Math on Metal

[Pages:263]Math

on

Metal

The Welding Fabrication Industry needs qualified welder fabricators who can deal with a variety of situations on the job. This portion of the training packet explores mathematics as it relates to industry requirements.

Welding Math Packet Table of Contents

MATH TOPICS

HOW TO USE THIS PACKET WHOLE NUMBERS

Reading whole numbers; Understanding the decimal point Adding & Subtracting whole numbers Multiplying whole numbers Dividing whole numbers

Page Number

5-6

7

8 9 10 11

USING YOUR SCIENTIFIC CALCULATOR

Using your calculator Using the fraction key on your calculator Checking answers for accuracy when using your calculator

12

13 14-15 16-18

FRACTIONS

Understanding Fractions Relative size of fractions- Which is smaller? Bigger? Reducing fractions to their lowest terms Changing improper fractions to mixed numbers and visa versa Adding & Subtracting fractions Multiplying Fractions Dividing Fractions Converting fractions to decimals Using your calculator to add, subtract, multiply, divide, reduce fractions and to change fractions to decimals

19

20-21 22

23-24 25-27 28-30 31-33 34-37 38-40 41-42

DECIMALS

Comparing Decimals to fractions Reading & Writing Decimals

43 44-46 47-49

Decimal size- determining the size of common objects in decimal inches Comparing Decimal sizes; Which is Larger? Smaller? Rounding decimals

50

51-54 55-57

2

Converting decimals to fractions Adding Decimals Subtracting Decimals

TOLERANCES- HOW TO CALCULATE THEM

Bilateral and Unilateral Tolerances Fractional tolerances Decimal Tolerances Angle tolerances Joint Preparation Tolerances

MEASURING TOOLS

Measuring with fractions- skills needed in using a ruler; reducing fractions, expressing fractions in higher terms Ruler- reading it with accuracy Metric ruler Converting decimals to the nearest 1/16th of an inch for reading rulers Protractor Bevel (Angle) Finder Micrometer

WIRE DIAMETER

Converting fractional wire sizes to decimal sizes

RATIO & PROPORTION

Introduction to ratio and proportion using the box method

PERCENTAGES

Solving percentage problems using the box method

ACCURATE SETTING AND ADJUSTMETNS

Making current adjustments (percentage reductions) Checking and adjusting wire feed speed Setting machine dials

58-59 60-61 62-63

64 65-66 67-68 69-71

72 73-74

75 76-79

80-83 84

85-86

87-90 91-92 93-101

102 103-104

105 106-108

109 110-112

113 114-115 116-121 122-130

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METRIC MEASUREMENTS

Using your hand as a metric measuring tool How big or little are linear metric measurements? Body reference chart Estimating length in millimeters Converting to metric equivalents using the box method Metric conversion chart Metric to Metric Conversions-converting from larger and smaller metric units Using a metric step ladder

SOLVING A FORMULA

Solving formulas; using Ohms law & temperature conversions as examples Order of Operations Squaring numbers Dimensional analysis

TEMPERATURE CONVERSIONS

Using what you know about solving formulas to convert from Celsius to Fahrenheit or visa versa

ELECRTRC POWER PROBLEMS

Using what you know about solving formulas to solve electric poser problems

GEOMETRY

Understanding circles and Pi Squaring numbers Square roots Area of rectangles Area of triangles Construction with angle/Bevels Area of circles Squaring your corners Squaring off & finding the center of your rectangle Geometric Construction for Fabrication on Metals Forming pipes and tubes out of flat metal Making trigonometry Work for You- finding missing

131 132 133

134 135-136

137 138-141

142-145

146 147-149

150-153 154-156

157 158 159-160

161 162-163

164 165-167 168-170 171-172 173-174 175-178 179-180 181-185 186-187 188-192 193-198 199-200 201-227

4

dimensions, fabrication

CALCULATING THE COSTS OF A WELDING JOB

What is Included in the Cost of Welding? Calculating Arc Time vs Prep Time- Using Percentages Calculating Direct Labor Costs Operating Factor Overhead Costs Calculating the Cost of Steel Calculating the Cost of Welding Consumables Calculating the Cost of Materials

228

229 230-231 232-235

236 237 238-242 243-248 249-252

HEAT INPUT

Heat input lab using current, voltage and speed

253 254-260

5

HOW TO USE THIS PACKET

This packet is meant to be used as a reference guide and a learning tool. It contains nearly all of the math worksheets that were developed for the Math on Metals Project which have been interspersed throughout all of the welding packets. The worksheets have been collected, edited, and rearranged in an order that we hope will be helpful to all welding students, whether you are taking just a few classes for welding skills upgrade or you are a degree or certificate seeking student.

When compiling this math reference packet, care was taken to build on skills, starting from the most basic (whole number, addition, subtraction, multiplication, division) moving on quickly to fractions, decimals, ratios, percentages, formulas and geometry. Throughout the math worksheets and this packet, applications of the skills have been tied directly to the welding projects and problems you will encounter in the classroom and on the job.

Although the skills build in a logical order, this reference guide is not necessarily meant to be started at the beginning and moved through on a step-by-step basis, but rather it is intended to be used to fill in math knowledge gaps and to provide examples of math applications that would be helpful to welders.

Using the detailed table of contents you should be able to locate the specific math application and also the background theory that you may need in order to gain a thorough understanding of any math related problem you encounter. An example might be that you are having trouble understanding how to calculate heat input on a welding job. You could go to the heat input section found in the table of contents. If all you need is a refresher on the formula it is located there. If you discover that you also need more information on how to solve formulas, then you would look to the formula section for more explanation on how to use a formula and order of operation.

At the end of each application worksheet you will find a list of other worksheets contained in this packet that may be helpful for a fuller understanding of the application worksheet.

6

Although the math in this packet is meant for the most part to be both self explanatory and self paced, you may encounter problems in using this packet. Please ask your instructor for clarification. Some answers have been provided in the math packet itself, your instructor will have separate detailed answer sheets that they can make available to you at their discretion.

7

WHOLE NUMBERS ADDING, SUBTRACTING, MULTPILYING &

DIVIDING

Applications: ? All welding applications ? Measurement ? Blueprint reading

8

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