MIG versus robotic MIG welding for OEM parts
MIG versus robotic MIG welding for OEM parts: the fit-up, access and quantity numbers that decide the route, and where a manual bench still wins.
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Topic hub · 30 guides
Bending, welding and finished assemblies
A bend is where a flat drawing becomes a part, and a weld is where several parts become an assembly that either fits at the customer's line or does not. Ganesh bends on a 200 T, 4,450 mm, 5-axis CNC press brake and welds on three CLOOS robotic cells plus more than 30 manual stations. These guides cover K-factor and bend allowance, minimum flange, springback, long-panel distortion, fixture design, weld sequence, assembly tolerance stack-up and inspection.
Guides in this topic, page 3
Press brake bending, bend allowance, fixtures, robotic MIG welding, distortion control and the tolerances a finished welded assembly can actually hold.
How to design a welding fixture for sheet metal parts
A welding fixture starts from the datum scheme and the weld sequence, not the part outline. Locator layout, clamp placement, torch access and the build tolerances that hold.
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Controlling weld distortion in frames
Why welded frames move, the sequence and fixture rules that hold the diagonal, and the distortion allowance to put on the drawing before quotation.
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Welding aluminium sheet assemblies
Welding aluminium sheet assemblies: filler choice, cleaning window, current range and the heat-affected zone strength that decides the joint design.
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Spot welding for panels and enclosures
Spot welding for panels and enclosures: nugget size, edge distance, spot pitch and electrode life, with the numbers that decide whether a panel holds.
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Welding inspection and traceability for sheet metal
Welding inspection and traceability: which quality level to call out, what to measure at each stage, and how the record survives coating and dispatch.
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How fixtures improve repeatability in welded assemblies
A fixture cuts the spread on a 900 mm welded frame from about ±3.0 mm to ±0.7 mm. Where that variation comes from, what the fixture must locate on, and how to prove it.
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Welded assembly tolerances that hold in production
Welded assembly tolerances: the stack of part, fixture and weld shrink, the values a frame can hold, and when a ±0.5 mm callout needs machining instead.
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How to quote a welded assembly: cost structure
A welded assembly quote is material, cutting, forming, weld time, fixture amortisation, coating, inspection and packing. A worked example showing which line decides the price.
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