DEBRE BIRHAN UNIVERSITITY

COLLAGE OF ENGINEERING
DEPARTMENT OF INDUSTRIAL ENGINEERING
GROUP ASSIGNMENT

COURS WELDING,FORMINGAND MACHINING

GROUP STUDENT NAME ID
1. YOHANIS MALAKU………………………………………………………DBUR0630/12
2. ARMIAS TASHOME………………………………………………………DBURO246/13
3. TAMERAT TADEYOS………………………………………………………DBUR1402434

SUBMITTED TO ABRAHAM W. (MSC.)

SUBMISSITION DATE 20/10/2016 E.C
 TABLE CONTENTS page

1 chapter one………………………………………………………………………………..
introduction ………………………………………………………………………………..
 Part One (introduction and background of welding and
machining operations, types of safety procedures and
precautions)
1.1 Introduction
There are four basic joining processes; mechanical joining such as rivets,
brazing and soldering, adhesive bonding, and welding. Traditionally, welding
is defined as one of the manufacturing processes for joining materials, mainly
metals and thermoplastics, by applying heat, or pressure, or both, on the
edges of the parts to melt together, then allowing them to cool to solidify.
The source of energy to heat and melt the materials has changed due to new
techniques. From the early ages until the end of the nineteenth century, forge
welding, using heating and forging, was the only welding to join iron and
steel. With the discovery of petrol, the chemical source was used for gas
welding, then the electrical source for arc welding methods, and, in the last
decade, new advanced methods have been launched, such as laser, electron
beam, friction, and ultrasound. In general, the new techniques attempt to
reduce the welded zone areas, by applying heat to a narrow area.
Consequently, fewer metallurgical changes occur during welding.
There are five basic welding joint types commonly used in the industry,
which are butt joint, tee joint, corner joint, lap joint, an edge joint. Thick
materials require edge preparation, which consists of removing material
along the edges to make grooves with a different shape. Appropriate filler
materials need to be used to fill the groves, by melting the base and the filler

BACKGROUND OF WELDING AND MACHINING OPERATION

Welding has a rich history that dates back to ancient times. Let me give you a brief overview:

Bronze Age: The earliest examples of welding involved pressure welding lap joints to create
small gold circular boxes over 2,000 years ago.
Iron Age: Egyptians and people in the eastern Mediterranean area learned to weld iron pieces
together during this period.

Middle Ages: Blacksmithing techniques developed, leading to iron items being welded by
hammering.
19th Century: Modern welding methods emerged:
Arc Welding: Sir Humphry Davy produced an arc between carbon electrodes using a battery in
1800.
Gas Welding and Cutting: Developed during the late 1800s.
Resistance Welding: Became practical for joining processes.
Carbon Arc Welding: Auguste De Meritens and Nikolai N. Benardos contributed to its
development.

Metal Electrode Arc Welding: C.L. Coffin received the first U.S. patent for this process in
1890.
20th Century: Welding technology advanced rapidly due to world wars, driving demand for
reliable and cost-effective joining methods12.
In modern times, welding machine operators play a crucial role. They skillfully operate welding
machines to bond, fuse, or join metal parts in various industries, ensuring high-quality welds
that meet safety standard
types of safety procedures and precautions
Safety procedures and precautions are crucial for maintaining a safe work environment. Here
are some essential safety rules and practices:

Follow the Dress Code: Adhere to workplace dress codes, which may include wearing
specific footwear, long sleeves, or pants to protect against common accidents1.

Wear Safety Gear: Use appropriate safety gear, such as hard hats, harnesses, or protective
equipment, depending on your job and workplace12.

Maintain Personal Hygiene: Good hygiene reduces illness risks and promotes overall health
and well-being1.
Take Responsibility for Personal Safety: Follow safety procedures and contribute to creating a
safe environment for everyone1.

Keep Your Workspace Clean: A tidy workspace minimizes hazards and promotes safety1.
Remember, safety precautions vary by industry and job role, so always follow specific guidelines
relevant to your work environment.
Part Two (welding operations: types, advantages and disadvantages,
applications)
Let’s explore different types of welding techniques, along with their
advantages, limitations, and applications:

1) Arc Welding:
Advantages:
Widely used for joining metals.
Suitable for repair and maintenance work.
Creates strong and durable bonds.
Disadvantages:
Requires skilled operators.
Generates spatter and fumes.
Applications:
Manufacturing industry, construction, and automotive repair.
2) Gas Welding:
Advantages:
Simple and portable.
Works well for thin materials.
Disadvantages:
Slow process.
Not suitable for reactive metals.
Applications:
Plumbing, sheet metal fabrication.
3) Resistance Welding:
Advantages:
Efficient and fast.
No additional filler material needed.
Disadvantages:
Limited to certain materials.
Requires precise control.
Applications:
Automotive, electronics, aerospace.
4) Laser Welding:
Advantages:
Precise and minimal heat-affected zone.
Suitable for small and intricate parts.
Disadvantages:
Expensive equipment.
Limited penetration depth.
Applications:
Medical devices, jewelry, electronics.
Part Three (machining operations: types of machining,
advantages and disadvantages, applications)

Types of Machining Operations

 1) Conventional Machining Process:
This traditional method involves direct contact between the cutting tool and the workpiece to
remove excess material.
Common conventional machining processes include:
Drilling Operation: Uses a multi-point cutting tool (drill bit) to create holes in the workpiece.
Boring Operation: An advancement of drilling, used to enlarge existing holes.
Turning: Rotates the workpiece against a single-point cutting tool to shape it.
Milling: Involves multi-point cutting tools to create complex shapes.
Planing: Removes material in a linear motion.
Broaching: Uses a specialized tool to cut internal shapes.
These processes rely on tools like lathes, drills, and milling machines.

2) Non-Conventional Machining:
These methods don’t rely on direct contact and include:
Electrical Discharge Machining (EDM): Uses electrical sparks to erode material.
Laser Cutting: Utilizes focused laser beams for precision cutting.
Ultrasonic Machining: Uses ultrasonic vibrations to remove material.
Waterjet Cutting: High-pressure water jets with abrasives cut through materials.
Chemical Machining: Chemical etching to shape the workpiece.
Non-conventional methods are useful for intricate shapes or hard-to-machine materials.

Advantages of Machining:
Precision: Machining offers high accuracy and tight tolerances.
Complex Shapes: It can create intricate geometries.
Material Versatility: Works with various materials.
Surface Finish: Provides smooth finishes.
Customization: Tailored to specific requirements.

Disadvantages of Machining:
Material Removal: Generates waste material (chips).
Energy Consumption: Requires power for cutting.
Tool Wear: Tools need replacement.
Setup Time: Preparing machines takes time.

Part Four (project presentations and cost estimations:

types of materials used, types of operations, dimensions
and measurements,CAD drawings of parts with BoM, cost
estimations, photograph of prototypes)
project presentations and cost estimations
 Tapered threads are a type of thread that has a cone shape. Unlike traditional
straight threads, which remain straight throughout, tapered threads taper to one
side. This design allows tapered threads to provide very high connection tightness
even without the use of additional seals.

Two common standards for tapered pipe threads are:

1) NPT (National Pipe Taper): Widely used in the United States and Canada,
NPT threads have a 60-degree angle and flattened peaks and valleys. They
form a seal when torqued, compressing the external and internal threads
against each other. NPT threads can be used with or without a thread
sealant.
 2) BSPT (British Standard Pipe Taper): BSPT threads have a 55-degree angle
and rounded peaks and valleys. They are incompatible with NPT threads
due to their different thread angles and shapes.
Remember that tapered threads are especially useful for gas or liquid-tight
connections, as they create stronger and leak-resistant seals.
 MACHINIG OPERATION - LATHE
1 FACING
2 TAPPER TURNING
3 COUNTER
4 FORM TURNING
5 CHAMFERING
6 CUTOFF
7 THREADING
8 BORING
9 DIRRILING