Box and Pan Brake and Category:MIG Welders: Difference between pages

From Artisans Asylum Wiki
(Difference between pages)
No edit summary
 
No edit summary
 
Line 1: Line 1:
{{ToolBox|tool_title=Box and Pan Brake|image=Metal_shop_brake_nolabels.jpg|caption=Box and Pan Brake|
[[Category:Tools]][[Category:Welders]]


location=Metal Shop|training=[https://www.artisansasylum.com/class-catalog Tool classes]|testing=
{{ToolBox|tool_title=MIG welders|image=Metal_shop_MIG_welder.png|caption=MIG welder in


[https://www.artisansasylum.com/tool-testing Tool testing], or [[:Category:Metal Shop#Tool Testing
the MEtal Shop|location=Metal Shop|training=[https://www.artisansasylum.com/class-


Night|come to the shop on Tool Testing Night]]|restrictions=red|make=Varied|model=Varied|
catalog Tool classes]|testing=[https://www.artisansasylum.com/tool-testing Tool
 
testing], or [[:Category:Metal Shop#Tool Testing Night|come to the shop on Tool  
 
Testing Night]]|restrictions=red|make=Varied|model=Varied|serial=Unknown|
 
manufacturer_specs=n/a|manual=[[Category:MIG_welders#Operation Notes]]|rubric=n/a|
 
tool_categories=}}
 
{{Warning|text=Extra precaution required for welders. Training / Tool Testing is
 
essential. See “Welding Safety” pages.}}
 
Manufacturers Manuals for each welder is available in the
 
[https://drive.google.com/drive/folders/1SdAqgZSwBteXBujK4x26A_QXCfu320cW Equipment
 
Manuals Directory]


serial=Unknown|manufacturer_specs=n/a|manual=n/a|rubric=n/a|tool_categories=}}


== Materials ==
== Materials ==


=== Use for: ===
'''Use for:'''
* Up to 22 Ga sheet metal (1/32")
 
* Mild Steel
* Mild Steel '''ONLY'''
* Soft Metals


'''Do not use for:'''


=== Do not use for: ===
* Galvanized
* Sheet metal exceeding 1/32" thickness
* Plated
* Stainless steel
* Painted
* High-carbon or Hardened steel
* Oiled
* Round or square stock
* Rusted
* Powder-coated


== Safety Hazards ==
== Safety Hazards ==


{{EyeWarning}}
{{EyeWarning}}


* Workpiece can unexpectedly snap
1.  '''UV damage to eyes.''' Welding Helmet with shade 12 protection or darker is required.


* Pinching injuries
2.  '''UV burns on exposed skin.''' The rays from the arc can cause severe radiation burn (worse than sunburn.) Cover exposed skin.


* Cuts/scrapes from sharp edges and burrs
3.  '''Burns''' from flame, sparks, hot workpieces. Wear welding gloves, cotton clothing (no synthetics) and closed toe shoes.
 
4.  '''Poisoning''' from breathing gases produced by welding. Use ventilation. Do not stick head in fumes. Respirator recommended.
 
5.  Keep workplace clear of flammable materials, including grease, oil, solvents, paper.
 
6.  '''Electrocution''' if welder is mishandled. Do not weld near puddles of water on floor or work area.


== Operation Notes ==
== Operation Notes ==


* Solvent based metal cleaning should be done with Simple Green or other low-intensity
cleaners.
* Abrasive cleaning methods are also appropriate.
* '''No brake cleaner.''' Brake cleaner contains chlorinated hydrocarbons that create
'''phosgene gas''' when combined with UV light.  '''Ventilation will not prevent
poisoning.'''
'''MIG Welders Available:'''
* Millermatic 212 Auto Set - welds material from 22 gauge to 3/8 in (9/5mm) thick.
* Millermatic 252- welds material from 22 gauge to 1/2 in. thick.
The shop supplies 025, .030, and .035 inch copper coated steel filler wire.
* The MIG welders in the shop use a gas mixture of 75% Argon and 25% CO2. Purge lines
after use.
* To reduce spatter build-up, lightly coat Torch Head with Nozzle Anti-Spatter Gel.
(Found in welding bays.)
== Set-up Procedure ==
1.  '''Safety First'''
* Turn on welding bay ventilation.
* Remove flammable materials and water from welding area.
* Protect bystanders from the arc-flash, If you can’t depend on the protective vinyl
flaps on the welding bays, use welding screens
2.  '''Attach the ground clamp to bare metal on the work table.'''
If workpiece is too large for the work table, clamp the workpiece.
3.  '''Check to see if the welder has been shut down properly.'''
* Is the power shut off?
* Is the gas shut off at the cylinder valve?
* Have the lines been bled (is the working pressure at zero)?
4.  '''Plug the machine in and turn it on.'''
5.  '''Turn the gas on.  If needed, adjust the pressure.'''
* SLOWLY crack the tank valve counterclockwise. Watch the regulator needle jump, and check that the needle has stopped moving before opening the valve (about half a turn).
This procedure lessens the impact of the initial jump in pressure on the regulator, reducing wear and tear.
* Hold the torch away from the workbench (more than 12 inches) and pull the torch trigger to start the gas cycle.
* Check the regulator dial to make sure the working gas pressure matches the recommendation listed on the shop tag attached to the regulator. Adjust if needed.
* Note: An inaccurate working pressure reading may occur if the welder has been shut down improperly by the previous user. Press the trigger on the Torch Head to lower the line pressure and reset the gauge.


{| class="infobox" cellspacing="5" style="width: 22em; text-align: left; font-size: 100%; line-height: 1.5em;"
6. '''Set the machine's voltage and wire speed.'''
! colspan="2" class="infobox-image" | [[File:Metal_shop_brake.jpg|450px|Brake]]
|-
| colspan="2" | Metal Shop Sheet Metal Brake
|-
|}


* Take note of the wire size (written on the spool inside the machine) and the thickness of the workpiece.


* Brake maximum capacity – 22 GA x 48” width
* Start with the settings recommended on the flip down chart located on the front of the machine. Adjust the settings further as needed.


* Attached gauge wheel is used to judge if your material is appropriate for the machine.
7.  '''When welding, avoid tight loops or extra loops in the torch cord.'''


* Spare parts, including an Allen wrench, are stored underneath.
Extra looping will stress the feed mechanisms and may slow down the wire speed.


* A 6 mm Allen wrench is used to adjust fingers. The proper size wrench will help to prolong the life of the screw heads.
8. '''Dross may build up on the gas nozzle and/or contact tip while welding.'''


== Basic Operating Instructions ==
Clean as necessary using MIG pliers. Spare torch parts, including replacement contact tips, are kept in the Metal Shop’s supply cabinet.


{| class="infobox" cellspacing="5" style="width: 22em; text-align: left; font-size: 100%; line-height: 1.5em;"
== Shut-Down Procedure ==
! colspan="2" class="infobox-image" | [[File:Metal_shop_brake_parts.jpg|450px|Brake Parts]]
|-
| colspan="2" | Parts of the Brake
|-
|}


{| class="infobox" cellspacing="5" style="width: 22em; text-align: left; font-size: 100%; line-height: 1.5em;"
1. '''Shut off the gas at the source.'''  Turn the cylinder valve clockwise.
! colspan="2" class="infobox-image" | [[File:Metal_shop_brake_adjustments.jpg|450px|Brake Adjustments]]
|-
| colspan="2" | Adjusting the Brake
|-
|}


* Align fingers by loosening all, then raising the apron to line them up. Re-tighten.
2.  '''Bleed the lines.'''


* Place sheet metal under fingers and position as needed.
* Turn the wire speed down as far as it will go.


* Use a 6 mm Allen wrench to adjust fingers 1/18” to 1/16” from edge. Material width from edge is a good rule of thumb.
* Pull the torch trigger and wait for the regulator gauge to read zero.


* Lock your material by pressing both clamp handles down. (Left one is bent, and tricky)
3. '''Flip the machine's power switch to "off." '''


* To bend sheet metal, grab Apron Handles and lift. (Remember, steel has spring-back.)
4. '''Turn the ventilation off if no one else is using the bays. '''


== Video ==
5.  '''Loosely coil the torch cord and store on the machine. '''


[https://www.youtube.com/watch?v=d4RWkf7eo1g '''Box and Pan Brake''']
6. '''Put all tools away and clean the work area. '''

Revision as of 20:32, 3 February 2024



MIG welders
MIG welder in the MEtal Shop
General Info
Make Varied
Model Varied
Serial Unknown
Specs n/a
Manual
Asylum Info
Location Metal Shop
Rubric n/a
Training [https://www.artisansasylum.com/class-

catalog Tool classes]

Testing [https://www.artisansasylum.com/tool-testing Tool

testing], or come to the shop on Tool Testing Night

Restrictions red


Warning Extra precaution required for welders. Training / Tool Testing is

essential. See “Welding Safety” pages.


Manufacturers Manuals for each welder is available in the

[https://drive.google.com/drive/folders/1SdAqgZSwBteXBujK4x26A_QXCfu320cW Equipment

Manuals Directory]


Materials

Use for:

  • Mild Steel ONLY

Do not use for:

  • Galvanized
  • Plated
  • Painted
  • Oiled
  • Rusted
  • Powder-coated

Safety Hazards

Warning Safety glasses Eye protection required!


1. UV damage to eyes. Welding Helmet with shade 12 protection or darker is required.

2. UV burns on exposed skin. The rays from the arc can cause severe radiation burn (worse than sunburn.) Cover exposed skin.

3. Burns from flame, sparks, hot workpieces. Wear welding gloves, cotton clothing (no synthetics) and closed toe shoes.

4. Poisoning from breathing gases produced by welding. Use ventilation. Do not stick head in fumes. Respirator recommended.

5. Keep workplace clear of flammable materials, including grease, oil, solvents, paper.

6. Electrocution if welder is mishandled. Do not weld near puddles of water on floor or work area.

Operation Notes

  • Solvent based metal cleaning should be done with Simple Green or other low-intensity

cleaners.

  • Abrasive cleaning methods are also appropriate.
  • No brake cleaner. Brake cleaner contains chlorinated hydrocarbons that create

phosgene gas when combined with UV light. Ventilation will not prevent

poisoning.

MIG Welders Available:

  • Millermatic 212 Auto Set - welds material from 22 gauge to 3/8 in (9/5mm) thick.
  • Millermatic 252- welds material from 22 gauge to 1/2 in. thick.

The shop supplies 025, .030, and .035 inch copper coated steel filler wire.

  • The MIG welders in the shop use a gas mixture of 75% Argon and 25% CO2. Purge lines

after use.

  • To reduce spatter build-up, lightly coat Torch Head with Nozzle Anti-Spatter Gel.

(Found in welding bays.)

Set-up Procedure

1. Safety First

  • Turn on welding bay ventilation.
  • Remove flammable materials and water from welding area.
  • Protect bystanders from the arc-flash, If you can’t depend on the protective vinyl

flaps on the welding bays, use welding screens

2. Attach the ground clamp to bare metal on the work table.

If workpiece is too large for the work table, clamp the workpiece.

3. Check to see if the welder has been shut down properly.

  • Is the power shut off?
  • Is the gas shut off at the cylinder valve?
  • Have the lines been bled (is the working pressure at zero)?

4. Plug the machine in and turn it on.

5. Turn the gas on. If needed, adjust the pressure.

  • SLOWLY crack the tank valve counterclockwise. Watch the regulator needle jump, and check that the needle has stopped moving before opening the valve (about half a turn).

This procedure lessens the impact of the initial jump in pressure on the regulator, reducing wear and tear.

  • Hold the torch away from the workbench (more than 12 inches) and pull the torch trigger to start the gas cycle.
  • Check the regulator dial to make sure the working gas pressure matches the recommendation listed on the shop tag attached to the regulator. Adjust if needed.
  • Note: An inaccurate working pressure reading may occur if the welder has been shut down improperly by the previous user. Press the trigger on the Torch Head to lower the line pressure and reset the gauge.

6. Set the machine's voltage and wire speed.

  • Take note of the wire size (written on the spool inside the machine) and the thickness of the workpiece.
  • Start with the settings recommended on the flip down chart located on the front of the machine. Adjust the settings further as needed.

7. When welding, avoid tight loops or extra loops in the torch cord.

Extra looping will stress the feed mechanisms and may slow down the wire speed.

8. Dross may build up on the gas nozzle and/or contact tip while welding.

Clean as necessary using MIG pliers. Spare torch parts, including replacement contact tips, are kept in the Metal Shop’s supply cabinet.

Shut-Down Procedure

1. Shut off the gas at the source. Turn the cylinder valve clockwise.

2. Bleed the lines.

  • Turn the wire speed down as far as it will go.
  • Pull the torch trigger and wait for the regulator gauge to read zero.

3. Flip the machine's power switch to "off."

4. Turn the ventilation off if no one else is using the bays.

5. Loosely coil the torch cord and store on the machine.

6. Put all tools away and clean the work area.

Retrieved from "http://wiki.artisansasylum.com/index.php?title=Box_and_Pan_Brake&oldid=1052"