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  1. Willers

    Severe Weakness/porosity with plasma welding

    Thanks for the replies. I will attempt to run through a few batches of material - Annealed Fully cleaned Lasered edges guillotined off Untreated material I will hopefully get a definative answer. While the gas lines appear to hold pressure over night, the gas consumption does appear to be...
  2. Willers

    Severe Weakness/porosity with plasma welding

    Hi all, I am looking for help regarding the welding of seams of generator housings that we produce. Short question - How can porosity occuring in a mild steel welded joint be avoided when plasma arc welding (argon, hydrogen/argon) Long question - The raw material is rolled into a cylinder...
  3. Willers

    Severe Weakness/porosity with plasma welding

    I have been trying to push this on my MD for a while now, however it is looking unlikely due to various customer pressures. I will continue trying to get this done though, thanks!
  4. Willers

    Severe Weakness/porosity with plasma welding

    Thanks itsmoked, i'd had an initial search for the welding forum, but ill try a little harder. Im due to be talking to someone from AirLiquide today, so hopefully that will yield some answered
  5. Willers

    Severe Weakness/porosity with plasma welding

    The company that installed the machine have sent technicians twice and the problem has remained unsolved. We didn't 'get rid' of anyone.
  6. Willers

    Severe Weakness/porosity with plasma welding

    Thanks for the reply TVP, There is no filler wire in the process, it is just a hydrogen/argon ionized gas with an argon shield. Luckily the welding gas and flow rates seems to be one of the few constants in this process between good and bad batches of parts. The material is strip mill pickled...
  7. Willers

    Severe Weakness/porosity with plasma welding

    Hi all, I am looking for help regarding the welding of seams of generator housings that we produce. Short question - How can porosity occuring in a mild steel welded joint be avoided when plasma arc welding (argon, hydrogen/argon) Long question - The raw material is rolled into a cylinder...
  8. Willers

    Severe Weakness/porosity with plasma welding

    Hi all, I am looking for help regarding the welding of seams of generator housings that we produce. Short question - How can porosity occuring in a mild steel welded joint be avoided when plasma arc welding (argon, hydrogen/argon) Long question - The raw material is rolled into a...
  9. Willers

    Setting up a 'Pounce Postion' in a robot welding cell

    Thanks for the reply Tygerdawg, I think my main problem is with my familiarity with the teach pendant and commands. Ive managed to locate a section in the menu labelled 'possible field to start' in the same section where the home position of the unit is defined. Whilst I think i have saved the...
  10. Willers

    Setting up a 'Pounce Postion' in a robot welding cell

    Hi all, SHORT QUESTION - How do you create a 'Pounce Position' for a robot welding cell? (OTC/DAIHEN Almega ax-v6 robot arm) LONG QUESTION - With little welding experience and zero robot welding experience, I was dumped with the task of programming a welding cell for a new product after 3...
  11. Willers

    Bending and torsion of a cylinder

    "In my formula above this would cause the factor 3 being replace by a 2 (50% difference!)" Testing, FEA, and your calculation Prex (and also the helical spring, although i appreciate that the use of this is tenuous at best) show a corrective force in the region of 10s of newtons, while the...
  12. Willers

    Bending and torsion of a cylinder

    It doesnt look like one persay, although as a system (forces etc) I believe it should behave in the same way.
  13. Willers

    Bending and torsion of a cylinder

    Just one more thing! The book hydtools linked give the formula for deflection of a helical rectangular x-section spring (given below)...
  14. Willers

    Bending and torsion of a cylinder

    Thankyou all so much for your help Using the calculation for the deflection of a rectangular x-section helix produced a deflection/force within a few newtons of the FEA and testing, and im sure I can justify the difference by the fact that 1 rotation of a helix isnt technically 1 link in a...
  15. Willers

    Bending and torsion of a cylinder

    Thanks very much Prex, thats the kind of thing im looking for, ill put some numbers in and see if i get a similar result to the FEA. "About welding the rolled plate the way it comes out and then trim off the ends, you'll then have a "circular" cylinder." This will only add another process to...
  16. Willers

    Bending and torsion of a cylinder

    "You already have tests showing what the force needs to be - are you really being required to somehow back this up with numbers?" I am only required to prove our manufacturing process to a customer, and i'm trying to do it as well as possible. You are right, if FEA matches with test data, more...
  17. Willers

    Bending and torsion of a cylinder

    The wall/sheet thickness is 4mm, outer diameter 300mm, and height approximately 400mm. I hope this helps you help me!
  18. Willers

    Bending and torsion of a cylinder

    A stage in one of our manufacturing processes involves the rolling of a cylinder. Inevitably, the cylinders are not fed into the roller perfectly square to the backstop. Attached is a pitiful attempt at explaining the resulting shape of the cylinder (exaggerated). The next process in production...

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