Welding Tips and Tricks

Ok, was tasked to fab a guided bend test jig for 1/4" 1018 CRS to do face and root bends. I've tracked down a 20tn bottle jack,1/2"X4" steel plate and have all the steel rod you could emagine. Only thing missing is plans.
I've seen one somewhere on the web where the jack is mounted in the fabbed U shaped base and makes the bend upward so you can see the face of the bend. This making any sense?

Is the rule for spacing and dia?
3x thickness= dia. for male bender.
3x thickness of sample +2.2x thickness of sample= spacing for the 2 outside guides inner distance.

So.....
3/4" dia male guide and 1.300" spacing between two 1"dia guides.

I'd hate to fab this thing just to find out it's wrong.
Someone spot check me please!!
Thanks!

What standard? ASME IX, AWS D1.1, AAR? There are many standards.

Plate, or pipe?

I can't tell you what the distinctions are, regarding bend radius, as I only have full access to one code (ASME IX), but knowing the standard will help me search. Even a CWI (and I think we have one or two here, now) will need to know what standard the weld is tested to.

A re-read of your post, reagrding the material tested, suggests this is structural. Additionally, since you are charged with this with inadequate information, you may not be working to a particular standard beyond the boss' "will it hold", and I'd recommend using AWS D1.1.

Any addition information you can give will help us help you, so the test is fair and appropriate.

Steve S

Sorry about the missing info. It's 1/4" plate in the flat position to D1.1 standard.
The school here wants to start trying to get the students an AWS cert and the program is pretty short so they're looking at 1G, ASTM A36 1/4" plate as the easiest. They only have 30 hrs of SMAW in the program (all positions, G and F)then they have to move on to other processes in the course.
Thanks,

Wow! 30 hours is a short course, so hopefully rather intensive.

Preliminarily, I agree with the numbers you gave regarding bends. I'll run it by a few people "in the know" and try a little research of my own, to try to confirm those specifications. To actaully give a AWS D1.1 cert, I wouldn't be surprised if the bend jig has to be checked by a properly rated CWI, so it needs to be right.

No side bends, I take it? Root and face only?

Steve S

Thanks!
Yea, root and face. They just want to see the students leave here with a "cert" of some sort. Figgure it's the easiest/quickest for them to acheive. I can fab the jig to very tight tollerances in the machine shop.
The whole course is 6weeks long. 10hrs a day, 7 days a week. Allied Trades Specialist. Just to give you a quick overview:
3 weeks in the machine shop: drilling,tapping,inserts,bolt extraction,shop math,layout,blueprint reading,drafting,shop safety,all types of lathe work,all types of mill work. Then a NIMMS benchwork test/cert
3 weeks in the welding shop: welding safety,all types and positions of oxy acet torch work,brazing,soldering, plasma torch,exothermic torch,all types/positions of SMAW,GMAW, and GTAW. Then composit pannel repair,fuel tank repair,glass cutting,radiator repair and titanium overview. PHEW!
On the plus side I have 2 of the Lincoln VRTEX machines and the video game generation loves them! Speeds up the learning curve. It evens does a virtual bend test on their "welds". I tried convincing them that the students were "certified" in the virtual world. No dice!

Whiterabbit,

I sent you a private message on the subject, as I'm waiting on some detailed info. If the fellow comes through, I''ll share it here, and with you on PM.

Steve S

Whiterabbit, I have the drawing for the bend-test jig, directly from AWS D1.1. I'll try to post it here, and I'll send it to you in a PM. I'm grateful to some new friends on another forum for sharing it with me.

EDIT: discovered I had the option to send it directly to your e-mail address, and did so.
Steve S

Here a picture of the one used in the Welding School I attend. I will check to see if there are others and will post picture of them.