Design improvement and vibration analysis of a fabricated pipe bevelling jig for welding preparation

Mohamad Harani, Muhammad Fathullah (2022) Design improvement and vibration analysis of a fabricated pipe bevelling jig for welding preparation. Project Report. Melaka, Malaysia, Universiti Teknikal Malaysia Melaka. (Submitted)

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Abstract

Pipe bevelling is a process in which an angle is produced between the end of the pipe and the surface that needs to be welded. In pipe bevelling, some standards need to be followed. The angle must be in a range between 30° to 45°. Vibration-induced white finger (VWF) is a long-term effect on the worker that results from prolonged use of vibrating hand tools. Preliminary testing was conducted to measure the vibration magnitude for the existing jig using a vibrometer. The highest vibration magnitude occurs during the bevelling of a 3.5- inch pipe which is 116.59 m/s2 within 5 minutes and 43 seconds. According to ISO European Standards, these exposure levels are nearing the exposure limits yellow indicator, which is between 105 m/s2 and 150 m/s2. This study intends to find the best methods to decrease or eliminate the vibration exposure for the worker when using the fabricated jig. Problems have been identified and possible solutions have been proposed for the existing jig to achieve the objectives. An automated pipe rotator and three-jaw chuck were developed. After the design improvement was well established, all the data and analysis were considered. It was then compared to the data analysis of bevel angle accuracy between the existing pipe bevelling machine and after the pipe bevelling machine undergoes the design improvement process. The precision of the bevel angle measurement was achieved as a result of the improved design of the fabricated jig. The average uncertainty value before the design improvement shows 0°34'41.15", whereas the value after the design improvement was lower 0°23'55.98". It indicates that precise measurements of bevel angles are possible when the motor can rotate the pipes at a constant speed, which results in a constant degree of bevel angle being produced. Reducing vibration exposure is an excellent approach to avoiding diseases related to vibration tools, such as Hand Arm Vibration Syndrome. This study is hoped to assist the metal and fabrication industry in the process of pipe welding preparation. This ensured a safe environment when using this jig to prepare a pipe bevel.

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