Design and Development of a Vibration Induction Setup for One Direction TIG Welding Router
This project is based on the design and development of a vibration induction setup for 1D TIG welding router. The fundamental part of the project is the fabrication of TIG welding fixture setup that includes a vibration induction mechanism of different frequency, waveform and amplitudes. The project
2025-06-28 16:31:19 - Adil Khan
Design and Development of a Vibration Induction Setup for One Direction TIG Welding Router
Project Area of Specialization Mechanical EngineeringProject SummaryThis project is based on the design and development of a vibration induction setup for 1D TIG welding router. The fundamental part of the project is the fabrication of TIG welding fixture setup that includes a vibration induction mechanism of different frequency, waveform and amplitudes. The project also includes the design and development of a Vibration sensing apparatus to read induced vibrations and combining both induction and sensing apparatus mentioned above to create a closed loop feedback control system for a TIG welding setup. The scope extends to using the apparatus to further research on effects of vibration on weldments. During the course of the project, it is aimed to select apparatus to induce vibrations and sense the vibrations in consideration of certain factors that are: cost of the components, availability of the components, material properties and structural constraints of the TIG welding setup.
Project Objectives- Design and Development of a Vibration induction mechanism of different frequency, waveform and amplitudes.
- Design and development of a Vibration sensing apparatus to read induced vibrations.
- Combining both induction and sensing apparatus mentioned above to create a closed loop feedback control system for a TIG welding setup.
- Using the apparatus to further research on effects of vibration on weldments.
The Linear Shaft Bearing Concept is a concept to design and manufacture. The setup is comparatively cheap to manufacture. It can be used as a multiaxial shaker for the study of vibrations in more than one direction. The waveform and frequency of the vibrations can be manipulated easily. This design, however, is prone to unwanted vibrations that may led to experimental errors. To reduce these unwanted vibrations, an additional damping system needs to be put in place. This design requires redesigning of the fixture as it is not suitable for heavier masses.
The vibrations were modelled mathematically using techniques described in “Inman Engineering Vibrations 4th Ed”. Based on the relations of our selected concept and literature, the vibrations produced would be having a case of Coulomb damping and are modelled as stated in the book with help of Coulomb and Viscous damping formulae as stated
Where,
X = Amplitude
mo = Rotating mass
e = Eccentricity
M = Mass of System
? = Damping ratio
Where,
?r = Rotating motor frequency
?n = Natural frequency of system
The above equations define the nature of vibrations in the setup and shall be used to design the system. For this project, MATLAB was used to model the equations and noticing the wide set of unknowns, a strategy for setting design constraints was established.
The first step was to select a motor for which a manageable range of mo and e using that data and putting it into the dynamic torque formula.
We found a torque value for our motor, and from torque-speed curves we selected a motor of reasonable operating frequency. From this motor mass we estimated a close value of M. For our ease and operability, we set a mean amplitude in y-direction of 1 mm.
The sensor selected to be used in the mechanism is LDT0-028K. The LDT0-028K is a flexible component involving a 28 ?m thick piezoelectric PVDF polymer film with screen-printed silver ink electrodes, layered to a 0.125 mm polyester substrate, and fitted with two crimped contacts.
Benefits of the ProjectThe project mainly targets the benefits of introducing vibrational effects to a 1D TIG Welding Mechanism and test its results on the existing weldment. This can be helpful in the manufacturing industry in making use of vibration methods to induce welding with reduced power input and improved quality.
This can also be helpful in research and development for those who are interested in researching on weldments.
Technical Details of Final DeliverableA relatively cheap mechanical vibration shaker of rotating unbalanced type with uniaxial shaking table was designed and fabricated to provide opportunities for experimental testing and purpose of vibration in experimental modal analysis, stress relief of weldments, effect of vibration on heat transfer and seismic testing of trusses. The shaker consists of five fundamental components are: shaker frame, shaker table, flexible support, drive motor, and eccentricity mechanism.
MATLAB code used:
The CAD model of the setup was designed on SolidWorks. The front, left, bottom and isometric views of the assembly is as follows:
| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 23785 | |||
| Aluminium shafts | Equipment | 1 | 1475 | 1475 |
| Steel Shaft | Equipment | 1 | 1000 | 1000 |
| Steel Sheet | Equipment | 4 | 200 | 800 |
| Aluminium Plate | Equipment | 1 | 1000 | 1000 |
| Aluminium Sheet | Equipment | 1 | 1900 | 1900 |
| Wood | Miscellaneous | 6 | 100 | 600 |
| Fastners Clamp | Equipment | 10 | 20 | 200 |
| Fastners Sheet | Equipment | 8 | 20 | 160 |
| Wood Work | Miscellaneous | 1 | 1100 | 1100 |
| Metal working | Miscellaneous | 1 | 1700 | 1700 |
| 20 Amp ESC | Equipment | 1 | 1200 | 1200 |
| A2212 BLDC Motor | Equipment | 1 | 750 | 750 |
| Raspberry Pi Model 3b | Equipment | 1 | 5500 | 5500 |
| LDT -028K | Equipment | 1 | 800 | 800 |
| ADXL 335 | Equipment | 1 | 350 | 350 |
| MCP 308 (ADC) | Equipment | 1 | 450 | 450 |
| Misc Wiring | Miscellaneous | 1 | 1000 | 1000 |
| LM10UU | Equipment | 8 | 375 | 3000 |
| Ball Bearing | Equipment | 4 | 25 | 100 |
| Coupling | Equipment | 3 | 100 | 300 |
| Springs | Equipment | 4 | 100 | 400 |