MINI PROJECT REPORT

Presented by

(Name: .........................................................)
(Reg. No: ......................................................)

Department of Mechanical Engineering

Government Polytechnic College, Adoor
 1
MINI PROJECT REPORT

DEPARTMENT OF MECHANICAL ENGINEERING

GOVERNMENT POLYTECHNIC COLLEGE
ADOOR

CERTIFICATE
This is to certify that this Mini Project entitled “Tank Cover Making” is presenting
by (..................................................................Reg. No...........................................)
during the year 2017-18 in partial fulfillment of the requirement for the award of
Diploma in Mechanical Engineering under the Department of Technical
Education,Government of Kerala.

Project Guide Project Co-ordinator

Internal Examiner External Examiner

GPTC, ADOOR
 2
MINI PROJECT REPORT

ACKNOWLEDGEMENT
I consider myself privileged to express gratitude and respect towards
allthose who guidedus through the completion of this Mini Project.
I am grateful to Sri.P.O.BOBEN, Head of the Depanment,Mechanical
Engineering for giving me the support and encouragement that was
necessary for the completion of this seminar presentation.
I convey thanks to my Mini Project guide Sri. JAYESH , LAB Insructor
for providing guidance which was of a great help to complete this Mini
Project successfully.
I would also like to express my gratitude to Sri. JOSE , Workshop
Superientendent for providing us encouragement and constant support
for the preparation and successful completion of this Mini Project.
I am also thankful to my family members for their constant support and
help throughout this entire process.
Afterall I am thanksful to God, the almighty for providing me this
opportunity and granting me the capability to do it.

(…………………………..)

GPTC, ADOOR
 3
MINI PROJECT REPORT

TABLE OF CONTENTS

no
NAME PAGE NO

 INTRODUCTION 4

 WELDING WORKSHOP 5

 Some of the best known 6

welding methods

 MACHINES USED 8

 OPERATIONS TO BE CARRIED OUT 9

 METHODOLOGY 10

 ESTIMATION 11

 DIGRAM 12

 PROCEDURE 13

 RESULT 14

GPTC, ADOOR
 4
MINI PROJECT REPORT

INTRODUCTION

The scope of the project is to develop mechanical skill of students as part

of the curriculum of 4th Semester Mechanical Engineering Diploma.The
project includes

1) Make a structure as per the diagram

2) Complete the work with suitable material

GPTC, ADOOR
 5
MINI PROJECT REPORT

WELDING WORKSHOP

Welding Workshop is core Part of the workshop. Which has an important part in
the Engineering field.

Safety Precautions

Keep fire fighting equipments at proper place.

Keep poured or immersed water system.

Keep well ventilated area.

Show the escape route.

The welding area should be painted by black colour for avoid reflection.

Wear proper PPE(Personal Protective Equipments) such as Safety shoe, Safety

glass, Welding helmet, Hand gloves, Apron, Leg Guard.

Arc Welding

Arc welding is a fusion welding process in which welding is done by producing heat
from an electric arc between work and electrode. Both direct current and alternating
current are used for this purpose.

In both the a.c and d.c power source , the arc serves the same
purpose.It produces heat to melt metal. If two pieces of metal that are to be joined
are placed so that they touch or almost touch one another and the arc from the
electrode is directed at this junction. The heat generated by the arc causes a small
section to the edges of both pieces of metal to melt. These molten portion along With
the molten portions of the electrode flow together .As the arc column is moved, the
molten puddle solidifies joining the two pieces of metal with a combination of
electrode metal and base metal.

GPTC, ADOOR
 6
MINI PROJECT REPORT

Some of the best known welding methods

 Oxy-fuel welding
Also known as oxyacetylene welding or oxy welding, uses fuel gases and
oxygen to weld and cut metals.

 Shielded metal arc welding (SMAW)

Also known as "stick welding" or "electric welding", uses an electrode that
has flux around it to protect the weld puddle. The electrode holder holds the
electrode as it slowly melts away. Slag protects the weld puddle from
atmospheric contamination.

 Gas tungsten arc welding (GTAW)

Also known as TIG (tungsten, inert gas), uses a non-consumable tungsten
electrode to produce the weld. The weld area is protected from atmospheric
contamination by an inert shielding gas such as argon or helium.

 Gas metal arc welding (GMAW) –

Commonly termed MIG (metal, inert gas), uses a wire feeding gun that
feeds wire at an adjustable speed and flows an argon-based shielding gas or a
mix of argon and carbon dioxide (CO2) over the weld puddle to protect it from
atmospheric contamination.

 Flux-cored arc welding (FCAW) –

Almost identical to MIG welding except it uses a special tubular wire filled
with flux; it can be used with or without shielding gas, depending on the
filler.

GPTC, ADOOR
 7
MINI PROJECT REPORT

 Submerged arc welding (SAW)

Uses an automatically fed consumable electrode and a blanket of granular
fusible flux. The molten weld and the arc zone are protected from
atmospheric contamination by being "submerged" under the flux blanket.

 Electroslag welding (ESW) –

A highly productive, single pass welding process for thicker materials
between 1 inch (25 mm) and 12 inches (300 mm) in a vertical or close to
vertical position.

 Electric resistance welding (ERW) –

A welding process that produces coalescence of laying surfaces where heat to
form the weld is generated by the electrical resistance of the material. In
general, an efficient method, but limited to relatively thin material.

Many different energy sources can be used for welding, including a gas flame, an
electric arc, a laser, an electron beam, friction, and ultrasound. While often an
industrial process, welding may be performed in many different environments,
including in open air, under water, and in outer space. Welding is a hazardous
undertaking and precautions are required to avoid burns, electric shock, vision
damage, inhalation of poisonous gases and fumes, and exposure to intense
ultraviolet radiation.

Until the end of the 19th century, the only welding process was forge welding,
which blacksmiths had used for millennia to join iron and steel by heating and
hammering. Arc welding and oxyfuel welding were among the first processes to
develop late in the century, and electric resistance welding followed soon after.
Welding technology advanced quickly during the early 20th century as the world
wars drove the demand for reliable and inexpensive joining methods. Following the
wars, several modern welding techniques were developed, including manual
methods like SMAW, now one of the most popular welding methods, as well as
semi-automatic and automatic processes such as GMAW, SAW, FCAW and ESW.
Developments continued with the invention of laser beam welding, electron beam

GPTC, ADOOR
 8
MINI PROJECT REPORT

welding, magnetic pulse welding (MPW), and friction stir welding in the latter half
of the century. Today, the science continues to advance. Robot welding is
commonplace in industrial settings, and researchers continue to develop new
welding methods and gain greater understanding of weld quality.

MACHINES USED
1. Welding machine
2. Cutting machine
3. Grinding machine

GPTC, ADOOR
 9
MINI PROJECT REPORT

OPERATION TO BE CARRIED
1.CUTTING

2.WELDING

3.GRINDING

GPTC, ADOOR
 10
MINI PROJECT REPORT

METHODOLOGY
STAGE 1

Cut the angle iron as per the required dimension. Join them by Arc
Welding as per the diagram. Select the proper current for welding.

STAGE 2

After Completion of welding, grinding with Grinding Machine. Make it

clean and primer painting has been done and fix the frame bottam of the
tank.

STAGE 3

Cut the angle iron as per the given dimension for making the frame. Weld
the frame and grind the edges.

STAGE 4

Cut the mesh as per the dimension and weild the mesh on the frame. And
fix the frame in the main frame or fixed frame.

STAGE 5

Painting has been done on the full work.

GPTC, ADOOR
 11
MINI PROJECT REPORT

ESTIMATION

Sl. NAME SPECIFICATION QUANTITY

no
1) Angle iron 25*25*3MM 48 kg

2) Weld mesh 44.5*44.5MM 60 sft

3) Electrode 3.16MM 1 nos

4) Cutting wheel 4 nos

5) Grinding wheel 1 nos

6) Paint 1 nos

7) Painting brush 2 nos

8) Ciment 20 kg

GPTC, ADOOR
 12
MINI PROJECT REPORT

DIGRAM

GPTC, ADOOR
 13
MINI PROJECT REPORT

PROCEDURE

1. Cut the angle iron as per the required dimension. Join them by Arc
Welding as per the diagram. Select the proper current for welding.
2. After Completion of welding, grinding with Grinding Machine.
Make it clean and primer painting has been done and fix the frame
bottam of the tank.
3. Cut the angle iron as per the given dimension for making the frame.
Weld the frame and grind the edges.
4. Cut the mesh as per the dimension and weild the mesh on the
frame. And fix the frame in the main frame or fixed frame.
5. Painting has been done on the full work.
6. Project is submitted for evaluvation

GPTC, ADOOR
 14
MINI PROJECT REPORT

RESULT

Obtained the work as per the required dimension and

structure. This will help to keep the works in the welding
workshop in future.

GPTC, ADOOR
 15
MINI PROJECT REPORT

GPTC, ADOOR
 1
MINI PROJECT REPORT

GPTC, ADOOR
 2
MINI PROJECT REPORT

GPTC, ADOOR
 3
MINI PROJECT REPORT

GPTC, ADOOR
 4
MINI PROJECT REPORT

GPTC, ADOOR
 5
MINI PROJECT REPORT

GPTC, ADOOR
 6
MINI PROJECT REPORT

GPTC, ADOOR
 7
MINI PROJECT REPORT

GPTC, ADOOR
 8
MINI PROJECT REPORT

GPTC, ADOOR
 9
MINI PROJECT REPORT

GPTC, ADOOR
 10
MINI PROJECT REPORT

GPTC, ADOOR