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Saw Wire Consumption Calculation

The document provides detailed data on welding parameters including angle, consumption, and wire usage for both ID and OD welding methods. It outlines the welding speed, current, voltage, wire diameter, and geometry specifications, along with corresponding wire consumption rates. Additionally, it calculates the total area and volume for the welding process, emphasizing the relationship between welding parameters and material consumption.

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friendy4u007
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7 views

Saw Wire Consumption Calculation

The document provides detailed data on welding parameters including angle, consumption, and wire usage for both ID and OD welding methods. It outlines the welding speed, current, voltage, wire diameter, and geometry specifications, along with corresponding wire consumption rates. Additionally, it calculates the total area and volume for the welding process, emphasizing the relationship between welding parameters and material consumption.

Uploaded by

friendy4u007
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as XLSX, PDF, TXT or read online on Scribd
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Angle Consumption / Value %

Unit
(Degree) Weld length (Rs.) Increase
35 0.3243 Kg / Mtr. 16 0%
40 0.3886 Kg / Mtr. 19 17%
45 0.4632 Kg / Mtr. 23 16%

* Weld geometry and bead height remains same for variable angle of milling
3 1.5

5 ID Welding
1

2
4
OD Welding
4
Method-1 By Use of Welding speed
Welding Speed 1.8 mtr/min

ID welding
DC Current 900 Amp AC Current 500
Voltage 29 Voltage 32
Wire Dia 4.00 mm Wire Dia 3.2
78 Inch/min 96
W.F.S W.F.S
1.98 mtr/min 2.44
Welding Welding
1 1
lenth mtr lenth

wire length in 1 mtr 1.10 mtr wire length in 1 1.35


welding mtr welding
Wire consumed 0.11 Kg/mtr Wire consumed 0.09

4.0 mm Dia 0.25 Kg/mtr


Total
Consumption 3.15 mm Dia 0.15 Kg/mtr
of Wire
0.39 Kg/mtr

Method-2 By Use of Weld Geometry


Welding Speed 1.8 mtr/min

Bevel Angle 30 Degree


Upper Chamfer 5 MM
Root Face 5 MM
Lower Chamfer 5 MM
ID Bead Height 1.5 MM
OD Bead Height 1.5 MM
X ID bead width 5.77 MM
Y OD bead width 5.77 MM

Area of Part-1 Area of Part-2

14.43 MM²
A1 A2
0.0000144 Mtr²

Area of Part-3 Area of Part-4

5.77 MM²
A3 A4
A3 A4
0.0000058 Mtr²

Total Area 0.0000404 Mtr²

Welding Lentgh 1 Mtr

Total Volume 0.0000404 Mtr^3

Wire Consumption for 1 Mtr Welding length


OD welding
Amp DC Current 915 Amp AC Current 480 Amp
Voltage 31.2 Voltage 32.5
mm Wire Dia 3.20 mm Wire Dia 3.2 mm
Inch/min 155 Inch/min 68 Inch/min
W.F.S W.F.S
mtr/min 3.94 mtr/min 1.73 mtr/min
Welding
1 1
mtr Welding lenth mtr lenth mtr

mtr wire length in 1 2.19 mtr wire length in 1 0.96 mtr


mtr welding mtr welding
kg/mtr Wire consumed 0.14 Kg/mtr Wire consumed 0.06 kg/mtr

A3 1.5

ID Welding
A1 5

A2
5 OD Welding

A4

Y
Area of Part-2
1/2*H*(X/2) H= Chamfer
14.43 MM² X=Bead width
0.0000144 Mtr²

Area of Part-4

5.77 MM² 2/3*X*h h=Bead Height


0.0000058 Mtr² X=Bead width

0.31725 Kg/Mtr Density = 7850 Kg/Mtr3

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