Huzaimi AHamid MFKM2010

DESIGN, FABRICATION AND TESTING OF A SEMI-AUTOMATIC WELDING
FIXTURE FOR CIRCUMFERENTIAL JOINING CYLINDERS USING MIG

WELDING
HUZAIMI BIN A. HAMID
UNIVERSITI TEKNOLOGI MALAYSIA
DESIGN, FABRICATION AND TESTING OF A SEMI-AUTOMATIC

WELDING FIXTURE FOR CIRCUMFERENTIAL JOINING CYLINDERS
USING MIG WELDING
A project report submitted in partial fulfillment of the

requirements for the award of the degree of
Master of Mechanical Engineering (Advanced Manufacturing Technology)
Faculty of Mechanical Engineering

Universiti Teknologi Malaysia
MAY 2010
iii
To my believed Allah s.w.t

And to my beloved mother and father
iv
ACKNOWLEDGEMENT
In preparing of this thesis, I was in dealing with a lot of people who are involved
with fabrication, information gathering, advisory and problem solving including the
academicians and practitioners. They have given with a full strength to contribute
towards of my understanding and thoughts. I wish to express my appreciation to my
main supervisor, Prof.Madya Zainal Abidin Ahmad for encouragement, guidance,
advised and friendship. I am also a very thankful to my Co-Supervisor En. Mohzani
Mokhtar, lecturer of Pusat Pengajian Kejuruteraan Mekanikal, Kampus Kejuruteraan,
Universiti Sains Malaysia (USM), for his guidance and being helpful to give an advised,
motivation, suggestion and guidance. Hopefully that Allah s.w.t will give them a better
of life as present and on future.
I am also indebted to Universiti Teknologi Malaysia (UTM) for funding my
Master study on information access either direct or indirect contact, to the Librarians of
Universiti Sains Malaysia (USM) also deserve special thanks for their assistance and
support in supplying the relevant material and literatures.
To my colleagues and other Master students should also be recognized by their
support that provided the knowledge and practical at various occasions. Unfortunately,
it is not possible to list all of them in this limited space. I am grateful to all my family
members for supporting, motivating and helping to achieve this opportunity.
ABSTRACT
This paper presents the systematic approach of design, fabrication and testing of
the circumferentially joining on welding fixture which is being carried out at Kolej
Kemahiran Tinggi MARA Balik Pulau (welding fabrication) and PPKM, Kampus
Kejuruteraan USM Nibong Tebal, Pulau Pinang (destructive testing). The MIG welding
unit is used to make a circumferential joining on tank and piping which are fixed onto
the welding fixture and a several parameters setting of voltage, current and travel speed
(rotational speed) is used for fabrication setup. The ASME (American Society of
Mechanical Engineers) Code VIII (Pressure Vessels and Piping) is applied based on
circumferential welding methodology standard. The research are focused to the
structure produce by emphasis on the mild steel (0.16 0.29% carbon) as the common
tank and piping materials. The fabrication fixture with constant speed of rotation by
revolved the tank or pipe is developed as a dynamic structure with electrical adjustable
speed control motor. The joint of mechanical properties are determined by means of
static tensile test, impact test and hardness test. The correlation between the welding
joint and destructive testing is evaluated of its welding joint structure by using
microscope.
vi
ABSTRAK
Kertas kajian ini menggunakan pendekatan sistematik terhadap rekabentuk,

fabrikasi and ujian terhadap penyambungan secara lilitan pada perkakasan kimpalan
yang mana dilaksanakan di Kolej Kemahiran Tinggi Mara Balik Pulau (untuk fabrikasi
kimpalan) dan di PPKM, Kampus Kejuruteraan, Universiti Sains Malaysia, Pulau
Pinang (untuk ujian dan analisa). Unit kimpalan MIG digunakan untuk menghasilkan
kimpalan lilitan pada tangki dan paip yang mana dipasang diatas perkakasan kimpalan
dan beberapa pelarasan parameter terhadap voltan, arus dan kelajuan gerakan (kelajuan
putaran) digunakan sebagai penetapan fabrikasi. Piawaian ASME (American Society of
Mechanical Engineers) Kod VIII (Kebuk Tekanan dan Pemaipan) digunakan
berdasarkan kaedah piawaian kimpalan lilitan. Kajian ini memfokuskan terhadap
struktur yang dihasilkan menggunakan keluli lembut (0.16 0.29% karbon) sebagai
bahan asas tangki dan paip. Peralatan yang difabrikasi, mempunyai kelajuan putaran
yang seragam dengan memutarkan tangki atau paip, yang menghasilkan struktur
dinamik melalui pelarasan pada motor jenis kawalan kelajuan. Penyambungan terhadap
sifat-sifat mekanikal ini ditentukan menggunakan ujian penegangan statik, ujian
hentaman dan juga ujian kekerasan. Perhubungan diantara penyambungan kimpalan dan
ujian destruktif ini dinilai dari segi struktur kimpalan oleh sambungannya menggunakan
mikroskop.
vii
TABLE OF CONTENTS
CHAPTER
TITLE
PAGE
DECLARATION
ii
DEDICATION
iii
ACKNOWLEDGEMENT
iv
ABSTRACT
ABSTRAK
vi
TABLE OF CONTENTS
vii
LIST OF TABLES
xi
LIST OF FIGURES
xiii
LIST OF SYMBOLS
xvi
LIST OF APPENDIX
xvii
INTRODUCTION
1.1
Introduction
1.2
Objective
1.3
Scope of project
1.4
Problem statement
LITERATURE REVIEW
2.1
Introduction
2.2
Introduction to MIG (Metal Inert Gas) Welding
2.3
Introduction of welding on tank and piping
viii
2.4
Overview the previous researches related to
circumferential joint welding

2.5
Overview the previous researches related on
11
cylindrical shape fabrications
DESIGN AND DEVELOPMENT OF WELDING

FIXTURE
3.1
Introduction
14
3.2
Method of welding fixture fabrication
16
3.3
Conceptual design and sketching
3.4
3.3.1
Sketching the concept
17
3.3.2
Pattern search
22
3.3.3
List of needs
24
3.3.4
List of metric
25
3.3.5
Needs-metrics matrix
26
3.3.6
Concept screening
27
3.3.7
Concept scoring
28
3.3.8
Final specifications
29
Project design
3.4.1
Part description and selection
30
3.4.2
Determination of workpiece rotation system
40
3.5
Project fabrication
3.6
Project controlling system

3.6.1
Working operation of pneumatic triggering
46
49
system
3.6.2
Working operation of electrical circuit for
50
rotation system
3.7
Bill of materials (BOM)
3.8
Project costing
51
3.8.1
Design cost
60
3.8.2
Fabrication cost
61
ix
4
METHODOLOGY
4.1
Experimental preparation
66
4.2
Material specification
70
4.3
Welding parameters
4.4
4.5
4.3.1
Welding voltages (V)
71
4.3.2
Welding current (Amp)
73
4.3.3
Travel speed
73
Testing and analysis

4.4.1
Tensile test
75
4.4.2
Hardness test
78
4.4.3
Impact test
81
4.4.4
Welding structure
83
ASME standard and application

4.5.1
ASME codes and application
84
4.5.2
ASME certification
86
RESULT AND DISCUSSION

5.1
Introduction
88
5.2
Destructive test
89
5.3
Result of testing
5.3.1
Criteria of welding joint by voltage
90
regulation
5.3.2
Criteria of welding joint by travel speed
92
regulation
5.3.3
Result of tensile test
93
5.3.4
Result of impact test
143
5.3.5
Result of hardness test
145
5.3.6
Welding structure
147
5.4
Discussion
152
5.5
Conclusion
152
x
6
CONCLUSION
6.1
Introduction
153
6.2
Conclusion
153
6.3
Recommendation
154
REFERENCES
156
APPENDIX A
161
APPENDIX B
164
APPENDIX C
183
APPENDIX D
189
APPENDIX E
202
xi
LIST OF TABLES
TABLE NO.
TITLE
PAGE
3.1
List of available needs
24
3.2
List of metric
25
3.3
26
3.4
Concept screening
27
3.5
Concept scoring
28
3.6
Project final specification
29
3.7
Description of rotational shaft
30
3.8
Description of attachment roller
30
3.9
Description of bearing housing
31
3.10
Description of drive pulley
31
3.11
Description of driven pulley
32
3.12
Description of motor support plate
32
3.13
Description of stabilizer wheel plate
33
3.14
Description of stabilizer wheel shaft
33
3.15
Description of welding gun arm
34
3.16
Description of welding gun holder
34
3.17
Description of welding gun clamp 1
35
3.18
Description of welding gun clamp 2
35
3.19
Description of earth channel connector
36
3.20
Description of aluminium frame
36
3.21
Description of dark acrylic transparent
37
xii
3.22
Description of control box
37
3.23
Description of stabilizer wheel holder
38
3.24
Description of cabinet
38
3.25
Motor speed selector without load
42
3.26
Motor speed selector with load
42
3.27
BOM for custom made parts
52
3.28
BOM for standard parts
55
3.29
Estimation of design cost
60
3.30
Estimation of fabrication cost
61
4.1
Workpiece material characteristic
70
4.2
Rockwell hardness scale
79
4.3
Standard guidelines of ASME applications chart
87
5.1
Setup by regulation of voltage
90
5.2
Setup by regulation of travel speed
92
5.3
Tensile test description for workpiece 74mm
93
5.4
Simplification of tensile test for workpiece 74mm
105
5.5
Tensile test description setup for workpiece 88mm
106
5.6
118
5.7
119
5.8
131
5.9
132
5.10
142
5.11
Speed selector for all specimen (114mm)
143
5.12
Result of impact energy on the workpiece
144
5.13
Description of Hardness Test
145
5.14
Measurement of hardness by XY axis
146
xiii
LIST OF FIGURES
FIGURE NO.
1.1
TITLE
General common tank and piping (Tank Wikipedia,
PAGE
1
Free Encyclopedia
1.2
Longitudinal and circumferential joints of tank
(Pressure Vessel, Wikipedia, Free Encyclopedia)

2.1
General MIG welding system structure (Sacks &
Bohnart, 2005)
2.2
Circumferential welding on tanks or pipe (Martha A.
Baker, 1995)
3.1
Flow chart of Project Fabrication Process
15
3.2
Concept classification tree for tank and piping
16
fabrication fixture
3.3
Concept 1
18
3.4
Concept 2
19
3.5
Concept 3
20
3.6
Concept 4
21
3.7
Apparatus for obtaining a butting contact of hollow
22
tank courses to be circumferentially welded

3.8
Apparatus of forming circumferential welding
22
3.9
Method of welding tanks
23
3.10
Total assembly of finish parts
39
3.11
Workpiece rotational system
40
xiv
3.12
Rotating system
41
3.13
Formation of speed control motor without load
43
3.14
Formation of speed control motor with load (4.15kg)
43
3.15
Flow chart of welding apparatus fabrication
47
3.16
Steps of assembly for welding apparatus
48
3.17
Pneumatic circuit for triggering system
49
3.18
Electrical circuit for rotating system
50
3.19
Physical views of welding fixture
51
4.1
Setup workpiece to the fixture
67
4.2
Setup the nozzle to correct position with the
67
workpiece
4.3
Start-up to rotate the workpiece and welding process
68
4.4
Simplification view the steps of circumferential
69
welding processes on welding apparatus

4.5
Comparison strength between the carbon contain on
70
mild steel
4.6
Voltage regulator on MIG welding unit (Miller
71
Migmatic)
4.7
Determination of proper setting on voltage
72
4.8
Determination of proper setting on travel speed
74
4.9
Tensile Strength Tester
75
4.10
Workpiece shape for testing and analysis
76
4.11
Workpiece preparation and result by tensile test
77
4.12
Rockwell Hardness Tester
78
4.13
Workpiece position on Rockwell Hardness Tester
79
4.14
Workpiece preparation and result by hardness test
80
4.15
Izod Impact Tester schematic view
81
4.16
Strike of impact energy on workpiece
82
4.17
Workpiece setup on impact tester
82
4.18
Welding joint structure on specimen
83
4.19
Layout certification test
86
xv
5.1
Welding by circumferential joint on cylindrical shape
89
5.2
Result on workpiece by regulation of voltage
90
5.3
Result on workpiece by regulation of travel speed
92
5.4
Graph Load vs Displacement for workpiece (74mm)
104
5.5
Graph Stress vs Strain for workpiece (74mm)
104
5.6
Graph Load vs Displacement for workpiece (88mm)
117
5.7
117
5.8
Graph Load vs Displacement for workpiece
130
(101mm)
5.9
130
5.10
Graph Load vs Displacement for workpiece
141
(114mm)
5.11
142
5.12
Axis being measured by Hardness tester
146
5.13
Structure view (specimen 1, 114mm) before etching
148
under 50x lens

5.14
Size of welding structure for specimen 1
149
5.15
Welding structure for specimen 1 under 50X lens
149
5.16
150
5.17
150
5.18
151
5.19
151
xvi
LIST OF SYMBOLS
Height
Width
Long
Amp
Ampere (Current)
Diameter
Voltage
Liter
Thickness
Rotational velocity
Phi = 3.142
Relay
CW
Clockwise
CCW
Counter-clockwise
ASME
American Society of Mechanical

Engineering
xvii
LIST OF APPENDIX
APPENDIX
TITLE
PAGE
A1
Project Gantt chart (Session I and Session II)
161
A2
Project schedule and project cost (custom made)
163
B1
Drawing : Rotational shaft
164
B2
Drawing: Attachment roller
165
B3
Drawing: Bearing housing
166
B4
Drawing: Drive pulley
167
B5
Drawing: Driven pulley
168
B6
Drawing: Motor support plate
169
B7
Drawing: Stabilizer wheel plate
170
B8
Drawing: Stabilizer wheel shaft
171
B9
Drawing: Welding gun arm
172
B10
Drawing: Welding gun holder
173
B11
Drawing: Welding gun clamp 1
174
B12
Drawing: Welding gun clamp 2
175
B13
Drawing: Earth channel connector
176
B14
Drawing: Aluminium frame
177
B15
Drawing: Dark acrylic transparent plate
178
B16
Drawing: Control box
179
B17
Drawing: Stabilizer wheel holder
180
B18
Drawing: Cabinet
181
B19
Drawing: Finish assembly
182
xviii
C1
Quotation: Aluminium profile frame
183
C2
Quotation: Electrical parts and common parts
184
C3
Quotation: Speed control motor
186
C4
Quotation: Pneumatic cylinder
187
C5
Quotation: Pneumatic multiple parts
188
D1
MIG welding catalogue
189
D2
Low carbon steel specification chart catalogue
200
E1
Piping Construction, A guide of owners, architect and
202
engineers
E2
Welder certification test-pipe
206
CHAPTER 1
INTRODUCTION
1.1
Introduction
A common tank and piping is a product with the cylindrical shape designed to
hold gases or liquids at pressure substantially different from the ambient pressure. The
pressure differential is potentially dangerous and many fatal accidents have occurred in
the history of their development and operation. Consequently, their design, manufacture
and operation are regulated by engineering authorities backed up by laws. Generally,
almost any material with good tensile properties that is chemically stable in the chosen
application can be employed (Pressure vessels, Encyclopedia).
Figure 1.1 General common tanks and piping (Tanks, Encyclopedia)
2
Many tanks and piping are made by steel. To manufacture a spherical tank as an
example, forged parts would have to be welded together. Some mechanical properties of
steel are increased by forging, but welding sometimes reduces these desirable properties.
In case of welding, in order to make the tank meet international safety standard, the
selecting of fabrication standard is being used (Martha A. Baker, 1995).
To apply a welding process for common tank fabrication, the cylinders of the
tank are usually made from flat plates which are rolled and then welded along
longitudinal joints. In the other hand, circumferential joints are used to attach end
closures to the cylinder, and to weld together rolled plates for along the tank if plate size
availability or rolling machine capacity is restricted. Weld types are usually different for
longitudinal and circumferential joints, and therefore the joint stresses in a tank must
satisfy the requirements (Larry Horath, 2001).
Figure 1.2 Longitudinal and circumferential joints of tank (Pressure Vessel, Encyclopedia)
The circumferential joint of the cylindrical shape are being controlled as it fixed on the
fixture for constant speed of rotation. The output of joining is a pair of workpiece with
same thickness and diameter.
The general welding parameters in fabrication of tanks and piping are usually
depends on weld techniques which consist voltage, current (ampere) and travel
3
speed(mm/min). More specifically, the welding equipment using the Metal Inert Gas
(MIG) will consider also the wire speed feed factors. The performance of wire feed
system can be crucial to the stability and reproducibility of MIG welding.
For the welding voltages or arc voltages, is determined by the distance between
the tip of the electrode and the workpiece. In the constant voltage system, the welding
voltage is controlled by the arc length held by the welder and the voltage sensing wire
feeder. To sure the constant speed of welding, the support jig is being developed. The
other parameters called welding current has the great effect on the deposition rate, the
weld bead size and shape, and the penetration of the weld (Martha A. Baker, 1995)
The standard of designed and fabrication of the tank and piping are accordance
with the ASME Code Section VIII. The specific requirements apply to several classes
of material used in pressure vessel construction, and also fabrication methods such as
welding, forging and brazing (J.Philip Ellenberger, P.E, 2004)
The present work is devoted towards establishing a model of constant welding
fixture which created the outcome of workpieces by welding effect through the different
parameters setting on the MIG welding unit. The investigation on the tensile strength,
hardness and impact test while viewing the structure under the microscope will be
carried out.
1.2
Objective
The main objective of this project is to design, fabricate and test a welding
fixture for welding the cylinder circumferentially using MIG process. A specified
welding standard and procedures was used to evaluate the welding quality.
4
1.3
Scope of project
The scope of work is clearly define the specific field of the research and ensure
that the entire content of this thesis is confined the scope. It will be:
i.
The MIG Welding set (Miller Migmatic383) will be employed.
ii.
Mild steel will be used as the workpiece material.
iii.
The common tank and piping which has a cylindrical shape will be used.
iv.
The specified welding standard and procedure will be applied.
v.
A welding quality will be evaluated based on the destructive testing to the

workpiece. (Tensile test, impact test and hardness test)
1.4
Problem statement
The evaluation to determine the exact parameters used on Metal Inert Gas (MIG)
welding system for tank and piping fabrication with steel material is a necessary
requirements to promote the proper circumferential joint. How does the setting of
voltage, current and travel speed causes the good joint in a subjected of circumferential
site of tanks and piping. The questions work out with:
i.
What are the relevant parameters should be used to determine the good of
welding bead and welding width?
ii.
What is the best method to use to sure the concentration of welding would be
done?
iii.
What type of fixture should be use to get the constantly welding process?
iv.
What are the best evaluations to use to determine the result of welding based on
parameters setting?
CHAPTER 2
LITERATURE REVIEW
2.1
Introduction
This section is conducted by introduction and overview the related features to

this project from multiple sources. The intensions for this arrangement were:
i.
Introduction to MIG (Metal Inert Gas) Welding.
ii.
Introduction of welding on tank and piping.
iii.
Overview the previous research related to circumferential joint welding.
iv.
Overview the previous research related on tank and piping fabrications.
2.2
Introduction to MIG (Metal Inert Gas) Welding
MIG (Metal Inert Gas) welding, also sometimes called GMAW (gas metal arc
welding), is a welding process that was originally developed back in the 1940's for
6
welding aluminium and other non-ferrous metals. MIG welding is an automatic or semi
automatic process in which a wire connected to a source of direct current acts as an
electrode joins two pieces of metal, as it is continuously passed through a welding gun.
A flow of an inert gas (originally Argon) is also passed through the welding gun at the
same time as the wire electrode. This inert gas acts as a shield, keeping air borne
contaminants away from the weld zone (Martha A. Baker, 1995).
Figure 2.1 General MIG welding system structure (Sacks & Bohnart, 2005)
The primary advantage of MIG welding is that it allows metal to be welded

much quicker than traditional welding "stick welding" techniques. This makes it ideal
for welding softer metals such as aluminium. When MIG welding was first developed,
the cost of the inert gas (i.e., argon) made the process too expensive for welding steel.
However, over the years, the MIG welding process has evolved and semi inert gases
such as carbon dioxide can now be used to provide the shielding function which makes
MIG welding cost effective for welding steel (Sacks & Bohnart, 2005).
7
Besides providing the capability to weld non-ferrous metals, MIG welding has
other advantages:
i.
It produces long continuous welds much faster than tradition welding

methods.
ii.
Since the shielding gas protects the welding arc, MIG welding produces a
clean weld with very little splatter.
2.3
Introduction of welding on tank and piping.
The practice of weld around the outside of cylindrical tank or pipe is for the
purpose of getting used to the changing position of torch (nozzle) while following the
contour around the shape. This is essential technique in tank and pipe welding. The
technique should be both downhill and uphill and both stringer and weaved beads
should be deposited.
For the circumferential weld or in other terms butt weld, preparation of tank or
pipe is as shown in figure 2.2. The angle of the nozzle while welding has a significant
effect on the final weld. The angle is especially critical in tank or pipe welding since it
changes constantly as the weld progresses around the tank. The welder can maintain
control of the weld pool and reduce the erratic effects of arc blow by varying the angle
of the nozzle to meet the conditions of welding (Sacks & Bohnart, 2005).
Current control is extremely important in welding the root pass. A high current
setting causes excessive penetration on the inside of the pipe and makes control of the
molten weld pool impossible. If the current setting is too low, there is little penetration
and fusion at the root. The voltage and the ampere provide the heat to melt the electrode
and the base metal to form the weld pool. High voltage caused by the long arc gap
provides a wide weld bead with little directional control and excessive weld spatter.
8
Low voltage caused by a short arc length causes the bead to pile up in the groove with
little fusion and penetration. Low voltage also causes an uneven burnoff rate of the
electrode, so that the slag covers the weld bead inadequately. Poor slag coverage causes
porosity in the weld metal (Larry Horath, 2001).
Figure 2.2 Circumferential welding on tanks or pipe (Martha A. Baker, 1995)
The speed travel is another important element in the formation of the weld bead
that is deposited especially during weld the tanks. A high speed tends to cause
undercutting and a high, narrow bead. Undercutting produces a stress concentration at
the point of the undercut and can result in joint failure. A low speed causes too much
9
metal to pile up. This causes poor fusion along each edge of the weld and seriously
affects the soundness of the weld (Sacks & Bohnart, 2005).
2.4
Overview the previous researches related to circumferential joint welding.
In this sub-chapter, the overview of the previous researches related to the

circumferential welding joint is briefly discussed in order to clearly justify the
necessitate sources of previous researches to be referred for this project.
Jianqiu Zhou and Shiming Shen (1998) carried out the study on the reliability
assessment methodology for pressure piping containing circumferential defects,
describes a computational method of failure probability of a welded joint containing
circumferential defects; the uncertainties of variables, relation of random variables and
three possible failure modes of the pipe are considered. Then a new probability limit
state model is set up, and the Monte-Carlo simulation method is employed to compute
the failure probability of welded joint.
Afzal M.Malik, Ejaz M.Qureshi, Naeem Ullah Dar and Iqbal Khan (2008) come out
with the analysis of temperature distributions and the subsequent residual stress fields
during the course of arc welding of thin-walled cylinders of low carbon steel.
Parametric studies based on numerical simulations are conducted to investigate the
effects of critical welding process parameter on weld-induced residual stresses.
Temperature-dependent thermo-mechanical behavior for low carbon steel, filler metal
deposition along with double ellipsoidal heat source model is incorporated. The
accuracy of the developed finite element simulation strategy is validated for transient
temperature distributions and residual stress fields through full-scale shop floor welding
10
experiments with proper instrumentation for data measurement. The aim is to present
data to confirm the validity of in-process circumferential welding technology for thinwalled cylinders so that the in service failures of these structures due to process specific
inherent stresses may be minimized.
Naeem Ullah Dar, Ejaz M.Qureshi and M.M.I Hammouda (2009) analyze of weldinduced residual stresses and distortions in thin-walled cylinders. Circumferential weld
specifically in thin-walled structures is a common joint type in the fabrication of
structural members in aerospace, aeronautical and pressure vessel industries. This type
of weld joint suffers various types of weld-induced residual stress fields (hoop and axial)
and deformation patterns (axial shrinkage, radial shrinkage). These imperfections have
negative effects on fabrication accuracies and result in low strength welded structures
that can lead to premature failures. To precisely capture the distortions and residual
stresses, computational methodology based on three-dimensional finite element model
for the simulation of gas tungsten arc welding in thin-walled cylinders is presented.
R.H. Leggatt (2008) worked out with the residual stresses in welded structures which
discussed in terms of their magnitude, directionality, spatial distribution, range and
variability. Examples are given of residual stress distributions in plate butt welds,
circumferential butt welds and weld cladding. These illustrate the different magnitudes
and distributions of residual stress that can be found in different joint geometries, and
demonstrate the effects of the mechanical, thermal and metallurgical properties of the
constituent materials and the sensitivity of residual stresses to pass sequence and to the
restraints applied during welding. Further examples for the common case of
circumferential butt welds in pipes and pressure vessels are used to illustrate the extent
of residual stresses as a function of distance from the weld and the effects of post-weld
heat treatment.
Tso-Liang Teng and Peng-Hsiang Chang (1998) used the three-dimensional

thermomechanical
analysis
of
circumferentially
welded
thin-walled
pipes.
Circumferentially welded pipes are frequently used in boiling water reactor piping
11
systems, oil pipe transport systems and steam piping systems. When two pieces of pipe
are welded together, residual stresses arise in the vicinity of the weld owing to the
circumferential welding of the pipes. Residual stresses are attributed to the elastoplastic
response of the object towards the transient thermal stresses generated by the thermal
cycle. They can be a major source of cracking and fracture problems in welded
structures. Finite element simulation of the welding process is a highly effective means
of predicting thermomechanical behavior.
Ario Sunar Baskoro, Rui Masuda, Masashi Kabutomori and Yasuo Suga (2008) carried
out an application of genetic algorithm for edge detection of molten metal pool in fixed
pipe welding. As circumferential buttwelded pipes are frequently used in power stations,
offshore structures, and process industries, it is important to investigate the
characteristic of the welding process. In pipe welding using constant arc current and
welding speed, the bead width becomes wider as the circumferential welding of smalldiameter pipes progresses.
2.5
Overview the previous researches related on cylindrical shape fabrications.
In this sub-chapter, the overview of the previous researches related to the on

tank and pipe fabrication is briefly discussed in order to clearly justify the necessitate
sources of previous researches to be referred for this project.
Hong-Sung Lee, Jong-Hoon Yoon, Jae-Sung Park and Yeong-Moon Yi (2005) reported
an experimental investigation of the failure behavior of pressure vessels during high
pressure of hydraulic loading. The pressure vessels were manufactured by two different
procedures.
12
Z.Sterjovski, D.P. Dunne and S.Ambrose (2004) worked out with the evaluation of
cross-weld properties of quenched and tempered pressure vessels before and after
PHWT (Post Weld Heat Treatment). It reports on the weld procedure and cross-weld
performance evaluation of weldments in 11 and 12 mm QT steel plate before and after
PWHT. Root bend (1808) tests showed no evidence of cracking or tearing in any of the
samples tested. After PWHT, tensile tests indicate a reduction in the ultimate tensile
strength of all samples and a decrease in yield strength for the 12 mm sample only. The
hardness results were consistent with the tensile test results because they revealed
significant softening in the HAZ and WM as a result of PWHT. Additionally, residual
stress measurements before and after PWHT showed that PWHT is effective in
reducing surface residual stresses to levels low in the elastic range. It is concluded that
although PWHT exerts the beneficial effect of reducing residual stresses, the ductility of
the weld region is satisfactory without PWHT, and PWHT decreases the cross-weld
tensile strength.
J.G Teng and X.Lin (2005) presents the study of fabrication of small models of large
cylinders with extensive welding for buckling experiments. An innovative technique for
the fabrication of small models of such large steel cylindrical shells constructed from
many welded panels. The experimental set-ups to implement this technique in the
laboratory are also described. The new technique consists of two stages: (a) production
of a high quality model by rolling two sheets (or a single sheet) and welding along
themeridional seams; and (b) welding in the form of controlled heat input in a required
pattern of circumferential and meridional welds on the central portion of the shell
surface. The imperfections in an example specimen are also examined to show that they
have a realistic pattern. The observed buckling behavior of this specimen is presented
and discussed. The specimen buckled at a very low load, confirming that the weldinginduced imperfections in such shells are severely detrimental to the buckling strength.
Roger R. Griffiths (2002) conducted an investigation into a major crack that occurred
during fabrication of thick walled alloy pressure vessel. This revealed that the primary
cause of cracking was the method by which preheat had been applied to the vessel for
13
the welding operation, coupled with the very low impact values achieved by the weld
metal in the as-welded condition. Investigation also centered on the use of
dehydrogenation heat treatment (DHT) instead of an intermediate stress relief (ISR),
and the oxidized nature of the fracture surface.
Inge Lotsberg (2008) analyzed the stress concentration factors at welds in pipelines and
tanks subjected to internal pressure and axial force. In this study, analytical expressions
for stress concentration factors in pipes subjected to internal pressure and axial force are
derived for a number of design cases based on classical shell theory. The effect of
fabrication tolerances in simple butt welds is assessed. Analyses based on classical
mechanics are compared with results from axisymmetric finite element analyses for
verification of the presented methodology. Stress concentration factors are presented for
circumferential butt welds in pipes welded together from pipes with different
thicknesses, welds at buckling arrestors, welds at flanged connections in pipelines, and
welds at ring stiffeners on the inside and the outside of the pipes. It also includes stress
concentration factors at end closures in pipes for gas storage. Larger pipes are fabricated
from plates with a longitudinal weld. This fabrication process introduces out-ofroundness in the pipes.
M.Pircher, P.A. Berry, X.Ding and R.Q.Bridge (2001) bring out the shape of
circumferential weld-induced imperfections in thin-walled steel silos and tanks. The
strength of thin-walled cylindrical shell structures is highly dependent on the nature and
magnitude of imperfections. Most importantly, circumferential imperfections have been
reported to have an especially detrimental effect on the buckling resistance of these
shells under axial load. Due to the manufacturing techniques commonly used during the
erection of steel silos and tanks, specific types of imperfections are introduced into
these structures, among them circumferential weld-induced imperfections between
strakes of steel plates. The shape of such a localized circumferential imperfection has
been shown to have a great influence on the degree of strength loss of thin-walled
cylindrical shell structures.
14
CHAPTER 3
DESIGN AND DEVELOPMENT OF WELDING FIXTURE
3.1
Introduction
On this chapter, firstly the project is conducted by developing the structure of

cylindrical shape (tank and piping) fabrication fixture until the output is produced and
being tested. The representative of fabrication fixture until specimen being tested is
illustrated as the flow chart on figure 3.1.
The concept of developing the welding fixture for constantly welding on
cylindrical shape is to indicate the strength along the joint to become more effectively
rather than the process by manually operation. This semi-automatic welding fixture is
developed by following the proper steps from the ideas creation until the exactly
welding fixture is physically being design and fabricate.
15
Start
Information Gathering
Literature review of tank and pipe model fabrication
Concept design and sketching
Reject
Satisfied
Model
Satisfied
Verification of standard and procedures
Standard
Verified
No
Yes
Material and part preparation
Fabrication of the fixture
Test run on the workpiece
No
Satisfied
Output
Yes
Produce an output (Specimen)
Preparation specimen for destructive testing
Destructive Testing
No
Verified
Testing
Yes
End
Figure 3.1 Flow chart of Project Fabrication Process
16
3.2
Method of Welding Fixture Fabrication
Concept of welding fixture fabrication is to create the constant welding feed. As

the workpiece being weld is decided as a cylindrical shape, so the circumferential
welding technique is used especially for common tank and piping. The longitudinal site
would not be focus on the fabrication fixture because the limitation requirement, not
involved with linear constant feed. This fixture is create with the rotational of the
workpiece by fixed the welding nozzle or in the other ways. To make the solution of
deciding the actual fixture fabrication, the stage of conceptual design and selection will
used as the guidelines for the optimum fabrication. Before proceed to the next stage, the
understanding about the requirements of the fixture in order to get a proper output must
be clear. The development of the fixture is followed the concept classification tree as
illustrated in figure 3.2.
Figure 3.2 Concept classification tree for tank and piping fabrication fixture
17
3.3
Conceptual design and sketching
To determine the selection of optimum concept is by fulfill the requirement as

illustrated in figure 3.2. The following steps are being conducted:
3.3.1
i.
ii.
Patent search
iii.
Concept screening
iv.
Concept scoring
v.
Final specifications
Sketching the concept is based on normal hand sketch. Four concepts are created
as in figure 3.3, 3.4, 3.5 and 3.6.
3.3.1.1 Description of concept 1 (figure 3.3)
i.
The concept use for rotational the workpiece by clamping on 2 unit of

jaw.
ii.
The fixed welding nozzle is at the perpendicular position to the

workpiece.
iii.
The rotational workpiece are being controlled by speed control motor at

the bottom and link by vertical belting.
18
Figure 3.3 Concept 1
i.
The vertical workpiece positioning is used as its step on the rotating plate.
ii.
The fixed welding nozzle is perpendicular to the workpiece but on side

welding technique.
iii.
Rotational workpiece in pairs is clamp together on top and bottom of

working plate and rotate directly from speed control motor.
19
i.
The horizontal workpiece is position on the rotating wheel or shaft at the

bottom by means direct contact between them.
ii.
The rotational of workpiece is by rotating two unit of wheel or shaft and

directly supports the workpiece for multiple size of diameter.
iii.
The rotating clamp is used to stabilize the workpiece and the welding
nozzle is fixed on the movable plate which allow for multiple positioning
of welding technique.
iv.
The constant speed of workpiece is produced by the speed control motor

which rotated one of the wheel or shaft.
20
i.
The workpiece is place horizontally by clamp the internal clamper with

supported by the supporting wheel at the bottom.
ii.
The welding nozzle is fixed at the top of frame and welding the
workpiece at the perpendicular position.
iii.
The rotational workpiece is generated by the rotate the pulley which

power up by the speed control motor.
21
22
3.3.2
Pattern search
Figure 3.7 Apparatus for obtaining a butting contact of hollow tank courses to be
circumferentially welded (Robert W. Randolph, 1977)
Figure 3.8 Apparatus of forming circumferential welding (Richard L.Frohlich, 1978)
23
Figure 3.9 Method of welding tanks (William F.Clavey, 1975)
24
3.3.3
List of needs
Table 3.1 : List of available needs

No
1
Needs
Constant speed of rotation
Importance
5
Place without slip
Anti-corrosion of all parts
Easy to handle
Portable equipment
Safety manner
Good material surface
Good finishing output (constant welding bead)
Cost effective/saving
10
Easy for structure assembly
11
Easy for material setup
12
Total light weight
13
Automated function
14
Variety size of tanks/workpiece (diameter)
15
Easily access of maintenance
16
Good penetration
17
Full nozzle triggering
18
Large area for welding process
Rate : Very important = 5, Important = 4, Required= 3,

Less required = 2, Very less required= 1
25
3.3.4
List of metric
Table 3.2 : List of metric

Metric
Need Nos
Metric
Imp.
Units
Rotational speed
m/min
2,4,5,15,17
Easy operation
Subj.
3,7
Aesthetic value
Subj.
Cover from spark light
Subj.
Voltage
Unit price
RM
10,11,13
Operation time
min
12
Total mass
kg
14,18
Size (H x W x L)
m2
10
16
Current
Amp
No
26

Place without slip
Easy to handle
Portable equipment
Safety manner
Total light weight
Automated function
Good penetration
Current
Size (H x W x L)
Total mass
Operation time
Unit price
Voltage
Cover from spark

light
26
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Aesthetic value
Easy Operation
Table 3.3 : Needs-metics matrix

Rotational Speed
3.3.5
27
3.3.6
Concept screening
Table 3.4 : Concept screening

Concept 1 (Ref.)
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
18
0
0
3
YES
Concept 2
0
0
+
+
+
0
0
0
0
3
6
9
-6
4
NO
Concept 3
+
+
0
+
0
+
+
+
0
+
0
0
+
+
0
0
+
10
7
1
9
1
YES
Concept 4
0
+
0
0
+
+
+
0
0
0
0
+
+
0
6
8
4
2
2
YES
27
Selection Criteria
Place without slip
Easy to handle
Portable equipment
Safety manner
Total light weight
Automated function
Good penetration
SUM +
SUM 0
SUM Net Score
Rank
Continue ???
28
3.3.7
Concept scoring
Table 3.5 : Concept scoring
Selection Criteria
Place without slip
Easy to handle
Portable equipment
Safety manner
Total light weight
Automated function
Good penetration
TOTAL SCORE RANK
RANK
CONTINUE???
Concept Selected
Weight
8.2%
8.2%
4.9%
4.9%
1.6%
6.6%
3.3%
8.2%
4.9%
4.9%
8.2%
4.9%
4.9%
8.2%
4.9%
3.3%
4.9%
4.9%
Concept 3(Ref.)
Rating Score
5
0.410
5
0.410
5
0.410
5
0.410
5
0.410
4
0.264
4
0.264
5
0.410
3
0.147
5
0.410
5
0.410
3
0.147
5
0.410
5
0.410
4
0.264
4
0.264
4
0.264
5
0.410
6.124
1
YES
Concept 1
Rating Score
5
0.410
3
0.147
5
0.410
2
0.098
5
0.410
3
0.147
4
0.264
2
0.098
4
0.264
3
0.147
3
0.147
4
0.264
5
0.410
3
0.147
3
0.147
3
0.147
4
0.264
3
0.147
4.068
2
NO
X
Concept 4
Rating Score
5
0.410
4
0.264
5
0.410
2
0.098
5
0.410
1
0.066
3
0.147
2
0.098
3
0.147
3
0.147
3
0.147
4
0.264
5
0.410
3
0.147
3
0.147
3
0.147
4
0.264
2
0.098
3.821
3
NO
X
28
29
3.3.8
Final Specifications
Table 3.6 : Project final specification
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
3.4
Metric
Motor speed (with gear head)
Place without slip
Portable equipment
Good finishing output (constant welding slag)
Structure assembly
Welding and material setup
Total net weight
Total gross weight
Variety size of tanks/piping (diameter)
Full nozzle triggering (pressure of pneumatic cylinder)
Overall space of the project (L x W x H)
Voltage regulation
Wire feed speed
MIG gas supply
Unit
Value
mm/s
0 7.30
rpm
0 3.47
Subj.
Subj.
Subj.
Subj.
RM
<10,000
hours
<1.5
hours
<0.25
Kg
90
Kg
105
mm
50 - 350
Subj.
bar
<4
m3
480x460x1550
V
5 - 18
mm/min
200
L/min
<5
Project Design
After the concept is being selected, with the preparation of the suitable final
specifications, the project design is begin with by surveying the available component in
the market. As in the concept 3 is selected, the main project structure is using the
aluminium profile which is non corrosion and good finishing material. The SolidWorks
2009 software is used to create the project design for every customizing part and the
total assembly of the finish parts (figure 3.10). First of all, the determination of parts
description and function must be evaluated to suit the reason of choosing the part.
30
3.4.1
Part description and selection
Table 3.7 : Description of rotational shaft

Part No.
1
Part Name : Rotational Shaft

Details dimension is on Appendix B1
Overall length
Material
Function
30 x 1000mm
length
(2 pcs)
Aluminium
As the rotation shaft

and support shaft to
link between the driven
pulley to the workpiece
through the attachment
roller
Reason of selection
1. Easy to fabricate.
2. Non-corrosion
material.
Table 3.8 : Description of attachment roller

Part No.
2
Part Name : Attachment Roller

Overall length
Material
100 x 30mm
thickness
(8 pcs)
Aluminium
Function
Reason of selection
Insert to the rotational 1. Easy to fabricate.

shaft and rotate the 2. Non-corrosion
workpiece
(direct
material.
contact with high 3. Required for high
friction needed)
gripping material.
31
Table 3.9 : Description of bearing housing
Part No.
3
Part Name : Bearing Housing

Overall length
Material
Function
Reason of selection
(94L x 30W x
50T)mm
( 4 pcs)
Aluminium
To grasp the rotational

and support shaft by
insert the bearing to
the housing and fix to
the aluminium frame
2. Non-corrosion
material.
3. Difficult to get in
market together with
the bearing.(custom
made)
Table 3.10 : Description of drive pulley

Part No.
4
Part Name : Drive Pulley

Overall length
Material
40 x 38.5mm
thickness
(1 pc)
Aluminium
Function
Reason of selection
Connecting to motor as 1. To protect the motor

requirement to use Voverloaded
if
belt through the driven
workpiece
is
pulley
jammed
by
providing slip.
32
Table 3.11 : Description of driven pulley
Part No.
5
Part Name : Driven Pulley

Overall length
Material
Function
Reason of selection
40 x 38.5mm
thickness
( 1pc)
Aluminium
Link between drive

pulley to the rotational
shaft by V-belt
1. Same as part 4
which to protect the
motor overloaded by
provide slip rather
than
use
other
instrument.
Table 3.12 : Description of motor support plate

Part No.
6
Part Name : Motor Support Plate

Overall length
Material
(132L x 100W x
42T)mm
(1 pc)
Aluminium
Function
Reason of selection
To grasp the motor by 1. To position the

tight it up using 4 pcs
motor at the side of
of screw and with
the main frame
adjustable position for
tightening the V-belt
33
Table 3.13 : Description of stabilizer wheel plate
Part No.
7
Part Name : Stabilizer Wheel Plate

Overall length
Material
(71L x 32W x
5T)mm
( 2 pcs)
Aluminium
Function
Reason of selection
To hold the connection 1. Easy to fabricate

between the stabilizer
with light material
wheel
and
the
requirement.
stabilizer wheel shaft
2. Non-corrosive
materials
requirements cause
closer to the welding
nozzle
when
sparking.
Table 3.14 : Description of stabilizer wheel shaft

Part No.
8
Part Name : Stabilizer Wheel Shaft

Overall length
Material
Function
Reason of selection
(450L x 25W x
25T)mm
(2 pcs)
Aluminium
To grasp the stabilizer

wheel through the plate
which can be slide as
follow to the size of
workpiece diameter
2. Non
corrosive
materials to stand
with the sparking by
welding.
34
Table 3.15 : Description of welding gun arm
Part No.
9
Part Name : Welding Gun Arm

Overall length
Material
Function
Reason of selection
(75L x 25W x
5T)mm
(1pc)
Aluminium
To grasp the whole

welding gun to the
sliding shaft. Its cn
rotate to adjust the
angle
of
welding
nozzle.
1. For easy install and

dismantle
of
welding gun.
2. Easy
for
angle
adjustment.
Table 3.16 : Description of welding gun holder

Part No.
10
Part Name : Welding Gun Holder

Overall length
Material
(120L x 40W x
5T)mm
(1 pc)
Aluminium
Function
Reason of selection
To grasp the front and 1. Part used to grasp at

back welding gun
the front and back of
through clamp 1 and 2
welding nozzle.
2. As position for
pneumatic cylinder
for triggering.
35
Table 3.17 : Description of welding gun clamp 1
Part No.
11
Part Name : Welding Gun Clamp 1

Overall length
Material
Function
Reason of selection
(93L x 30W x
18.5T)mm
(2 pcs)
Aluminium
To clamp the welding

nozzle at the front by
using the tightening
screw and bolt.
1. Easy to fabricate to
suit the shape of
welding nozzle at
the front.
Table 3.18 : Description of welding gun clamp 2

Part No.
12
Part Name : Welding Gun Clamp 2

Overall length
Material
Function
Reason of selection
(120L x 40W x
5T)mm
(2 pcs)
Aluminium
To clamp the welding

nozzle at the back by
using the tightening
screw and bolt.
1. Easy to fabricate to
suit the shape of
welding nozzle at
the back.
36
Table 3.19 : Description of earth channel connector
Part No.
13
Part Name : Earth Channel Connector

Overall length
Material
(38L x 30W x
23T)mm
(1 pc)
Copper
Function
To completed
current flow on
earth connection
clamp it directly to
workpiece
Reason of selection
the 1. A proper current
the
flow cause directly
by
contact
to
the
the
workpiece without
sparking.
Table 3.20 : Description of aluminium frame

Part No.
14
Part Name : Aluminium Frame

Overall length
Material
Function
Reason of selection
(100L x 40W x
40T)mm
(6 pcs)
Aluminium
As the main frame

structure for project
body and can be fixing
by a lot of parts easily
at any length of
aluminium profile.
1. The best material

and structure which
easily can get from
market.
2. Easy for assembly
and dismantle.
3. Good
finishing
view.
(600L x 40W x
40T)mm
(16 pcs)
37
Table 3.21 : Description of dark acrylic transparent
Part No.
15
Part Name : Dark Arcylic Transparent

Overall length
Material
Function
Reason of selection
(1000L x 600W x
2T)mm
(1 pc)
Plastic PVC
As a cover to the
aluminium frame on
side and at back. It use
to protect the operator
from
light
during
welding progress that
will injured the eyes.
1. An easy material to
install
to
the
aluminium frame.
2. Easy to form based
on the shape of the
frame.
(600L x 600W x
2T)mm
(2 pcs)
Table 3.22 : Description of control box

Part No.
16
Part Name : Control Box

Overall length
Material
Function
Reason of selection
(254L x 204W x
112T)mm
(1 pc)
Mild Steel
Plate
As
the
centralize
control of workpirce
motion and triggering
system. To fix all the
pneumatic
and
electrical
control
components
1. The best use as

external control that
make easy for the
operator to control
motion and trigger
during welding.
38
Table 3.23 : Description of stabilizer wheel holder
Part No.
17
Part Name : Stabilizer Wheel Holder

Overall length
Material
Function
Reason of selection
(85L x 55W x
30T)mm
(2 pcs)
Plastic PVC
To hold the position of

stabilizer shaft when
sliding to stabilize the
workpiece
1. The better method to

hold the square shaft
shape
through
tightening screw.
2. Easy to clamp and
release the stabilizer
shaft to adjust the
position.
Table 3.24 : Description of cabinet

Part Name : Cabinet
Part No.
18
Overall length
Material
Function
Reason of selection
(915L x 420W x
20T)mm
(5 pcs)
Mild Steel
Plate (With
paint
coating)
As
additional
compartment
for
increase the height of
welding area and as the
additional storage for
welding fixture
1. Easy to manufacture
based on the shape
of welding fixture.
2. Easy to install and
dismantle.
(520L x 420W x
20T)mm
(2 pcs)
39
Details view is on Appendix B19
39
Figure 3.10 Total assembly of finish parts
40
3.4.2
Determination of workpiece rotation system
There are a few criteria need being considered when designing the workpiece
rotational system which could be determine the ideal rotation as required which produce
a good of welding output by circumferential joint. The criteria could be:
i.
Speed control of rotation (mostly used speed control motor)
ii.
Link instrument between motor to the workpiece
iii.
Less friction of rotation when being driven
iv.
High friction on surface contact to prevent slip of workpiece
v.
Workpiece constantly support to maintain the gap between nozzle and

workpiece
The general mechanical method could be solved to determine the rotating speed
of workpiece that be generate by the motor. As in figure 3.11 and 3.12, the calculating
of general method using V-belt and pulleys are being conducted.
Figure 3.11 Workpiece rotational systems
41
Figure 3.12 Rotating system
The formation of motor speed is as in table 3.25 and table 3.26 that being
conducted for good welding joint by workpiece rotation between 0.59mm/s to
2.35mm/s (selecting of throttle between 1 to 3) with load or without load. The graph by
motor formation speed is shown on figure 3.13 and 3.14.
42
Table 3.25 : Motor Speed Selector without load
Throttle
Selector
Time per
single
rotation (s)
Speed
(mm/s)
1
2
3
4
5
6
7
8
9
10
186
52
35
24
19
16
14
13
12
11
0.43
1.54
2.29
3.33
4.21
5.00
5.71
6.15
6.67
7.27
Distance of
pulley (Driven
pulley
diameter)
80
80
80
80
80
80
80
80
80
80
Load
Without load
Without load
Without load
Without load
Without load
Without load
Without load
Without load
Without load
Without load
Table 3.26 : Motor Speed Selector with load

Throttle
Selector
Time per
single
rotation (s)
Speed
(mm/s)
1
2
3
4
5
6
7
8
9
10
136
54
34
24
19
16
14
13
12
11
0.59
1.48
2.35
3.33
4.21
5.00
5.71
6.15
6.67
7.27
Distance of
pulley (Driven
pulley
diameter)
80
80
80
80
80
80
80
80
80
80
Load
4.15kg
4.15kg
4.15kg
4.15kg
4.15kg
4.15kg
4.15kg
4.15kg
4.15kg
4.15kg
43
Motor Speed Without Load

8.00
7.27
7.00
6.00
5.71
6.15
6.67
5.00
5.00
4.21
4.00
3.33
3.00
2.29
2.00
1.54
1.00
0.43
0.00
1
10
Figure 3.13 Formation of speed control motor without load
Motor Speed With Load (4.15kg)

8.00
7.27
7.00
6.00
5.71
6.15
6.67
5.00
5.00
4.21
4.00
3.33
3.00
2.35
2.00
1.48
1.00
0.59
0.00
1
10
Figure 3.14 Formation of speed control motor with load (4.15kg)
44
For minimum speed (0.59mm/s),
V2
= DN
N2
(3.1)
V
D
0.59
= (40) x60
mm /min
mm
= 0.28 rpm
Ratio, i
=
=
driven pulley
drive pulley
80
40
=2
Belt drive
D1N1
= D2N2
(3.2)
N1
= D2N2 / D1
= 40(0.28) / 80
= 0.14 rpm
N3
= N1
Nworkpiece
Workpiece speed
N2
N1
N2
N workpiece
N2
i
0.28
2
= 0.14 rpm
(3.3)
45
For maximum speed (2.35mm/s),
Based on equations 3.1, 3.2 and 3.3, the evaluations for maximum speed is using the
same method.
V2
= DN
N2
V
D
2.35
= (40) x60
mm /min
mm
= 1.12 rpm
Ratio, i
=
=
driven pulley
drive pulley
80
40
=2
Belt drive
D1N1
= D2N2
N1
= D2N2 / D1
= 40(1.12) / 80
= 0.56 rpm
N3
= N1
Nworkpiece
Workpiece speed
N2
N1
N2
N workpiece
N2
i
1.12
2
= 0.56 rpm
The speed of rotating shaft being conducted for proper welding

joint on workpiece is between 0.14 rpm to 0.56 rpm.
46
3.5
Project Fabrication
By referred to the final design and specifications, before the fabrication begins,
some of the parts (as list on the standard part) need to be ordered first for reason of
suitable pairing when make an assembly. Simplification of the project fabrications are
illustrated by the flow chart (figure 3.15) below and the assembly step as in figure 3.16.
List out the final design and
specifications
Order the standard parts and
some of the customizing
parts
Reject
Specified the
parts with the
specifications
Accept
Fabrication of workpiece
rotating system
Fabrication of welding gun

clamper and trigger
Installation of electrical
control parts
PART 1
Standard parts:
1. Speed control motor
2. Screw, nut, half round nut,
steel bush connector (size
M6 x16mm & M8x
16mm)
3. Arcylic (Dark
Transparent)
4. Pneumatic cylinder, etc
Customizing parts:
1. Aluminium profile
2. Body casing (mild steel
plate)
3. Etc.
1.
2.
3.
4.
5.
6.
Rotating shaft.
Bearing housing.
Drive pulley
Driven pulley
Attachment wheel
Welding gun clamper and
triggering
7. Motor holding plate
8. Switch control box
9. Etc.
1. Welding gun clamper
2. Welding trigger
3. Welding gun arm
1.
2.
3.
4.
Selector switch
Relay
Motor speed controller
Indicator light
47
PART 2
Installation of pneumatic
control parts
Pneumatic:
1. Cylinder and tubing
2. 3/2 way selector valve
3. 5/2 way valve with single
pilot and spring return
4. Air service unit
Assembly of main structure
1. (40x40)mm x 1000mm
aluminium profile
2. (40x40)mm x 600mm
aluminium profile
3. Dark acrylic transparent
plate
4. Wheel,
5. Etc.
Specified the
structure with
specifications
Rebuild
Accept
Assembly of parts to the
main structure
Reassembly
Specified the
parts with
structure
1.
2.
3.
4.
5.
6.
7.
8.
Rotation shaft.
Bearing housing.
Drive and driven pulley
Speed control motor and
holding plate
Switch control box
Welding gun holder, etc
Stabilizer, etc
Etc
Accept
Test run and calibration
Retest
Specified
running
Accept
End of fabrication
Figure 3.15 Flow chart of welding fixture fabrication
48
1.
Assembly of
aluminium Profile
2. Fixing the Bearing

Housing to the
aluminium profile
9. Installation of
electrical and
pneumatic circuit
10. Fix the Motor Speed

Controller, Selector
switch
and
Pneumatic selector
8. Fixing the Drive and

driven
pulley
together with V-belt.
11. Assemble
the
additional cabinet
for workpiece and
component storing
3. Install
the
rotational shaft to
the bearing housing
4. Fixing the Stabilizer

Wheel and Welding
Gun Holder
7. Fixing the motor with

plate
to
the
aluminium frame
6.Install the set of

welding gun
4. Insert the shaft for

the stabilizer wheel
and welding gun
5. Assemble the set of

welding gun clamper
12. Align the rotational

shaft
13. View after finish
installations
48
Figure 3.16 Steps of assembly for welding fixture
49
3.6
Project controlling system
The controlling system that which applied for this welding fixture is using the
pneumatic system as welding gun triggering system and electrical source for rotating
system. The pneumatic and electrical circuit (design by Festo FluidSim 4.0 software)
for both systems is as figure 3.17 and 3.18.
3.6.1
Working operation of pneumatic triggering system
As a compress air being delivered, the initial condition for the double acting
cylinder would be on extending position. Manual input given by the operator to the 3/2
way selector valve, will activate the 5/2 way single pilot valve to supply the compress
air to the cylinder which will retract to the minimal stroke. The retraction of the cylinder
will trigger the welding gun which the cylinder shaft is attached with the trigger arm. To
release the trigger, signal is given to the selector valve and cylinder is extended to initial
condition.
Figure 3.17 Pneumatic circuit for triggering system
50
3.6.2
Working operation of electrical circuit for rotation system
For a general application, the electrical supply for this welding fixture is used to
generate the motion of the speed control motor and the motor is connecting together to
the rotating shaft which will rotate the workpiece. The input signal from the operator by
selecting the change over switch, the motor will run continuously either by clockwise or
anti-clockwise rotation. The motor (with gear head attachment) speed is being
controlled by the speed controller means given an effect to the rotating shaft. The
controllers will determine the suitable speed need to be set for proper welding joint.
When the 240V supply is delivered to the circuit, and the operator selecting the
rotation of the motor, it would activate the relay coil (K1 for clockwise rotation and K2
for anti-clockwise rotation). Activation of coil K1 or K2 will activate the contact of
their relay which directly supply to the motor within the controlling by speed controller.
As the selector switch is release, the relay will deactivate and the motor will stopped
running.
Figure 3.18 Electrical circuit for rotating system
51
3.7
Bill of Materials (BOM)
The bill of materials (BOM) is a simplest form, a list of parts or components

required to build a product. It provides the manufacturers part number (MPN) and the
quantity needed of each component. At most complex, the BOM is a multi-level
document that provides build data for multiple sub-assemblies (products within
products) and includes for each items part number, approved manufacturers list (AML),
mechanical characteristics and a whole range of component descriptors. It may also
include attached reference files, such as part specifications (Joseph Edward Shigley and
Charles R.Mishke, 1989).
In this project, the BOM is included with the raw material which would be
produced manually and the standard part by directly purchased. The lists of BOM are as
in table 3.27 (custom part) and table 3.28 (standard part). The physical view of the
projects is illustrated in figure 3.19.
a) End of 1st Session
b) End of 2nd Session
Figure 3.19 Physical views of welding fixture
52
Table 3.27 : BOM for Custom Made parts

Custom Parts
No. Components
Dimension
Quantity
Price per
unit
(RM)
60.00
34.50
30.00
25.00
Amount
(RM)
Main frame (aluminium

profile)
a. Length (1000mm)
b. Length (600mm)
c. Length (520mm)
d. Length (400mm)
6 pcs
6 pcs
13 pcs
1 pc
Pulley
a. Diameter : 80mm
b. Diameter : 40mm
1 pc
1 pc
50.00
35.00
50.00
35.00
Aluminium plate for motor

base
a. Overall size : (134 x 40

x 100)mm
1 pc
80.00
80.00
Views
360.00
207.00
390.00
25.00
52
53
Rotational shaft
(aluminium)
a. Overall Diameter
30mm
b. Overall
length
1000mm
2 pcs
130.00
260.00
Attachment roller
(aluminium)
a. Overall
Diameter
100mm
b. Thickness : 30mm
8 pcs
60.00
480.00
Bearing housing block

(aluminium)
a. Overall size : (94L x

30W x 50H)mm
4 pcs
45.00
180.00
Stabilizer wheel shaft

(aluminium)
a. Overall size : (25H x

25W x 300L)mm
3 pcs
20.00
60.00
53
54
Stabilizer wheel holder
a. Overall size :(94L x

30W x 50H)mm
3 pcs
30.00
90.00
Welding gun holder

i. Welding gun arm
ii. Welding gun holder
iii. Welding gun clamp 1
iv. Welding gun clamp 2
Overall dimension: (130 x

130 x 50)mm
1 set
265.00
265.00
Acrylic Plate (Transparent

Dark)
a. (1000H x
3Thick)mm
b. (600H x
3Thick)mm
1 pc
2 pcs
75.00
60.00
75.00
120.00
1 pc
120.00
120.00
10
Switch Box
(Mild steel plate)
600W
600W
Overall dimension: (350 x

285 x 190)mm
54
55
11
12
Additional Cabinet
(Mild steel plate with paint
coating)
Overall dimension:
i. (520 x 420 x 20)mm
ii. (915 x 420 x 20)mm
iii. (450 x 420 x 20)mm
Earth channel connector

(Copper)
Overall dimension : (38 x

30 x 23)mm
2 pcs
3 pcs
2 pcs
1 pc
100.00
150.00
75.00
30.00
200.00
450.00
150.00
30.00
Total 3,627.00
Table 3.28 : BOM for Standard parts
Standard Part
No. Components
1
Speed control motor c/w

gear head[24]
Specification
Model :
GGMK91G40NC-SU
Speed :1250 rpm
Gear ratio : 1 : 150
Voltage :230V
Quantity
1 unit
Price
(RM)
810.00
Amount
(RM)
810.00
View
55
56
Ball bearing
Inner Diameter :11mm

Outer Diameter :35mm
Thickness :10mm
4 pcs
2.00
8.00
Rubber wheel c/w mounting
Diameter :50mm
4 pcs
20.00
80.00
Steel connector bush
Diameter :18mm
Thick : 12mm
60 pcs
2.00
120.00
Allen cap screw:

M4 x 20mm
M6 x 16mm
M6 x 20mm
M8 x 30mm
Material : Stainless steel

Thread type : Metric
20 pcs
60pcs
12pcs
40 pcs
1.20
1.30
1.40
1.60
24.00
78.00
16.80
64.00
56
57
M6 half round nut
Material : Carbon steel

with sliding steel
ball
80 pcs
3.00
240.00
Door hinge
Material : Hard plastic
4 pcs
3.00
12.00
Rubber reinforced belting
Material : Reinforced
rubber
Length : 610mm
1 pc
8.00
8.00
Stabilizer wheel
Material : Rubber
2 pcs
24.00
48.00
57
58
10
Double acting cylinder
Brand : TPC Pneumatic

Model : AXSL20-100S
Bore size :20mm
Stroke :50mm
Material :Stainless steel
1 pc
197.00
197.00
11
Pneumatic tubing
Brand : TMC Pneumatic

Material : PVC
1 lot
50.00
50.00
12
5/2 way valve with single

pilot and spring return

Model :DP301
1 pc
105.00
105.00
13
3/2 way selector valve with

spring return

Model :DM230-01S
1 unit
190.00
190.00
58
59
14
1 way flow control valve

Model :TAS2201F
2 unit
18.00
36.00
15
Relay with base
Brand : Omron
Volt : 240V
2 set
24.00
48.00
16
Selector switch
Brand : Omron
Volt : 240V
Types : 3 selector switch
1 pc
16.00
16.00
17
Cable (1.5mm)
Color: Red
Type : Single wire
1 roll
25.00
25.00
Total
2,175.80
Total estimation price for purchase the standard and custom part for this project = RM 3,627.00 + RM 2,175.00
59
= RM 5,802.80 (without fabrication cost)
60
3.8
Project Costing
The estimation of the project cost is evaluated by calculated between a few

criteria as list as below:
i.
Custom made cost (including material cost)
ii.
Standard part cost
iii.
Design cost
iv.
Fabrication cost (Labor + Utilities + Tooling)
v.
Total cost
As the custom made and standard part price already evaluated before on BOM, the next
evaluation are focusing on design, fabrication and total cost of the projects.
3.8.1
Design cost
Design cost for the project is evaluated on the cost of ideas, software design
(SolidWorks 2009), part and fabrication as proposed. The list of cost is as table 3.29
below:
Table 3.29 : Estimation of design cost

NO.
Cost Criteria
Quantity
1
2
3
Creation of ideas
Design cost for all custom parts
Fabrication purposed (for suitable
parts used and machining)
1 lot
18 unit
18 unit
Unit
Price
(RM)
200.00
50.00
20.00
Amount
(RM)
TOTAL
1,460.00
200.00
900.00
360.00
61
3.8.2 Fabrication cost
The fabrication costs are including with the use of tools and labor cost or every types of machining in rate/hour. The estimation
of the fabrication cost is as table 3.30 below:
Table 3.30 : Estimation of fabrication cost.

Machine type
EDM Wire cut
Conventional Milling
Parts to Fabricated
Quantity
Time
Used
(hours)
9.0
Rate per
hour
(RM)
30.00
270.00
360.00
90.00
105.00
120.00
45.00
990.00
20.00
10.00
20.00
10.00
30.00
40.00
80.00
40.00
61
1. Attachment roller (cutting

8 pcs
by thickness)
2. Workpiece (114mm)
5 pcs
12.0
3. Motor support plate
1 pc
3.0
4. Welding gun clamp 1
1 pc
3.5
1 pc
4.0
6. Stabilizer wheel holder
3 pcs
1.5
TOTAL COST OF EDM WIRE CUT
1. Motor support plate
1 pc
0.5
20.00
2. Stabilizer wheel plate
2pcs
0.5
3. Stabilizer wheel shaft
2 pcs
1.0
4. Welding gun arm
1 pc
0.5
5. Welding gun holder
1 pc
1.5
6. Earth channel connector
1 pc
2.0
7. Aluminium
frame 19 pcs
4.0
(connector bush mounting)
8. Stabilizer Wheel holder
2 pcs
2.0
Amount
(RM)
62
Conventional Turning
1. Rotational shaft
2. Attachment
roller
knurling process)
CNC Turning
1. Attachment roller
formation)
2. Drive pulley
3. Driven pulley
Power Saw Cutting
1. Workpiece
cutter
74mm,
88mm
101mm)
3. Aluminium frame
TOTAL COST OF CONV. MILLING

2 pcs
3.0
18.00
(for
8 pcs
1.0
250.00
54.00
18.00
TOTAL COST OF CONV. TURNING

(shape
8 pcs
4.0
35.00
72.00
140.00
1 pc
1 pc
1.5
1.5
TOTAL COST OF CNC TURNING

(for 15 pcs
1.5
10.00
and
2 pcs
19 pcs
0.25
1.5
52.50
52.50
245.00
15.00
2.50
15.00
62
63
CNC Milling
MIG Welding Unit
Shearing Machine
TOTAL COST OF POWER SAW CUTTING

1. Bearing housing
4 pcs
2.0
35.00
32.50
70.00
TOTAL COST OF CNC MILLING

1. Workpiece circumferential 45 times
11.5
20.00
joint fabrication
70.00
230.00
TOTAL COST OF MIG WELDING UNIT

1. Control box
1 set
1.0
10.00
2. Additional cabinet (1.5mm
7 pcs
2.0
mild steel plate)
230.00
10.00
20.00
63
64
Bending Machine
Drilling
TOTAL COST OF SHEARING MACHINE

1. Control box
1 set
1.0
10.00
2. Additional cabinet (1.5mm
7 pcs
2.0
mild steel plate)
30.00
10.00
20.00
TOTAL COST OF BENDING MACHINE

1. Drive pulley (for tapping)
1 pc
0.17
10.00
2. Driven pulley (for tapping)
1 pc
0.17
3. Stabilizer wheel plate
2 pcs
0.17
2 pcs
0.17
5. Welding gun arm
1 pc
0.25
6. Welding gun holder
1 pc
0.25
1 pc
0.25
1 pc
0.25
9. Earth channel connector
1 pc
0.5
10. Dark acrylic transparent
3 pcs
0.5
plate
11. Control box
1 set
1.0
12. Stabilizer wheel holder
2 pcs
0.17
13. Additional cabinet
7 pcs
1.0
30.00
1.70
1.70
1.70
1.70
2.50
2.50
2.50
2.50
5.00
5.00
10.00
1.70
10.00
64
65
Disk Cutter
TOTAL COST OF DRILLING MACHINE

1. Workpiece
(74mm, 30 pcs
2.0
10.00
88mm and 101mm) for
length 100mm
48.50
20.00
TOTAL COST OF DISK CUTTER
20.00
TOTAL FABRICATION COST FOR ALL MACHINING PROCESS
2,018.00
*The details of estimation cost for fabrication the projects is as Appendix A2.
*Some of the standard part price is as quotation in Appendix C.
Total cost to manufacture this project (Welding fixture)
= Custom Made Part Cost
= 3,627.00
+ Standard Part Cost
+ 2,175.80
+ Fabrication Cost
+ 2,018.00
+ Design Cost
+ 1,460.00
= RM 9,280.80
65
66
CHAPTER 4
METHODOLOGY
4.1
Experimental preparation
The preparation of experiment will include the welding equipment

(Circumferential welding apparatus) and the cylindrical shape of workpiece (piping and
tank). The experiment will conduct by following 3 major steps as below.
Step 1: Setup the workpiece (figure 4.1)
1.
The workpiece are being setup by using the cylindrical shape (commonly piping
and tank) which in pairs (same diameter and same thickness)
2.
Place the workpiece on top of the rotational shaft. Set the rotational shaft on
certain distance between each other depends on the diameter size of workpiece.
Determination of distance between rotational shaft is as being evaluated before
on chapter 3 section 3.4 (Project design). Align the workpiece using dial
indicator.
67
3.
Tight it by using the stabilizer wheel by extended its square sliding shaft. The
stabilizer is use to guide the workpiece on tracks of drive rotational roller
without slip or misplace.
Figure 4.1 Setup workpiece to the fixture
Step 2: Setup the welding nozzle (figure 4.2)
1.
As the workpiece are already on position and tight up, set the welding nozzle as
between 45 to 60 angle to the workpiece. The proper distance of nozzle to the
workpiece will be setup when the actual model already on action.
2.
The nozzle will be on position between the pairs of the workpiece. The nozzle
will be grasped by the adjustable holder which being control by linear
movement and by the angles
a) Nozzle angle to wrokpiece b) Nozzle position on welding

arm
Figure 4.2 Setup the nozzle to correct position with the workpiece
68
Step 3: Start-up the workpiece movement (figure 4.3)
1.
Workpiece rotational will move by rotating of drive shaft at the bottom which
link together with speed control motor.
2.
On the certain speed after determination of workpiece feed been done, the
pneumatic trigger will pull up the shaft and start the gas flow and the feed of the
wires.
3.
The rotational of workpiece must come first before the triggering, to sure the
effective welding on the initial condition.
4.
Test run the rotational of the workpiece to as confirmation of the welding wires
are in position along the workpiece.
5.
By manual observe, the welding process will taking on action until the end
position of rotation which need the operator to shut off the trigger and stop the
workpiece rotation.
6.
By loose all the grasp part, workpiece are being taking out and check the weld
part.
7.
Check the welding quality and use the multiple of parameter setting (voltage,
ampere and travel speed) for actual running.
a) Process during triggering
b) Output after welding
Figure 4.3 Start-up to rotate the workpiece and welding process
69
2. Workpiece Chamfering
1. Workpiece Preparation
3. Setup Workpiece on
Welding Apparatus
8. Retract the triggering

and stop the rotation
6. Triggering the
pneumatic cylinder and
start the welding
process
7. Welding progress in
constant rotation
4. Select Motor Speed and

Workpiece Rotation
5. Selection of voltage
and wire feed
9. Output from the

welding process
69
Figure 4.4 Simplification view the steps of circumferential welding processes on welding fixture
70
4.2
Material specification
Mild steel is the most common form of steel as its price is relatively low while it
provides material properties that are acceptable for many applications. Low carbon steel
contains approximately 0.050.15% carbon and mild steel contains 0.160.29% carbon,
therefore it is neither brittle nor ductile (figure 4.5). Mild steel has a relatively low
tensile strength, but it is cheap and malleable, surface hardness can be increased through
carburizing. For many applications, preheating is not required except on thick sections,
highly restrained joints, or where codes required pre-heating (Pressure vessels,
DANotes, www.school.mech.edu.au).
As the material becomes a workpiece for this project, the requirement of specific
criteria is illustrated as in table 4.1 below.
Table 4.1 : Workpiece material characteristic

Materials
Shape
Mild steel
(Piping
and tank)
Cylindrical hollow
Material properties
Welding
Characteristic
1. Contain
low 1. For low carbon
carbon with 0.16
steels,
the
0.29% C.
weldability
is
excellent.
Figure 4.5 Comparison strength between the carbon contain on mild steel (Pressure
vessels, DANotes, www.school.mech.edu.au).
71
4.3
Welding parameters
The parameters that being conducted and investigated for this project which
effected to the quality of circumferential welding to the piping and tank are welding
voltage, current and travel feed speed. The aims of selecting the parameters is caused
of the major control of welding process which formation of the weld bead that effecting
items such as bead width, bead height, depth and penetration. These are the best
controls over welding because there are correctly measured and can continually
adjusted over a wide range (Martha A. Baker, 1995).
4.3.1
Welding voltages.(V)
a) Fine voltage regulator
b) Voltage selector
Figure 4.6 Voltage regulator on MIG welding unit (Miller Migmatic)
The welding voltage or arc voltage is determined by the distance between the tip
of the electrode and the workpiece. In a constant voltage system, the welding voltage is
adjusted by the knob on the front of the power source (figure 4.6) because the machine
maintains a given voltage which maintains a certain arc length. In a constant current
72
system, the welding voltage is controlled by the arc length held by the welder or
equipment and the voltage sensing wire feeder. The arc voltage required for an
application is dependent on the electrode size, type of joint and base metal thickness
(Martha A. Baker, 1995).
For this project, the dependent variables are fixed base on current facilities has
at KKTM Balik Pulau. From experiences, when the other parameters are held constant
and the arc voltage is increased, the weld bead becomes flatter and wider. The
penetration will increase up to an optimum voltage level and then begin to decrease as
illustrated in figure 4.7.
Figure 4.7 Determination of proper setting on voltage (Martha A. Baker, 1995).
73
4.3.2
Welding current (Amp)
The amount of welding current used has the greatest effect on the deposition rate,
the weld bead size and shape and the penetration of the weld. In constant voltage system,
the welding current is controlled by the knob on the wire feed speed. As the wire feed
speed is increased, the welding current is increases. In a constant current system, the
welding current is set by a knob on the front of the welding machine. An investigation
will carried out to determine the best of the current will be set especially for tank and
piping fabrication (Martha A. Baker, 1995).
4.3.3
Travel speed
The travel speed is the rate at which the arc travels along the workpiece. The
travel speed is controlled by the adjustable speed control motor. Increasing and
decreasing speed from this point will reduce the amount of penetration. When the travel
speed is decreased, the amount of filler metal deposited per unit length increases which
creates a large, shallow weld puddle. Weld metal tends to get slightly ahead of the arc
which reduces the amount of penetration and produces a wide weld bead. Reducing the
travel speed will increase the bead height as illustration on figure 4.8 (Martha A. Baker,
1995). Determination of the proper setting of travel speed for cylindrical shape
fabrication on the circumferential welding site will be analyzes.
74
Figure 4.8 Determination of proper setting on travel speed (Martha A. Baker, 1995).
4.4
Testing and analysis
The testing that being conducted under this project consist of tensile test,
hardness test and impact test. The testing will be located at Universiti Sains Malaysia
(USM) Nibong Tebal, Pulau Pinang which the preparation of the workpiece will be
welded at KKTM Balik Pulau.
75
4.4.1
Tensile Test
The tensile test is used to determine the tensile properties of a material. Included
in the tensile properties of a material is the tensile strength. The tensile strength of a
material is the maximum tensile stress that may be developed in the material. As the
guidelines mention on the ASME standard of welding joint testing, the tensile test is the
major destructive test to evaluate the strength of joint by pairs of steel as the workpiece
(Dyer E.Carroll and Dyer E.Carroll Jr. (1997).
To conduct a tensile test, a suitable workpiece by shape and size must be

suitable. This workpiece must have known cross-sectional area and suitable gage length
for the test conditions. Once a suitable test workpiece has been obtained, the workpiece
is loaded into the test machine using the proper grippers. The actual machine that being
use for testing the workpiece are as in the figure 4.9 below.
Figure 4.9 Tensile Strength Tester
76
As the applicable of specimen used for the tensile test, the workpiece are being
cut in a single cross-section. The suitable purposed for the shape of workpiece are as
illustrated in figure 4.10. The simplification of steps to prepare the workpiece specimen
is as on figure 4.11.
Welded joint
Figure 4.10 Workpiece shape for testing and analysis
77
2. Cleaning from dust

1. Output from
and paint for current
welding processes
flow purposes
(Polishing by hand
grinding)
9.
Workpiece break on
maximum load and
displacement
3. Setup workpiece on
the EDM wire cut
machine
8. Setup the workpiece on

tensile strength tester
4. Setup workpiece by
circumferential cutting
using MDI mode on
EDM
5. Double siding
for length 100mm
(50mm from center of
welding bead)
7. Polishing of surfaces
and welding bead
6. For single cutting, will

cut for 2 pieces
simultaneously
10. Result after tensile

testing
77
Figure 4.11 Workpiece preparation and result by tensile test
78
4.4.2
Hardness test
The principle behind the hardness test involves the idea that hardness is
measured by resistance to indentation, which serves as the basis for a variety of
instruments. As the guidelines provide by the ASME standard, the hardness test are
required to the specimen which correlative with the tensile strength. The Rockwell Test,
one of the older tests for hardness will be applied. The Rockwell scale is
a hardness scale based on the indentation hardness of a material. The test determines the
hardness by measuring the depth of penetration of an indenter under a large load
compared to the penetration made by a preload. There are different scales, which are
denoted by a single letter, that use different loads or indenters. The result, which is a
dimensionless number, is noted by HRB where B is the scale letter for the steel soft
material (e.g Low carbon mild steel)
When testing metals, indentation hardness correlates linearly with tensile

strength. This important relation permits economically important of destructive testing
of bulk metal deliveries with lightweight, even portable equipment, such as hand-held
Rockwell hardness testers.
The Rockwell tester is as illustrated of figure 4.12 and the scale categories are as
table 4.2.
Figure 4.12 Rockwell Hardness Tester
79
Table 4.2 : Rockwell hardness scale (Rockwell Scale, Encyclopedia).
Various Rockwell scales
Scale Abbreviation
A
HRA
B
HRB
Load (kgf)
60
100
C
D
E
HRC
HRD
HRE
150
100
100
HRF
60
HRG
150
Indenter
Use
120 diamond cone Tungsten carbide
1/16 in diameter Aluminium,
steel sphere
brass, and soft
steels
120 diamond cone Harder steels
120 diamond cone
1/8 in diameter
steel sphere
1/16 in diameter
steel sphere
1/16 in diameter
steel sphere
The workpiece are being positioned in 2 axis of test which is determined the hardness
on top and on side of welding bead. The workpiece position is as on figure 4.13 below
and the preparation step of specimen is on figure 4.14.
a) Tested from top position
b) Tested from side position
Figure 4.13 Workpiece position on Rockwell Hardness Tester
80
2. Cleaning from dust

1. Output from
and paint for current
welding processes
flow purposes
(Polishing by hand
grinding)
9.
Setup the workpiece

on hardness tester for
side position (X axis).
3. Setup workpiece on
the EDM wire cut
machine
8. Setup the workpiece on

hardness tester for top
position (Y axis).
4. Setup workpiece by
using MDI mode on
EDM
7. Polishing of surfaces
and welding bead
5. Double siding
for length 100mm
(50mm from center of
welding bead)
6. For single cutting, will

cut for 2 pieces (10mm
thick) simultaneously
Figure 4.14 Workpiece preparation and result by hardness test

80
81
4.4.3
Impact Test
Impact test is used to measure the transfer of energy required to break a given
volume of material. Impact strength is then an indication of how well a material can
withstand shock loading. Because energy cannot be created or destroyed, the energy in
the impact must be released through different channels. The application to the project
workpiece for testing are based on strength of the welded joint to determined the best
result for the welding parameter are being set.
The object of the impact test is to determine the work done in breaking the
object under a sudden blow. This can be accomplished by dropping a known weight on
the workpiece material from a known height. Schematic view of the impact test is as
figure 4.15 below.
Figure 4.15 Izod Impact Tester schematic view (Izod Impact test, Encyclopedia).
82
The Izod test involves striking a suitable test piece with a striker, (figure 4.16)
mounted at the end of a pendulum. The test piece is clamped vertically with the notch
facing the striker. The striker swings downwards impacting the test piece at the bottom
of its swing (Impact test, Wikipedia, Free Encyclopedia).
Figure 4.16 Strike of impact energy on workpiece (Izod Impact Test, Encyclopedia)
The setup for impact test being done for this project is given as figure 4.17 below.
a) Izod Impact Tester machine
b) Level setup for impact
Figure 4.17 Workpiece setup on impact tester
83
4.4.4
Welding structure
After all destructive test is done on setup and evaluate its criteria, the next
evaluation of welding quality can be determined by viewing its welding joint structure
on the specimens. It will show the construction of welding bead, penetration and also its
heat affected zone (HAZ) is developing by the effect of parameters setup. The
construction structure is as figure 4.18 below.
Welding Bead
Welding Penetration
Heat
Affected
Zone
Figure 4.18 Welding joint structure on specimen
84
4.5
ASME standard and application
The American Society of Mechanical Engineers (ASME) is a professional body,

specifically an engineering society, focused on mechanical engineering. The ASME was
founded in 1880 by Alexander Lyman Holley, Henry Rossiter Worthington, John
Edison Sweet and Matthias N. Forney in response to numerous steam boiler pressure
vessel failures. The organization is known for setting codes and standards for
mechanical devices. The ASME conducts one of the world's largest technical publishing
operations through its ASME Press, holds numerous technical conferences and
hundreds of professional development courses each year, and sponsors numerous
outreach and educational program (Molinder L.Nayyar, 2000).
For this project, the similarity of using the ASME codes for standard and
procedures are apply as in the boiler and pressure vessels. The application of ASME
standard is being focused on the testing the material or generally conducted on
destructive test.
4.5.1
ASME codes and application
The available information code provide by the ASME that could applied was
B31.9 (for building services and piping) for guidelines of pipe welding and ASME WPS
B2.1-1-201-96 or ASME WPS B2.1 -1-209-96 (welder certification test-pipe).
85
The B31.9 code (J.Philip Ellenberger, P.E, 2004), prescribes minimum
requirements for the piping systems contained water for heating and cooling, steam and
steam condensate, air, combustible liquids and other nontoxic, nonflammable fluids in
industrial, institutional, commercial and public buildings, or multi-unit residences These
requirements cover:
i.
Design
ii.
Materials
iii.
Fabrication
iv.
Installation
v.
Inspection
vi.
Examination
vii.
Testing
This code applies to piping containing piping not exceeding the following:
i.
Dimensional limits
Carbon steel: NPS 42 (DN 1050) and 0.500 (12.7mm) wall
Stainless steel: NPS 24 (DN 600) and 0.500 (12.7mm) wall
Aluminum: NPS 12 (DN 300)
Brass and copper NPS 12 (DN 300), 12.125 (308 mm) for
copper tube.
ii.
Thermoplastics: NPS 24 (DN 600)
Ductile Iron: NPS 24 (DN 600)
Reinforced Thermosetting Resin: NPS 24 (DN 600)
Pressure and temperature limits
Compressed air, steam and steam condensate to 1035 kPa (150

psi) gage
Steam and steam condensate from ambient to 186C (366F)
Other gases from ambient to -18 to 93C (0 to 200F)
Liquids to 2415 kPa (350 psi) gage and from -18 to 121C (0 to
250F)
86
The code does not apply to certain types of piping already covered by local
codes and other ASME standards. For example, B31.9 does not cover:
i.
Refrigeration Piping
ii.
Potable water piping
iii.
Sanitary and storm drainage systems
iv.
Fire protection
v.
Other fuel piping
By involve with the MIG welding method of joining B31.9 requires that the
operator must carrying with a "welding procedure specification (WPS)," which is a
"recipe" for making a weld. The WPS describes the base metals that may be welded, the
welding process, the electrode or filler metal, the groove design to be used, the preheat
temperature and post-weld heat treatment that is required and other welding conditions.
4.5.2
ASME certification (J.Philip Ellenberger, P.E, 2004)
Figure 4.19 below shows the layout of the actual certification test.
Figure 4.19 Layout certification test
87
Table 4.3 : Standard guidelines of ASME applications chart (J.Philip Ellenberger, P.E, 2004)
87
88
CHAPTER 5
RESULT AND DISCUSSION
5.1
Introduction
Criteria of selections for fabrication fixture as obtained on chapter 3 is being

concluded that the concept no.3 is the best criteria to fulfill the optimum requirements
to suit the constant speed of rotational. The circumferential method of welding is
applied on this model/fixture which determined the best output to implement of the
workpiece joint (cylindrical shape).
The part of the workpiece is be cut using the specimen cutter provide at USM
Nibong Tebal and the result of the quality welding by multiple setting on the MIG
welding unit (voltage, current and travel speed) is analyze. As the cylindrical
requirement to stand with the load, the mechanical destructive test is applied on the
workpiece that being used to relate with the quality of the welding joint.
The result for the circumferential welding joint is evaluated on its impaction test,
tensile test and hardness test. The illustrated welding joint, effect by MIG welding on
cylinder shape can be seen on figure 5.1.
89
Heat Affected Zone
Welding Bead
Figure 5.1 Welding by circumferential joint on cylindrical shape
5.2
Destructive Test
In destructive testing, sample portion of the welded specimen is required. These

samples are subjected to loads until they actually fail. The failed pieces are then studied
and compared to known standards to determine the quality of the weld. The most
common types of destructive testing are known as tensile test, impact test of welding
joint and hardness tester to evaluate the stand of welding (Destructive test,
Encyclopedia).
As the circumferential joint of welding, the test actually shows that the
fabrication fixture is produced the good quality of joint by its constant feed.
90
5.3
Result of testing
As been mention before, the parameters being set on the welding unit to conduct
the welding test is a voltage, amperes and the travel speed of workpiece. Exactly the
voltage and travel speed can be regulate for welding test but the amperes is
automatically determination by the welding unit itself which is depends on the arc
length and voltage selected. The result on table 5.1 and table 5.2 will shows the
regulation of setting by voltage and the travel speed during welding.
5.3.1
Criteria of welding joint by voltage regulation
Table 5.1 : Setup by regulation of voltage

Setup
no.
Voltage
Voltage
Motor
Wire
Ampere
Gas
Welding
regulator
value
speed
feed
selector Pressure Quality
selector (on
(V)
selector selector
(L/min)
welding unit)
1
2
7.1
2
2
A
5
b
2
3
8.6
2
2
A
5
b
3
4
10.0
2
2
A
5
a
4
5
13.3
2
2
A
5
b
5
6
15.5
2
2
A
5
c
6
6
15.3
2
2
A
5
c
*Welding quality = a. Good b. Intermediate c. Bad
91
Figure 5.2 Result on workpiece by regulation of voltage
By refer to figure 5.2 and table 5.1, the criteria of welding joint produce on the
workpiece is as below, based on its voltage selection.
i.
The voltage selector is 2, too low to suit with the speed of rotation
workpiece. Produce too thin of welding width.
ii.
The voltage selector is 3, still low to produce a good quality of joint. It s

produce a thin welding width.
iii.
The voltage selector is 4, an ideal voltage selector and suit with the
workpiece rotation speed. It produced a good welding width and totally
penetrated the joint which required for good strength.
iv.
The voltage selector is 5 and little bit higher, but still produced a good
welding width on certain joint only.
v.
The voltage selector is 6 and quietly higher, which produce bad of

welding joint.
vi.
The voltage selector was 6, and tried to increase the speed of workpiece
but still producing a bad welding joint.
92
5.3.2
Criteria of welding joint by travel speed regulation
Table 5.2 : Setup by regulation of travel speed

Setup
no.
Voltage Motor
value
speed
(V)
selector
Workpiece
Wire
Ampere
Gas
Welding
Speed
feed
selector Pressure Quality
Value
selector
(L/min)
(mm/s)
1
10.1
3.0
2.35
2
A
5
c
2
10.0
2.5
1.85
2
A
5
c
3
10.0
2.0
1.48
2
A
5
b
4
10.3
1.5
0.82
2
A
5
b
5
10.4
1.0
0.59
2
A
5
a
*Welding quality = a. Good b. Intermediate c. Bad
Figure 5.3 Result on workpiece by regulation of travel speed
By referring to figure 5.3 and table 5.2, the selecting of motor speed that will
affect the travel speed by good welding width is the selection no.5. Other selection is
produce too thin of welding width which not a good joint for welding and also produce
a light strength.
93
5.3.3
Result of tensile test
The result by tensile test is conducted by types of workpiece diameter. Every

diameter is tested by using 5 pieces of specimens with different setting parameters of
welding except workpiece 114mm with 4 pieces specimen only.
5.3.3.1 Result 1 (74mm)
Table 5.3 : Tensile test description setup for workpiece 74mm

Machine Setup (Instron)
Series IX version 8.25.00
Version date
Sample ID
Test Date
Test Type
Method
Operator Name
Edit date
Units
Geometry
Number of specimens
Number of channels
Machine type
Machine Control
Data Rate
Extensometer
Crosshead Speed
Second Speed
Temperature
Humidity
Auto-start
: 07 May 2002
: Tensile
: 23 Mar 2010
: Tensile
: 96
: Huzaimi Hamid
: 00 Mar 2000
: SI
: Rectangular
:5
:2
: ------: STANDARD
: 5.000000 pts/sec
: Disabled
: 5.00000 mm/min
: ------: 73 Deg F
: 50 %
: Disabled
94
Input Data (Specimen 1)
User Defined Fields:
1:[
][
2:[
][
3:[
][
4:[
][
5:[
][
]
]
]
]
]
Auxiliary Sample Inputs:

1: 0.000000
2: 0.000000
3: 0.000000
4: 0.000000
5: 0.000000
6: 0.000000
7: 0.000000
8: 0.000000
9: 0.000000
Sample comments:
Specimen
Test end reason
Width
Thickness
Spec gauge length
Ext. gauge length
Specimen label
Number of data points
Maximum Load point
Maximum Load
Maximum Extension point
Maximum Extension
Second Speed point
Second Speed Extension
Relaxation Start point
Range Change point
Extensometer Removal point
: 1 (74mm)
: Break detected
: 20.0000000 mm
: 2.0000000 mm
: 40.0000000 mm
: 60.0000000 mm
:[
]
: 44
: 38
: 5.32236 kN
: 44
: 1.88566 mm
: ------: ------: ------: ------: -------
95
Results (Specimen1)
Displacement
Load
1,
2,
3,
4,
5,
6,
7,
8,
9,
10,
11,
12,
13,
14,
15,
,
,
35,
36,
37,
38,
39,
40,
41,
42,
43,
44,
0.000000, 0.000236
0.015107, 0.049694
0.032625, 0.161826
0.049929, 0.409346
0.066375, 0.636009
0.083089, 0.852453
0.100071, 1.047544
0.116518, 1.210326
0.133286, 1.338287
0.149893, 1.443283
0.166500, 1.533942
0.183482, 1.615125
0.199928, 1.684924
0.216482, 1.750917
0.233411, 1.810175
..,
..
..,
..
1.299963, 4.626258
1.383267, 4.906097
1.466731, 5.157223
1.550195, 5.322363
1.583302, 4.962686
1.666552, 4.820635
1.749909, 4.851501
1.833588, 4.390433
1.866909, 4.057148
1.885660, -0.163855
View
Break at welding joint
96
1:[
][
2:[
][
3:[
][
4:[
][
5:[
][
]
]
]
]
]

1: 0.000000
2: 0.000000
3: 0.000000
4: 0.000000
5: 0.000000
6: 0.000000
7: 0.000000
8: 0.000000
9: 0.000000
Sample comments:
Specimen
Test end reason
Width
Thickness
Spec gauge length
Ext. gauge length
Specimen label
Maximum Load point
Maximum Load
Maximum Extension
Second Speed point
Range Change point
: 2 (74mm)
: Break detected
: 20.0000000 mm
: 2.0000000 mm
: 40.0000000 mm
: 60.0000000 mm
:[
]
: 135
: 120
: 10.71079 kN
: 135
: 6.03364 mm
: ------: ------: ------: ------: -------
97
Results (Specimen 2)
Displacement
Load
1,
2,
3,
4,
5,
6,
7,
8,
9,
10,
11,
12,
13,
14,
15,
,
,
116,
117,
118,
119,
120,
121,
122,
123,
124,
125,
126,
127,
128,
129,
130,
131,
132,
133,
134,
135,
0.000000, 0.000468
0.015054, 0.068952
0.032571, 0.270200
0.049875, 0.524607
0.066429, 0.791493
0.083089, 1.045423
0.100071, 1.280397
0.116464, 1.501861
0.133232, 1.713324
0.149839, 1.905829
0.166446, 2.091377
0.183428, 2.264145
0.199875, 2.424346
0.216428, 2.584825
0.233357, 2.735122
.,
.,
4.716479, 10.654601
4.799783, 10.667458
4.883354, 10.680214
4.966764, 10.697266
5.050336, 10.710791
5.133479, 10.457432
5.216568, 9.744572
5.234086, 8.198228
5.316960, 7.755831
5.383443, 7.059618
5.400318, 5.926848
5.483246, 5.619664
5.566604, 5.472607
5.650067, 5.023397
5.699996, 4.189854
5.783460, 3.729339
5.833817, 2.688807
5.916746, 2.258062
6.000210, 1.759744
6.033638, 0.112192
View
98
1:[
][
2:[
][
3:[
][
4:[
][
5:[
][
]
]
]
]
]

1: 0.000000
2: 0.000000
3: 0.000000
4: 0.000000
5: 0.000000
6: 0.000000
7: 0.000000
8: 0.000000
9: 0.000000
Sample comments:
Specimen
Test end reason
Width
Thickness
Spec gauge length
Ext. gauge length
Specimen label
Maximum Load point
Maximum Load
Maximum Extension
Second Speed point
Range Change point
: 3 (74mm)
: Break detected
: 20.0000000 mm
: 2.0000000 mm
: 40.0000000 mm
: 60.0000000 mm
:[
]
: 102
: 84
: 9.13682 kN
: 102
: 4.39998 mm
: ------: ------: ------: ------: -------
99
Displacement
Load
1, 0.000000, 0.001383
2, 0.015000, 0.136139
3, 0.032625, 0.254017
4, 0.049929, 0.405965
5, 0.066429, 0.585177
6, 0.083143, 0.766815
7, 0.100071, 0.936895
8, 0.116464, 1.095732
9, 0.133286, 1.236457
10, 0.149893, 1.347201
11, 0.166500, 1.448333
12, 0.183482, 1.537956
13, 0.199928, 1.615268
14, 0.216482, 1.687543
15, 0.233411, 1.752719
, ,
..
, ,
..
83, 3.299837, 9.128288
84, 3.316819, 9.136821
85, 3.399908, 9.101103
86, 3.483426, 8.898427
87, 3.516747, 8.386639
88, 3.566783, 7.638560
89, 3.600426, 6.953921
90, 3.633587, 6.388727
91, 3.666694, 5.906316
92, 3.716569, 5.425162
93, 3.783480, 4.879141
94, 3.849962, 4.343500
95, 3.933265, 3.891210
96, 4.016837, 3.389708
97, 4.066979, 1.911237
98, 4.150014, 1.716047
99, 4.233587, 1.526140
100, 4.316730, 1.061446
101, 4.383426, 0.367259
102, 4.399979, -0.125230
View
100
1:[
][
2:[
][
3:[
][
4:[
][
5:[
][
]
]
]
]
]

1: 0.000000
2: 0.000000
3: 0.000000
4: 0.000000
5: 0.000000
6: 0.000000
7: 0.000000
8: 0.000000
9: 0.000000
Sample comments:
Specimen
Test end reason
Width
Thickness
Spec gauge length
Ext. gauge length
Specimen label
Maximum Load point
Maximum Load
Maximum Extension
Second Speed point
Range Change point
: 4 (74mm)
: Break detected
: 20.0000000 mm
: 2.0000000 mm
: 40.0000000 mm
: 60.0000000 mm
:[
]
: 290
: 222
: 11.14294 kN
: 290
: 13.15087 mm
: ------: ------: ------: ------: -------
101
Displacement
Load
1, 0.000000, 0.001111
2, 0.015054, 0.075155
3, 0.032625, 0.149999
4, 0.049929, 0.305316
5, 0.066429, 0.505388
6, 0.083143, 0.707839
7, 0.100071, 0.908831
8, 0.116464, 1.095565
9, 0.133232, 1.267442
10, 0.149839, 1.413919
11, 0.166500, 1.548335
12, 0.183428, 1.668391
13, 0.199875, 1.780138
14, 0.216482, 1.891832
15, 0.233357, 1.997996
, ,
.
, ,
.
213, 7.133407, 11.128138
214, 7.216387, 11.127874
215, 7.299852, 11.129399
216, 7.383209, 11.129147
217, 7.466781, 11.132368
218, 7.550299, 11.138824
219, 7.633442, 11.139772
220, 7.716477, 11.140271
221, 7.799834, 11.137908
222, 7.816869, 11.142942
223, 7.899851, 11.140403
230, 8.483298, 11.128259
,
..., .
,
..., .
284, 12.833401, 5.085205
285, 12.899938, 4.459299
286, 12.966794, 3.826911
287, 13.033384, 3.165937
288, 13.083420, 2.564810
289, 13.133615, 1.559132
290, 13.150866, -0.169886
View
Break out of welding joint
102
1:[
][
2:[
][
3:[
][
4:[
][
5:[
][
]
]
]
]
]

1: 0.000000
2: 0.000000
3: 0.000000
4: 0.000000
5: 0.000000
6: 0.000000
7: 0.000000
8: 0.000000
9: 0.000000
Sample comments:
Specimen
Test end reason
Width
Thickness
Spec gauge length
Ext. gauge length
Specimen label
Maximum Load point
Maximum Load
Maximum Extension
Second Speed point
Range Change point
: 5 (74mm)
: Break detected
: 20.0000000 mm
: 2.0000000 mm
: 40.0000000 mm
: 60.0000000 mm
:[
]
: 180
: 161
: 11.19357 kN
: 180
: 8.06710 mm
: ------: ------: ------: ------: -------
103
Displacement
Load
1, 0.000000, -0.000094
2, 0.015107, 0.002354
3, 0.032679, 0.015701
4, 0.049929, 0.263131
5, 0.066375, 0.564983
6, 0.083089, 0.836385
7, 0.100018, 1.079732
8, 0.116464, 1.306313
9, 0.133232, 1.512734
10, 0.149786, 1.688719
11, 0.166446, 1.849453
12, 0.183428, 1.995821
13, 0.199875, 2.134805
14, 0.216482, 2.272933
15, 0.233357, 2.403890
, ..., ..
, ..., ..
159, 6.700067, 11.181787
160, 6.783424, 11.188496
161, 6.816799, 11.193575
162, 6.899781, 11.193230
163, 6.983191, 11.179761
164, 7.066549, 11.131734
165, 7.150388, 10.188304
166, 7.183656, 9.547688
167, 7.250031, 8.831704
168, 7.333441, 8.343550
169, 7.416853, 7.971580
170, 7.500210, 7.501284
171, 7.583245, 7.195811
172, 7.666603, 6.698113
173, 7.733620, 5.990498
174, 7.783602, 5.258592
175, 7.817029, 4.658222
176, 7.866959, 4.076417
177, 7.917101, 2.672381
178, 7.933547, 1.988674
179, 8.016638, 1.520993
180, 8.067101, -0.071374
View
Break nearest to welding joint
104
Figure 5.4 Graph Load vs Displacement for workpiece (74mm)
From graph on figure 5.4 above, it shows that the maximum load and
displacement produce was the specimen no.4 which was the highest strength of welding
joint. It also can be shown on the stress vs strain graph on figure 5.5 for the criteria
setting of welding by specimen no.4 which has a maximum value rather than other
specimen.
Figure 5.5 Graph Stress vs Strain for workpiece (74mm)
105
5.3.3.2 Conclusion of the result 1(74mm)
Table 5.4 : Simplification of tensile test for workpiece 74mm
Speci
men
Displacement
at
Max.Load
(mm)
Load at
Max.
Load
(kN)
Maximum
Displacement
(mm)
Modulus
Young
(MPa)
Stress
Max.Load
(MPa)
1
2
3
4
5
Mean
S.D
1.550
5.050
3.317
7.817
6.817
4.910
2.546
5.322
10.711
9.137
11.143
11.194
9.501
2.481
1.886
6.034
4.400
13.151
8.067
6.707
4.254
10,703.9
13,624.6
9,019.5
9,525.0
12,661.3
11,106.8
1,986.0
133.059
267.770
228.421
278.574
279.839
237.532
62.021
Strain at
Max.
Load
(mm/m
m)
0.039
0.126
0.083
0.195
0.170
0.123
0.064
From table 5.4 above, the result shows that the maximum load produced by
specimen 4 and 5 is the highest. Parameter (Voltage) setting at welding unit for all
result is 15.5V (Voltage selector = 6 at welding unit) but the rotation speed of
workpiece is adjustable which specimen 4 is 1.48mm/s (throttle selector = 2) and for
specimen 5 is 2.35mm/s (throttle selector = 3). So, it can be conclude that the best
setting MIG welding unit by using the welding fixture is for specimen 4, which have
maximum displacement rather than specimen 5. Other specimen setup produce low
stand of load and displacement that not being consider.
106
5.3.3.3 Result 2 (88mm)

Version date
Sample ID
Test Date
Test Type
Method
Operator Name
Edit date
Units
Geometry
Number of specimens
Number of channels
Machine type
Machine Control
Data Rate
Extensometer
Crosshead Speed
Second Speed
Temperature
Humidity
Auto-start
Separate Dimension Entry
: 07 May 2002
: Tensile
: 23 Mar 2010
: Tensile
: 96
: Huzaimi Hamid
: 00 Mar 2000
: SI
: Rectangular
:5
:2
: ------: STANDARD
: 5.000000 pts/sec
: Disabled
: 5.00000 mm/min
: ------: 73 Deg F
: 50 %
: Disabled
: Enabled
107
1:[
][
2:[
][
3:[
][
4:[
][
5:[
][
]
]
]
]
]

1: 0.000000
2: 0.000000
3: 0.000000
4: 0.000000
5: 0.000000
6: 0.000000
7: 0.000000
8: 0.000000
9: 0.000000
Sample comments:
Specimen
Test end reason
Width
Thickness
Spec gauge length
Ext. gauge length
Specimen label
Maximum Load point
Maximum Load
Maximum Extension
Second Speed point
Range Change point
: 1 (88mm)
: Break detected
: 20.0000000 mm
: 2.0000000 mm
: 40.0000000 mm
: 60.0000000 mm
:[
]
: 270
: 244
: 14.49354 kN
: 270
: 12.28360 mm
: ------: ------: ------: ------: -------
108
Displacement
Load
1,
0.000000,
0.001940
2,
3,
4,
5,
6,
7,
8,
9,
10,
11,
12,
13,
14,
15,
,
,
0.015000,
0.032518,
0.049875,
0.066429,
0.083143,
0.100125,
0.116464,
0.133286,
0.149893,
0.166500,
0.183482,
0.199875,
0.216482,
0.233357,
..,
..,
0.271645
0.469357
0.658901
0.845410
1.012065
1.140200
1.243975
1.343063
1.425347
1.497595
1.563115
1.619602
1.676407
1.727631
...
...
242,
243,
244,
245,
246,
,
,
10.216440,
10.299850,
10.316726,
10.399815,
10.483225,
..,
..,
14.490742
14.490924
14.493545
14.491021
14.485917
...
...
260,
261,
262,
263,
264,
265,
266,
267,
268,
269,
270,
11.650064,
11.733689,
11.802689,
11.817743,
11.883420,
11.950116,
12.016813,
12.083296,
12.116832,
12.199973,
12.283599,
13.391681
12.973589
7.003596
5.301742
4.567964
3.659966
2.902577
2.076428
1.129466
0.756641
-0.003521
View
109
1:[
][
2:[
][
3:[
][
4:[
][
5:[
][
]
]
]
]
]

1: 0.000000
2: 0.000000
3: 0.000000
4: 0.000000
5: 0.000000
6: 0.000000
7: 0.000000
8: 0.000000
9: 0.000000
Sample comments:
Specimen
Test end reason
Width
Thickness
Spec gauge length
Ext. gauge length
Specimen label
Maximum Load point
Maximum Load
Maximum Extension
Second Speed point
Range Change point
: 2 (88mm)
: Break detected
: 20.0000000 mm
: 2.0000000 mm
: 40.0000000 mm
: 60.0000000 mm
:[
]
: 280
: 249
: 14.44846 kN
: 280
: 12.86206 mm
: ------: ------: ------: ------: -------
110
Displacement
Load
1,
0.000000, 0.001431
2,
3,
4,
5,
6,
7,
8,
9,
10,
11,
12,
13,
14,
15,
....,
....,
248,
249,
250,
....,
....,
270,
271,
272,
273,
274,
275,
276,
277,
278,
279,
280,
0.015054,
0.032625,
0.049875,
0.066375,
0.083089,
0.100071,
0.116518,
0.133286,
0.149839,
0.166500,
0.183482,
0.199928,
0.216482,
0.233411,
...,
...,
10.249922,
10.316726,
10.399815,
...,
...,
12.050295,
12.133385,
12.216582,
12.299884,
12.383349,
12.466760,
12.550331,
12.633474,
12.716455,
12.800027,
12.862063,
0.109075
0.195059
0.450736
0.694973
0.916860
1.125484
1.285428
1.421573
1.528120
1.618399
1.696501
1.762116
1.822219
1.876526
...
...
14.444143
14.448458
14.445530
...
...
4.205191
3.581520
3.064398
2.517999
2.043979
1.667082
1.190579
0.685131
0.023498
0.023327
0.023122
View
111
1:[
][
2:[
][
3:[
][
4:[
][
5:[
][
]
]
]
]
]

1: 0.000000
2: 0.000000
3: 0.000000
4: 0.000000
5: 0.000000
6: 0.000000
7: 0.000000
8: 0.000000
9: 0.000000
Sample comments:
Specimen
Test end reason
Width
Thickness
Spec gauge length
Ext. gauge length
Specimen label
Maximum Load point
Maximum Load
Maximum Extension
Second Speed point
Range Change point
: 3 (88mm)
: Break detected
: 20.0000000 mm
: 2.0000000 mm
: 40.0000000 mm
: 60.0000000 mm
:[
]
: 234
: 208
: 13.80985 kN
: 234
: 10.51687 mm
: ------: ------: ------: ------: -------
112
Displacement
Load
1, 0.000000, 0.001767
2, 0.015107, 0.033748
3, 0.032571, 0.272995
4, 0.049875, 0.508217
5, 0.066375, 0.733266
6, 0.083089, 0.964029
7, 0.100071, 1.183529
8, 0.116464, 1.401788
9, 0.133232, 1.595195
10, 0.149786, 1.748277
11, 0.166446, 1.887397
12, 0.183482, 2.007032
13, 0.199875, 2.107918
14, 0.216482, 2.203317
15, 0.233411, 2.288266
...., ..., ...
...., ..., ...
207, 8.699941, 13.804788
208, 8.733530, 13.809852
209, 8.816620, 13.808717
...., ..., ...
...., ..., ...
224, 9.817440, 6.088964
225, 9.834797, 3.474018
226, 9.916868, 3.112256
227, 10.000119, 2.791448
228, 10.083314, 2.439128
229, 10.166510, 2.072059
230, 10.249922, 1.730140
231, 10.333440, 1.244990
232, 10.416743, 0.838773
233, 10.500261, 0.332124
234, 10.516869, -0.064531
View
113
1:[
][
2:[
][
3:[
][
4:[
][
5:[
][
]
]
]
]
]

1: 0.000000
2: 0.000000
3: 0.000000
4: 0.000000
5: 0.000000
6: 0.000000
7: 0.000000
8: 0.000000
9: 0.000000
Sample comments:
Specimen
Test end reason
Width
Thickness
Spec gauge length
Ext. gauge length
Specimen label
Maximum Load point
Maximum Load
Maximum Extension
Second Speed point
Range Change point
: 4 (88mm)
: Break detected
: 20.0000000 mm
: 2.0000000 mm
: 40.0000000 mm
: 60.0000000 mm
:[
]
: 282
: 246
: 14.87978 kN
: 246
: 12.90101 mm
: ------: ------: ------: ------: -------
114
Displacement
Load
1, 0.000000, 0.001944
2, 0.015054, 0.105744
3, 0.032625, 0.159838
4, 0.049929, 0.362550
5, 0.066375, 0.605233
6, 0.083089, 0.846055
7, 0.100071, 1.060941
8, 0.116464, 1.254655
9, 0.133232, 1.431180
10, 0.149839, 1.580121
11, 0.166446, 1.709422
12, 0.183482, 1.809456
13, 0.199928, 1.887011
14, 0.216482, 1.965654
15, 0.233411, 2.032729
...., ..., ...
...., ..., ...
245, 10.000119, 14.876631
246, 10.083314, 14.879779
247, 10.166458, 14.876706
...., ..., ...
...., ..., ...
272, 12.100224,
273, 12.183580,
274, 12.266725,
275, 12.349813,
276, 12.433170,
277, 12.516580,
278, 12.600206,
279, 12.683563,
280, 12.766652,
281, 12.849849,
282, 12.901010,
1.623842
0.905487
0.029580
0.029341
0.029345
0.029153
0.028953
0.029212
0.029472
0.029323
0.029138
View
115
1:[
][
2:[
][
3:[
][
4:[
][
5:[
][
]
]
]
]
]

1: 0.000000
2: 0.000000
3: 0.000000
4: 0.000000
5: 0.000000
6: 0.000000
7: 0.000000
8: 0.000000
9: 0.000000
Sample comments:
Specimen
Test end reason
Width
Thickness
Spec gauge length
Ext. gauge length
Specimen label
Maximum Load point
Maximum Load
Maximum Extension
Second Speed point
Range Change point
: 5 (88mm)
: Break detected
: 20.0000000 mm
: 2.0000000 mm
: 40.0000000 mm
: 60.0000000 mm
:[
]
: 233
: 201
: 14.99382 kN
: 233
: 10.66676 mm
: ------: ------: ------: ------: -------
116
Displacement
Load
1, 0.000000, 0.000970
2,
3,
4,
5,
6,
7,
8,
9,
10,
11,
12,
13,
14,
15,
....,
.......,
200,
201,
202,
....,
....,
223,
224,
225,
226,
227,
228,
229,
230,
231,
232,
233,
0.015054,
0.032625,
0.049929,
0.066375,
0.083089,
0.100071,
0.116518,
0.133232,
0.149839,
0.166446,
0.183482,
0.199875,
0.216482,
0.233357,
...,
...,
8.050226,
8.083335,
8.166637,
...,
...,
9.833405,
9.916922,
10.000172,
10.083314,
10.166565,
10.249973,
10.333386,
10.416798,
10.500207,
10.583242,
10.666759,
0.141490
0.283830
0.491421
0.733775
0.971306
1.172035
1.345730
1.501914
1.637770
1.767407
1.891464
2.008537
2.129910
2.247029
...
...
14.990121
14.993821
14.986609
...
...
4.633089
3.991554
3.385192
2.945284
2.464239
2.074431
1.683186
1.313012
1.000401
0.588407
-0.062610
View
117
From figure 5.6 above, it shown that the maximum load and displacement was
specimen 1,2 and 4. This result shows for the constant welding joint between each
specimen by using the single setting of voltage that was voltage selector no.4 on
welding unit. At the same time the same result also give the specimen 1,2 and 4 for the
maximum stress and strain.(figure 5.7)
118
Spec.
Displacement
at Max.Load
(mm)
Load at
Max.
Load
(kN)
Maximum
Displacement
(mm)
1
2
3
4
5
Mean
S.D
10.317
10.317
8.734
10.083
8.083
9.507
1.033
14.494
14.448
13.810
14.880
14.994
14.525
0.465
12.284
12.862
10.517
12.901
10.667
11.846
1.172
Modulus
Young
(MPa)
Stress at
Max.
Load
(MPa)
5549.458
5713.921
12516.126
5269.795
9443.186
7698.497
3190.180
362.339
361.211
345.246
371.994
374.846
363.127
11.619
Strain at
Max.
Load
(mm/m
m)
0.258
0.258
0.218
0.252
0.202
0.238
0.026
From table 5.6 above, the result shows that the maximum load produced by
specimen 5 is the highest but the maximum displacement produce is on specimen 1,2
and 4. Either from the result shows that the constantly break by tensile strength is out of
welding joint. It means that the output is nearly same between all specimens.
119
5.3.3.5 Result 3 (101mm)

Version date
Sample ID
Test Date
Test Type
Method
Operator Name
Edit date
Units
Geometry
Number of specimens
Number of channels
Machine type
Machine Control
Data Rate
Extensometer
Crosshead Speed
Second Speed
Temperature
Humidity
Auto-start
: 07 May 2002
: Tensile
: 23 Mar 2010
: Tensile
: 96
: Huzaimi Hamid
: 00 Mar 2000
: SI
: Rectangular
:5
:2
: ------: STANDARD
: 5.000000 pts/sec
: Disabled
: 5.00000 mm/min
: ------: 73 Deg F
: 50 %
: Disabled
: Enabled
120
1:[
][
2:[
][
3:[
][
4:[
][
5:[
][
]
]
]
]
]

1: 0.000000
2: 0.000000
3: 0.000000
4: 0.000000
5: 0.000000
6: 0.000000
7: 0.000000
8: 0.000000
9: 0.000000
Sample comments:
Specimen
Test end reason
Width
Thickness
Spec gauge length
Ext. gauge length
Specimen label
Maximum Load point
Maximum Load
Maximum Extension
Second Speed point
Range Change point
: 1 (101mm)
: Break detected
: 20.0000000 mm
: 2.0000000 mm
: 40.0000000 mm
: 60.0000000 mm
:[
]
: 27
: 25
: 3.29583 kN
: 27
: 1.06720 mm
: ------: ------: ------: ------: -------
121
Displacement
Load
1, 0.000000, 0.000883
2, 0.014946, 0.229308
3, 0.032518, 0.474710
4, 0.049875, 0.658094
5, 0.066429, 0.827614
6, 0.083143, 0.966199
7, 0.100125, 1.082124
8, 0.116518, 1.179312
9, 0.133339, 1.266231
10, 0.149839, 1.339891
11, 0.166500, 1.409110
12, 0.183482, 1.471512
13, 0.199875, 1.526374
14, 0.216536, 1.576742
15, 0.299839, 1.746881
16, 0.383303, 1.861083
17, 0.466660, 1.972099
18, 0.550232, 2.082806
19, 0.633482, 2.250364
20, 0.716464, 2.420687
21, 0.800035, 2.615414
22, 0.849910, 2.788245
23, 0.899839, 2.977344
24, 0.950035, 3.155215
25, 1.016732, 3.295828
26, 1.051499, 0.174513
27, 1.067196, -0.079672
View
122
1:[
][
2:[
][
3:[
][
4:[
][
5:[
][
]
]
]
]
]

1: 0.000000
2: 0.000000
3: 0.000000
4: 0.000000
5: 0.000000
6: 0.000000
7: 0.000000
8: 0.000000
9: 0.000000
Sample comments:
Specimen
Test end reason
Width
Thickness
Spec gauge length
Ext. gauge length
Specimen label
Maximum Load point
Maximum Load
Maximum Extension
Second Speed point
Range Change point
: 2 (101mm)
: Break detected
: 20.0000000 mm
: 2.0000000 mm
: 40.0000000 mm
: 60.0000000 mm
:[
]
: 37
: 35
: 3.30859 kN
: 37
: 1.56750 mm
: ------: ------: ------: ------: -------
123
Displacement
Load
1, -0.000054, 0.000562
2, 0.015161, 0.152747
3, 0.032571, 0.368800
4, 0.049821, 0.581263
5, 0.066375, 0.773443
6, 0.083089, 0.937760
7, 0.100071, 1.062351
8, 0.116411, 1.166105
9, 0.133286, 1.256581
10, 0.149839, 1.330652
11, 0.166446, 1.400193
12, 0.183428, 1.465326
13, 0.199821, 1.525289
14, 0.216482, 1.584559
15, 0.233357, 1.637669
16, 0.249750, 1.685759
17, 0.266571, 1.735960
18, 0.283339, 1.779529
19, 0.299732, 1.822054
20, 0.316821, 1.866228
21, 0.399857, 2.019437
22, 0.483214, 2.133676
23, 0.566517, 2.245425
24, 0.649928, 2.353015
25, 0.733339, 2.449417
26, 0.816857, 2.542872
27, 0.899839, 2.627738
28, 0.983142, 2.703326
29, 1.066606, 2.780519
30, 1.149910, 2.864450
31, 1.233428, 2.965288
32, 1.316624, 3.072394
33, 1.399767, 3.187826
34, 1.483124, 3.295552
35, 1.500160, 3.308587
36, 1.550249, 2.979990
37, 1.567499, -0.090790
View
124
1:[
][
2:[
][
3:[
][
4:[
][
5:[
][
]
]
]
]
]

1: 0.000000
2: 0.000000
3: 0.000000
4: 0.000000
5: 0.000000
6: 0.000000
7: 0.000000
8: 0.000000
9: 0.000000
Sample comments:
Specimen
Test end reason
Width
Thickness
Spec gauge length
Ext. gauge length
Specimen label
Maximum Load point
Maximum Load
Maximum Extension
Second Speed point
Range Change point
: 3 (101mm)
: Break detected
: 20.0000000 mm
: 2.0000000 mm
: 40.0000000 mm
: 60.0000000 mm
:[
]
: 78
: 77
: 11.01068 kN
: 78
: 3.53823 mm
: ------: ------: ------: ------: -------
125
Displacement
Load
1, 0.000000, 0.001796
2, 0.015054, 0.178754
3, 0.032571, 0.413294
4, 0.049875, 0.668957
5, 0.066429, 0.902043
6, 0.083143, 1.111678
7, 0.100125, 1.287664
8, 0.116411, 1.437458
9, 0.133286, 1.575447
10, 0.149839, 1.692284
11, 0.166446, 1.804005
12, 0.183482, 1.906820
13, 0.199821, 1.993521
14, 0.216536, 2.059813
15, 0.233411, 2.110764
, ..., ..
, ..., ..
60, 2.050231, 7.484040
61, 2.133374, 7.892002
62, 2.216409, 8.290847
63, 2.299980, 8.675019
64, 2.383230, 9.036563
65, 2.466748, 9.378917
66, 2.550052, 9.683014
67, 2.633409, 9.888769
68, 2.716444, 10.092596
69, 2.799962, 10.273652
70, 2.883212, 10.418204
71, 2.966677, 10.569125
72, 3.050141, 10.709632
73, 3.133391, 10.825534
74, 3.216533, 10.909190
75, 3.299837, 10.943796
76, 3.383301, 10.987499
77, 3.449944, 11.010684
78, 3.538229, -0.011060
View
126
1:[
][
2:[
][
3:[
][
4:[
][
5:[
][
]
]
]
]
]

1: 0.000000
2: 0.000000
3: 0.000000
4: 0.000000
5: 0.000000
6: 0.000000
7: 0.000000
8: 0.000000
9: 0.000000
Sample comments:
Specimen
Test end reason
Width
Thickness
Spec gauge length
Ext. gauge length
Specimen label
Maximum Load point
Maximum Load
Maximum Extension
Second Speed point
Range Change point
: 4 (101mm)
: Break detected
: 20.0000000 mm
: 2.0000000 mm
: 40.0000000 mm
: 60.0000000 mm
:[
]
: 27
: 25
: 3.04283 kN
: 27
: 1.10079 mm
: ------: ------: ------: ------: -------
127
Displacement
Load
1, -0.000054, 0.000676
2, 0.015054, 0.073223
3, 0.032518, 0.297940
4, 0.049821, 0.506648
5, 0.066375, 0.707236
6, 0.083089, 0.899055
7, 0.100018, 1.065960
8, 0.116411, 1.211085
9, 0.133232, 1.337272
10, 0.149786, 1.441076
11, 0.166446, 1.537547
12, 0.183375, 1.625312
13, 0.199821, 1.700944
14, 0.216428, 1.773046
15, 0.233303, 1.837847
16, 0.299732, 2.021245
17, 0.383250, 2.177374
18, 0.466607, 2.308326
19, 0.550178, 2.439790
20, 0.633428, 2.563948
21, 0.716410, 2.679971
22, 0.800035, 2.794632
23, 0.883232, 2.905036
24, 0.966642, 3.005829
25, 1.016678, 3.042831
26, 1.083321, 2.703423
27, 1.100785, -0.097347
View
128
1:[
][
2:[
][
3:[
][
4:[
][
5:[
][
]
]
]
]
]

1: 0.000000
2: 0.000000
3: 0.000000
4: 0.000000
5: 0.000000
6: 0.000000
7: 0.000000
8: 0.000000
9: 0.000000
Sample comments:
Specimen
Test end reason
Width
Thickness
Spec gauge length
Ext. gauge length
Specimen label
Maximum Load point
Maximum Load
Maximum Extension
Second Speed point
Range Change point
: 5 (101mm)
: Break detected
: 20.0000000 mm
: 2.0000000 mm
: 40.0000000 mm
: 60.0000000 mm
:[
]
: 65
: 57
: 7.47640 kN
: 65
: 2.71752 mm
: ------: ------: ------: ------: -------
129
Displacement
Load
1, -0.000054, 0.001743
2, 0.014946, 0.104714
3, 0.032464, 0.365267
4, 0.049821, 0.599848
5, 0.066375, 0.806977
6, 0.083089, 0.989500
7, 0.100071, 1.142145
8, 0.116411, 1.272270
9, 0.133232, 1.392318
10, 0.149786, 1.494454
11, 0.166446, 1.580364
12, 0.183375, 1.662100
13, 0.199821, 1.734774
14, 0.216428, 1.805681
15, 0.233303, 1.867014
, ..., ..
, ..., ..
45, 1.466624, 4.082245
46, 1.550142, 4.296103
47, 1.633285, 4.539272
48, 1.716374, 4.811966
49, 1.799677, 5.140867
50, 1.883302, 5.496296
51, 1.966659, 5.859000
52, 2.050177, 6.226697
53, 2.133374, 6.587829
54, 2.216356, 6.923079
55, 2.299927, 7.188402
56, 2.383177, 7.429128
57, 2.416766, 7.476400
58, 2.466855, 7.083647
59, 2.533659, 5.780558
60, 2.550480, 4.982038
61, 2.566873, 4.569797
62, 2.583534, 3.851162
63, 2.666570, 3.313709
64, 2.699891, 2.735726
65, 2.717516, -0.129397
View
130
By refer to figure 5.8 and 5.9, it shows that the maximum load, stress and strain
produce before break is specimen no.3 and also the result on maximum displacement.
The graph conclude that the effect of setting by this result is cause by the speed of
workpiece setup to be low and ideal for produce a good welding joint. Too low of speed
will create the bad welding joint cause over melting.
131
Spec.
Displacement
at Max.Load
(mm)
Load at
Max.Load
(kN)
Maximum
Displacement
(mm)
1
2
3
4
5
Mean
S.D
1.017
1.500
3.450
1.017
2.417
1.880
1.047
3.296
3.309
11.011
3.043
7.476
5.627
3.532
1.067
1.567
3.538
1.101
2.718
1.998
1.089
Modulus
Young
(MPa)
14553.728
11313.826
11031.215
11794.870
11978.964
12134.521
1403.829
Stress at
Max.
Load
(MPa)
82.396
82.715
275.267
76.071
186.910
140.672
88.293
Strain at
Max.
Load
(mm/mm)
0.025
0.038
0.086
0.025
0.060
0.047
0.026
From table 5.8 above and by referring to figure 5.8 and figure 5.9, the result
shows that the maximum load before break produced by specimen 3 is the highest. It
also shows that the value of stress is the highest, which means the setup of speed for
welding workpiece with size 101mm and thickness 2mm need to use between range
0.6 to 1.5mm/s. If low than minimum value, welding joint will be over melting and if
high than that range, will produce thin welding bead which is bad in welding joint.
132
5.3.3.7 Result 4 (114mm)

Version date
Sample ID
Test Date
Test Type
Method
Operator Name
Edit date
Units
Geometry
Number of specimens
Number of channels
Machine type
Machine Control
Data Rate
Extensometer
Crosshead Speed
Second Speed
Temperature
Humidity
Auto-start
: 07 May 2002
: Tensile
: 23 Mar 2010
: Tensile
: 96
: Huzaimi Hamid
: 00 Mar 2000
: SI
: Rectangular
:5
:2
: ------: STANDARD
: 5.000000 pts/sec
: Disabled
: 5.00000 mm/min
: ------: 73 Deg F
: 50 %
: Disabled
: Enabled
133
1:[
][
2:[
][
3:[
][
4:[
][
5:[
][
]
]
]
]
]

1: 0.000000
2: 0.000000
3: 0.000000
4: 0.000000
5: 0.000000
6: 0.000000
7: 0.000000
8: 0.000000
9: 0.000000
Sample comments:
Specimen
Test end reason
Width
Thickness
Spec gauge length
Ext. gauge length
Specimen label
Maximum Load point
Maximum Load
Maximum Extension
Second Speed point
Range Change point
: 1 (114mm)
: Break detected
: 10.0000000 mm
: 5.0000000 mm
: 40.0000000 mm
: 60.0000000 mm
:[
]
::: 0.00000 kN
:: 0.00000 mm
: ------: ------: ------: ------: -------
134
Displacement
Load
View
Break before being pulls
135
1:[
][
2:[
][
3:[
][
4:[
][
5:[
][
]
]
]
]
]

1: 0.000000
2: 0.000000
3: 0.000000
4: 0.000000
5: 0.000000
6: 0.000000
7: 0.000000
8: 0.000000
9: 0.000000
Sample comments:
Specimen
Test end reason
Width
Thickness
Spec gauge length
Ext. gauge length
Specimen label
Maximum Load point
Maximum Load
Maximum Extension
Second Speed point
Range Change point
: 2 (114mm)
: Break detected
: 10.0000000 mm
: 5.0000000 mm
: 40.0000000 mm
: 60.0000000 mm
:[
]
: 24
: 23
: 4.58412 kN
: 24
: 0.95266 mm
: ------: ------: ------: ------: -------
136
Displacement
Load
1, 0.000000, 0.000192
2, 0.013875, 0.243001
3, 0.032196, 0.535964
4, 0.049554, 0.740816
5, 0.066482, 0.902403
6, 0.083250, 1.049568
7, 0.100018, 1.186415
8, 0.116518, 1.308359
9, 0.133232, 1.428797
10, 0.150161, 1.541713
11, 0.166500, 1.642467
12, 0.183161, 1.742509
13, 0.200089, 1.835157
14, 0.266464, 2.108445
15, 0.333321, 2.388624
16, 0.416678, 2.690704
17, 0.499768, 2.995320
18, 0.583285, 3.298047
19, 0.650035, 3.550091
20, 0.733232, 3.867340
21, 0.816321, 4.181767
22, 0.899946, 4.468851
23, 0.933374, 4.584123
24, 0.952660, -0.435556
View
137
1:[
][
2:[
][
3:[
][
4:[
][
5:[
][
]
]
]
]
]

1: 0.000000
2: 0.000000
3: 0.000000
4: 0.000000
5: 0.000000
6: 0.000000
7: 0.000000
8: 0.000000
9: 0.000000
Sample comments:
Specimen
Test end reason
Width
Thickness
Spec gauge length
Ext. gauge length
Specimen label
Maximum Load point
Maximum Load
Maximum Extension
Second Speed point
Range Change point
: 3 (114mm)
: Break detected
: 10.0000000 mm
: 5.0000000 mm
: 40.0000000 mm
: 60.0000000 mm
:[
]
: 99
: 93
: 16.01318 kN
: 99
: 4.38878 mm
: ------: ------: ------: ------: -------
138
Displacement
Load
1, 0.000000, -0.000004
2, 0.014625, 0.270904
3, 0.032518, 0.551160
4, 0.049661, 0.724201
5, 0.066589, 0.862398
6, 0.083250, 0.989990
7, 0.100071, 1.106115
8, 0.116571, 1.209427
9, 0.133286, 1.302448
10, 0.150214, 1.367167
11, 0.166553, 1.428144
12, 0.183214, 1.493502
13, 0.200143, 1.557352
14, 0.216536, 1.619188
15, 0.233250, 1.686028
, ..., ..
, ..., ..
80, 3.049766, 13.314465
81, 3.133337, 13.578843
82, 3.216587, 13.833811
83, 3.300159, 14.092123
84, 3.383462, 14.343187
85, 3.466766, 14.583573
86, 3.549694, 14.812829
87, 3.633158, 15.034387
88, 3.716408, 15.242334
89, 3.800033, 15.447956
90, 3.883497, 15.636961
91, 3.966801, 15.816082
92, 4.049944, 15.966406
93, 4.100141, 16.013176
94, 4.183444, 15.149555
95, 4.233533, 14.058312
96, 4.283515, 13.231228
97, 4.333712, 12.318937
98, 4.366980, 11.344458
99, 4.388783, -0.271087
View
Break of welding bead at welding joint
139
1:[
][
2:[
][
3:[
][
4:[
][
5:[
][
]
]
]
]
]

1: 0.000000
2: 0.000000
3: 0.000000
4: 0.000000
5: 0.000000
6: 0.000000
7: 0.000000
8: 0.000000
9: 0.000000
Sample comments:
Specimen
Test end reason
Width
Thickness
Spec gauge length
Ext. gauge length
Specimen label
Maximum Load point
Maximum Load
Maximum Extension
Second Speed point
Range Change point
: 4 (114mm)
: Break detected
: 10.0000000 mm
: 5.0000000 mm
: 40.0000000 mm
: 60.0000000 mm
:[
]
: 141
: 130
: 20.05767 kN
: 141
: 6.30450 mm
: ------: ------: ------: ------: -------
140
Displacement
Load
1, 0.000000, 0.001553
2, 0.014411, 0.259515
3, 0.032357, 0.576449
4, 0.049714, 0.816332
5, 0.066321, 1.028583
6, 0.083089, 1.223043
7, 0.100071, 1.396574
8, 0.116464, 1.560390
9, 0.133232, 1.717734
10, 0.149839, 1.859098
11, 0.166393, 1.996770
12, 0.183428, 2.128996
13, 0.199821, 2.251381
14, 0.216482, 2.375917
15, 0.233357, 2.491282
, ..., ..
, ..., ..
120, 4.849818, 18.423409
121, 4.933014, 18.603878
122, 5.016479, 18.791124
123, 5.100211, 18.981781
124, 5.183515, 19.168755
125, 5.266658, 19.352077
126, 5.349854, 19.527254
127, 5.433050, 19.696346
128, 5.516621, 19.860182
129, 5.600032, 19.997238
130, 5.666461, 20.057665
131, 5.750086, 19.548923
132, 5.783782, 18.268826
133, 5.816943, 17.018364
134, 5.850317, 15.901725
135, 5.900032, 14.723760
136, 5.950174, 13.686844
137, 6.016656, 12.655044
138, 6.100121, 11.732911
139, 6.183478, 11.004575
140, 6.266727, 10.286551
141, 6.304496, -0.328980
View
Break 1/4 of welding bead at

welding joint
141
As the result shown on figure 5.10 above, the maximum displacement and load
produce was the specimen no.3, which has a good welding joint by its welding bead and
penetration. Cause the specimen has 5mm thickness, the voltage setup are being
maintain as selection to 6 and the speed are being decreased to 1.8 (as selector on speed
controller) allowed more penetration. The confirmation shows the thicker of workpiece
affect the increasing of ampere and the voltage also shown to be increase either the
setting was same as thinner material setup. The voltage shown was 17.6V on selector
no.6. The same result also shown on the stress vs strain graph (figure 5.11).
142
Spec.
Displacement
at Max.Load
(mm)
1
2
3
4
Mean
S.D
0.933
4.100
5.666
3.567
2.411
Load at
Max.
Load
(kN)
4.584
16.013
20.058
13.552
8.025
Maximum
Displacement
(mm)
0.953
4.389
6.304
3.882
2.712
Modulus
Young
(MPa)
12012.177
3775.229
6378.880
7388.762
4210.312
Stress at
Max.Load
(MPa)
91.682
320.264
401.153
271.033
160.502
Strain at
Max.Load
(mm/mm)
0.023
0.103
0.142
0.089
0.060
143
From table 5.10, and by referring to figure 5.10 and figure 5.11, the result shows
that the maximum load before break produced by specimen 4 is the highest. It also
shows that the value of stress, strain and displacement is also break on the highest point,
which means the setup of voltage and speed are the main effect to produce the quality of
welding joint. The voltage and speed selected for all specimens is as table 5.11 below.
Table 5.11 : Speed selector for all specimen (114mm)

Specimen
1
2
3
4
Voltage
Selector
2
3
4
5
Voltage actual
value
(V)
6.5
9.0
14.0
17.6
Speed
selector
2.2
2.0
1.8
1.6
Speed
actual value
(mm/s)
1.65
1.48
1.20
1.02
It means that, the lowest speed and increasing the value of voltage will
produce the large welding bead and penetration which is good in welding joints
that could be stand from load especially as using in common tank and pressure
piping.
5.3.4
Result of impact test
Four types of workpiece involved for evaluation by impact test which is same as
evaluation done by tensile test. The specimen to fit into the jaw of impact test must be
in square (10mm x 10mm) with top length from welding bead is 27mm and bottom
length for 50mm. The result as table 5.12 will shows the impact energy produce to
determine if the workpiece meets specific impact properties or to compare materials for
general toughness.
144
Table 5.12 : Result of impact energy on the workpiece
Specimens
1
(J)
2.0
2
(J)
2.0
3
(J)
2.2
4
(J)
2.5
5
Means
(J)
(J)
2.5
2.24
88mm
(2mm
thickness)
2.0
2.5
1.5
2.0
2.5
2.10
101mm
(2mm
thickness)
2.0
1.5
2.5
1.5
2.0
1.9
114mm
(5mm
thickness)
8.0
9.0
10.2 14.5 14.5
11.24
Workpiece
74mm
(2mm
thickness)
From the result shows the most toughness of specimen are the highest
rate of energy develop during impaction. For workpiece 74mm, specimen 4
and 5 shows the highest value of impact energy that gives the same reason with
tensile testing method which using the voltage setup on 15.5V (Voltage selector
= 6) on welding unit. The speed rotation of workpiece is between 1.48mm/s and
2.35mm/s.
145
For workpiece 88mm, specimen 2 and 5 are the highest rate of impact energy.
The consideration of specimen 5 is the best which is also have a good tensile strength
rather than specimen 2. The cause of the highest rate of impaction energy is by the
lowest of rotational workpiece speed.
5.3.5
Result of Hardness Test
The tested will shows the hardness created by the welding joint using the
welding fixture. The hardness will test on the welding bead which is determined the
good circumferential joint of workpiece. Description of machine been tested are as table
5.13 below.
Table 5.13 : Description of Hardness Test

Machine
Hardness Machine types
Unit scale
Load applied
Indenter type
Description
=
=
=
=
Rockwell Hardness tester

HRB
100 kg
Steel ball
Workpiece that are going to be tested are being measured on dual sided which is
included x axis and y axis as shown on figure 5.12 and the result shows on table 5.14.
146
Y axis
X axis
Figure 5.12 Axis being measured by Hardness tester
Table 5.14 : Measurement of hardness by XY axis

Workpiece
Specimen
74mm
(2mm thick)
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
88mm
(2mm thick)
101mm
(2mm thick)
114mm
(5mm thick)
Reading
(Unit HRB)
X axis
Y axis
79.3
84.0
75.0
75.0
86.0
80.0
77.0
77.0
75.2
76.0
88.6
66.0
87.0
65.7
63.5
58.0
73.0
60.3
66.5
61.0
70.0
66.0
77.0
87.0
82.0
63.5
84.0
73.0
79.1
66.5
75.0
109.8
75.0
122.1
84.0
123.0
89.4
89.5
79.0
79.0
View
147
From the results shows on table 5.14, mostly the hardness on X axis is tougher
rather than Y axis except workpiece 114mm. It can be conclude that, with thicker
material, high voltage and very good depth of penetration by the welding will create
more hardness on joint and also have a good strength. The effect of welding for
workpiece 74mm, 88mm and 101mm only have a small value different between X
and Y axis, and means that the hardness between both sided of welding bead are nearly
same.
For workpiece 114mm, for specimen 1, 2 and 3 shows a large different value
between X and Y axis. It means that the hardness is only on welding bead but not on
material. Clearly the result concluded that these specimens only have a small depth of
penetration rather than specimen 4 and 5 which shows the value of hardness on X and Y
axis is nearly same and a thicker depth of penetration. A good result can be conclude
that, a thicker depth of penetration will create a good joint between 2 workpiece which
can stand a load especially for tank and piping fabrication.
5.3.6
Welding structure
To evaluate the proper selection on welding parameters to produce a good

circumferential welding joint, the solution can be make it by viewing its internal
structure of welding bead and penetration. The structure that can be view is for the
specimen preparation before the destructive test be conducted. The sample of welding
structure specimen that can be view is by using the workpiece with diameter 114mm
and thickness 5mm. The other types of specimen are not being considered cause of the
limitation to work out microscope.
148
5.3.6.1 Structure view of specimen 1 (Workpiece 114mm)
There are two condition of viewing the structure which is before etching and
after etching. The etching fluid used was hydrochloric acid (specialize for mild steel
material).
i.
Structure view before etching
50m
Welding bead
Welding joint
Gap between
workpiece
Figure 5.13 Structure view (specimen 1, 114mm) before etching under 50X lens
149
ii.
Structure view after etching
Welding bead
Heat Affected
Zone
Gap between
workpiece
10mm
Figure 5.14 Size of welding structure for specimen 1
50m
Welding bead
Welding joint
Gap between
workpiece
Figure 5.15 Welding structure for specimen 1 under 50X lens
150
i.
Welding bead
Heat Affected
Zone
Gap between
workpiece
10mm
50m
Welding bead
Welding joint
Gap between
workpiece
151
i.
Welding bead
Heat Affected
Zone
Gap between
workpiece
10mm
50m
Welding bead
Welding joint
Gap between
workpiece
152
5.4
Discussion
As the result shown on the criteria of evaluation by tensile test, mostly the effect
of voltage regulation and the travel speed on the specimen, will show clearly function of
the welding fixture to produce the constantly welding joint between one pieces to
another by using the same setting and parameters.
First of all, to investigate the ideal parameters used to weld the specimen based
on their diameter and thickness, this welding fixture is a correct selection especially for
circumferential joint on tank or piping.
By the other test (impact and hardness), the result will help to prove either the
quality of joint are totally being accepted. As the manual operation of welding will give
the same hardness and strength that produce by this welding fixture, the different is
producing the welding with same bead and penetration only can be done by constantly
movement and the effect hardness and strength also effect along the joint.
5.5
Conclusion
As the result already being done on tensile, impact and the hardness test, it can
be shown that, the quality of welding on circumferential joint of tank and piping will
give a good determination function of using the welding fixture. The fabrication of
welding fixture can be conclude that with the constant speed of workpiece rotational,
the determination of depth of penetration can be controlled by a certain setup on motor
speed and voltage regulator with a different thickness of material. As known, with a
large depth of penetration will produced a good strength of joint that can stand a large
load especially for tank and piping fabrication.
153
CHAPTER 6
CONCLUSION
6.1
Introduction
At the end of this session, the conclusion that can make is to construct the
suggestive for further improvement based on the limitation and the effectiveness of the
project when already being done. By reviewing the result or output from the design and
testing, it will be sure that some modification and revision need to conduct for
implementation the better result or output.
6.2
Conclusion
At the end of the session, it been shows that, the objective for evaluation of the
welding quality is already being carried out by fabricating the welding fixture and
measuring the output based on circumferential joint on cylindrical shape using MIG
154
welding. From the result, the application by the proper design is been prove based on
the output of circumferential joint. It can be sure that, the implication from the
adjustment of voltage and travel speed given a lot of impact to form, strength, hardness
and the joint quality.
By using this fixture, all the parameters can be determined because the easy way
to get the constant shape of welding joint at all joining. Additional from that, the
application of low carbon mild steel can be differentiate and determined of the
maximum and minimum level of parameters setup. The larger output from
determination of parameters differentiation was the workpiece with outer diameter
114mm which shown with the all adjustable parameters will act to produce the quality
of joining. It cause by the thickness of the workpiece (5mm) rather than other
workpiece.
Although by using the different outer diameter of the cylinder, in fact it will not
influence with the adjustment unit and the quality of joining because the thickness is a
major rules to stand with the strength, hardness and impact of pressure.
At the end, by using the welding fixture, the evaluation by determination of
joining quality can easily being used, especially for circumferential joint on tank and
piping with cylindrical shape.
6.2
Recommendation
The recommendation suggested for this project is based on the project design,
fabrication and evaluation of the output from the welding fixture. As the
recommendation based on design and fabrication of the project is as list below:
155
i.
By refer to the project and design that already being produce, the gap between
welding nozzle and the workpiece is not constant cause an error produce by the
rotational shaft and the actual workpiece. The rotational shaft produce are left
with the center support. The important requirement for the center support is
cause the rotational shaft are carrying the load by the workpiece and this will
make the shaft not in center of rotation.
ii.
Upgrading the welding nozzle positioning to make more effectively to weld the
workpiece by more than one axis and more precisely. The present welding
fixture can only weld in one axis or one position only. The upgrading suggestion
was including with the angle control and the gap control.
iii.
Improve the rotational system to become more automatically function which

include with the sensor or timer to determine the completion of welding process.
iv.
Mostly for better of producing the welding quality, the proper size of wire
especially for MIG welding must be selected. The thicker the wire means
increasing the penetration and bead. Large depth of penetration will give a
warranty of the high strength of joint that being develop.
v.
Improve the test of fixture calibration by using special equipment to evaluate the
precise of rotating speed and rotating centralization.
As recommendation based on evaluation of output is correlate with the test

being conducted to determine the goods of welding quality. The recommendation list is
as below:
i.
Apply the testing segments with the non-destructive test. e.g Visual test, dye
penetrants test, pressure test and X-ray test which is given more reliable result
about the testing specimen.
ii.
Run the design of experiment (DOE) methodology to evaluate more constantly

results but need a lot of workpiece preparation based on number of variables and
responses.
156
REFERENCES
Afzaal M.Malik, Ejaz M.Qureshi, Naeem Ullah Dar and Iqbal Khan (2008), Analysis of
circumferentially arc welded thin-walled cylinders to investigate the residual stress
fields. Proceeding by Elsevier Journal of Thin-Walled Structures 46 p.p 1391-1401.
Ario Sunar Baskoro, Rui Masuda, Masashi Kabutomori and Yasuo Suga (2008), An
application of genetic algorithm for edge detection of molten metal pool in fixed
pipe welding. Proceeding by International Journal of Advanced Manufacturing
Technology, D.O.I 10.1007/s00170-009-2048-1.
ASME Codes, Wikipedia, The Free Encyclopedia

(http://en.wikipedia.org/wiki/American Society of Mechanical Engineers)
Destructive test, Wikipedia, The Free Encyclopedia

(http://en.wikipedia.org/wiki/Destructive testing)
Dyer E.Carroll and Dyer E.Carroll Jr. (1997), The ASME Code Simplified (Power
Boilers), McGraw Hill.
Festo Catalogue (2006), Festo Didactic (Gmbh)
Ho-Sung Lee, Jong-Hoon Yoon, Jae-Sung Park and Yeong-Moo Yi (2005), A study on
failure characteristic of spherical pressure vessel. Proceeding by Journal of
Materials Processing Technology 164-164, p.p 882-888.
Inge Lotsberg (2008), Stress concentration factors at weld in pipelines and tanks
subjected to internal pressure and axial force. Proceeding by Marine Structures 21,
p.p 138-159.
157
Izod Impact Test, Wikipedia, The Free Encyclopedia.
(http://en.wikipedia.org/wiki/Izod_impact_strength_test)
J.G. Teng and X.Lin (2005), Fabrication of small models of large cylinders with
extensive welding for buckling experiments. Proceeding by Thin-Walled Structures
43, p.p 1091-1114.
Jianqiu Zhou and Shiming Shen (1998), A study on the reliability assessment
methodology for pressure piping containing circumferential defects. Proceeding of
the International Journal of Pressure Vessels and Piping 75, p.p 679-684.
Joseph Edward Shigley and Charles R. Mishke (1989), Mechanical Engineering Design,
Fifth Edition, McGraw Hill.
J.Philip Ellenberger, P.E (2004), Pressure Vessels: The ASME Code Simplified, Eight
Edition, McGraw Hill.
Karl T.Ulrich and Steven D. Eppinger (2008), Product Design and Development. Fourth
Edition, McGraw Hill.
Larry Horath (2001), Fundamentals of Materials Science for Technologies (Properties,

Testing and Laboratory Exercise), Second Edition, Prentice Hall.
Martha A. Baker (1995), Gas Metal Arc Welding, Hobalt Institute of Welding
Technology.
Molinder L.Nayyar (2000), Piping Handbook, Seventh Edition, McGraw Hill.
M.Pircher, P.A. Berry, X.Ding and R.Q. Bridge (2001), The shape of circumferential
weld-induced imperfections in thin-walled steel silos and tanks. Proceeding by
Thin-Walled Structures 39, p.p 999-1014.
158
Naeem Ullah Dar, Ejaz M.Qureshi and M.M.I Hammouda (2009), Analysis of weldinduced residual stresses and distortions in thin-walled cylinders. Proceeding by
Journal of Mechanical Science and Technology 23, p.p 1118-1131.
Overview of materials for Low Carbon Steel

(http://www.matweb.com)
Pressure vessels, DANotes: Introduction

(http://www.school.mech.edu.au)
Pressure vessels, Wikipedia, Free Encyclopedia.

(http://en.wikipedia.org/wiki/Pressure_vessel)
R.H. Leggatt (2008), Residual stresses in welded structures. Proceeding by International

Journal of Pressure Vessels and Piping 85, p.p 144-151.
Richard L.Frohlich (1978), Apparatus of Forming Circumferential Welding, U.S Patent

No. 4,121,746, Westinghouse Electric Corp, Pittsburgh, Pa.
Robert W.Randolph (1977), Apparatus for Obtaining a Butting Contact of Hollow Tank
Courses to be Circumferentially Welded, U.S Patent No. 4,039,115, New York
Rockwell Scale, Wikipedia, The Free Encyclopedia.

(http://en.wikipedia.org/wiki/Rockwell scale)
Roger R.Griffiths (2002), Investigation into a major crack occurred during fabrication
of a thick walled alloy pressure vessel. Proceeding by International Journal of
Pressure Vessels and Piping 79, p.p 591-595.
RS Component Catalogue (2006), Mechanical and Electrical Component (Malaysia)
159
Sacks & Bohnart (2005), Welding Principles And Practices, Third Edition, McGraw
Hill.
Tso-Liang Teng and Peng-Hsiang Chang (1998), Three-dimensional thermomechanical

analysis of circumferentially welded thin-walled pipes. Proceeding by International
Journal of Pressure Vessels and Piping 75, p.p 237-247.
William F.Clavey (1975), Method of Welding Tanks, U.S Patent No. 3,918,628, Paccar
Inc, Bellevue, Washington D.C.
Z.Sterjovski, D.P Dunne and S.Ambrose (2004), Evaluation of cross-weld properties of

quenched and tempered pressure vessel steel before and after PWHT. Proceeding by
International Journal of Pressure Vessels and Piping 81, p.p 465-470.
APPENDIX
APPENDIX A1
Month
Week
Project Gantt Chart (Session I)

Duration
10 days
Start
Wed 01/07
Finish
Fri 10/07
1 day
Fri 03/07
Fri 03/07
25 days
Thu 02/07
Sun 26/07
1 day
Mon 27/07
Mon 27/07
1 day
Tue 28/07
Tue 28/07
Discussion with the course co-ordinator for manage

the project
Discussion with the supervisor to prepare the
project synopsis
Submission project synopsis to supervisor
1 day
Fri 07/08
Fri 07/08
Submission the project registration to faculty
1 day
Thu 23/07
Thu 23/07
Preparation of the concept modeling for

circumferential welding apparatus
Discussion with the supplier for the project
apparatus standard part and raw material
preparation
Final selection of the project design.
14 days
Mon 10/08
Mon 24/08
1 day
1 day
1 day
3 days
Thu 09/07
Tue 28/07
Mon 03/08
Wed 26/08
Thu 09/07
Tue 28/07
Mon 03/08
Fri 28/08
Discussion with the supervisor about the final

design.
1 day
Thu 27/08
Thu 27/08
1
2
3
4
5
10
11
Task
Determination of project title.
Visiting Small Medium Industries for project
searching
Information gathering and literature review
Month
Week
12
13
Task
Purchasing the standard part and raw materials
Duration
2 weeks
Start
Mon 07/09
Finish
Mon 21/09
1 day
Fri 02/10
Fri 02/10
1 day
Wed 30/09
Wed 30/09
56 days
Tue 01/09
Mon 26/10
1 day
Thu 08/10
Thu 08/10
36 days
Mon 21/09
Mon 26/10
15
Project development and fabrication
16
17
Discussion with the co-supervisor about the

measurement facilities as USM Nibong Tebal
Preparation of project 1 report
18
Submission project 1 report to supervisor
1 day
Fri 23/10
Fri 23/10
19
Project Seminar
2 day
Sat 31/10
Sun 01/11
20
Approval of project 1 report
2
06/07
10
01/09
11
07/09
July
3
13/07
4
20/07
5
27/07
6
03/08
August
7
8
10/08
17/08
9
24/08
September
12
13
14/09
21/09
14
28/09
15
05/10
October
16
17
12/10
19/10
18
26/10
161
14
Discussion with the co-supervisor about the proper

project preparation
Project approval
1
01/07
162
F033
APPENDIX A2
OPERATOR NAME
MATRIX NO.
Prepared by
Checked by
PROF.MADYA ZAINAL ABIDIN AHMAD
Approved by
PROF.MADYA ZAINAL ABIDIN AHMAD
DRILLING
TAPERING
HAND SAW CUTTING
DISK CUTTER
13
30
Nil
Nil
20.00
TOTAL FAB COST
14
13
05/04-11/04 2010
12
29/03-04/04 2010
11
22/03-28/03 2010
8
22/02-28/02 2010
15/03-21/03 2010
6
08/02-14/02 2010
5
01/02-07/02 2010
10
08/03-14/03 2010
25/01-31/01 2010
18
01/03-07/03 2010
17
18/01-24/01 2010
15
09/10-25/10 2009
11/01-17/01 2010
14
05/10-11/10 2009
(Session2) 1
12
28/09-04/10 2009
7
10/08-16/08 2009
14/09-20/09 2009
6
03/08-09/08 2009
5
27/07-02/08 2009
11
4
20/07-26/07 2009
07/09-13/09 2009
3
29/6-05/07 2009
24/08-30/08 2009
2
06/07-12/07 2009
TWK
(Session1) 1
DATE
TOTAL
48.50
PAINTING
38L x 30W 23T
Nil
BENDING MACHINE
71L x 30W x 17.5T
30.00
SHEARING MACHINE
93L x 30W x 18.5T
30.00
MIG WELDING
120L x 40W x 5T
230.00
CNC MILLING
75L x 25W x 5T
70.00
PNEUMATIC INSTALLATION
450L x 25W x 25T
Nil
ELECTRICAL WIRING
71L x 32W x 5T
Nil
POWER SAW CUTTING
132L x 100W x 42T
32.50
EDM WIRE CUT
80Dia. x 33.5T
990.00
CNC TURNING
40Dia. x 38.5T
245.00
CONVENTIONAL TURNING
94L x 30W x 50T
72.00
CONVENTIONAL MILLING
100 Dia. X 30 T
250.00
DESIGN (SOLIDWORKS 2009)
30 Dia. x 1000 L
1,460.00
Rotational Shaft
29/06-05/07 2009
(DIA X L)mm
MACHINING PROCESSES & OTHERS
PL
QUANTITY
(L X W X T)mm
MATERIAL PRICE (RM)
FINISHED MATERIAL SIZE
SCHEDULE
UNIT PRICE
PART NAME / TASK
DATE
30 MAC 2010
MATERIAL DETAILS
MATERIAL TYPE
PART NO.
INITIAL
MMP 2914 MASTER PROJECT II
DESIGN AND FABRICATION OF

CIRCUMFERENTIAL JOINT ON
CYLINDRICAL SHAPE USING MIG WELDING
PART NAME / TASK
NAME
04/01-10/01 2010
SUBJECT CODE
PROJECT SCHEDULE AND PROJECT COST
Strip Layout/ Product
MM081524
Attachment Roller
PL
AC
Aluminium
Bearing Housing
PL
AC
Aluminium
Drive Pulley
PL
AC
Aluminium
Driven Pulley
PL
AC
Aluminium
Motor Support Plate
PL
AC
Aluminium
Stabilizer Wheel Plate
PL
AC
Aluminium
Stabilizer Wheel Shaft
PL
AC
Aluminium
Welding Gun Arm
PL
AC
Aluminium
10 Welding Gun Holder
PL
AC
Aluminium
11 Welding Gun Clamp 1
PL
AC
Aluminium
12 Welding Gun Clamp 2
PL
AC
Aluminium
13 Earth Channel Connector
PL
AC
Aluminium
14 Aluminium Frame (1 set)
1000L x 40W x 40T
600L x 40W x 40T
16
1000L x 600W x 2T
600L x 600W x 2T
254L x 204W x 112T
85L x 55W x 30T
915L x 420W x 20T
520L x 420W x 20T
PL
AC
Copper
PL
15 Dark Arcylic Transparent Plate
AC
Aluminium
PL
16 Control Box
AC
Plastic PVC
17 Stabilizer Wheel Holder
PL
AC
Mild Steel Plate
18 Cabinet
PL
AC
Aluminium
AC
Mild Steel Plate

TOTAL
REMARKS :
3,627.00
STANDARD PART COST (RM)
2,175.80
FABRICATION COST (RM)
2,018.00
AC = Actual
DESIGN COST (RM)
1,460.00
TOTAL COST (RM)
9,280.80
163
CUSTOMADE PART COST (RM)
PL = Plan
2,018.00
SCHEDULE :
32
16
124
991
30
FINISH:
DO NOT SCALE DRAWING
APPENDIX B1
NAME
DRAWN
50
CHK'D
APPV'D
SIGNATURE
DATE

TITLE:
HUZAIMI
PROF.ZAINAL
PROF.ZAINAL
F
MATERIAL:
DWG NO.
Material
1
REVISION
SCALE:1:10
Rotational Shaft
Drawing No.1
PAGE :
164
A4
100
32
D
R1
4
50
FINISH:
APPENDIX B2
NAME
DRAWN
CHK'D
APPV'D
SIGNATURE
DATE

TITLE:
HUZAIMI
PROF.ZAINAL
PROF.ZAINAL
Attachment Roller
F
MATERIAL:
DWG NO.
Aluminium
1
REVISION
SCALE:1:1
Drawing No.2
PAGE :
165
A4
50
10
60
16
25
25
20
20
90
30
FINISH:
APPENDIX B3
NAME
DRAWN
CHK'D
APPV'D
SIGNATURE
DATE

TITLE:
HUZAIMI
PROF.ZAINAL
PROF.ZAINAL
F
MATERIAL:
DWG NO.
Aluminium
1
REVISION
SCALE:1:1
Bearing Housing
Drawing No.3
PAGE :
166
A4
20
40
12
26
10
1.7
18.5
20
FINISH:
APPENDIX B4
NAME
DRAWN
CHK'D
APPV'D
SIGNATURE
DATE

TITLE:
HUZAIMI
PROF.ZAINAL
PROF.ZAINAL
F
MATERIAL:
DWG NO.
Material
1
REVISION
SCALE:2:1
Drive Pulley
Drawing No.4
PAGE :
167
A4
80
A
9
1.7
18.5
10
30
66
16
C
FINISH:
APPENDIX B5
NAME
DRAWN
CHK'D
APPV'D
SIGNATURE
DATE

TITLE:
HUZAIMI
PROF.ZAINAL
PROF.ZAINAL
F
MATERIAL:
DWG NO.
Material
1
REVISION
SCALE:1:1
Driven Pulley
Drawing No.5
PAGE :
168
A4
8
A
25
16
40
6x2
140
132
R4
R1
2
40
.50
100
15
50
25
24.1
8.9
41.1
FINISH:
APPENDIX B6
NAME
DRAWN
CHK'D
APPV'D
SIGNATURE
DATE

TITLE:
Motor Support Plate
HUZAIMI
PROF.ZAINAL
PROF.ZAINAL
F
MATERIAL:
DWG NO.
Aluminium
1
REVISION
SCALE:1:2
Drawing No.6
PAGE :
A4
169
32
R1
6
B
55
R1
6
8
D
FINISH:
APPENDIX B7
NAME
DRAWN
CHK'D
APPV'D
SIGNATURE
DATE

TITLE:
HUZAIMI
PROF.ZAINAL
PROF.ZAINAL
Stabilizer Wheel Plate
F
MATERIAL:
DWG NO.
Aluminium
1
REVISION
SCALE:2:1
Drawing No.7
PAGE :
A4
170
25
A
450
10
12.5
D
25
FINISH:
APPENDIX B8
NAME
DRAWN
CHK'D
APPV'D
SIGNATURE
DATE

TITLE:
HUZAIMI
PROF.ZAINAL
PROF.ZAINAL
Stabilizer Wheel Shaft
F
MATERIAL:
DWG NO.
Aluminium
1
REVISION
SCALE:1:5
Drawing No.8
PAGE :
A4
171
25
A
15
12.5
75
16
6
6.3
6.3
12.5
E
FINISH:
APPENDIX B9
NAME
DRAWN
CHK'D
APPV'D
SIGNATURE
DATE

TITLE:
HUZAIMI
PROF.ZAINAL
PROF.ZAINAL
Welding Gun Arm
F
MATERIAL:
DWG NO.
Aluminium
1
REVISION
SCALE:2:1
Drawing No.9
PAGE :
A4
172
120
3
B
15
40
6x
17.5
62.5
102.5
C
FINISH:
APPENDIX B10
NAME
DRAWN
CHK'D
APPV'D
SIGNATURE
DATE

TITLE:
HUZAIMI
PROF.ZAINAL
PROF.ZAINAL
Welding Gun Holder
F
MATERIAL:
DWG NO.
Aluminium
1
REVISION
SCALE:1:1
Drawing No.10
PAGE :
173
A4
16
6x
2
16
51
93
61
18.5
D
30
FINISH:
APPENDIX B11
NAME
DRAWN
CHK'D
APPV'D
SIGNATURE
DATE

TITLE:
HUZAIMI
PROF.ZAINAL
PROF.ZAINAL
Welding Gun Clamp 1
F
MATERIAL:
DWG NO.
Aluminium
1
REVISION
SCALE:1:1
Drawing No.11
PAGE :
174
A4
39
11
49
71
11
6x
17.5
30
FINISH:
APPENDIX B12
NAME
DRAWN
CHK'D
APPV'D
SIGNATURE
DATE

TITLE:
HUZAIMI
PROF.ZAINAL
PROF.ZAINAL
Welding Gun Clamp 2
F
MATERIAL:
DWG NO.
Aluminium
1
REVISION
SCALE:1:1
Drawing No.12
PAGE :
175
A4
10
38
11.5
10.8
6
D
23
30
FINISH:
APPENDIX B13
NAME
DRAWN
CHK'D
APPV'D
SIGNATURE
DATE

TITLE:
HUZAIMI
PROF.ZAINAL
PROF.ZAINAL
Earth Channel Connector
F
MATERIAL:
DWG NO.
Copper
1
REVISION
SCALE:2:1
Drawing No.13
PAGE :
176
A4
40
6.3
15
3.5x4
7.5
5
B
520
FINISH:
APPENDIX B14
NAME
DRAWN
CHK'D
APPV'D
SIGNATURE
DATE

TITLE:
HUZAIMI
PROF.ZAINAL
PROF.ZAINAL
Aluminium Frame
F
MATERIAL:
DWG NO.
Aluminium
1
REVISION
SCALE:1:5
Drawing No.14
PAGE :
177
A4
1000
375
225
50
600
950
FINISH:
APPENDIX B15
NAME
DRAWN
CHK'D
APPV'D
SIGNATURE
DATE

TITLE:
Arcylic Transparent Plate
HUZAIMI
PROF.ZAINAL
PROF.ZAINAL
F
MATERIAL:
DWG NO.
Plastic Arcylic
1
REVISION
SCALE:1:5
Drawing No.15
PAGE :
178
A4
204
200
30
254
249.3
102.7
52
D
98.5
112
FINISH:
APPENDIX B16
NAME
DRAWN
CHK'D
APPV'D
SIGNATURE
DATE

TITLE:
HUZAIMI
PROF.ZAINAL
PROF.ZAINAL
F
MATERIAL:
DWG NO.
Mild Steel
1
REVISION
SCALE:1:5
Control Box
Drawing No.16
PAGE :
179
A4
45
15
25
55
32.5
10
10
45
10
25
6x
85
15
30
10
22.5
FINISH:
APPENDIX B17
NAME
DRAWN
CHK'D
APPV'D
SIGNATURE
DATE

TITLE:
Stabilizer Wheel Holder
HUZAIMI
PROF.ZAINAL
PROF.ZAINAL
F
MATERIAL:
DWG NO.
Aluminium
1
REVISION
SCALE:1:1
Drawing No.17
PAGE :
180
A4
591.5
1000
456
C
606
FINISH:
APPENDIX B18
NAME
DRAWN
CHK'D
APPV'D
SIGNATURE
DATE

TITLE:
HUZAIMI
PROF.ZAINAL
PROF.ZAINAL
F
MATERIAL:
DWG NO.
Mild Steel Plate

1
REVISION
SCALE:1:10
Cabinet
Drawing No.18
PAGE :
181
A4
PAGE :
182
183
APPENDIX C1
APPENDIX C2
184
185
APPENDIX C3
186
APPENDIX C4
187
APPENDIX C5
188
189
APPENDIX D1
190
191
192
193
194
195
196
197
198
199
200
APPENDIX D2
201
202
203
204
205
206
APPENDIX E2

Huzaimi AHamid MFKM2010

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DESIGN, FABRICATION AND TESTING OF A SEMI-AUTOMATIC WELDING

FIXTURE FOR CIRCUMFERENTIAL JOINING CYLINDERS USING MIG

HUZAIMI BIN A. HAMID

UNIVERSITI TEKNOLOGI MALAYSIA

DESIGN, FABRICATION AND TESTING OF A SEMI-AUTOMATIC

HUZAIMI BIN A. HAMID

A project report submitted in partial fulfillment of the

Faculty of Mechanical Engineering

To my believed Allah s.w.t

Kertas kajian ini menggunakan pendekatan sistematik terhadap rekabentuk,

Introduction to MIG (Metal Inert Gas) Welding

Introduction of welding on tank and piping

Overview the previous researches related to

circumferential joint welding

Overview the previous researches related on

cylindrical shape fabrications

DESIGN AND DEVELOPMENT OF WELDING

Method of welding fixture fabrication

Conceptual design and sketching

Sketching the concept

Part description and selection

Determination of workpiece rotation system

Project controlling system

Working operation of pneumatic triggering

Working operation of electrical circuit for

Bill of materials (BOM)

Welding voltages (V)

Welding current (Amp)

Testing and analysis

ASME standard and application

ASME codes and application

RESULT AND DISCUSSION

Criteria of welding joint by voltage

Criteria of welding joint by travel speed

Result of tensile test

Result of impact test

Result of hardness test

List of available needs

Project final specification

Description of rotational shaft

Description of attachment roller

Description of bearing housing

Description of drive pulley

Description of driven pulley

Description of motor support plate

Description of stabilizer wheel plate

Description of stabilizer wheel shaft

Description of welding gun arm

Description of welding gun holder

Description of welding gun clamp 1

Description of welding gun clamp 2

Description of earth channel connector

Description of aluminium frame

Description of dark acrylic transparent

Description of control box

Description of stabilizer wheel holder

Motor speed selector without load

Motor speed selector with load

BOM for custom made parts

BOM for standard parts

Estimation of design cost

Estimation of fabrication cost

Workpiece material characteristic