Department Of Mechanical Engineering School Of Mechanical Engineering .
GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 2368 GSJ: Volume 9, Issue 10, October 2021, Online: ISSN 2320-9186 www.globalscientificjournal.com INCREASE THE FATIGUE LIFE/STRENGTH OF FILLET WELDING IN FRAME/CHASSIS BY INTRODUCING A TIGTOE DRESSING ON WELD TOE Submitted in partial Fulfilment of the requirements for the award of Bachelor of Engineering degree in Mechanical Engineering By SUNDAR C ( Reg no : 38450084 ) SURESH R ( Reg no : 38450085 ) DEPARTMENT OF MECHANICAL ENGINEERING SCHOOL OF MECHANICAL ENGINEERING SATHYABAMA INSTITUTE OF SCIENCE AND TECHNOLOGY (DEEMED TO BE UNIVERSITY) Accredited with grade “A” by NAAC JEPPIAAR NAGAR, RAJIV GANDHI SALAI, CHENNAI – 600119 October 2021 GSJ 2021 www.globalscientificjournal.com
GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 2369 SATHYABAMA INSTITUTE OF SCIENCE AND TECHNOLOGY (DEEMED TO BE UNIVERSITY) Accredited with “A” grade by NAAC Jeppiaar Nagar, Rajiv Gandhi Salai, Chennai - 600 119 www.sathyabama.ac.in DEPARTMENT OF MECHANICAL ENGINEERING BONAFIDE CERTIFICATE This is to certify that this Project Report is the bonafide work of SUNDAR C ( Reg no : 38450084 ) and SURESH R ( Reg no : 38450085 ) who carried out the project entitled “INCREASE THE FATIGUE LIFE/STRENGTH OF FILLET WELDING IN FRAME/CHASSIS BY INTRODUCING A TIG-TOE DRESSING ON WELD TOE” under our supervision from June 2021 to October 2021. Internal Guide Dr.R.B.DURAIRAJ M.Tech., Ph.D., Head of the Department Dr. G. ARUNKUMAR, ME., Ph.D., Submitted for Viva voice Examination held on Internal Examiner External Examiner GSJ 2021 www.globalscientificjournal.com
GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 2370 SATHYABAMA INSTITUTE OF SCIENCE AND TECHNOLOGY (DEEMED TO BE UNIVERSITY) Accredited with “A” grade by NAAC Jeppiaar Nagar, Rajiv Gandhi Salai, Chennai - 600 119 www.sathyabama.ac.in DEPARTMENT OF MECHANICAL ENGINEERING DECLARATION We SUNDAR C ( Reg no : 38450084 ) and SURESH R ( Reg no : 38450085 ) hereby declare that the Project report entitled “INCREASE THE FATIGUE LIFE/STRENGTH OF FILLET WELDING IN FRAME/CHASSIS BY INTRODUCING A TIG-TOE DRESSING ON WELD TOE” done by us under the guidance of Dr.R.B.Durairaj M.Tech., Ph.D., is submitted in partial fulfilment of the requirements fo the award of Bachelor of Engineering degree in Mechanical Engineering. DATE : SIGNATURE OF THE CANDIDATE PLACE : CHENNAI GSJ 2021 www.globalscientificjournal.com
GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 2371 SATHYABAMA INSTITUTE OF SCIENCE AND TECHNOLOGY (DEEMED TO BE UNIVERSITY) Accredited with “A” grade by NAAC Jeppiaar Nagar, Rajiv Gandhi Salai, Chennai - 600 119 www.sathyabama.ac.in DEPARTMENT OF MECHANICAL ENGINEERING ACKNOWLEDGEMENT I am pleased to acknowledge my sincere thanks to Board of Management of SATHYABAMA for their kind encouragement in doing this project and for completing it successfully. I am grateful to them. I convey my sincere thanks to Dr. S. Prakash, M.E., Ph.D., Dean, School of Mechanical Engineering and Dr. G. Arunkumar M.E., Ph.D., Head of the Department, Department of Mechanical Engineering for providing me necessary support and details at the right time during the progressive reviews. I would like to express my sincere and deep sense of gratitude to my Project Guide Dr.R.B.Durairaj M.Tech., Ph.D., for his valuable guidance, suggestions and constant encouragement paved way for the successful completion of my project work. I also express my thanks to all Teaching and non-teachimg staff members of the Department of Mechanical Engineering who were helpful in many ways for the completion of the project. GSJ 2021 www.globalscientificjournal.com
GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 2372 ABSTRACT Fatigue cracks have emerged as an important issue in the joints and connections of existing steel structures over the last few decades. Therefore, these are the main inspection and maintenance items for steel structure operators. This underscores the importance of determining crack size using reliable detection methods and assessing the severity of such cracks with respect to the structural integrity of the structure. In this article, we investigated the effectiveness of strain measurement in detecting fatigue cracks in lateral unloaded support welded attachments that receive an out-of-plane axial load. Numerical analysis and experimental research have been able to correlate the strain reduction measured by the attached gauge to the crack depth at the weld toe. In addition, various strain growth patterns were found during the fatigue test, and the fracture surface of the test piece was observed to interpret these patterns. In addition, the location of cracks relative to the weld toe was predicted by strain measurements. III GSJ 2021 www.globalscientificjournal.com
GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 2373 TABLE OF CONTENTS CHAPTER No. 1 TITLE PAGE No. ABSTRACT v LIST OF FIGURES ix LIST OF TABLES xi LIST OF SYMBOLS AND ABBREVIATIONS xii INTRODUCTION 1 – Preparation 2 - GMAW Welding 2 – Fillet Welding 2 – Visual Inspection 2 – TIG Welding 2 - Pre Check 2 – TIG TOE Dressing 2 – TIG TOE Dressing 2 - Visual Inspection 2 - NDT UT Inspection 2 2 2 LITERATURE SURVEY 5 3 AIM AND SCOPE 7 3.1 AIM AND SCOPE 7 3.2 AREA 7 4 MATERIALS AND EXPERIMENTAL METHOD 7 4.1 7 OBJECTIVES / METHODOLOGY GSJ 2021 www.globalscientificjournal.com
GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 2374 CHAPTER No. TITLE 4.2 5 Application & Advantages PAGE No. 7 4.3 Methodology Flow 8 4.4 Methodology Flow 8 4.5 Methodology Flow 9 4.6 Comparison Graph 9 RESULTS AND DISCUSSION 10 5.1 RESULT 10 5.2 NDT UT INSPECTION REPORT 10 5.3 DT MACRO ETCHING INSPECTION COMPLETED 11 III GSJ 2021 www.globalscientificjournal.com
GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 2375 CHAPTER 1 INTRODUCTION A successful system must balance performance, support, and cost of ownership. The R & D phase and design process of armored amphibious military ground vehicles will meet system requirements and optimize vehicle performance in many aspects such as survivability, buoyancy, amphibious mobility, land performance and durability. I am aiming for it. Operational availability, reliability, and maintainability are important indicators of system supportability. These important indicators, and therefore the success of the mission, are affected by the durability of the vehicle. Given the success factors of the system, performance and support depend not only on the durability of the vehicle, but also on the cost of the design. Vehicle manufacturing and operation is affected by durability. Looking at the system costs incurred in each phase, R & D accounts for 2% and operations and support account for 85% of the total cost. For military land systems, these percentages can be given as 9% and 54%. Recent reports show these shares as 4% and 63%, respectively. On the other hand, the cost of influencing decision making is 70% during the R & D phase and the design process. Therefore, durability constitutes an important phase of the design process, with performance, support and cost in mind. The durability design consists of determining the load spectrum and vehicle fatigue strength, and comparing these data. In this project, the range of durability is the hull of the vehicle, so from this point of view, durability can be called the possibility of structural integrity of the vehicle's hull as a function of loading history. The hull structure of an armored amphibious military ground vehicle is as follows: Although designed to be constructed by welding aluminum armor plates of various types of joint configurations, the fatigue strength of welded connections is due to many factors such as manufacturing quality, weld toe angle, plate thickness, welding, etc. I am strongly influenced. It can indicate the defect, load type, and level of residual stress. All of these elements are specific to design, product, manufacturing process, materials, workmanship, and environment. Therefore, the fatigue strength GSJ 2021 www.globalscientificjournal.com
GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 2376 properties of welded joints have an inherently statistical distribution, and durability can be designed using either a high factor of safety or a vague factor of safety inherent in the case. The importance of welded connections in durability design allows for purpose-built designs with specific safety margins by properly determining the fatigue strength of aluminum welded joints. The focus of the project consists of designing methods for precise fatigue life calculations and manufacturing methods that improve the fatigue strength of welded joints. These enable the design of more reliable and lightweight military ground vehicles. INTRODUCTION 1.1 PREPARATION - Prepare the Test Plate for “T”- Joint 1.2 GMAW WELDING - Setup the GMAW Welding machine parameters 1.3 FILLET WELDING - 8 mm FILLET WELD to be done on “T” - JOINT 1.4 VISUAL INSPECTION - Check the Welding – LEG SIZE & THROAT for Required 8mm FILLET WELD 1.5 TIG WELDING - Setup the TIG Welding machine Parameters 1.6 PRE CHECK - Setup the 100% Argon gas flow at 17 LPM for protect the Welding 1.7 TIG TOE DRESSING - TIG-TOE Dressing done on Weld Toe Upper Leg 1.8 TIG TOE DRESSING - TIG-TOE Dressing done on Weld Toe Lower Leg 1.9 VISUAL INSPECTION - Check the UNDERCUT by using BRIDGE CAM on Weld Toe 1.10 NDT – UT INSPECTION - NDT – UT Inspection & Micro ETCHING Testing to be done on Welding to found the Penetration in Parren Metal III GSJ 2021 www.globalscientificjournal.com
GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 2377 1.11 1.12 GSJ 2021 www.globalscientificjournal.com
GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 2378 1.13 III GSJ 2021 www.globalscientificjournal.com
GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 2379 CHAPTER 2 LITERATURE SURVEY Sjors H.J. Van Es , Henk Kolstein,R.J.M. Pijpers and F.S.K. Bijlaard According to IIW recommendations, the purpose of TIG dressing is to eliminate defects in the weld toe by remelting the material at the weld toe. It is also intended to reduce the local stress concentration effect of the local weld toe profile by providing a smooth transition between the plate and the welded surface. In this paper, the area of influence of the TIG dressing process on the shape of the weld toe and the hardness of the weld is analyzed. For this reason, measurements were performed on nine plates with different specifications. All specimens include a V butt weld that connects the two plates. Both of these may be rolled steel, or the rolled steel sheet may be connected to a cast steel sheet (test piece marked with a C). Steel types S460, S690, S890, and S1100 were investigated (test pieces marked 46, 69, 89, and 11). Example: Plate C69 is the connection between a rolled plate and a cast plate of grade S690. The output of the weld toe shape measurement contains a complete 3D image of the weld area. Weld cross sections were analyzed at regular intervals to investigate changes in weld toe shape. A fatigue test was conducted on the test piece whose shape was measured. Only the weld cap was investigated, as all relevant specimens showed breakage from the weld cap. Rehabilitation of Hassan Alkarawi, Ruediger Ulrich Franz Von Bock und Polach and Mohammad Al-Emrani welded structures has received increasing attention recently. The purpose of this paper is to investigate the efficiency of tungsten inert gas (TIG) remelting and TIG remelting followed by radio frequency mechanical impact treatment in extending fatigue life. Fatigue tests were performed on treated, as-welded specimens and cracked specimens. The lifespan of processed specimens was significantly increased by two methods. Many of the processed specimens ran out after a load of 10 million cycles and broke at the clamp position when tested over higher stress ranges. Improved compressive residual stress, hardness, and weld toe radius were the reasons behind extended life. Weld GSJ 2021 www.globalscientificjournal.com
GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 2380 fatigue can be due to three reasons: residual stress in tensile welds, high stress concentration on the toes, and the presence of various forms of weld defects (such as undercuts). Several post-weld treatment methods have been proposed in the literature to extend the life of the weld and increase fatigue strength. These methods can be divided into two categories based on their effectiveness. Weld shape improvers (TIG remelting, burr grinding, etc.) and residual stress improvers (peening, stress relaxation, etc.) mainly aimed at reducing the stress concentration coefficient. The purpose is to remove tensile residual stress or induce compressive residual stress. Asma Mana, Ruediger Ulrich Franz Von Bock und Polach, Mohammad Al-Emrani welding is a heating cycle-related joining process that causes significant changes in the microstructure of local materials and creates high residual stresses in welded joints. To do. Residual stress can adversely affect the fatigue strength of welded joints. This paper summarizes previously published data from the measurement of residual stress in various types of welded joints. A total of over 100 test results surveyed on steels with yield strengths of 307MPa to 1050MPa at different welding details of different thicknesses (butt joints, longitudinal and lateral attachments, cross joints, and K joints). It has been. The data collected is used to investigate the distribution of weld residual stress (regardless of weld parameters) across the thickness of the weld toe and weld plate. Residual stress data is collected in this extensive literature search measurement. However, most of them are limited to giving only the magnitude of the measured surface residual stress. Only 29 measurements provided information on the distribution of RS over the thickness of the plate. Since the purpose of the current work is to investigate the distribution of residual stresses throughout the thickness of the weld joint, only measurements that provide such information are used in the evaluation. III GSJ 2021 www.globalscientificjournal.com
GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 3.1 2381 Aim : To Increase The Fatigue Life/Strength of Fillet Welding in Frame/Chassis by Introducing A TIG-TOE Dressing on Weld Toe. 3.2 Area : We are concentrating on the Welding & Material science. 4.1 OBJECTIVES / METHODOLOGY : We are trying to increase the Fatigue Life/Strength of FILLET WELDING which are welded on Frame / Chassis On Weld Toe, we create a radius surface (5mm Radius) by using a TUNGSTEN Rod (2.4 dia) In this TIG- TOE Dressing process, we use only Tungsten Rod. Filler Material (Rod) not used. 4.2 Application & Advantages : While Fatigue loads have appeared in Automobile Truck Chassis, CRACK was generated on weld toe. Then the crack was developed to full chassis. TIG-TOE Dressed Fillet welds can defend from the WELD CRACKS TIG- TOE Dressed Radius surface can relief the fatigue load from Weld Toe to Chassis So, Fatigue load was equally released to Weld Toe & Chassis Also, we have eliminated the OVERLAP- DEFECT on Weld Toe by TIGTOE Dressing operation GSJ 2021 www.globalscientificjournal.com
GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 2382 4.3 Methodology Flow chart 4.4 III GSJ 2021 www.globalscientificjournal.com
GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 2383 4.5 4.6 Comparison Graph GSJ 2021 www.globalscientificjournal.com
GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 2384 5.1 Result : Increase The Fatigue Life/Strength of Fillet Welding in Frame/Chassis by Introducing A TIG-TOE Dressing on Weld Toe Project are completed. 5.2 III GSJ 2021 www.globalscientificjournal.com
GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 2385 5.3 5.4 GSJ 2021 www.globalscientificjournal.com
GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 2386 5.5 5.6 III GSJ 2021 www.globalscientificjournal.com
GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 2387 5.7 GSJ 2021 www.globalscientificjournal.com
GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 2388 Project Report 1 Project Report 2 III GSJ 2021 www.globalscientificjournal.com
GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 2389 Project Report 3 Project Report 4 GSJ 2021 www.globalscientificjournal.com
GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 2390 Project Report 5 Project Report 6 III GSJ 2021 www.globalscientificjournal.com
5.3 DT MACRO ETCHING INSPECTION COMPLETED 11 . GSJ: Volume 9, Issue 10, October 2021 ISSN 2320-9186 2374 . UT Inspection & Micro ETCHING Testing to be done on Welding to found the Penetration in Parren Metal GSJ: Volume 9, Issue 10, October 2021 . A fatigue test was conducted on the test piece whose shape was measured. Only the weld cap was .
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