Table of Contents

1 INTRODUCTION ...................................................................................... Error! Bookmark not defined.

1.2 Aims and objectives ............................................................................................................................ 1
2 LITERATURE REVIEW ............................................................................................................................. 2
2.1 Description of the milling and welding process ............................. Error! Bookmark not defined.
2.2 Theory of the strength of Square and V-butt welds ..................................................................... 4
3 METHODOLOGY .................................................................................................................................... 6
3.1 LIST OF MATERIALS USED .............................................................................................................. 6
3.2 PROCEDURES ................................................................................................................................. 8
3.2.1 Milling and welding process for the square butt weld ......................................................... 8
3.2.2 Millng and welding process for the v-butt weld ................................................................... 9
3.2.3 Grinding process for both weld types ................................................................................. 10
4 SAFETY IN THE WORKSHOP .................................................................... Error! Bookmark not defined.
4.1 General Safety precautions ............................................................ Error! Bookmark not defined.
4.2 Personal protective gear ................................................................ Error! Bookmark not defined.
5 RESULTS AND DISCUSSION ..................................................................... Error! Bookmark not defined.
5.1 Tensile forces.................................................................................. Error! Bookmark not defined.
5.2 Shear forces ................................................................................................................................. 16
6 MICROSTRUCTURE ................................................................................. Error! Bookmark not defined.
6.1 V-Butt ............................................................................................. Error! Bookmark not defined.
6.2 Square-Butt ................................................................................................................................. 18
6.3 Size of grains................................................................................................................................ 18
6.4 Microstructure ............................................................................................................................ 19
7 CONCLUSION ....................................................................................................................................... 19
8 APPENDICES ........................................................................................................................................ 20
8.1 Cooling rates for steel ................................................................................................................. 20
8.2 weld-metal properties................................................................................................................. 20
9 REFERENCES ........................................................................................... Error! Bookmark not defined.
 List of Tables and figures
Table 1: Permissible Stress in welded joints .................................... Error! Bookmark not defined.
Table 2: Weld eletrode specification ............................................... Error! Bookmark not defined.

Figure 1: Face milling operation ...................................................... Error! Bookmark not defined.

Figure 2: Illustration of arc welding ................................................. Error! Bookmark not defined.
Figure 3: Tensile loading and Shear loading .................................... Error! Bookmark not defined.
Figure 4:Face Shield ........................................................................................................................ 6
Figure 5: Leather gloves .................................................................................................................. 6
Figure 6: Chipping Hammer ............................................................................................................ 7
Figure 7: Wire Brush ....................................................................................................................... 7
Figure 8: Leather apron................................................................................................................... 7
Figure 9: Pliers................................................................................................................................. 9
Figure 10: Square Butt weld ........................................................................................................... 9
Figure 11: The universal Milling machine and the process .......................................................... 10
Figure 12: V-Butt weld ..................................................................... Error! Bookmark not defined.
Figure 13: Cross sectional view of square butt weld ....................... Error! Bookmark not defined.
Figure 14: Schematic of square butt weld in tension with base metal dimensions ................ Error!
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Figure 15: Penetration and fusion line dimensions ......................... Error! Bookmark not defined.
Figure 16: Cross sectional view of V butt weld ................................ Error! Bookmark not defined.
Figure 17: Schematic of a single v-butt weld in shear with base metal dimensions ............... Error!
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Figure 18: Penetration and fusion line dimensions ......................... Error! Bookmark not defined.
Figure 19: Schematic of a square butt weld in shear with base metal dimensions .................... 16
Figure 20: Schematic of a single v-butt weld in shear with base metal dimensions ................... 17
Figure 21: Micrographic of weld metal and base metal for V butt weld...................................... 18
Figure 22: Micrographic of weld metal and base metal for square butt weld ............................. 18