EMM430 Book UAQ

STS-G09-Mechanical Engineering Fundamental III- EMM430-Term3
1
STS-G09-EMM430 Umm-Al Quwain-V02-2016/2017
The welding I course introduces the welding to the students in virtual reality experience in a safe and realistic environment. This course
first of all highlights the risks and hazards associated with welding to reduce the injuries. Then explain the important of how to select
the appropriate personal protective equipment for welding to recognize and follow safe work practice, This course explains what is
virtual reality and the key benefits of virtual reality in welding training, students will learn in details about welding simulation machine
components (The touchscreen monitor, USB port , The VR GMAW/FCAW gun, The VR SMAW device, and The helmet) , specifications and
the different welding process can be implemented on these machines GMAW,FCAW and SMAW. Students will learn how to use the user
interface of welding simulator correctly and safely to demonstrate, operate and setup the welding parameters for the SMAW and GMAW.
Also they will learn how to access information/data inputting and storing information used in manufacturing, engineering or related
environments, using computing technology. Finally the students will be able to practice how to weld butt joint in 1G, 2G, 3G and 4G
positions and fillet joints, in1F, 2F, 3F and 4F positions for SMAW and GMAW.
Objectives:
On successful completion of this module (and practical tasks), the student should be able to:
1- The meaning of welding.

2- Welding types.
3- Identify Risks and hazards associated with welding.
4- Use and select the correct PPE for Welding.
5- Describe Welding simulation machine components and specifications.
6- Describe and demonstrate welding simulator setup for ARC (MMA and MIG).
7- Access information/data, Inputting and storing information used in manufacturing, engineering or related environments, using
computing technology.
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Content:
N0 Learning Outcomes Page
1 Welding definition. 5
2 Classification of Welding Process. 6
3 Identify the risks and hazards associated with welding. 11
4 Identify and select the appropriate personal protective equipment for Welding. 14
5 What is Virtual Reality 16

6 Key benefits of Virtual reality in welding training. 18
7 Welding simulation machine components and specifications 19
8 Welding simulation machine describe, demonstrate, operate and setup for SMAW ( current, electrode, position and work 26
piece)
Welding positions: According ASME & ISO 6947 46
9 Describe and Demonstrate butt joints (1G, 2G, 3G, 4G) for SMAW 54-55
10 Describe and Demonstrate fillet joints (1F, 2F, 3F, 4F) for SMAW
11 Welding simulation machine describe, demonstrate, operate and setup for GMAW ( current, electrode, position and work
piece)
12 Describe and Demonstrate butt joints (1G, 2G, 3G, 4G) for GMAW
13 Describe and Demonstrate fillet joints (1F, 2F, 3F, 4F) for GMAW
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Course Assessment Scheme
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Introduction welding
1-Welding Definition
Welding is a process of permanent joining two materials (usually metals), usually by raising the temperature at the joint so that parts
are united by fusion, or by forging under pressure.
Welding is the most economical and efficient way to join metals permanently. It is the only way of joining two or more pieces of metal to
make them act as a single piece.
During welding the metal at the point of contact between the components to be joined is melted and fused together. To achieve this
fusion in mild steel components, very high temperatures are necessary (3800oC to 4300oC). Welding is used where strength in the joint
is required.
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2-Classification of Welding Process
Welding processes can be classified based on the source of energy to three most common:
1. Gas welding. http://www.youtube.com/watch?v=kPW06n-27FY
Fig-1
2. Arc welding. http://www.youtube.com/watch?v=CoHVA7nr82A
Fig-2
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3. Resistance welding http://www.youtube.com/watch?v=z44AlvQimm0
Fig-3
Arc welding types:-

1. Shielded Metal Arc Welding (SMAW).or Manual Metal Arc Welding(MMAW)
2. Gas Metal Arc Welding (GMAW) or Metal Inert Gas(MIG)
3. Gas Tungsten Arc Welding (GTAW) or Tungsten Inert Gas(TIG)
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8
9
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3- Identify the risks and hazards associated with welding.
http://www.youtube.com/watch?v=K5JZUVxEEYg
When we are doing welding we need to protect ourselves from any danger. (Potential contingencies are identified and solutions are
considered)The main dangers are:
1. Electrical shock.
Even though welding generally uses low voltage, there is still a danger of electric shock. Which can result from even a small
shock; brain damage and death can result from a large shock.
REMEMBER: the current return cable is NOT an earth
Fig 7- Electrical shock.

2. Fumes and gases.
Welding “smoke” is a mixture of very fine particles (fumes) and gases. All welding processes produce fumes and gases which can
harm you. Don’t stand over the work
Ventilation:-
1- Use exhaust trunking to remove fumes. Fume extraction system
2- Use respirator pad for toxic fumes.
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Respirator pad for toxic fumes
Flexible exhaust trunking
Fig-8 Fume extraction system

3. Heat.
Welding produces heat and a very bright light called “arc rays” which will burn your eyes and skin.
4. Visible Light, and Ultraviolet and Infrared Radiation
The intense light associated with arc welding can cause damage to the retina of the eye,
While infrared radiation may damage the cornea and result in the formation of cataracts.
5. Fires and Explosions
The intense heat and sparks produced by welding, or the welding flame, can cause fires or explosions if combustible or
flammable materials are nearby.
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6. Electrical shock.
Even though welding generally uses low voltage, there is still a danger of electric shock. Which can result from even a small
shock; brain damage and death can result from a large shock.
7. Fumes and gases.
Welding “smoke” is a mixture of very fine particles (fumes) and gases. Many of the
Substances in welding smoke
8. Heat.
The intense heat of welding and sparks can cause burns. Eye injuries have resulted from contact with hot slag, metal chips,
sparks, and hot electrodes.
9. Visible Light, and Ultraviolet and Infrared Radiation
The intense light associated with arc welding can cause damage to the retina of the eye,
while infrared radiation may damage the cornea and result in the formation of cataracts.
10. Fires and Explosions

The intense heat and sparks produced by welding, or the welding flame, can cause fires or explosions if combustible or
flammable materials are nearby
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4- Identify and select the appropriate personal protective equipment for Welding..
http://www.youtube.com/watch?v=L7yajEmMQvE
We must protect ourselves by wearing the correct clothing as shown in the picture
Below Fig-4:
a) Welding mask
b) Welding gloves
c) Leather apron
d) Safety shoes
e) Overalls
Fig-4 welding PPE
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Practical task 01: Use PPE correctly and recognize their role in protection [10 marks, 1 each]
Teacher will take the students to the workshop and practice with them how to wear the PPE and explain the role of these equipment in
protection, on the other day he should conduct this skill set observation.
Skill set observation and questions to support observation
During the demonstration of skills, Did the candidate perform the following skills?
Yes No
1. Wear the leather apron correctly.
2. Wear the helmet correctly.
3. Inspect and wear the gloves correctly.
4. Return the PPE in their place after finish from this task.
5. Q1-What is the material welding apron should be made from and why?
6. Q2-How can you protect yourself from Visible Light, Ultraviolet and Infrared Radiation?
7. Q3-How can you protect yourself from Fumes and gases?
8. Q4-Which conditions can cause fires or explosions?
9. Q5-Is it true that the current return cable is an earth cable.

10. Q6-Is it true that there are no electrical shock hazards because welding generally uses low voltage?
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Welding Simulation
5-What is Virtual Reality? http://www.youtube.com/watch?v=UT5xtpHRdlE
The concept of Virtual Reality uses:
Computer technology to create a simulated, three dimensional world.
Goal - the feeling that the user is in that world.
Tracking technology that allows the user to interact with the environment in a meaningful way
Goal – Teach a skill using these interactions.
Examples:
Virtual Driving Trainer Virtual Avionics trainer Virtual Dental Training
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Virtual welding training machine:
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6- Key benefits of Virtual reality in welding training. http://www.youtube.com/watch?v=Hs1H-TNyJQg
1. Promotes faster learning: Trainees can complete more practice welds within a fixed amount of training time.
2. Go Green Reduce waste and save energy.
3. Save money on base material & other materials.
4. Improve trainee/worker safety.
5. Welders learn new techniques or practice their skills in a safe environment without risk of injury
6. Provide High-Tech training tool for welding education.
7. Instant feedback from each weld pass allows the trainee to hone the specific skills that need improvement until the full technique of
laying a quality weld is achieved.
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2.3 Welding simulation machine components and specifications.
WAVE NG WORKBENCH the welding simulator
http://learnvirtual.eu/en/simulators/43-wave-ng-workbench-the-welding-simulator
Monitor
Master switch
Simulator Stand
Computer cupboard
(Adjustable legs) for Balance
Fig-5.WAVE NG Workbench
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Mig Torch
TIG Tools
Torch Rod Box
screen
MMA Electrode handle
6 emitters around the screen
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USER INTERFACE OVERVIEW
The WAVE NG is a virtual reality arc welding trainer. This computer based training system is an educational tool designed to allow
students to practice their welding technique in a simulated environment. It promotes the efficient transfer of welding skills to the
welding booth, while reducing material waste and energy consumption associated with traditional welding training. See Fig-5 for
locations of operator controls and indicators.
The WAVE NG training application user interface is displayed once the application is started. Interaction devices vary according to the
hardware you are using.
1-DISPLAY AREA.
The WAVE NG screen can be divided into three distinct zones:
1. The status area located on top of each page,

2. The content of the page in the middle area,
3. The navigation area located at the bottom of each page.
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Current active tool Connection status
Logged-in/ user name.
Previous page Main page Calibration
Sound management
Closing session
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1-Status area
It indicates to the user the system status (from left to right):
 Current active tool,
Changing from one tool to the other is automatic before starting an exercise if you selected a different process from the active one.
 Screen configuration (vertical or horizontal),
 Connection status with the server,
 Logged-in user name.
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2-Navigation area
The navigation area enables to quickly access the common functionalities of all the application pages. Some of these functionalities
might be disabled depending on the page which the user is on.
 Previous page.
 Main page.
 Sound management.
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 Calibration.
 Closing session.
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3. Welding Simulation
(3.1/4.1.)Welding simulation machine describe, demonstrate, operate and setup for MMA and MIG
Starting Power on: put the master switch on 1

1 beep from the UPS
The system starts: Initializing process time: ~ 40 s
Then screen will move in a vertical position

Always at 90°
IF the screen is at 90°Request for rotation

Automated vertical motion
IF the screen is in a flat position90°rotation (manual action hold push button)

Automated vertical motion
Shutdown Power off: put the master switch on 0

After 10 s, UPS beeps during 1 min 1 final beep
Shutdown time ~ 1 min 20 sec
Restart: wait 30 seconds after the last beep to dissipate the residual current
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Workbench Input devices:
1. MIG Torch
2. MMA Electrode handle
3. TIG Tools: Torch and Rod Box
4. Ultrasonic motion sensors
5. 6 emitters around the screen
6. Microphones on the tools
1. Use of Input devices:
2. Motion facing the screen to move the cursor
3. Click on the trigger to activate an element on the screen
4. For TIG tools, use torch for selections
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I. Exercise selection:- Non ordered curriculum
1) Log in.
 Select trainee button (or other for trainer, manager and administrator)
 Select your name
 Enter your password (4 digits 0-9)
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2) Selecting the welding process:-
The first step in selecting an exercise is the choice of the welding process. Standard choices are MIG (semi-automatic),
MMA (coated electrodes), or TIG.
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3) Selecting the assembly type:-
Two assembly types are proposed, regardless of the welding process chosen:
 BW (butt),
 FW (fillet).
30
The proposed position choices depend on the welding process and the assembly type.
31
4) Selecting the welding cord:-
Cords choices depend on the welding process, assembly and position type.
32
You can select the welding direction (forehand or backhand) when working with horizontal pieces on the GMAW process.
33
5) Level selection page:-
User may have the choice between three levels of difficulties regarding exercises included in the curriculum.
A level is defined by target values and tolerances range on each parameter. Tolerance range is lowering when level gets harder.
Level page displays expected values for each parameter (speed, straightness, distance and angles). You can see each value by selecting
the level name (beginner, advanced, expert).
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6) Step selection page:-
Steps in a training path include a set of parameters. User will only be tracked on parameters included in a step. Step selection page
displays a list of steps with their active parameters.
A step filter is available on the left; select/unselect a parameter in the step in order to show/hide steps with this parameter.
35
7) Preparation page:-
Before starting the exercise, a page provides a synthetic display of the parameter(s) worked. This page also displays a
video demonstration.
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II. PERFORMING THE EXERCISE:-
1. Represent on the screen
When executing the exercise, the piece to be welded is represented in 3D format on the screen.
 With the MIG and TIG process, a cross represents the current position of the torch end.
Cross for MAG and TIG torch
 For the MMA process, the tool is shown entirely on the screen with its electrode.
Electrode handle
 For the TIG process, the rod and its support are represented on the screen.
TIG rod
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2. Start and finish an exercise
To start and finish an exercise, simply click on the tool button. An additional click on the torch button with the current position of the tip
outside the weld pool area will allow you to exit the exercise screen .Before starting an exercise; an informative frame displays the
selected exercise and the worked parameters.
Exercise 3D screen
3. Exercise sequence
If the guides are active, you must be careful with respect to the error indicators in order to apply a corrective action. The visual
metaphors of each guide are governed by the following rules:
 A red signal appears when you are out of tolerance,

 A yellow signal means that you are within tolerance but dangerously approaching the limit zone,
 A green sign indicates the perfect position to reach.
38
4. visual guides:-welding parameters
a) Trajectory
The indicator is a green line describing the trajectories to follow
Good trajectory, the cross is on the green line representing the trajectory to follow.
Errors (Cursor out of the line), a yellow band appears around the perfect value of the trajectory.
You will soon leave the tolerances.
Errors (Cursor out of the line), the band is red. You are outside the tolerances for the trajectory.
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b) Speed
The spot indicates the correct speed. This is the target where the end of the wire or electrode must be maintained.
Good speed, the cross is in the grey welding pool.
Near tolerance limits a yellow sign appears in the welding pool. You are too fast and will soon leave the tolerances.
(Errors (too slow/quick) the sign is red. You are too fast and out of the tolerances.
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c) Angles
The orientation is represented by two angles; the work angle and the lead angle.
Correct a blue spot represents your current orientation and when the orientation is correct, it must appear in the middle of the cross.
Close to the tolerance limits a yellow circle appears around your cross and the blue spot is moving away from the middle of the
cross. You will soon leave the tolerances.
Errors a red circle appears around your cross and the blue spot is out of this circle. You are out of the tolerances.
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d) Arc length
When the distance parameter is active, the visual indication is the same for both the nozzle work distance and the arc length.
Two blue lines (on each side of the piece centre) provide an indication regarding the distance to the piece.
 These lines move away from the piece centre when you move the tool away from the screen,
 They come closer when you bring the tool towards the screen.
 These lines come together, the tool is in contact.
For the MMA welding,

if you are not working the distance parameter, an indicator is positioned on the tip of the electrode to help you position yourself.
Good, when the position of the electrode holder is at the correct distance (or within the tolerance limits), the cylinder at the end
of the electrode is green.
Too far, when the electrode is too far from the piece, the cylinder on the end of the electrode becomes red.
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Too close, when the electrode moves towards the metal plates, the size of the green cylinder decreases and ultimately disappears,
meaning that the electrode is in contact.
For the MIG welding,
Correct: when the parameter is correct, the blue lines are in the centre of each metal piece.
Close to the tolerance limits: When the parameter approaches the limit values, two yellow bands appear at the centre of the pieces to be
welded. You must then correct your work by lining up the blue lines and the green lines.
Errors: When the parameter moves out of the limit values, two red areas appear on the piece to be welded. The green lines indicate the
ideal value. You must then correct your work by lining up the blue and green lines.
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RESULTS
The results of the exercises are analysed and displayed on this page. An overview of results is provided when the user obtains access to
this page just after his exercise. Then, the user can select one of the parameters he has been practicing to have a closer look at his
results.
 Overview
On this page, the user can have a general view of his work. All the curves representing the analysed parameters are displayed. On the left
side of the page, there is a percentage associated to each parameter. This percentage represents the level of accuracy of the trainee.
100% means that the trainee stayed in the tolerance area and mastered the parameter at this level.
A global rate for this attempt is also displayed on the left side of this page together with the time spent to perform the work.
Results page – global overview
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 Details regarding a parameter
By clicking on a result tab, you can display details regarding the selected parameter.
The curve is larger, and on the bottom, a 3D window replays the recorded exercise focusing on the selected parameter.
For each curve, user can see a green line (the perfect value), a black line (what he performed), and two red areas. When the black curve
is inside the white area, the exercise is still good; when outside there is a mistake.
The 3D window view depends on the selected parameter and provides an aid to understand what the user did.
Results page –
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(3.2-3.3-4.2-4.3)Describe and Demonstrate butt and fillet joints for MMA and MIG
Use the machine manual to practice welding joints for MMA and MIG
Students results should be printed out and kept in their file, feedback for the students should be given.
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Welding positions: According ASME & ISO 6947
There are four basic welding positions. These positions are used for welder certification. Welders’ certification is based on a number of
factors, which include the welding joint type and the position in which the test weld was performed. Welding positions have been given
a number designation, as follows:
1 - Flat Position.
2 - Horizontal Position.
3 - Vertical Position.
4 - Overhead position.
The number designations are used in conjunction with one of two letter designations:
F - Fillet Weld.
G - Groove Weld.
Butt joints:
ASME(USA)-UK ISO/BS EN
1G PA
2G PC
3G PF-vertical up, PG-vertical down
4G PE
Fillet joints:
ASME(USA)-UK ISO/BS EN
1F PA
2F PB
3F PF-vertical up, PG-vertical down
4F PD
47
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6.4- Welding symbols on drawings:
Type of weld Section through weld symbol

Square butt
Double J butt
Single U butt
Single bevel butt
Fillet
Single Vee butt
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Welding symbols on drawings
Like other aspects of drafting, there’s a set of symbols for welding to simplify the communication between designer and builder (i.e. the
welder). This language may seem a little strange at first, so it's best to learn it one symbol at a time
 These figures represent the core structure of every drafting specification for a weld to be performed.
 The welding symbol has an arrow, which points to the location on the drawing where a weld is required.
 The arrow is attached to a leader line that intersects with a horizontal reference line.
Finally, there's a tail at the opposite end of the reference line that forks off in two directions. The tail is optional and needed only for
special instructions.
Example 01
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Example 02
Example 03
Example 04
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Practical task
Write the welding position name and the symbol in the table below. [10marks, 2 each]
Welding joint symbol Welding symbols on drawings marks
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9-13
 -Describe and Demonstrate butt and fillet joints for MMA and MIG
Use the machine manual to practice welding joints for MMA and MIG
Students results should be printed out and kept in their file, feedback for the students should be given.
 Welding simulation machine operate and setup: - (Access information/data, Inputting and storing information).
https://drive.google.com/open?id=0B-3jfGkga-2sYkptSzJfZG9zY1E
Assessment
Check the quality and accuracy of your finished weld once you achieve a score greater than 60% you will be
assessed as competent. Save the result on USB and print it and keep in students file as evidence.
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STS-G09-Mechanical Engineering Fundamental III- EMM430-Term3

1- The meaning of welding.

N0 Learning Outcomes Page

2 Classification of Welding Process. 6

3 Identify the risks and hazards associated with welding. 11

5 What is Virtual Reality 16

2. Arc welding. http://www.youtube.com/watch?v=CoHVA7nr82A

Arc welding types:-

REMEMBER: the current return cable is NOT an earth

Fig 7- Electrical shock.

Flexible exhaust trunking

Fig-8 Fume extraction system

10. Fires and Explosions

Fig-4 welding PPE

Skill set observation and questions to support observation

2. Wear the helmet correctly.

3. Inspect and wear the gloves correctly.

7. Q3-How can you protect yourself from Fumes and gases?

8. Q4-Which conditions can cause fires or explosions?

9. Q5-Is it true that the current return cable is an earth cable.

The concept of Virtual Reality uses:

Computer technology to create a simulated, three dimensional world.

Goal - the feeling that the user is in that world.

Goal – Teach a skill using these interactions.

Virtual Driving Trainer Virtual Avionics trainer Virtual Dental Training

WAVE NG WORKBENCH the welding simulator

(Adjustable legs) for Balance

Torch Rod Box

MMA Electrode handle

6 emitters around the screen

The WAVE NG screen can be divided into three distinct zones:

1. The status area located on top of each page,

Logged-in/ user name.

Previous page Main page Calibration

It indicates to the user the system status (from left to right):

 Current active tool,

 Screen configuration (vertical or horizontal),

 Connection status with the server,

 Logged-in user name.

Starting Power on: put the master switch on 1

Then screen will move in a vertical position

IF the screen is at 90°Request for rotation

IF the screen is in a flat position90°rotation (manual action hold push button)

Shutdown Power off: put the master switch on 0

3. TIG Tools: Torch and Rod Box

4. Ultrasonic motion sensors

5. 6 emitters around the screen

6. Microphones on the tools

1. Use of Input devices:

2. Motion facing the screen to move the cursor

3. Click on the trigger to activate an element on the screen

4. For TIG tools, use torch for selections

Cross for MAG and TIG torch

 A red signal appears when you are out of tolerance,

The indicator is a green line describing the trajectories to follow

Good speed, the cross is in the grey welding pool.

For the MMA welding,

For the MIG welding,

Results page – global overview

Type of weld Section through weld symbol

Single bevel butt

Single Vee butt

Welding joint symbol Welding symbols on drawings marks

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