User talk:Omega weldrod systems

Manufacturing of Welding Electrodes
PROCESS OF MANUFACTURE FOR WELDING ELECTRODES

DETAILS OF EQUIPMENT & FUNCTIONS

WIRE DRAWING In theses machines, Wire rod of size 5.5mm or 6.35 will be drawn to required standard size 2.5 mm, 3.2 mm, 4.00 or 5 mm

WIRE STRAIGHTENING AND CUTTING MACHINE These machines straighten and cut coils of wire into the required standard length. The tolerance on length is accurately maintained.

DRY MIXER The powders which constitute the flux are mixed together in the mixer so that the constituents are blended into a homogeneous batch.

WET MIXER In this machine the dry mixed flux and binding agent ( Potassium / Sodium silicate ) in measured quantity are mixed and kneaded to get a wet paste and this wet paste will be transferred to briquetting press.

BRIQUETTING PRESS The past obtained from the kneading machine is compressed into cylindrical cakes which can be fed neatly into the extrusion cylinder

WIRE FEEDER WITH WIRE HOPPER This equipment can be set and reset with ease for different diameters and lengths of electrodes. One complete set of  change over parts is provided to enable production of 2.50mm,  3.15mm, 3.25mm, 4.00mm and 5.00mm change over parts consist of pickup rollers, wire guides, guide tubes mouth pieces. All change over parts are made out of hardened and tempered alloy steel. The wire feeder systems is driven by a train of gears through a gear box. The speed of the wire feeding is adjustable.

EXTRUDER The extruder is equipped with a hydraulic cylinder, hydraulic pump, pressure control valve and directional control valve. The piston has a fast return stroke to enable fast raffling of the paste cylinder. The paste cylinder has dia meter of 150 mm and the stroke of the paste piston is approximately one meter The following is the mechanism of operation of the wire feeder / extruder. The pieces of wire which are ejected from the wire feeder at high speed pass through the press block and there after through the coating die. Simultaneously the paste is compressed through the press block, takes a right angle turn and covers the space between the coating die and the wire. Thus the bare gats the coating.

CONVEYOR The conveyor takes over the coated electrode from the transfer belt and performs the following operation 1.Spacing the electrodes apart 2. Aligning the electrodes 3.Brushing the bare ends 4.Grinding / Brushing the arc striking ends After the above operation are done, the electrodes are taken over by a slower belt from where they are manually lifted and placed on trays. The quality of workmanship and the alignment of various moving parts will be such as to maintain a low rejection level on the conveyor.

BAKING OVEN The baking oven is of the walk-in type so that the trollies can be pushed in and out. A spare set of trollies is provided as standard accessory and the oven is manufactured specially to cope with the feed drying of electrodes.

DE – COATING MACHINE This equipment enables the coating of rejected / damaged electrodes to be separated from the core wire so that both the wire and the flux may be recycled.

PACKING TABLES These tables enable quick manual packing of electrodes, segregation of damaged electrodes and filling up of good electrodes in polythene bags / cartons.

MICROMETER FOR CONCENTRICITY MEASUREMENT This instrument can measure the concentricity of the semi-dry green coating on the electrodes to an accuracy of 0.010 mm.

CHEMICAL & MECHANICAL LAB A complete set of laboratory equipment for wet analysis and mechanical testing equipment comprising of Rockwell hardness tester & charpy / lzod impact tester and universal testing machines may be provided as optional extras. For More details about machinery for Welding Electrode Manufacturing Visit www.Omegaweldrod.com Omega weldrod systems (talk) 07:42, 14 May 2013 (UTC)