B. ENG (Hons) MECHANICAL ENGINEERING In collaboration with.

B. ENG (Hons) MECHANICAL ENGINEERING
In collaboration with
Proposal
Design a turntable for TIG welding with a linear velocity of 70mm/min~120mm/min per
AWS D1.2 structural code for aluminum.
[April/2019]
Supervisor : MR MOHD HILMAN BIN MOHD AKHIL TAN
Name: HENRY WILFRED MASCARENHAS
US ID: 169041115
A final year project report submitted in partial fulfillment of the regulations for the award of
B.Eng.(Hons) in Mechanical Engineering at the University of Sunderland (2019)

Contents
List of Figures............................................................................................................. 4
List of Tables.............................................................................................................. 5
Nomenclature............................................................................................................. 5
Acknowledgment........................................................................................................ 6
DECLARATION............................................................................................................. 6
ABSTRACT.................................................................................................................. 8
CHAPTER 1................................................................................................................. 9
PROJECT BACKGROUND........................................................................................... 9
INTRODUCTION....................................................................................................... 9
SCOPE OF THE PROJECT..................................................................................... 11
PROBLEM STATEMENT........................................................................................ 11
AIM..................................................................................................................... 12
OBJECTIVE.......................................................................................................... 12
THESIS OVERVIEW.............................................................................................. 12
CHAPTER 2............................................................................................................... 14
LITERATURE REVIEW............................................................................................. 14
Principles of TIG welding.................................................................................... 14
How the turntable is built................................................................................... 30
Deep Penetration Welding.................................................................................. 31
CHAPTER 3............................................................................................................... 35
DESIGN SPECIFICATIONS, THEORETICAL CALCULATIONS, CONCEPT DESIGN........35
Mechanical Design................................................................................................ 37
Parts of the design............................................................................................. 37
Advantages of DC motors...................................................................................... 38
Disadvantages of Stepper and AC motors.............................................................39
Warm shaft design............................................................................................. 39
Worm Wheel Shaft Design.................................................................................40
Key Design......................................................................................................... 40
Worm Design as well as the worm wheel design...............................................42
Bearing Selection............................................................................................... 42
Worm Gear Design............................................................................................. 45
CHAPTER 4............................................................................................................... 50
DESIGN DRAWING................................................................................................. 50

New and old design comparison.......................................................................51
Proposed Turntable Operating Velocity Verification...........................................54
Budget................................................................................................................... 57
CHAPTER 5............................................................................................................... 58
DISCUSSION, CONCLUSION, AND RECOMMENDATION...........................................58
Incorporation of the new TIG welding Turntable in Cell Manufacturing (CM) Process
.............................................................................................................................. 64
Conclusion and Recommendations.......................................................................71
GHANTT CHART........................................................................................................ 71
REFERENCES............................................................................................................ 73
APPENDIX................................................................................................................. 77

List of Figures
Figure 1: Equipment of conventional TIG welding
Figure 2: Activities of TIG welding.
Figure 3: Conceptualized design of Rotary.
Figure 4: Decks
Figure 5: Configuration of the Disk.
Figure 6: Motion path illustration.
Figure 7: Bolt Location points.
Figure 8: Parts Installation process/procedure.
Figure 9: Proposed TIG welding turntable design.
Figure 10: Possible layout or procedure of operation.
Figure 11: Main components of the design.
Figure 12: Incorporation of TIG welding applications in the Cell Manufacturing

List of Tables
Table 1: Shaft Dimensions selection.
Table 2 Dynamic and Static selection.
Table 3: Worm Wheel dimensions.
Table 4: Summary of Design components.
Table 5: The specifications of the selected DC motor.
Nomenclature
CM: Cell Manufacturing
AC: Alternating Current
DC: Direct Current
F= Force
E = modulus of elasticity
I = moment of inertia
K = coefficient of fixity
L =length

Acknowledgment
Firstly, I would like to extend my appreciation & gratitude to my project supervisor Mr. Mohd
Hilman Bin Mohd Akhil Tan. It was through his continuous guidance & assistance that this
thesis was materialized. I would like to also thank him for his support & encouragement
provided to me when I encountered obstacles during this project, it was his suggestions that
helped me to push thru & find solutions that lead to the fruition of this thesis.
I would also like to take this opportunity to thank Segi College Subang Jaya which provided me
with the conducive environment with its abundance of information thru its journals & books that
helped me with the thesis. Lastly, I would like to show my appreciation for my family & friends
who helped me emotionally thru this whole process & gave me the encouragement to complete
this thesis.
DECLARATION

I hereby declare this final year project submission entitled “Design a turntable for TIG
welding with a linear velocity of 70mm/min~120mm/min per AWS D1.2 structural code for
aluminum" to the University of Sunderland, the UK as a partial fulfillment of the requirements
for Bachelor of Mechanical Engineering is my own project except where reference where made.
Furthermore, this project has been done with the help & guidance of my course lecturers &
project supervisor.
----------------------------------------------------
(HENRY WILFRED MASCARENHAS)

ABSTRACT
This particular proposed project deals with the construction or design as well as working of all
the components required for TIG Welding by the use of the turntable. Considering the increase
of the complexity of the welding requirements in the today's set up, there is need to develop new
techniques which will help to ease the burden of the operator as well as allow for the efficient
circular welding. In this particular paper, several components of a turntable for TIG welding with
a linear velocity of 70mm/min~120mm/min per AWS D1.2 structural code for aluminum" will
be critically designed, taken through the manufacturing process and tested. The testing of the
components will be done along with other parameters of costs as well as time to the maid the
processes of manufacturing. The arc torch will be expected to be in an adjustable position.