Introduction to Turning and Welding

 

•       Overview of turning and welding processes.
•       Turning: Explanation of the lathe machine, its components, and basic operations.
•       Welding: Introduction to welding types (MIG, TIG, Stick), safety, and basic equipment.
•       Proper PPE (Personal Protective Equipment) for both turning and welding.
•       Workplace safety protocols for handling machines and welding tools.

      Hands-on Activities:

•   Turning: Basic lathe machine operation (off and on, adjusting speed).
•   Welding: Safety gear fitting and proper positioning.

 

 

Introduction to the Lathe Machine

 

•       Understanding the lathe machine: components (bed, headstock, tailstock, carriage, etc.), controls, and functions.
•       Different cutting tools and their functions.
•       Setting tool height and cutting speed.
•       Advanced operations: threading, boring, and knurling.
•       Understanding cutting fluids and their importance.

 

      Hands-on Activities:

 

•   Creating various shapes on the lathe (e.g., tapered shapes, faces, and grooves).
•   Setting up the lathe for threading.
•   Creating internal and external threads.

      Exercises:

 

 

•   Practicing face turning and cutting external threads.
•   Knurling a piece of metal.
•   Boring a hole with proper alignment.

Advanced Turning Operations

 

•       Complex turning operations: multi-axis turning, profile turning, and contouring.
•       Understanding advanced tool paths, tool wear, and cutting tool materials.
•       Optimization of cutting speed and feed rates.

 

      Hands-on Activities:

 

•   Execute advanced turning techniques such as profile turning and tapering on cylindrical parts.
•   Setting up for multi-axis CNC turning operations (if available).

 

      Exercises:

 

•   Turn a tapered shaft with a specific finish.
•   Perform contour turning on a complex piece.

 

 

CNC Lathe Programming and Operations

 

•       Introduction to CNC lathe programming: G-codes and M-codes.
•       Programming strategies for complex parts.
•       CNC toolpath simulation and optimization.

 

      Hands-on Activities:

 

•   Create basic CNC programs for turning complex parts.
•   Run simulated CNC programs on the lathe and observe the effects of the settings.

 

      Exercises:

 

•   Program and machine a simple part with multiple features (e.g., grooving, boring, threading) using CNC lathe.
•   Troubleshoot errors during CNC program execution.

Advanced Welding Techniques: MIG and TIG Welding

 

•       Advanced MIG welding techniques: pulse welding, spray transfer, and short-circuit transfer.
•       Advanced TIG welding techniques: using a foot pedal for heat control, back-purge gas, and multi-pass welding.

 

      Hands-on Activities:

 

•   Practice on advanced MIG welding using pulse welding and adjusting wire speed for specific materials.
•   TIG welding on thicker materials (e.g., ¼-inch or thicker) with precise heat control.

 

      Exercises:

 

•   Perform a MIG weld using pulse mode to improve control of heat and penetration on a thicker piece.
•   TIG weld a multi-pass weld on stainless steel.

 

 

Advanced Welding Techniques: Stick and Flux Core Arc Welding

 

•       Stick welding (SMAW): welding with different electrodes, including low-hydrogen electrodes.
•       Flux core arc welding (FCAW): understanding its use on thicker materials and its applications.

 

      Hands-on Activities:

 

•   Perform deep penetration welding with stick welding on thicker materials.
•   Weld using flux-cored wire on a heavy-duty pipe or plate for multi-pass applications.

 

     Exercises:

 

•   Complete a deep penetration weld using SMAW.
•   Use FCAW for heavy-duty welding on plates or structural steel.

Advanced Joint Design and Welding Positioning 

 

•       Joint design: bevel angles, weld types, and preparing complex joints (butt, corner, T-joints).
•       Welding in different positions (flat, horizontal, vertical, overhead).
•       Factors influencing weld strength: material, joint geometry, and heat input.

 

      Hands-on Activities:

 

•   Prepare and weld complex joint types, such as double bevels or reinforced butt joints.
•   Practice welding in difficult positions (overhead and vertical-up welding).

 

      Exercises:

 

•   Complete a fillet weld on a complex joint with specific angle requirements.
•   Perform a vertical-up and overhead weld.

 

 

Welding Process Optimization and Troubleshooting

 

•       Understanding welding parameters: voltage, current, travel speed, and their impact on the weld.
•       Common welding defects and their causes (porosity, undercut, lack of fusion, etc.).
•       Techniques for optimizing efficiency in welding: proper heat control, proper fit-up, and pre-heating.

 

      Hands-on Activities:

 

•   Troubleshoot common welding defects and adjust parameters to resolve them.
•   Optimize travel speed, voltage, and current for a specific application.

 

      Exercises:

 

•   Identify and correct welding defects in practice pieces.
•   Perform test welds with optimized parameters, ensuring no defects like porosity or spatter.

Advanced Metallurgy for Welding and Turning

 

•       Understanding metallurgy: material properties (hardness, tensile strength, heat treatment).
•       The effects of heat on different materials during turning and welding.
•       Pre- and post-welding heat treatments to improve weld quality and material properties.

 

      Hands-on Activities: 

 

•   Weld on different materials, such as mild steel, stainless steel, and aluminum, to understand the impact of heat on each.
•   Turn and finish parts made from high-carbon steel and alloy steel to demonstrate the effects of heat treatment on turning operations.

 

      Exercises:

 

•   Weld a multi-material assembly (e.g., mild steel and aluminum) and observe material behavior.
•   Perform precision turning on a hardened steel workpiece.

 

 

Integration of Turning and Welding Skills

 

•       Integrating turning and welding in manufacturing processes.
•       Tolerances and finish requirements when welding turned parts.