Problem NO: 22

An axle-bearing surface made of high carbon steel has worn beyond its useful life. When it was\nnew, the diameter was 4.00 in. In order to restore it,

An axle-bearing surface made of high carbon steel has worn beyond its useful life. When it was

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new, the diameter was 4.00 in. In order to restore it, the diameter was turned to 3.90 in to provide a

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uniform surface. Next the axle was built up so that it was oversized by the deposition of a surface

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weld bead, which was deposited in a spiral pattern using a single pass on a lathe. After the weld

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buildup, the axle was turned again to achieve the original diameter of 4.00 in. The weld metal

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deposited was a similar composition to the steel in the axle. The length of the bearing surface was

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7.0 in. During the welding operation, the welding apparatus was attached to the tool holder, which

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was fed toward the head of the lathe as the axle rotated. The axle rotated at a speed of 4.0 rev/min.

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The weld bead height was 3/32 in above the original surface. In addition, the weld bead penetrated

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1/16 in into the surface of the axle. The width of the weld bead was 0.25 in, thus the feed on the

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lathe was set to 0.25 in/rev. Assuming the heat transfer factor was 0.80 and the melting factor was

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0.65, determine (a) the relative velocity between the workpiece and the welding head, (b) the rate of

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heat generated at the welding source, and (c) how long it took to complete the welding portion of

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this operation.

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