The project undertaken is titled as “Automation of MIG welding to manufacture mechanical components”. The project is to manufacture metal products using additive manufacturing technique to produce some common mechanical metal components. Additive layer manufacturing, commonly referred to as 3-D printing, has progressively matured technically, creating rapid growth. Economists speculate it to cause a revolution in manufacturing industry. However, this technology has been restricted to the manufacture of ceramic and polymer components due to its high cost to manufacture metallic products.

1. Project Guide:
Dr. Mohammed Viquar Mohiuddin
(Mechanical Engg. Dept. MJCET, Hyd)
Submitted By:
Syed Muazzam Ahmed(1604-11-736-006)
Karan Kumar Sadarangani(1604-11-736-007)
Mohammed Abdul Haq(1604-11-736-005)
Automation Of MIG Welding To
Manufacture Mechanical
Components
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Proposal
• To fabricate a machine that can manufacture
mechanical components using MIG welder.
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Introduction
• To Manufacture components with Additive layer
manufacturing(ALM) technology, commonly referred
to as 3-D printing.
• ALM has progressively matured technically, creating
rapid growth.
• This technology has been mostly limited to polymers
and ceramic materials due to high cost to manufacture
metal products.
• To manufacture metal components with this
technology at lower costs.
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3 Axis Machine

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Automated 3-axes workbench
• It is a 3-axes actuated stage on which metal is
deposited.
• It is actuated with motors at desired RPM.
• The motion is actuated with the help of rack and
pinion and slide on linear bearings.
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Actuation
• For the actuation of the machine, stepper motors were
used in all the 3 axes.
• The X and Y axes are actuated by pulley and belt
mechanism and the distance per revolution is
calculated according to the number of teeth in pulley
and the pitch of the belt
• The Z axes is actuated by lead-screw mechanism with
a screw of 8mm pitch diameter with a pitch of
1.25mm and the distance per revolution is calculated
using it.
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Electronics Hardware
• The electronics hardware includes the different
components that were used in the completion of the
project.
• It is embedded as part of a complete device including
hardware and mechanical parts.
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Arduino MEGA 2560
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The Arduino Mega is a microcontroller board
based on the ATmega1280 . It has 54 digital
input/output pins.

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RAMPS
– Reprap arduino mega pololu shield, mainly
designed for using the pololu stepper driven board
– It works on arduino mega 2560 mother board. It
has been specially designed for the DIY 3d
printers.
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Motor Driver
• A motor driver circuit is designed to drive an
electromagnetic load, such as a brushed or brushless
motor, stepper motor or a solenoid or relay.
• The motor driver provides the interface between the
signal processing circuitry and the motor.
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Stepper Motor
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Working
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CAD Model
Conversion to .stl format
Slicing using Slicer
Generation of G-Codes
Interfacing of Arduino using Repetier Host
Arduino to Motor Drivers
Actuation Of Workbench + Initiation of Printing

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CAD Model
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STL Format
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Slicing
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Repetier Host
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MIG Welding
• Also referred to as Gas Metal Arc Welding(GMAW).
• A welding process in which an electric arc forms
between a consumable wire electrode and the
workpiece.
• Along with the wire electrode, a shielding gas feeds
through the welding gun, which shields the process
from contaminants in the air
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MIG Welder setup
• The wire electrode used is mild steel.
• The machine will be supplied with a constant voltage
and current
• Shielding gas mixture of 100% CO2 will be supplied
to the machine.
• Wire of 0.9 mm diameter is fed at a rate 4.23 mm/s.
• Deposition rate of 44.1 g/min is achieved.
• deposition rate m = (5.1* (10^-13) (I^
2*L)/S)+(2.2*10^-6)*I
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MIG welder holder
• The GMAW torch is to be fixed over the workbench on a
pillar rod.
• The pillar rod is a standard fixture which is fixed into the
ground.
• The pillar rod holds the torch at 90 ° to the ground.
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Additive Layer Manufacturing
(ALM)
• Additive layer manufacturing is a process in which a
component is built up in discreet layers.
• Digital 3D model is sliced and is used to build up a
component in layers by depositing material.
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Advantages of ALM
• Freedom to design and innovate.
• Material Efficiency
• Green manufacturing.
• Predictability.
• No tool required.
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WORKING VIDEO
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Problems Faced
• Printing a layer perfectly upon another layer was a bit
difficult.
• The entire process of 3d printing was time taking. Since
for printing a layer of 2mm height and 40mm width
consisted 6 weld beads. So printing this layer took
around 2 minutes. Then we had to give a gap of 3
minutes for it cool down. So with this rate it would take
around 4 hours to print the cuboid with a height of
30mm.
• Also, when the 2nd layer was printed, the total height of
these two layers wasn’t 4mm unlike expected, because
the 2nd layer had to start by melting and making a pit into
the already printed 1st layer.
• The heat released during the process took a toll on the
electronics , as a result the motor drivers got heated up
and stalled the motors randomly in between. Now to
continue printing layers for 4 hrs, the setup needs to be
set in an air conditioned atmosphere.
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ANY QUESTIONS?
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