Advice of how to avoid plate distorting

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Hi,I am hoping somebody can help me.I am wanting to have some small metal fabrications made for me. They are basically the same as a MetPost Bolt Down fence post support (see attached drawing).I am wanting these units to be fabricated from 2mm Mild Steel plate. The units are simply constructed by welding together the bottom plate and the top collar.The problem I am encountering is that the bottom plate is warping during the welding process, even when the two pieces are clamped together.If I can resolve this problem I am hoping that I will be able to have quite a large number of these manufactured on a continuous basis, therefore I am quite happy to invest in constructing a suitable jig if this is the answer.If anybody has any suggestions on how to remedy this warping and advice on the best form of welding to utilise I would greatly appreciate it.Thanks.Nick. Attached ImagesCOLLAR C WELD Model (1).pdf (130.8 KB, 207 views)
Reply:Take a piece of 1/2" (13mm?) plate and make a square cutout amply sized for the square tube and weld. Then clamp this piece down over the plate. Weld and allow to cool, then unclamp. It does not need to come back to room temp, just cool for a few minutes.
Reply:what kind of production numbers are you looking at?If you are talking real high, you should think about redeigning it as a stamped piece.I'm no welding expert but here my impressions: You'd have to run the numbers yourself, but it sounds like you need 2 or 3 jigs per welder to allow cool down, or more if someone else is doing the assembly and disassembly.If you still have warping with a flat jig, you might have to put a slight bend in the jig to counteract it. I'd also hold it to the jig with the the nuts in the picture to simplify the jig and keep them aligned properly too.
Reply:The only weld you can make that will not warp the bottom plate is a spot weld.  If you can, redesign the part with a flange around the bottom and spot weld it to the plate.  Do the same with the nuts or use self-clinching PEM Nuts or welding them will cause the same problem.Dynasty 300DXSmith He/Ar gas mixerMM350PHobart Handler 120Smith LW7, MW5, AW1A
Reply:i see no information oin the drawing concerning the thickness of the metal
Reply:The weld does not need to be very large since the thickness is 2 mm.  Putting down a 2 mm weld manually is difficult.  Flanging and spot welding is an excellent suggestion.  If you cannot resistance spot weld then have holes in the flange and do a series of plug welds,
Reply:Originally Posted by weldbeadi see no information oin the drawing concerning the thickness of the metal
Reply:Originally Posted by DSWWeldbead, the thickness is dimensioned on the drawing. Base plate thickness is dimensioned on the base plate on the right side ( side view, top drawing).  Vertical "tube" thickness is dimensioned in the middle of the tube on the right. ( overhead view, bottom drawing)
Reply:A jig(s) is the solution to position and hold the parts straight through welding.  A heavy aluminum or copper quench plate under the fabbrication base plate should carry the heat away quickly to reduce the time for removal from the jig."The reason we are here is that we are not all there"SA 200Idealarc TM 300 300MM 200MM 25130a SpoolgunPrecision Tig 375Invertec V350 ProSC-32 CS 12 Wire FeederOxweld/Purox O/AArcAirHypertherm Powermax 85LN25
Reply:Put a 1/16" piece of tig wire underneeth it before welding...Clamp..Weld..Let cool..http://weldingweb.com/vbb/showthread.php...ight=Bend+WeldPresto!No warping..Now about posting prints on line with the customers name and specs is NOT a good thing and would cost you your job in certain shops..I suggest you do not do it again..Or at least blank out all pertained information.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:you might check into plasma welding, submerged arc, maybe pulsed mig.Last edited by brucer; 10-21-2011 at 05:39 AM.tackleexperts.comwww.necessityjigs.comhttps://www.facebook.com/groups/mach...dingequipment/
Reply:That jumped out at me too, but I assumed you were the print owner.
Reply:Originally Posted by GrooThat jumped out at me too, but I assumed you were the print owner.