D-M-E Pro Weld Скачать руководство пользователя страница 7 | Manualshive

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D-M-E Pro Weld Скачать руководство пользователя страница 7

I

I.

Introduction

Please read this instruction manual thoroughly before using your
Pro Weld

™

system.

Pro Weld is a newly developed resistance-type welder. It effectively
builds up material to repair or redesign molds and dies. [Note: It is
not recommended for use on press dies, blow molds (usually made
from aluminum) or aluminum molds.]

The resistance welding method creates high energy discharges in
very short cycles through a capacitance circuit. Almost no heat is
created and, therefore, the base mold material is not altered or
damaged.

The Pro Weld micro welding technique is revolutionizing the repair
of molds by keeping this work in-house. Pro Weld welds 0.1mm,
0.2mm and 0.3mm thick metal sheets or strips, metal wire and
metal powder to the damaged area. It is extremely easy to use,
reduces downtime and improves quality.

Advantages

♦

No scaling or flaking occurs after welding as the sheet, wire and
powder metals used are free from impurities, and because the
weld has high strength, homogeneity and reliability.

♦

Easy to operate, no special training necessary.

♦

Hand and machine finishing is easier as the amount of weld
metal is not excessive.

♦

As the process emits almost no heat, there will be no shrinkage,
distortion, deformation or discoloration of the mold.

♦

No welding fumes or toxic gases are emitted.

5

Introduction

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Содержание Pro Weld

Страница 1: ...D M E Pro Weld USER GUIDE ...

Страница 2: ...for plastics rubber die casting and compression molds Welds can be applied on as rolled steel pre hardened steel quenched and tempered steel free cutting steel stainless steel and others To build up parting lines mold seams 3 point corners and edges To fill in pores repair of pinholes To repair wear worn areas on slides ejector pins sharp edge molds and thin core parts To design modification of in...

Страница 3: ...D M E Pro Weld Model No UMW0001 USER GUIDE ...

Страница 4: ...3 Usage of Electrodes 13 Operational Tip 14 IV 4 Start Up Procedure 14 Operational Tip 16 V Operation 17 V 1 Cautions in Welding Work 17 V 2 Discharge of Stored Energy 18 VI Welding 19 VI 1 Workpiece Electrode Welding Materials 19 VI 2 Pro Weld Control Features 20 Operational Tip 21 VI 3 Shaping Electrodes 22 VI 4 Recommended Current Output Levels 23 VI 5 Mold Material Welding Material 25 VI 6 Pro...

Страница 5: ...ntact 38 Positioning of the Sheet Material 38 Welding to a Flat Surface 39 Sheet Material Recession 39 Repair of a 3 Point Corner Collapse 40 Repair of a Parting Line or Edge 41 Repair of a Scratch or V Notched Flaw and Pinhole 42 Multi Layer Padding 43 Repair of Base Metal Impurities 45 Repair of an Inner Corner 45 Welding to a Rising Wall 46 Welding to a Narrow or Concave Mold Section 46 VIII Ex...

Страница 6: ......

Страница 7: ...ding technique is revolutionizing the repair of molds by keeping this work in house Pro Weld welds 0 1mm 0 2mm and 0 3mm thick metal sheets or strips metal wire and metal powder to the damaged area It is extremely easy to use reduces downtime and improves quality Advantages No scaling or flaking occurs after welding as the sheet wire and powder metals used are free from impurities and because the ...

Страница 8: ...le in 30 seconds As the capacitor system charges slowly and unloads quickly an input power can be used with low loading capacity A built in microprocessor allows stored energy to be easily adjusted High quality selection of welding materials in 0 1 and 0 2mm thick metal sheet 0 2 0 5mm diameter wire and powder metal After the initial weld if more padding is required re welding can be done easily P...

Страница 9: ...5W x 100L 38 40 Rc for P 20 P 21 steels NTA1 Ni Alloy sheet 10 sheets 0 1T x 30W x 70L 135HV for all steels NTA2 Ni Alloy sheet 10 sheets 0 2T x 30W x 70L 135HV for all steels Protective glasses Catalog No Description Complete Pro Weld system includes Dimensions in millimeters UMW0001 UMW0002 UMW0003 UMW0004 UMW0005 UMW0006 UMW0007 Model Pro Weld UMW0001 Input Voltage 120 VAC Consumable Power 600 ...

Страница 10: ... used with UMW0011 and UMW0012 Standard electrode holder black used with UMW0016 Standard electrode holder black used with UMW0013 Standard electrode holder black used with UMW0014 Magnet electrode holder brown used with UMW0009 and UMW0010 Tool box Sheet metal shears Screw and wrench set Fuse 2A Insulation tape UMW0008 UMW0009 UMW0010 UMW0011 UMW0012 UMW0013 UMW0014 UMW0015 UMW0016 UMW0017 UMW001...

Страница 11: ...PS017 PHM 2 50 grams Rc 30 35 for P 20 SNCM Good Choice N 15 UMPS018 HPM17 50 grams Rc 30 35 for P 20 SNCM Good Choice N 16 UMPS019 2767 50 grams Rc 30 35 for P 20 N 55 UMP0071 NAK55 50 grams Rc 38 41 P 21 Welding Material Fine Powder Precision Work Welding D M E Japanese Quantity Hardness U S Mold Steel Materials Catalog No Mold Steel Rockwell C Equivalent SP 51 UMPS010 SKH 51 50 grams Rc 63 Min ...

Страница 12: ...T x 5w x 100L Rc 38 40 P 21 Improved HPM 38 UMD0107 HPM38 10 0 2T x 5w x 100L Rc 30 33 420SS STAVAX UMD0104 STAVAX 10 0 2T x 5w x 100L Rc 50 52 STAVAX 420SS SCM440 HPM 2 UMD0101 IMPAX 10 0 2T x 5w x 100L Rc 30 50 P 20 HPM 2 MAS1 UMD0103 10 0 2T x 5w x 100L Rc 50 53 P 20 NAK 55 UMD0106 NAK55 10 0 2T x 5w x 100L Rc 38 40 P 21 Welding D M E Japanese Hardness U S Mold Steel Materials Catalog No Mold S...

Страница 13: ...re for Pro Weld UMW0001 D M E Pro Weld Carrying Handle Amp Output Meter Slidac Amp Output Control Automatic Manual Function Main Power Switch Output for Grounding Cord Output for Electrode Holder Cord Power Indicator Lamp Timer Input for Foot Switch Operation Mode Lamp ...

Страница 14: ...III 12 Parts Nomenclature for Pro Weld UMW0001 Carrying Handle Fan Specifications and Serial Number Plate Fuse Holder Fuse Input Power Socket Pro Weld UMW0001 Back Panel ...

Страница 15: ...in the Electrode Holders To use the opposite end of an Electrode or to replace an Electrode use the supplied Allen Head Wrenches Do not over tighten leave approximately 25mm of the Electrode exposed IV 3 Usage of Electrodes Electrodes are of two types Magnetic Electrodes and Non magnetic Electrodes Magnetic Electrodes are pre mounted in the brown Electrode Holders Use these Electrodes to pick up m...

Страница 16: ... to Output the Grounding Cord to Output and Foot Switch to Foot Switch Input on the Pro Weld according to Parts Nomenclature diagrams see III Check to ensure correct single phase voltage available is the same as that marked on the specifications plate located on the rear panel Connect the power cable to the Main supply and put Main power switch ON In the ON position the Power Indicator Lamp will i...

Страница 17: ... welding material must be covered by the Electrode to ensure a 100 bond Rolling the Electrode slowly over the welding material forms interconnecting scallop shaped weld spots approximately 1 to 2mm 0 04 0 08 in diameter This is the type of weld needed to ensure complete bonding If greater build up is desired repeat the process over the initial build up area by applying another layer of powder shee...

Страница 18: ... Tip Be sure the Electrode Holder Cord and Grounding Cord are fully tightened in their respective sockets If not completely tight conductivity will be lost resulting in bad welding 16 General Description of Use IV ...

Страница 19: ...th medical devices like Pacemakers Magnetic products such as magnetic cards floppy discs audio and video tapes Electromechanical devices such as watches clocks and televisions Do not remove the mold welder cover The unit s transformer carries high voltage Ensure the welder is properly grounded Main voltage must not exceed or 10 from the voltage stated on the Specifications Plate on back panel Unit...

Страница 20: ...scharge the stored voltage when the unit is not in use to avoid any danger and to save energy Except at the time of welding which is done by the discharge of stored voltage Pro Weld has a special circuit which discharges the stored voltage automatically 10 minutes after the machine s Main Power Switch is turned OFF Operation ...

Страница 21: ...s or steel brush remove any oxidation Clean and smooth the Electrode surface with a fine emery cloth before welding unless the Electrode is new previously unused Use fine emery cloth on the Copper Grounding Plate to ensure good contact with the mold surface Clean the welding material of oil with acetone or some other alcohol absorbent and remove oxidation with a fine emery cloth Place the mold on ...

Страница 22: ...l Features Manual Function 1 Select the Manual Function by pushing the Automatic Manual Function 10 so that the push button light does not illuminate If this button light is illuminated the unit is in the Automatic welding mode 2 The manual mode is used for tack welding metal powder in place with a magnetic electrode or metal strip or wire in place with a standard non magnetic electrode Welding FI...

Страница 23: ...Automatic mode Pro Weld discharges current in constant intervals according to the Timer Function setting For constant current discharges depress the Foot Switch and leave depressed until a new wrist position must be started in the roll welding proc ess see VI 7 Roll Welding Technique Lift your foot from the Foot Switch each time you finish a roll and before lifting the Electrode off the weld surfa...

Страница 24: ...mechanism automatically reduces pulse rate when the unit s optimal internal operating temperature is exceeded The unit will automatically resume selected pulse rate when the unit senses it is again operat ing within its optimal internal temperature range Pro Weld s thermal protection mechanism will not adversely affect welding results VI 3 Shaping of Standard Non magnetic Electrodes Although the o...

Страница 25: ... material used for a repair The type and diameter of the Electrode used for a repair To obtain a good strong weld it is important to acquire optimal current values Use the following chart as a guide to amperage settings While welding keep a note pad handy and note the optional current values used after obtaining a good weld Amperage output is adjusted by turning the Slidac Amp Output Control Turni...

Страница 26: ...lectrode angled at 10 3 300 500 500 700 4 5 400 600 600 800 800 1000 Roll Welding to a flat 2 surface inclined at 45 3 300 500 400 600 4 5 400 600 500 700 900 1200 Spot Welding to a flat surface 2 3 200 400 400 600 900 1100 Re Welding powder material After welding 2 300 500 300 500 powder re weld with a bare standard electrode 4 400 600 400 600 900 1200 for a stronger weld period 5 Current Amperag...

Страница 27: ...harder sheet material see Welding Materials Chart below Matching the base metal hardness to the welding material hardness will produce the ideal weld but using the above described procedure produces very good weld results The following charts list all the welding materials available for Pro Weld 25 VI Welding SP 51 UMPS010 SKH51 50 grams Rc 63 Min D 2 M 2 S 7 SP 11 UMPS011 SKH 11 50 grams Rc 50 Mi...

Страница 28: ... Steels N 80 UMW0003 NAK80 50 grams Rc 38 40 P 20 P 21 N 90 UMP0061 Ni Alloy 50 grams Rc 16 20 All Mold Steels SCM Good Choice N 14 UMPS017 PHM 2 50 grams Rc 30 35 for P 20 SNCM Good Choice N 15 UMPS018 HPM17 50 grams Rc 30 35 for P 20 SNCM Good Choice N 16 UMPS019 2767 50 grams Rc 30 35 for P 20 N 55 UMP0071 NAK55 50 grams Rc 38 41 P 21 Welding Material Powder Welding D M E Japanese Hardness U S ...

Страница 29: ...All Mold Steels NS 1 UMA0054 SS Alloy 10 0 1T x 30w x 70L Rb 90 All Mold Steels NS 2 UMA0055 SS Alloy 10 0 2T x 30w x 70L Rb 90 All Mold Steels NAK 80 UMW0004 NAK 80 10 0 1T x 5w x 100L Rc 38 40 P 20 P 21 NTA 1 UMW0005 Ni Alloy 10 0 1T x 30w x 70L HV135 All Mold Steels NTA 2 UMW0006 Ni Alloy 10 0 2T x 30w x 70L HV135 All Mold Steels HPM 50 UMD0102 HPM50 10 0 2T x 5w x 100L Rc 38 40 P 21 Improved H...

Страница 30: ...be a constant 0 1 0 2mm every discharge This procedure will ensure the strongest weld by automatically bonding the weld material to the mold surface Operational Tip Good conductivity results in a good weld It is important to clean the surfaces of the repair area of the mold the mold surface in contact with the Grounding Plate the Grounding Plate itself the Electrode and the Weld sheet material The...

Страница 31: ...elp you guide the Electrode across the weld material surface Further control can be obtained by using finger s from the other hand also pressed against the Electrode C Control over the roll welding process is important to gain a strong and homogenous weld Control will also keep the Electrode on only the weld material and with the right amount of pressure Failure to use pressure on the weld materia...

Страница 32: ...t as you roll as far as comfortable in the opposite direction Lift your foot off the Foot Switch each time you finish a roll and before lifting the Electrode off the surface This will prevent the possibility of sparking Continue to weld where you stopped with the Electrode by turning your wrist again and rolling to the opposite direction A strong weld is obtained by rolling across all of the weld ...

Страница 33: ...I Examples of Welding VII 1 Focalization of Current Electrode Shape and Formation of the Weld Spot Examples of Welding Good O Bad X FIG 8 Electrode Shape Ra 0 2 0 5mm FIG 9 FIG 7 Current Dispersion Good O Bad X ...

Страница 34: ...ine Welding a second layer should be done in the same manner VII 2 Powder Metal Application Powder metal is an excellent material for welding on corners edges and for repairing pinholes and cracks Powder metal will form a stronger weld for these applications than will sheet mate rial Powder welding is done in two steps Using a magnetic Electrode to pick up the powder tack the powder in place and o...

Страница 35: ...re Electrode after the first layer If second or third layers are needed also re roll weld between layer applications This will ensure a strong weld Roll the Electrode along an edge or parting line in a clockwise and counterclockwise direction to obtain weld build up Hold the Electrode at different angles while rolling to cover all areas of the repair Examples of Welding FIG 11 FIG 12 ...

Страница 36: ...l point pen magnetic Electrodes cannot be shaped without their losing magnetism weld the powder down spot by spot With a round Electrode whose edge has been shaped with a small radius roll weld the repair area This Electrode can also be used for the bare re roll welding of the area Welding an Inner Corner 34 VII Examples of Welding FIG 13 ...

Страница 37: ...bare re roll welding Welding a Pinhole Put a small amount of powder into the hole and then for best results add a small piece of sheet material on top of the hole Weld both materials with a tapered Electrode If the repair is a deep blowhole caused by argon weld ing first hammer a centering punch into the pinhole This expanded hole can now have powder put into it Welding a Crack For repairing crack...

Страница 38: ... 0 15mm thick layers Weld one layer and then another and so on Wire welding material is also effective in filling and repairing cracks Welding in a Rib The rib opening can be welded using a 2mm Electrode 36 Examples of Welding VII FIG 16 FIG 17 3 2 1 ...

Страница 39: ...hout losing their magnetism To wear these Electrodes down as little as possible clean them when it becomes necessary using fine sand paper Some weld repairs will require the use of a shaped standard non magnetic Electrode To use powder material in a confined space make a paste by dipping the shaped Electrode into a drop of light machine oil and then into the powder material Alternately powder can ...

Страница 40: ...e Sheet Material The sheet material should be slightly larger than the repair area and extend beyond the edge of the area to be repaired This is true whether the repair is an edge concave surface v notched flaw or pinhole Welding to a Flat Surface Position the sheet material on the repair area to be welded Set 38 Examples of Welding VII FIG 19 Good Bad Good Bad a 0 5 1 0mm b 0 1 0mm a b a b ...

Страница 41: ...cond layer can be either 0 1T or 0 2T Re roll welding the area with slightly higher amperage setting will strengthen the weld Sheet Material Recession Sheet Material will recess 15 30 when welded For example in FIG 21 below if the sheet material d 0 2mm after welding c will 0 15mm Take this into consideration when doing build up repair or design changes Repair of a 3 Point Corner Collapse This rep...

Страница 42: ...al moving the Electrode in various directions see FIG 22 and 23 below Re roll weld the material at a slightly higher amperage setting to strengthen the weld If a second and third layer is applied use the same procedure used with the first layer Repair of a Parting Line or Edge 40 Examples of Welding VII FIG 23 Movement of the Electrode in Top View FIG 22 Movement of the Electrode in Side View ...

Страница 43: ...o Auto and with the profile side of a round Electrode roll weld the material ensuring that each weld spot half overlaps the next This should also be the case if a second layer is added and when re roll welding Weld the strip in the 1 to 4 sequence depicted in FIG 25 below Movement and angles of Electrode in side view Repair of a Scratch or V Notched Flaw and Pinhole 41 Examples of Welding FIG 24 F...

Страница 44: ...G 27 below FIG 27 A pinhole can be repaired using powder sheet material or a combi nation of both When using sheet material if the hole diameter is less than 1mm press weld the material directly into the hole see FIG 28 below Small diameter pinhole FIG 28 To repair a pinhole larger than 1mm in diameter weld in layers First 42 Examples of Welding VII ...

Страница 45: ...5 or 6 discharges of current Use the same procedure for a second layer Multi Layer Padding Proper multi layer padding will take some time as each layer must be tack welded at many points and then thoroughly roll welded Tack weld with a round Electrode tapered and rounded like a ball point pen For complete welding to the base metal use 0 1mmT sheet material in the first layer Before the second laye...

Страница 46: ...ed with a small radius FIG 30 When two pieces of sheet material are used on the same metal face weld the sheet material parting line with a narrow strip of additional material FIG 31 At any time during multi layer padding or other types of welding repairs where it is important that surrounding areas to the weld not be touched by the Electrode use the supplied Masking Tape and cover those areas FIG...

Страница 47: ...Corner To weld at an inner corner use a length of wire material 0 2 0 4mm in diameter Tack the wire in place using an Electrode with its end shaped like a ball point pen Weld the wire in place by using the same Electrode and welding spot by spot or with a flat Electrode shaped like a spatula with its edge rounded Roll the Electrode from its point down onto its side along the wire material FIG 34 4...

Страница 48: ... the Masking Tape to protect any surrounding areas not to be touched by the Electrode FIG 35 Welding to a Narrow or Concave Mold Section Using the Pro Weld micro welder repair welding into very small or very confined areas can be accomplished It is unlikely welding of this nature can be done by argon arc TIG or other types of welders In each case shape the Electrode according to the area to be wel...

Страница 49: ...p the next by half its diameter Subsequent weld material layers must be done in this same manner FIG 37 VIII 2 Improperly Shaped Electrodes Proper welding can only be done with Electrodes that have a rounded end or edge with a slight radius Electrodes with flattened ends or those that give linear contact will cause a bad weld even if the contact area is very small FIG 38 47 Examples of Bad Welding...

Страница 50: ... to clean the surface of the mold repair area the mold surface in contact with the Grounding Plate the Grounding Plate the Electrode and the weld sheet material Check to ensure the Electrode Holder Cord and Grounding Cord are fully tightened in their sockets The copper Grounding Plate should be placed as close to the repair area as possible firmly anchored against the base material and the Plate t...

Страница 51: ... M E stating the date of purchase and serial number of the unit The Manufacturer shall in no way be liable for Damages in shipment Failures or damages due to misuse abuse improper installation or abnormal conditions of temperature dirt or corrosives Failures due to operation intentional or otherwise above rated capacities Non authorized expenses for removal inspection transportation repair or rewo...

Страница 52: ...D M E Company 29111 Stephenson Highway Madison Heights MI 48071 Phone 800 626 6653 248 398 6000 Fax 248 398 6174 D M E Pro Weld User Guide ...

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