Prototype tooling provides a concept of what the production tooling is meant to be. It is not meant for production tooling. When the prototype tooling is tried out, final tooling could be quoted to you and provided.
Prototype tooling does not include: part presence sensors, tooling design drawings or pneumatic clamping and isn't subjected to a customer's specifications or original design. Prototype tooling demonstrates the correct way to weld the part and also shows how tooling can be instituted at low cost to the customer.
ROI = [(x + y) * 4 - z] * t
x = Hourly Rate of Welder
y = Equipment Cost Per Hour
z = Robotic System Cost Per Hour
t = 2080 Hours Per Year
Typically used in the automotive and sheet metal industries, GMAW can be an automatic or semi-automatic process. GMAW provides high quality welds at a low cost to the manufacturer.
This arc welding application feeds a GMAW metal consumable electrode and shielding gas through the welding gun. An electrical current travels down the electrode and strikes the arc between the metal being welded and the wire electrode.
The advantages of GMAW include:
Speed - GMAW is a fast welding application
User-friendly - This welding approach is easy to set up and implement.
Cheap - GMAW equipment tends to be more affordable and more available than other welding equipment.
GMAW is used on these materials:
Steel, Aluminum, Copper, Nickel, Magnesium and other non-ferrous materials.
Axes - The number of axes a robot has define its flexibility level. The typical industrial robot has six axes of movement.
Length of arm segments - The robot's axes link arm segments which each vary in length. The length of the arms combined with the capabilities of each axis determine a robot's reach.
Placement - Robots have different mounting options. Their work envelopes vary in scope depending on whether they are shelf, ceiling, wall, or floor mounted. Some robots can be mounted to tracks or gantry systems, which further expands their work envelopes.
Construction - A robot's strength effects its work space. Robots have different payload capacities which in turn determine the type of EOAT that can be attached.
This crater results from the force of the arc and the contraction of melted metal when it cools and solidifies. The size of each crater relates directly to the welding current. Craters are not desirable because they cause a welding defect due to slag wrapping.
Crater welding is one method used to fill craters. It requires regular welding current. There are control sequences that allow you to switch to a crater filler current.