Normally wire-feed-speed is something you MEASURE, not calculate.
Expensive MIG (GMAW) sets have a "soft-start" where the wire feeds
forward slowly until the arc strikes - which makes measurement
difficult. If you have these cost scales though, you could have a
tachometer, which runs a small wheel on the wire for the sole purpose
of measuring how fast the wire is moving past it (the tachometer).
For all normal MIG/GMAW sets where the wire-feed motor spins at a
constant rate from the moment you squeeze the trigger:
Eject a short length of wire from the torch by squeezing the trigger
for a short time
Sweep your hand in front of the torch and put a right-angle bend in the
Looking at a clock with a seconds-hand, hold the torch-trigger on for
a chosen time like 6seconds.
Put another right-angle kink in the wire at the nozzle.
Eject the wire a bit more by squeezing the trigger again.
Measure the distance between the two right-angle kinks.
Then do your maths. You've got wire fed in time taken. You can
quickly get WFS in wire fed per unit time.
Looked at your question again.
Answered the wrong question.
You don't use software to calculate what you want. It's easy to do
wire-cross-sectional-area x wire-feed-speed = weld-bead-length x
So that's volume of wire fed = volume of fillet / weld-bead produced.
OK, there's some metal loss to spatter. Knowing how much that is is
useful information you need to discover.
For a wire, CSA_wire = Pi dia^2 / 4 (or Pi r^2 if you want)
In the easier case of a fillet which is triangular to a good
CSA_fillet = leg-length^2 / 2
(you've got LL in one direction, LL in right-angle direction, but the
area you sweep between the two axes is only half that because the
triangular shape of tthe fillet fills only half that area swept)
For a given fillet size, there is a constant ratio between WFS and
weld travel speed. If you increase the WFS by x%, you increase the
travel speed by x%.
I looked up migmeter.com
That is good for costing the work done.
It's the "grand sum".
The instantaneous rate of wire feed dictates the current which will be
drawn from the welding machine. It's an almost linear relationship.
I = k * v_w
I = current
v_w (velocity subscript w - w signifies "the wire")
k is that constant number
Both devices have a wheel which touches the wire being fed and
identically spin in relation to the wire feed.
The mechanism is different.
"Yours" tallies the grand sum.
The one I want says how fast that wheel is going round - converted to
an inches-per-minute / metres-per-second of wire fed.
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