finish the project on time because you didn’t have clamps of the right size.



(e) Correct alignment: The fundamental function of welding clamps is to hold metal legs and sheets securely together at the right angles. If your clamps can’t hold items together at the right alignment, you can’t expect a great project finish. So before you hit up the arc, make sure that you are able to secure and align the metals properly in the clamps. If they seem off, get new and better clamps. Material Characteristics ; Quality material delivers quality tools. With a ground clamp the material affects a few critical characteristics including conductivity, corrosion resistance, hardness, and strength. 1.Conductivity: Conductivity measures how easily electrons flow within a material. The higher the conductivity the less resistance electrons face. Materials with greater conductivity need less cross-sectional area because they provide less resistance to flow. As resistance builds up the material begins to heat up and can even burn through. As heat increases resistance also increases leading to a run-away effect that can quickly destroy your conductor.



2.Corrosion Resistance: Materials can tarnish. Tarnish is a thin layer of corrosion that forms on the surface of material. Tarnishing occurs when the surface layer of material undergoes a chemical reaction, typically with oxygen. This tarnished layer substantially increases the contact resistance of a ground clamp making it far less effective at transferring current. There are a few ways of preventing tarnish from ruining your ground clamps. You can polish the clamping surface with steel wool or another abrasive. You can clean off the surface with baking soda, or even coca cola which is a common trick for auto mechanics to clean car battery terminals. Alternatively you can use nickel or gold plating to provide a tarnish free surface. Benzotriazole can also work as a temporary corrosion inhibitor, but it will wear off far faster than gold or nickel plating. You can also use aluminum or a copper chromium or other alloy that provides superior corrosion resistance with a slight decrease in conductivity compared to pure copper.



3.Hardness: • At the microscopic level surface contacts look far different than they do at the macroscopic level. At the microscopic level, what would seem to be a smooth surface is actually filled with ridges and uneven terrain. As a result of these ridges and uneven terrain, there is far less microscopic contact area on a smooth surface than we would expect. Unfortunately for us, electrons only care about what occurs at the microscopic level. Having a clamp with increased hardness compared to the material being clamped allows for greater pressure to be used so that these ridges can be shoved together tighter which increases the real contact area and therefore increases the total amount of current that can flow freely. • Hardness also prevents a clamp surface from wearing down and becoming smooth. When an electrical contact smooths it's contact area where electricity is transferred actually decreases due to the pressure decreasing.



4.Strength: Clamps need strength to apply adequate pressure to transfer electricity. The more pressure that a clamp can apply, the greater the contact conductivity. Many materials that offer substantial conductivity do not have adequate strength to also apply enough force to transfer electricity through a contact point. Alloys are great at combiningg conductivity with strength. (Professional welders will probably advise getting as many welding clamps as you can as long as they are different varieties. They argue that a variety of clamps will make it easier for you to take on diverse projects and you will always be prepared to take on any kind of work.)



DIMENSIONS OF 90 Degree WELDING CLAMP;



• As 2d Dimensions



asmebly dimension (All dimensions are in mm)



CLEARANCES OF 90 DEGREE WELDING CLAMP;



DESIGN AND FABRICATION OF 90 DEGREE WELDING CLAMP; CAD/CAM DESIGN OF 90 DEGREE WELDING CLAMP:



(a)Top view



(d)Left view



(b)bottom veiw



(e) Right veiw



(c) Front veiw



3D VEIWS OF 90 DEGREE WELDING CLAMP;



ASSEMBLY OF WELDING CLAMP;



FABRICATION OF 90 DEGREE WELDING CLAMP; MAKING OF WELDING CLAMPS: You can create a variety of clamps for your needs. If you are just starting out, it is recommended to go with something easier like an angled jig that helps hold metal legs in place. Here’s a short guide on how to get started. MATERIALS NEEDED: You don’t need a lot of materials for this. You can create an angle jig with a bar of 2x2x1/4” angle steel and a flat bar steel of 2×1/4”.use mild steel as recommended.



MILD STEEL



However, if you want you can use heavy duty stuff and go up to 10” pieces of angles. Heavier weight steel does not warp as much and since you will keep this tool for a long time, make it out of the good stuff. BUILDING OF CLAMP:



picture of a 90 degree welding clamp



STEPS INVOLVED:



• Start by cutting the two pieces of the angle steel in equal lengths and the flat bar at a length that can be joined together with these. The flat bar should be cut at a 45* angle at either end to make a smooth joint with the angle steel. • After cleaning the metal legs with a flap, place them at a 90 degree angle to each other. You can use an L-square to align the pieces together. Secure them in place at the corners by using four C-clamps. Check the inside corner with a framing square for accuracy. There should be no wiggling movement of the square when properly adjusted to 90. • Once you have the assembly in place and where you want it, flip the piece over and start welding. Tack weld the pieces in place, check alignment is correct, and then complete the welds. Do not go full on and simply weld the whole corner clamp up in one go. Allow the form to cool and check it with the framing square repeatedly. Keep the c-clamps on the assembly until the clamp is complete. • After the welding is complete, you can check for preciseness using a different framing square. Sometimes framing squares get tweaked and are no longer square. It is better to check them with more than one scale if you have an additional scale around. This will create a basic, 90-degree clamp that can be used for securing metal legs. You can fit bolts on the clamp or use powerful magnets to keep it firmly on the welding table in the future.



SELECTION OF CLAMP;



• As discussed earlier, welding clamps serve different functions on different projects. Table clamps are used for securing metal sheets on the table while pipe clamps allow tighter welding on pipes and valves. • A project that requires frequent adjustment of angles will be better served with a quick release clamp than a clamp that is screwed shut to the table. CLAMP CUSHIONS REDUCE ABRASIONS: • If possible, try to buy cushioned clamps. They are much better at keeping your metal legs getting scratches during a weld.



• If you can’t buy cushioned clamps, you can place padding -like a piece of fabric – between the clamp and the materials to reduce unwanted marks.



NEVER OVER TIGHTEN CLAMP: Always make sure that you tighten clamps on the metal plates just up to the point where the metal feels secure enough but do not over tighten it. When you over-tighten the clamps on the material, it can damage both the clamps and the metal sheets. THE COST OF WELDING CLAMPS: Welding clamps are not that expensive. They cost anything between a few rupees to a couple of hundred. The price of an individual clamp depends on its type, material and quality. The clamps that cost a few dollars shouldn’t be a major concern and you can buy them with ease. Welding clamps that are more expensive however may cause some concerns. You may be wondering how you will spend a few hundred dollars on clamps alone. Well there are two things to consider here. First, you may not necessarily need these clamps for your project. You can delay purchasing them until later, when you actually need to work on projects that require these clamps. Another thing you can do to solve this problem is to build your own clamps. These will probably not be as high quality as commercial grade clamps, but they get the job done and you don’t have to spend a fortune on them either.



IMAGE OF OUR PROJECT; 90 DEGREE WELDING CLAMP



FINISHED PROJECT IMAGE:90 DEGREE WELDING CLAMP



90 DEGREE WELDING CLAMP WITH WORKPIECE:



90 Degree welding clamp with workpiece(mild steel workpiece) WELDING OF THE SQUARE PIPE IN THE 90 DEGREE WELDING CLAMP:



SAFETY TIPS FOR USING WELDING CLAMPS: • Always ensure that you are working safely when using clamps for your welding projects. Here are some tips that will ensure better safety. • Remove clamps as soon as the job is finished. Clamps serve only as temporary devices for holding work securely in place. • Keep all moving parts of clamps lightly oiled and keep tools clean to prevent slippage.



well dressed welder



REFERENCES; https://workshopwelding.com https://weldingheadquarters.com https://grabcad.com Hillman-Crouch, Barry (2003). "Historic Ironwork Repairs to Timber Framed Buildings"