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Robotization of industry is very important in these days. It is possible to replace human workers with robots and because of that make manufacturing faster. This master’s thesis includes feasibility study of robotic welding for stainless steel part guide rail. Quality of robotic welding was evaluated on testing pieces. Robotic welding was 88,5 % faster than current welding method. Costs of manufacture of one piece were 40 % cut.

Aero engines are made up of a large number of blades which are subject to wear and damage. They are expensive and must be repaired wherever possible. Engines also have small components which are required in small numbers that need to be developed rapidly. The first part of this research work focuses on developing a robust automated blade repair method using robotic welding. Optimal weld parameters were developed for build-up of edges having different thicknesses. Samples with varying Current and varying travel speed were produced and their micro hardness values were compared. Blade profiles were welded upon. The second part involves a methodology for producing small components using rapid prototyping (RP) techniques. This part involves use of 3D robotic welding for layered manufacturing. Tensile samples produced using the metal RP method were tested and results were found to be well above the minimum cast specifications for the given material.

Aero engines are made up of a large number of blades which are subject to wear and damage. They are expensive and must be repaired wherever possible. Engines also have small components which are required in small numbers that need to be developed rapidly. The first part of this research work focuses on developing a robust automated blade repair method using robotic welding. Optimal weld parameters were developed for build-up of edges having different thicknesses. Samples with varying Current and varying travel speed were produced and their micro hardness values were compared. Blade profiles were welded upon. The second part involves a methodology for producing small components using rapid prototyping (RP) techniques. This part involves use of 3D robotic welding for layered manufacturing. Tensile samples produced using the metal RP method were tested and results were found to be well above the minimum cast specifications for the given material.

Resumo: A utilização do alumínio em escala industrial vem crescendo cada vez mais nos últimos anos e um dos principais motivos é o espaço que esse material vem conquistando em substituição ao aço. O interesse da indústria em ter um maior controle das distorções provocadas pela soldagem de alumínio se deve ao fato das tolerâncias dimensionais e geométricas estarem cada vez mais precisas nas especificações de projeto, motivando a engenharia de fabricação a desenvolver processos estáveis e que garantam a rotina de produção. O elevado coeficiente de expansão linear desse metal, se comparado ao aço, é uma das suas principais características que geram dificuldades nesse cenário. Visando isso, o presente trabalho tem como principal objetivo analisar o quanto situações rotineiras utilizadas na soldagem robotizada de alumínio podem influenciar nas distorções angulares deste material, sem comprometer a integridade mecânica da junta soldada e com confiabilidade estatística. Utilizando a liga AA 5052 H34, e a soldagem robotizada no processo GMAW pulsado, foram aplicados três tipos de tecimento ao longo do comprimento da solda, em juntas de topo montadas sem chanfro e com chanfro de 60º, dispostas tanto transversais quanto longitudinais ao sentido de conformação da chapa. A medição das distorções foi realizada por um braço tridimensional, antes e após a soldagem, em três regiões distintas nos corpos de prova. O perfil do cordão de solda foi o fator determinante para as diferentes formas das distorções encontradas, assim como revelado pelas análises macrográficas. A junta com chanfro de 60º apresentou maiores amplitudes das distorções que a junta sem chanfro. O tecimento não foi uma variável de influência estatística significativa nessas amplitudes. Ensaios de tração foram realizados para se avaliar o comportamento mecânico das juntas soldadas / Abstract: The use of aluminum by industry has been recently growing more and more each time and one of the main reasons is the position that this material is gaining as a replacement for steel. The industry's interest in having a greater control of the distorcions caused by aluminum welding is due to the geometric and dimensional tolerances been more and more precise in the project specifications, motivating the manufacturing engineering to develop stable processes and to ensure routine production. The high coefficient of linear expansion of this metal, which is one of its main features, can create a difficult scenario when compared to the steel. Aiming at it, the main goal of this present work is to analyze how much routine situations used int the robotic aluminum welding can influence in the angular distortions of this material, without affecting the mechanical integrity of the welded joint and with statistical reliability. Using the alloy AA 5052 H34, and the robotic welding in pulsed GMAW process, it was applied three types of weaving throughout the length of the weld, in butt joints assembled without groove and with 60º single-V-groove, arranged transversely as well as longitudinally to the rolling direction of the plate. The measurement of the distortions was made by a three-dimensional equipment, before and after the welding, in three distinct regions in the speciments. The profile of the weld bead was the main factor for the different types of distortions found, as revealed by macrographical analysis. The 60º single-V-groove had higher amplitudes of distortions as the joint without groove. The weaving wasn't a variable of statistically significant influence in this amplitudes. Tensile tests were made to evaluate the mechanical properties of the welded joints / Orientador: Yukio Kobayashi / Coorientador: Gilberto de Magalhães Bento Gonçalves / Banca: Américo Scotti / Banca: Luiz Eduardo de Angelo Sanchez / Mestre

Made available in DSpace on 2014-06-11T19:28:20Z (GMT). No. of bitstreams: 0 Previous issue date: 2011-01-24Bitstream added on 2014-06-13T20:17:58Z : No. of bitstreams: 1 coraini_r_me_bauru.pdf: 4046838 bytes, checksum: 246be85a1178880a9bdc9bbb5df7fbde (MD5) / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / A utilização do alumínio em escala industrial vem crescendo cada vez mais nos últimos anos e um dos principais motivos é o espaço que esse material vem conquistando em substituição ao aço. O interesse da indústria em ter um maior controle das distorções provocadas pela soldagem de alumínio se deve ao fato das tolerâncias dimensionais e geométricas estarem cada vez mais precisas nas especificações de projeto, motivando a engenharia de fabricação a desenvolver processos estáveis e que garantam a rotina de produção. O elevado coeficiente de expansão linear desse metal, se comparado ao aço, é uma das suas principais características que geram dificuldades nesse cenário. Visando isso, o presente trabalho tem como principal objetivo analisar o quanto situações rotineiras utilizadas na soldagem robotizada de alumínio podem influenciar nas distorções angulares deste material, sem comprometer a integridade mecânica da junta soldada e com confiabilidade estatística. Utilizando a liga AA 5052 H34, e a soldagem robotizada no processo GMAW pulsado, foram aplicados três tipos de tecimento ao longo do comprimento da solda, em juntas de topo montadas sem chanfro e com chanfro de 60º, dispostas tanto transversais quanto longitudinais ao sentido de conformação da chapa. A medição das distorções foi realizada por um braço tridimensional, antes e após a soldagem, em três regiões distintas nos corpos de prova. O perfil do cordão de solda foi o fator determinante para as diferentes formas das distorções encontradas, assim como revelado pelas análises macrográficas. A junta com chanfro de 60º apresentou maiores amplitudes das distorções que a junta sem chanfro. O tecimento não foi uma variável de influência estatística significativa nessas amplitudes. Ensaios de tração foram realizados para se avaliar o comportamento mecânico das juntas soldadas / The use of aluminum by industry has been recently growing more and more each time and one of the main reasons is the position that this material is gaining as a replacement for steel. The industry's interest in having a greater control of the distorcions caused by aluminum welding is due to the geometric and dimensional tolerances been more and more precise in the project specifications, motivating the manufacturing engineering to develop stable processes and to ensure routine production. The high coefficient of linear expansion of this metal, which is one of its main features, can create a difficult scenario when compared to the steel. Aiming at it, the main goal of this present work is to analyze how much routine situations used int the robotic aluminum welding can influence in the angular distortions of this material, without affecting the mechanical integrity of the welded joint and with statistical reliability. Using the alloy AA 5052 H34, and the robotic welding in pulsed GMAW process, it was applied three types of weaving throughout the length of the weld, in butt joints assembled without groove and with 60º single-V-groove, arranged transversely as well as longitudinally to the rolling direction of the plate. The measurement of the distortions was made by a three-dimensional equipment, before and after the welding, in three distinct regions in the speciments. The profile of the weld bead was the main factor for the different types of distortions found, as revealed by macrographical analysis. The 60º single-V-groove had higher amplitudes of distortions as the joint without groove. The weaving wasn't a variable of statistically significant influence in this amplitudes. Tensile tests were made to evaluate the mechanical properties of the welded joints

This thesis deals with the construction of the welding clamping device for the robot cell. It is divided into two parts – the theoretical part describes welding of aluminium, MIG and TIG methods, welding robots and manipulators. The goal of the thesis is to design and construct the welding clamping device for the robot cell. In the last part of the thesis the return on investment into production of welding clamping device is evaluated.

This master thesis deals with the design of a robotic workplace concept for motorcycle frame welding. At the beginning the aim of work are determined parameters of welding line. Next part is description of a analysis motorcycle welded frame. The design of layout follows especially with regards to safety. The second half of the work is focused on the design of welding jig. Parts of this thesis are 3D model of the welding shop and simulation of the production process.

This diploma thesis is focused on the design of a robotic workplace for arc welding and its subsequent virtual commissioning. The summary deals with knowledge from industrial robotics and arc welding, the system analysis is focused on the composition of the workplace and the principle of arc welding, including acting influences. In the practical part, several variants of the solution are proposed, the most suitable variant is processed in the form of a 3D model. This model is then simulated, including all processes, a control program is created, and virtual commissioning of the workplace is demonstrated.