DESIGN AND MANUFACTURING OF JIGS & FIXTURES FOR YOKE MACHINING

BITS ZC423T: Project Work

by ANBUSELVAN.R Id No.200918TS010

Project Work work carried out at

AL JABER PRECISION ENGINEERING L.L.C Abu Dhabi, United Arab Emirates

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE PILANI (RAJASTHAN) March 2012

DESIGN AND MANUFACTURING OF JIGS & FIXTURES FOR YOKE MACHINING

BITS ZC423T: Project Work

by ANBUSELVAN.R Id No.200918TS010
Project Work work carried out at

AL JABER PRECISION ENGINEERING L.L.C Abu Dhabi, United Arab Emirates

Submitted in partial fulfillment of B.S. Engineering Technology degree Under the Supervision of
MR. FOLANE SAHEBRAO SHAMRAO SENIOR PLANNING ENGINEER AL JABER PRECISION ENGINEERING Abu Dhabi, United Arab Emirates

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE PILANI (RAJASTHAN) March 2012

CERTIFICATE

This is to certify that the Project Work entitled DESIGN AND MANUFACTURING OF JIGS AND FIXTURES FOR YOKE

MANUFACTURING and submitted by ANBUSELVAN.R having ID-No. 200918TS010 for the partial fulfillment of the requirements of B.S.Engineering Technology degree o of BITS, embodies the bonafide work done by him under my supervision.

______________________ Signature of the Supervisor

FOLANE SAHEBRAO SHAMRAO AL JABER PRECISION ENGINEERING L.L.C Abu Dhabi, United Arab Emirates

Place: ABU DHABI Date: 26-03-2012

Birla Institute of Technology & Science, Pilani Work-Integrated Learning Programmes Division Second Semester 2011-2012 BITS ZC423T: Project Work
BITS ID No : 200918TS010

NAME OF THE STUDENT

ANBUSELVAN R

EMAIL ADDRESS

[email protected]

STUDENTS EMPLOYING ORGANIZATION & LOCATION

AL JABER PRECISION ENGINEERING, Abu Dhabi, United Arab Emirates

SUPERVISORS NAME

MR. FOLANE SAHEBRAO SHAMRAO

SUPERVISORS EMPLOYING ORGANIZATION & LOCATION

AL JABER PRECISION ENGINEERING, Abu Dhabi, United Arab Emirates

SUPERVISORS EMAIL ADDRESS:

[email protected]

PROJECT WORK TITLE

DESIGN AND MANUFACTURING OF JIGS & FIXTURES FOR YOKE MACHINING

ABSTRACT The use of jigs and fixtures plays a major role in modern production engineering. This project tries to give a machining solution for AL JABER PRECISION ENGINEERING L.L.C specialized in total solution with in manufacturing and material handling technology. To be more competitive in the market, many companies are trying to speed up the manufacturing process and quote more attractive prices. Therefore, we have identified a need for Jigs and Fixtures support in the production in order to reduce the lead time and ensure a high level of accuracy and rate of production. The basic methods for determining the requirements and configuration of these devices are described. The project was successfully carried out in Al Jaber Precision Engineering L.L.C, Abu Dhabi and jig and fixture was handed over to production in good working condition and using regularly. I hope this project will help to design engineers and production engineers with an overview of the jigs and fixtures design and manufacturing process. I am glad to submit the detailed project report of Design and manufacturing of Jigs & Fixtures for yoke machining

Broad Academic Area of Work: CAD & CAM Key words CAD CAM CNC AWS L.L.C = = = = = Computer Aided Design Computer Aided Manufacturing Computerized Numerical Control American Welding Society Limited Liability Company

Signature of the Student

ANBUSELVAN.R

Signature of the Supervisor

MR. FOLANE SAHEBRAO SHAMRAO

Place: Abu Dhabi Date: 26/03/2012

Place: Abu Dhabi Date: 26/03/2012

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI WORK-INTEGRATED LEARNING PROGRAMMES DIVISION Second Semester 2011-2012 BITS Z BITS ZC423T Project Work EC-3 Final Evaluation ID No. NAME OF THE STUDENT EMAIL ADDRESS NAME OF THE SUPERVISOR PROJECT WORK TITLE : : : : : 200918TS010 ANBUSELVAN R [email protected] MR. FOLANE SHAEBRAO SHAMRAO DESIGN AND MANUFACTURING OF JIGS AND FIXTURES FOR YOKE MACHINING Excellent Good Fair Poor

S No. 1. 2. S.No. 1 2 3 4 5 6

Evaluation Component Final Project Work Report Final Seminar and Viva-Voce Evaluation Criteria Technical/Professional Competence Work Progress and Achievements Documentation and expression Initiative and Originality Research & Innovation Relevance to the work environment

Excellent

Good

Fair

Poor

Please ENCIRCLE the Recommended Final Grade: Excellent / Good / Fair / Poor

Remarks of the Supervisor:

Supervisor MR. FOLANE SAHEBRAO SHAMRAO

Additional Examiner MR. PALANI KUMARA SWAMY

Name
Qualification Designation Employing Organization & Location Phone Number Mobile Number Email Address Signature Place & Date AMIE (INDIA) SENIOR PLANNING ENGINEER AL JABER PRECISION ENGINEERING LLC., ABUDHABI, U.A.E 0097125020658 00971507169924 [email protected] MASTER OF TECHNOLOGY PLANT & COMMERCIAL MANAGER AL JABER IRON & STEEL FOUNDRY LLC., ABUDHABI, U.A.E 0097125541524 009715061992429 [email protected]

26-03-2012

26-03-2012

ACKNOWLEDGEMENT

I take this opportunity to sincerely thank my Supervisor Mr. FOLANE SAHEBRAO SHAMRAO and additional Examiner Mr. PALANI KUMARA SWAMY, Plant &Commercial Manager, Al Jaber Iron &Steel foundry L.L.C, Abu Dhabi, United Arab Emirates for their valuable guidance and timely advice in preparing the project.

I would like to thank my colleagues in my team for their support during the preparation of the project.

I would also like to thank entire BITS - Pilani Team for offering such wonderful opportunities for us to prepare a project, which would help us and our organization in future.

I would like to extend my sincere appreciation to my several well wishers who helped me a lot in preparing the project.

Table of Contents Chapter Chapter 1 Company overview 1.1 Introduction to group 1.2 Products Project Objectives 2.1 Project Location 2.2 Necessity of the project Jigs & fixtures overview 3.1 3.2 3.3 3.4 Overview Jigs Fixture Why use jig & Fixture 03 04 05 06 Title Page

01 01

Chapter 2

02 02

Chapter 3

Chapter 4

Jigs & Fixtures design 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 Design process Elements of fixture Importance of fixture manufacturing General requirements of a fixture Fixture design fundamentals Fixture design Fixture design criteria Fixture design procedure Locating principles Clamping Principles Basic principles of clamping Types of clamps Automation in fixture design Novel Clamping System Design 07 08 09 11 12 12 13 13 14 15 15 16 16 17

Chapter 5

selected Component for project work 5.1 5.2 5.3 5.4 5.4 5.5 Component description Selected component (Four Stub Anode Yoke) Assembled view of fixture without component Fixture Model Assembled view (with component) Proposed Fixture drawings Component in use (actual picture) 18 19 20 21 22-27 28

Chapter 6

Manufacturing process of fixture 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 Manufacturing Process Inspection Assembly Trail run with fixture Handing over Prefabrication process (actual photo) Welding Process Machining process Final assembly of fixture Actual component before machining Component machining Component machining without fixture Component with fixture Finished products 29 29 29 29 30 31 32 33 34 35 36 37 37 38

Chapter 7

Jigs Design 7.1 7.2 7.3 7.4 Proposed Jig design Advantages of Jigs & Fixtures Jigs Drawings Jig Photos 39 39 40-46 47-49

Chapter 8

Design Economy 8.1 8.2 8.3 8.4 8.5 Design Economy Estimating tool cost and productivity Calculating labor expense Calculating the cost per part Formula sheet 50 50 51 51 52

Summary Conclusions & Recommendations Reference Abbreviations

54 55 56 56

List of Photos Photos 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Descriptions During Pre fabrication During Pre fabrication V blocks During inspection Ready for marching After machining Trail test Trail Test Un machined component Un machined component Component machining Component machining Component without fixture Component with fixture Finished product Finished product Jig assembly Bush assembly Stopper assembly Jig during use Jig assembly Finished product Page 31 31 32 32 33 33 34 34 35 35 37 37 38 38 39 39 47 47 48 48 49 49

List of Drawings

Drawings 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Descriptions Four Stub Anode yoke Fixture Parts drawings Fixture parts drawings V block fabrication details V block fabrication details Base plate details Base frame details Jig assembly drawing Jig plate drawings Jig assembly drawings Jig assembly drawings Jig assembly drawings Jig bush details Jig bush drawings

Page 18 22 23 24 25 26 27 40 41 42 43 44 45 46

List of Flow Charts

Flow chart 1 2 3

Description Effect of setting and handling time chart No: 1 Fixture design Jigs &Fixtures design

Page no 10 12 30

List of Figures Page No 19 20 21 28

Figure 01 02 03 04

Description Component Model Fixture Model Fixture Assembled View Component in use

CHAPTER -1

1. COMPANY OVERVIEW:

1.1.

Introduction

Based in Abu Dhabi, United Arab Emirates, Al Jaber Group (AJC) operates in many dimensions: AJC constructs and develops some of the most important infrastructure, buildings and the industrial sites. AJC owns and operates some of the largest industries in the Middle East. AJC operates some of the largest fleet of equipment, cranes and ships. AJC hosts a multi-faceted portfolio of leading brands. Under the leadership of its founder, H.E. Obaid Khaleefa Jaber Al Murri, AJC grew to become one of the largest diversified groups of companies in the Middle East.

Al Jaber Precision Engineering is a division of Al Jaber group and leading Fabrication and erection company for Architectural and structural steel in the UAE. Also it is the only company in the UAE that has a machine shop capable of handling products up to 22 meters in length and 3.5 meters in diameter along with a well equipped fabrication shop that complies with many international recognized standards such as ISO 9001:2000, API...etc. And handle mega electro-mechanical projects from design to complete assembly.

1.2.

Products :

Fabrication or many kinds or architectural and structural steel Architectural and Structural steel Storage tanks Pressure Tanks, Silos, ...etc Boxes, Pontoons, etc...

Mechanical works: Gears and gearboxes Mandrels and shafts Overhead cranes Tools for aeronautic industries. Pump repair (mechanical repairs only) Engineering Parts of Machineries and Equipments. Concrete & Plastic Pipe Moulds (Mandrels) Dumpers: 1.5 to 5 tons.

CHAPTER -2

2.

PROJECT OVERVIEW:

2.1

Project Location

Al Jaber Precision Engineering has used rotary table and machine table used for machining of yokes for many years. Every month the delivery time becomes a great task for the production department. As well as the demand also increased every month almost double the quantity. So we decide to go for a special tool which will give more production rate as well as same accuracy. Mainly Jig and Fixtures are used in the machine shop for mass production of the components. Here we are going to use the fixture for three step yoke machining. Increase the production rate by limited availability.

2.2

Necessity for the Project: Mass production methods demand a fast and easy method of positioning work for accurate operations on it. Jigs and fixtures are production tools used to accurately manufacture duplicate and interchangeable parts. Jigs and fixtures are specially designed so that large numbers of components can be machined or assembled identically, and to ensure interchangeability of components. The economical production of engineering components is greatly facilitated by the provision of jigs and fixtures. The use of a jig or fixture makes a fairly simple operation out of one which would otherwise require a lot of skill and time. Both jigs and fixtures position components accurately; and hold components rigid and prevent movement during working in order to impart greater productivity and part accuracy. Jigs and fixtures hold or grip a work piece in the predetermined manner of firmness and location, to perform on the work piece a manufacturing operation.

CHAPTER -3 3.1 Jig & Fixtures Overview

Over the past century, manufacturing has made considerable progress. New machine tools, high-performance cutting tools, and modern manufacturing processes enable today's industries to make parts faster and better than ever before. Although work holding methods have also advanced considerably, the basic principles of clamping and locating are still the same. Mass production methods demand a fast and easy method of positioning work for accurate operations on it. Jigs and fixtures are production tools used to accurately manufacture duplicate and interchangeable parts. Jigs and fixtures are specially designed so that large numbers of components can be machined or assembled identically, and to ensure interchangeability of components. The economical production of engineering components is greatly facilitated by the provision of jigs and fixtures. The use of a jig or fixture makes a fairly simple operation out of one which would otherwise require a lot of skill and time. Both jigs and fixtures position components accurately; and hold components rigid and prevent movement during working in order to impart greater productivity and part accuracy. Jigs and fixtures hold or grip a work piece in the predetermined manner of firmness and location, to perform on the work piece a manufacturing operation. A jig or fixture is designed and built to hold, support and locate every component (part) to ensure that each is drilled or machined within the specified limits. The correct relationship and alignment between the tool and the work piece is maintained. Jigs and fixtures may be large (air plane fuselages are built on picture frame fixtures) or very small (as in watch making). Their use is limited only by job requirements and the imagination of the designer. The jigs and fixtures must. be accurately made and the material used must' be able to withstand wear and the operational (cutting) forces experienced during metal cutting. Jigs and fixtures must be clean, undamaged and free from chips and grit Components must not be forced into a jig or fixture. Jigs and fixtures are precision tools. They are expensive to produce because they are made to fine limits from materials with good resistance to wear. They must be properly stored or isolated to prevent accidental damage, and they must be numbered for identification for future use. Jigs and fixtures are devices used to facilitate production work, making interchangeable pieces of work possible at a savings in cost of production. A jig is a guiding device and a fixture a holding device. Jigs and fixtures are used to locate and hold the work that is to be machined. These devices are provided with attachments for guiding, setting, and supporting the tools in such a manner that all the work pieces produced in a given jig or fixture will be exactly alike in every way. The employment of unskilled labor is possible when jigs and fixtures can be used in production work. The repetitive layout and setup (which are time-consuming activities and require considerable skill) are eliminated. Also, the use of these devices can result in such a degree of accuracy that work pieces can be assembled with a minimum amount of fitting.

3.2

JIGS

A jig is a special device that holds, supports, or is placed on a part to be machined. It is a production tool made so that it not only locates and holds the work piece but also guides the cutting tool as the operation is performed. Jigs are usually fitted with hardened steel bushings for guiding drills or other cutting tools. A jig is any of a large class of tools in woodworking, metalworking, and some other crafts that help to control the location or motion (or both) of a tool. Some types of jigs are also called templates or guides. The primary purpose for a jig is for repeatability and exact duplication of a part for reproduction. An example of a jig is when a key is duplicated the original is used as a jig so the new key can have the same path as the old one. Since the advent of automation and CNC machines, jigs are often not required because the tool path is digitally programmed and stored in memory. The most-common jigs are drill and boring jigs. These tools are fundamentally the same. The difference lies in the size, type, and placement of the drill bushings. Boring jigs usually have larger bushings. These bushings may also have internal oil grooves to keep the boring bar lubricated. Often, boring jigs use more than one bushing to support the boring bar throughout the machining cycle. Jig that expedites repetitive hole center location on multiple interchangeable parts by acting as a template to guide the twist drill or other boring device into the precise location of each intended hole center. In metalworking practice, typically a hardened bushing lines each hole on the jig to keep the twist drill from cutting the jig. Jigs or templates have been known long before the industrial age. There are many types of jigs, and each one is custom-tailored to do a specific job. Many jigs are created because there is a necessity to do so by the tradesmen. Some are to increase productivity, to do repetitious activities and to do a job more precisely. Because jig design is fundamentally based on logic, similar jigs used in different times and places may have been created independently. Specialized industry applications have led to the development of specialized drill jigs. For example, the need to drill precisely located rivet holes in aircraft fuselages and wings led to the design of large jigs, with bushings and liners installed, contoured to the surface of the aircraft. A portable air-feed drill with a bushing attached to its nose is inserted through the liner in the jig and drilling is accomplished in each location.

3.3

FIXTURES

A fixture is a device for locating, holding and supporting a workpiece during a manufacturing operation. It is a production tool that locates, holds, and supports the work securely so the required machining operations can be performed. Fixtures have a much-wider scope of application than jigs. These workholders are designed for applications where the cutting tools cannot be guided as easily as a drill. With fixtures, an edge finder, center finder, or gage blocks position the cutter. Examples of the more-common fixtures include milling fixtures, lathe fixtures, sawing fixtures, and grinding fixtures. Moreover, a fixture can be used in almost any operation that requires a precise relationship in the position of a tool to a workpiece. Fixtures are essential elements of production processes as they are required in most of the automated manufacturing, inspection, and assembly operations. Fixtures must correctly locate a workpiece in a given orientation with respect to a cutting tool or measuring device, or with respect to another component, as for instance in assembly or welding. Such location must be invariant in the sense that the devices must clamp and secure the workpiece in that location for the particular processing operation. There are many standard work holding devices such as jaw chucks, machine vises, drill chucks, collets, etc. which are widely used in workshops and are usually kept in stock for general applications. Fixtures are normally designed for a definite operation to process a specific workpiece and are designed and manufactured individually. Jigs are similar to fixtures, but they not only locate and hold the part but also guide the cutting tools in drilling and boring operations. These work holding devices are collectively known as jigs and fixture. Set blocks and feeler or thickness gauges are used with fixtures to reference the cutter to the work piece. A fixture should be securely fastened to the table of the machine upon which the work is done. Though largely used on milling machines, fixtures are also designed to hold work for various operations on most of the standard machine tools. Fixtures vary in design from relatively simple tools to expensive, complicated devices. Fixtures also help to simplify metalworking operations performed on special equipment. Fixtures are most often identified by the machine tool where they are used. Examples include mill fixtures or lathe fixtures. But the function of the fixture can also identify a fixture type. So can the basic construction of the tool. Thus, although a tool can be called simply a mill fixture, it could also be further defined as a straddle-milling, plate-type mill fixture. Moreover, a lathe fixture could also be defined as a radius-turning, angle-plate lathe fixture. The tool designer usually decides the specific identification of these tools. It, use set blocks and thickness, or feeler, gages to locate the tool relative to the workpiece.

3.4 Why use Jig & Fixtures

There is a tendency to throw newer technologies at all parts that require manufacturing. Especially NC machines, robotic handling, and special purpose machinery-the reasons cited for doing this are highly pervasive: Automatic process Repeatability of process Semi-skilled operators

But in many instances the very reasons for promoting these manufacturing processes cause expense. These are not very cost efficient mechanisms for production because Expensive machinery with a high overhead Operations chosen are not totally appropriate for non-NC applications (i.e no profiling) Special propose machines have little or no flexibility if the product line changes Expensive tooling Tying up a machine that could be used for more suitable work Extensive pre-machining required such as fixtures, programming, installation and space requirements. Not fast enough for high volume due to tool changing and a lack of multipurpose tooling Taking up valuable machining time at a high cost Some require power clamping that in itself requires compressors

In place of these expensive machines we have the ability to use Jigs and Fixtures to both prevent the need for the expensive and difficult setups and to make the operation simple. This allows us to Utilize inexpensive machine tools with low overheads Utilize unskilled/ semi-skilled labor Make the process foolproof, easy to load using ordinary tools or special purpose tools High repeatability, cheap Process

Both NC and Jig and Fixture design rely on fairly expensive design and /or programming skills, however, the cost of manufacturing thousands of parts will always make the creation of jigs and Fixtures feasible, often working out to less than new cents per part. Fixtures are used on all processes requiring effective location and clamping. These include all machining operations, most welding and inspection requirements and assembly operations. In the scope of Jigs on other hand support the workpiece and also guide the tool for hole operations. Of the two tools, jigs are less used than fixtures. Manufacturing then, fixtures are ubiquitous in all modern manufacturing and assembly. This courses main objective is to design effective tooling to economize the manufacturing process.

CHAPTER -4
4.1
I.

Design process
Draw the part model: Keep it simple because they are only going to be used for relationship purposes, so filets and rounds, ribs and the like are not really required unless you are using the model for other operations such as sales or NC programming. On the other hand make sure that the positions of the holes and machined surfaces are correct. We have Metric pars so that model is created in Millimeters. The part can be created in its finished (post machined) form or using various configurations (Solidworks) that represent the stages at which the part is manufactured. Start with the locators-using the part model start an assembly and place or create various location devices using the standard rules. These locators and rests can be created in place within the assembly or part files and then inserted into the assembly. The major advantage to in place creation will be if the part model is changed. The locators will update automatically. Another point is that we can create parts in both metric and inch system regardless of the part template used. Place the drill bushings in the correct location. Try to conform to the rules of bushing placement and size also considers placing them with preferred sizes in mind. Bushing sizes must be from the standard sizes or manufacturing of special bushings. Determine the clamping techniques, this may be an integral part of the location device, but make sure that you clamp over the support mechanisms or into the locators. Build up the tool body around the locator, clamps and drilling bushings. Decide how each of the details (clamps, locators and buttons) are attached to the body this can be threaded, press fir or doweled and cap screwed. But no glue please expects it may require attaching some softer material pad to prevent damage to the part. Create a full Bill of Materials. Fully dimension and tolerance each detail part. Try to stay with preferred sizes whenever we can. There will be some instances when this is not possible but for most dimensions you will be able to comply with this. Use standard template drawings to ensure that all of the information is consistent as far as fonts, text heights, line thickness and dimension variable are concerned. Only create one drawings file that contains both assembly and detail drawings. Make sure the property information is maintained so that the title block information updates correctly. Use a standard naming convention so that the parts are all titled similarly within the Bill of materials. Make use of the various property variable to output what you need. Go back and make any changes. it is very likely that the process will show a you areas where you think improvement can be made. If you think they are worthwhile then go ahead but in the end make mind up, stick with and complete the design.

II.

III.

IV.

V.

VI. VII.

VIII.

IX.

4.2 Elements of Fixtures

Generally, all fixtures consist of the following elements:

Locators

A locator is usually a fixed component of a fixture. It is used to establish and maintain the position of a part in the fixture by constraining the movement of the part. For work pieces of greater variability in shapes and surface conditions, a locator can also be adjustable.

Clamps

A clamp is a force-actuating mechanism of a fixture. The forces exerted by the clamps hold a part securely in the fixture against all other external forces.

Supports

A support is a fixed or adjustable element of a fixture. When severe part displacement/deflection is expected under the action of imposed clamping and processing forces, supports are added and placed below the work piece so as to prevent or constrain deformation. Supports in excess of what is required for the determination of the location of the part should be compatible with the locators and clamps.

Fixture Body

Fixture body, or tool body, is the major structural element of a fixture. It maintains the spatial relationship between the fixturing elements mentioned above, viz, locators, clamps, supports, and the machine tool on which the part is to be processed.

4.3 Importance of Fixtures in Manufacturing

Modern manufacturing aims at achieving high productivity to reduce unit cost. This necessitates workholding devices to be efficient, i.e. to increase the rate of loading and unloading to speed up the manufacturing cycle time. If t is the total time in seconds or minutes required for producing a part, then Q = 1/t is the number of pieces produced in unit time, or the production rate. Considering the fact that the total manufacturing time is usually composed of: T=tm+th Where tm is the actual machining time and th is the setting up and handling time, hence, the production rate is given by: Q=1/tm+th piece per unit time Supposing Qt is the ideal production rate whereby there is no handling time loss for a given machining operation, hence we have: Q= Now

The variation of h with respect to Q, is shown in Chart for the various values of t h For an operation with a value of tm= th,h is 0.5 whereas, if th = 2 tm,h is 0.33 and the production rate is reduced. Chart shows how tm and th affect production rate. It is clear from Chart that (a) For a given tm, reduction of th increases Q , (b) For a given th, reduction of tm enhances Q .

The use of fixtures has twofold benefits. It eliminates individual marking, positioning and frequent checking before machining operation starts, thereby resulting in considerable saving in set-up time. In addition, the usage of workholding devices saves operator labour through simplifying locating and clamping tasks and makes possible the replacement of skilled workforce with semi-skilled labour, hence effecting substantial saving in labour cost which also translates into enhanced production rate. Furthermore, the use of well-structured fixtures with higher locating and clamping rigidity would allow for increase in cutting speeds and feeds, thereby reducing t,, hence improving production rate. Besides improving the productivity in terms of the rate of production, there are also other benefits accrued through the use of fixtures. They are: (a) Increases machining accuracy because of precise location with fixtures, (b) Decreases expenditure on quality control of machined parts as fixtures facilitate uniform quality in manufacturing, (c) Widens the technology capacity of machine tools and increases the versatility of machining operations to be performed, (d) Either fully or partly automates the machine tool.

Chart NO: 1

10

4.4

General Requirements of a Fixture

In order to maintain the workpiece stability during a machining process, an operational fixture has to satisfy several requirements to fully perform its functions as a workholding device. The following constraints must be observed while designing a viable fixture: Deterministic location A workpiece is said to be kinematically restrained when it cannot move without losing contact with at least one locator. The workpiece is constrained by a set of appropriately placed locators so that it is presentable for the machining operation. Locating errors due to locators and locating surfaces of the workpiece should be minimized so as to accurately and uniquely position the workpiece within the machine coordinate frame. Total constraint A workpiece should be fully constrained at all times to prevent any movement. Clamps should provide locking forces to hold the workpiece in place -once it is located. A totally restrained part should be able to remain in static equilibrium to withstand all possible processing forces or disturbance. A necessary and sufficient condition to warrant workpiece stability is to satisfy the condition of force closure.

Contained deflection Workpiece deformation is unavoidable due to its elastic/plastic nature, and the external forces impacted by the clamping actuation and machining operations. Deformation has to be limited to an acceptable magnitude in order to achieve the tolerance specifications. Geometric constraint Geometric constraint guarantees that all fixturing elements have an access to the datum surface. They also assure that the fixture components do not interfere with cutting tools during a machining operation. In addition to these requirements, a fixture design should have desirable characteristics such as quick loading and unloading, minimum number of components, accessibility, design for multiple cutting operations, portability, low cost, etc.

11

4.5 Fixture Design Fundamentals

Fixture design consists of a number of distinct activities: fixture planning, fixture layout design, fixture element design, tool body design, etc. They are listed in Chart in their natural sequence, although they may be developed in parallel and not necessarily as a series of isolated activities in actual execution. Fixture design deals with the establishment of the basic fixture concepts: Fixture layout is an embodiment of the concepts in the form of a spatial configuration of the fixture, Fixture element design is concerned with the concrete details of the locators, clamps and supports, Tool body design produces a structure combining the fixture elements in the desired spatial relationship with the machine tool.

4.6 Fixture Design

Fixture planning is to conceptualism a basic fixture configuration through analyzing all the available information regarding the material and geometry of the workpiece, operations required, processing equipment for the operations, and the operator. The following outputs are included in the fixture plan: Fixture type and complexity Number of workpieces per fixture Orientation of workpiece within fixture Locating datum faces Clamping surfaces Support surfaces, if any

Flow chart: 1

12

4.7 Fixture Design Criteria

The following design criteria must be observed during the procedure of fixture design: Design specifications Factory standards Ease of use and safety Economy

4.8 Fixture Design Procedure

In the design of a fixture, a definite sequence of design stages is involved. They can be grouped into three broad stages of design development. Stage One deals with information gathering and analysis. These include product analysis such as the study of design specifications, process planning, examining the processing equipment and considering operator safety and ease of use. In this stage, all the critical dimensions and feasible datum areas are examined in detail. Stage Two involves the consideration of clamping and locating schemes. A clamping scheme is devised in such a way that it will not interfere with the tools or cutters and are fully compatible with proposed locating surfaces or areas. The locating scheme, using standard elements such as pins, pads, etc. is designed to be consistent with clamping and tool-guiding arrangements. Stage Three is the design of the structure of the fixture body frame. This is usually built around the workpiece as a single element which links all the other elements used for locating, clamping tool-guiding, etc. into an integral frame work. The above procedures are quite general and can be modified depending on the relative importance of the various elements in providing for the required accuracy of the workpiece to be located and secured into the fixturing device. With the popular adaptation of modular fixturing elements, the fixture body frame is usually a standard block with fixed arrays of locating and fixing holes or slots. It becomes a matter of selecting the most suitable body frame to accommodate the various elements, provide good support of the workpiece and access to cutters and tools.

13

4.9

Locating Principles

One of the principal purposes of a machining fixture is to locate the workpiece surfaces for performing a machining operation. This is usually done with respect to a nurnber of factors to be considered such as the reference datum, supporting surfaces, features that are likely to obstruct the tool movement or access direction, etc. In general, the following surfaces should be distinguished:

Active surfaces

These are surfaces to be machined, i.e. surfaces which are subjected to the action of cutting tools. Supporting and locating surfaces These are surfaces by means of which the workpiece is to be located with respect to set-to-size cutting tools. Clamping surfaces Clamping surfaces are subjected to the clamping forces for obtaining invariant location. Clamping surfaces are usually not finish-machined surfaces as clamping marks could damage the finish.

Datum surfaces

Datum surfaces are reference surfaces where the dimensions are to be maintained and measured. Free surfaces Free surfaces are surfaces not involved in the set-up for the particular machining operation.

14

4.10 Clamping Principles

In every machining operation, clamping of workpieces is an essential requirement. A clamp can be defined as a device for providing an invariant location with respect to an external loading system. In other words, the process of clamping induces a locking effect which, through frictional or some other forms of mechanism, provides a stability of location which cannot be changed until and unless external loading is able to overcome the locking effect. Hence, when a cutting force is producing a load or moment on the workpiece, it is necessary that a sufficient clamping force must be exerted to withstand such actions. The creation and retention of locking effect against external loads are the principal objectives of any locking devices.

The generalized requirements of locking elements can be summarized as: To provide a suitable locking for achieving the stability of the location

To produce sufficient frictional effects for the above purpose but without causing any undesirable effects to the workpiece such as distortion or surface damage.

It is also essential that the idle time involving loading, locking, unlocking and unloading of workpieces should be minimized as much as possible to reduce the overall set-up and non-machining time. Certain additional requirements are therefore to be fulfilled with respect to clamping devices: The clamping devices must be easy to manipulate manually or otherwise, These devices must be quick-acting so as to reduce time for setting the clamping and simultaneous locating,

4.11

They must be low-cost so that their application in small lot sizes is economical.

Basic Principles of Clamping

Orientation of Locators vis-a-vis Clamping Force It is necessary in all clamping devices that the clamping forces hold the workpiece in its located position and should not cause any positional displacement or excessive distortion under the action of the clamping forces. Clamping forces should be directed towards supporting and locating elements on overhanging or thin sections of the workpiece. In addition, the force should be transmitted to the rigid sections of the body frame of the fixture. Cylindrical workpieces located in V-blocks can be clamped using another V-block, making a 4-point clamping, or clamped in a 3-jaw chuck, in a 3-point clamping configuration. The latter is usually more common, especially in turning operations. Effect of External Forces on the Clamping Action Clamping elements can be classified in accordance with their force-deflection characteristics. There are two broad sub-divisions, viz.: Type I: clamping elements in which the elastic deformation increases with clamping force, such as screws, levers, cams, etc., Type 11: clamping elements in which the clamping force assumes a constant value independent of the elastic deformation at the contact surfaces such as

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fixtures operated with hydraulic or pneumatic pressures. Within the elastic region, clamping elements based on elastic deformation, i.e. Type I clamps, would exhibit a linearly increasing clamping force in proportion to the deformation of the clamping element, if the workpiece or the locator is assumed to be rigid. If the workpiece or locator deforms, it will cause a relaxation of the clamping element and the clamping force will decrease. A limiting case arises when the clamping is lost and the force becomes zero. In Type I1 clamps, the clamping force remains constant at pre-set values and is independent of workpiece and locator deformation. This type of clamping device is therefore more reliable and would not relax over time.

4.12

Types of Clamps

Clamping elements may be either manually operated or actuated by pneumatic, hydraulic or a combination of other power facilities. They are also classified according to the mechanism by which a mechanical advantage is attained. The two basic classes include: Application of inclined plane theory, i.e. wedges, screws, cams, etc., Application of lever principle, i.e. levers, toggles, etc. Manual clamping of workpieces has the following disadvantages: Each workpiece is clamped with varying force, It is difficult to determine the required force for reliable clamping, Fatigue of operator due to manual clamping takes place, Time required to actuate manual clamping is longer compared to power-actuated clamping, Comparatively small amount of force is available without large force amplification devices. Pneumatic and hydraulic clamping devices have eliminated most of the above disadvantages but at much higher cost as well as greater demand for space requirement and maintenance. Justification would be a balance between cost, efficiency, accuracy, operator safety and comfort. As will be explained in the subsequent sections of this book, clamping with such devices forms the basis of variable-force clamping, which is very useful in controlling the intensity of the clamping force during a machining operation and helps to reduce workpiece deformation.

4.13

Automation in Fixture Design

With the advent of CNC machining technology and the capability of multi-axis machines to perform several operations and reduce the number of set-ups, the fixture design task has been somewhat simplified in terms of the number of fixtures which would need to be designed. However, there is a need to address the faster response and shorter lead-time required in designing and constructing new fixtures. The rapid development and application of Flexible Manufacturing System (FMS) has added to the requirement for more flexible and cost-effective fixtures. Traditional fixtures (dedicated fixtures) which have been used for many years are not able to meet the requirements of modern manufacturing due to the lack of flexibility and low

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reusability. The replacement of dedicated fixtures by modular and flexible fixtures is eminent in automated manufacturing systems, due to much smaller batch sizes and shortened time-to-market requirement. Modular fixtures are constructed from standard fixturing elements such as baseplates, locators, supports, clamps, etc. These elements can be assembled together without the need of additional machining operations and are designed for reuse after disassembly. The main advantages of using modular fixtures are their flexibility and the reduction of time and cost required for the intended manufacturing operations. Automation in fixture design is largely based on the concept of modular fixtures, especially the grid-hole-based systems, due to the following characteristics:

4.14

Predictable and finite number of locating and supporting positions which allow heuristic or mathematical search for the optimum positions, Ease in assembly and disassembly and the potential of automated assembly using robotic devices, Relative ease of applying design rules due to the finite number of element combinations

Novel Clamping System Design

A good fixture design is critical to the quality of the finished workpiece in terms of dimensional accuracy, form precision and surface finish. One of the essential considerations in designing a good workable fixture is the generation of clamping configuration that includes the clamp placement, clamping sequence, and clamping intensities. Placing the clamps in wrong positions may disturb the equilibrium of the workpiece on the locators, resulting in the lost position of the part. Likewise, using an inadequate clamping intensity may give rise to slippage andlor lift-off of the workpiece during the machining process. On the other hand, an application of excessive clamping forces would result in excessive deflection and high contact deformation of the workpiece. In short, a poor clamping layout could cause the final accuracy of the workpiece to be out of the specified tolerances and bring about unnecessary rejects. A less addressed research area is the performance of a fixture during machining in terms of its dynamic response and deformation. The issue is to guarantee machining accuracy through the proper control of workholding operation during machining. Therefore, a best approach to the fixturing problem is to integrate optimal fixture design with optimum fixturing execution in a unified approach.

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CHAPTER 5 5.1 Selected Component for project work Component description

Name: Four stub anode yoke Material: Carbon steel (BS3100 Grade A1) Weight: 475 kg Used Industries: Aluminum melting industries In electrolytic furnaces in an aluminum work, the current is supplied with anodes. The anodes comprise an aluminum rod which over a steel yoke with steel studs is moulded into an anode block. The difference in linear expansion of the carbon anode and the steel yoke or spider of the anode rod at high temperatures in the reduction cell means that the yoke expands more than the anode, bending the stubs which are anchored in the anode block. Stubs become bent inwards just above the iron thimble, changing the geometry of the yoke, and stubs can no longer be correctly located in the anode holes during subsequent Roding. Ultimately the stubs will no longer fit into the holes.

Drawing: 1

Four stub Anode Yoke

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5.2

Selected component (Four Stub Anode Yoke)

Figure: 1 Component Model and shows the machining areas

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5.3

Assembled view of Fixture without component

Figure: 2 Shows the Fixture assembly view (Without component)

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5.4

Proposed Fixture Model Assembled view (with component)

Figure: 3 Fixture assembled view with component

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5.5

Proposed Fixture Drawings

Drawing: 2 Fixture parts drawings for material cut

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Drawings: 3 Fixture parts details drawings

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Drawing: 4 V Block fabrication details

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Drawings: 5 V Block fabrication details

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Drawing: 6 Base plate fabrication details

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Drawings: 7 Base frame fabrication details

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5.5

Component in use (Actual Picture)

Figure: 4 Component in use

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CHAPTER -6
6.1 Manufacturing Process

We have used SOLDWORKS software for design and modeling of the fixture. Cut the raw materials to required profile and shape we used much CAM software like TOPS 100, Uni graphics (NX), Burney and Master Cam. Here we have done the manufacturing process in two phases. 1. Fabrication and welding of base frame, locators and supports 2. Machining of base frame, supports and bushings Here we have used our fabrication facilities to fabricate the fixture as per our requirements. Welding process used the American Welding society standards for material preparation and electrode selection. Mild steel plates are used for all the constructions of the fixture. Our machine shop facilities are utilized for machining of the fixture parts and the frames. We start the fabrication process from pre fabrication (Material cutting). After completed the CAD design, CAD drawings convert to CAM drawings and the CAM drawings sent CNC cutting machines for material cut. The machines operator will cut the material as per the requirements with help of CAM software. Once the material cut completed it will goes to stage inspection. After inspection approval its goes to fabrication and machining process. During Fabrication AWS Procedures followed for welding electrode selection and welding process. During machining we take care about dimensions control and tolerances for proper assembly. We have given a slot step for locating with table bed slotted guideways. Which is giving reputability while fix with machine bed. 6.2 Inspection

After the fabrication and machining of the fixture its go to the inspection process to make sure dimension and tolerance are according to the standards and requirements. After the conformation its goes to assembly or it will go to re work if required. 6.3 Assembly

After completing the final inspection its goes to assembly section to assembly the fixture with component. Make sure about the supports, stoppers positions to ensure before clamp the component. 6.4 Trail run with fixture

Load the fixture with component on the boring machine table with guide with locating pin with table guideways which will give parallel with spindle axis for machining of both faces. Then start machining with standard parameters and observe the spindle cutting force and vibration of the spindle and spindle head. If find any vibration or any other abnormal sounds to be rectified.

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6.5

Handing over the fixture for production

After verifying the machining performance and productivity we have handed over the fixture for mass production. Monitoring and measuring the performance and training the operators for continuous improvement.

Flow chart: 2 Fixture design criteria

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6.6

During Pre Fabrication (ctual Photos)

Photo: 1 Pre fabrication (Material cut)

Photo: 2 Pre fabrications (Material cut)

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6.7

During Welding

Photo: 3 V blocks welding completed

Photo: 4 during inspection

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6.8

During Machining

Photo: 5 Ready for machining

Photo: 6 after machining

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6.9

Final assembly with component

Photo: 7 loaded with milling machine for trail test

Photo: 8 loaded with milling machine for trail test is going on

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6.10

Actual component before machining machining

Photo: 9 Yoke stub without machining

Photo: 10 Un machined yoke

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6.11

During component machining

Photo: 11 handed over the fixture for production

Photo: 12 Production is going on Component

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6.12

Without fixture single piece machining

Photo: 13 Yoke without fixture 6.13 With fixture

Photo: 14 with fixture

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6.14 Finished product

Photo: 15 finished product

Photo: 16 finished component

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CHAPTER 7 7.1 Proposed Jig Design

We have proposed a drill jig for drilling job and we have taken a component which is used for tower crane booms. The material is mild steel. The angle to be dril Required to drill the holes in both ends and center too. So I have advised the drill jig concept for production. The concept CAD drawings are follows. 7.2 Advantages of Jigs &Fixtures

Generally, Jigs and fixtures have many advantages like the productivity, interchangeability and so on. Productivity Jigs and fixtures eliminate individual marking, positioning and frequent checking which is reduce operation time and increases productivity. Interchangeability Jigs and fixtures facilitate uniform quality in manufacture. There is no need for selective assembly. Any type of machining center would fit properly in assembly and all similar components are interchangeable. Skill Reduction Jigs and fixtures simplify locating and clamping of the workpieces. Tool guiding elements ensure correct positioning of the tools with respect to the workpieces. These are no need for skillful setting of the workpiece or tool. Any average person can be trained to use jigs and fixtures. The replacement of skilled workman with unskilled labor can effect substantial saving in labor cost. Cost reduction It increases productivity with advantages of clamping rigidity. the help of increased cutting parameters

It is reduced the handling time and reduced man power. It makes the manufacturing process and eliminates many operations like marking, setting, and stage inspections.

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7.3 Jigs drawings

Drawing: 8 Jigs assembly drawings

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Drawing: 9 Jig plate drawings

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Drawing: 10 Jigs assembly drawings

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Drawing: 11Jigs assembly drawings

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Drawing: 12 Jigs assembly drawings

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Drawing: 13 Jigs Bush details

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Drawing: 14 Jigs bush drawings

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Photo: 17 Jigs assembly

Photo: 18 bush assembly

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Photo: 19 stopper assembly

Photo: 20 Jigs during use

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Photo: 21 Jigs assembly

Photo: 22 finished product

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CHAPTER-8
8.1 Design Economy

The demands of modern industries for maximum productivity at minimal cost are a challenge to the tool designer. In addition to developing design for efficient and accurate jigs and fixture the tool designer is responsible for finding way to keep the cost of special tools as low as possible. To do this, he must know and apply design economy. Design economy begins with tool designer idea and carried through to the completion of the tool. Design details should be carefully studied to find ways to reduce cost and still maintain part quality. The tool designer is aided in this task by following principles of economic design. 8.2 Estimating tool cost and productivity

The simplest and most direct way to determine the cost of a tool design is to add the total cost of material and labor needed to fabricate the tool. This must be done carefully so that no part or operation is forgotten. One method is to label each part of the tool (Table 1.1) and list the materials in a separate part list .then using a cost work sheet (1.2) the time allowed for each machining operation include time for setup. The next step is estimating is calculating the number of parts per hour the tool will produce. The simplest method is to divide 1 hour by the single-part time or the time it takes to load, machine and unload each part .Expressed as a formula this, calculation becomes Ph = 1/S Where Ph = parts per hour S= Single part time We have used the following chat to convert standard clock time from hours, minutes and seconds into decimal hours for easier calculation. 1 hour = 1.0 hour hour = 0.5 hour hour = 0.25 hour 6 minutes= 0.1 hour 1 second = 0.000277 hour

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Example: How many parts per hours will a jig produce if machining time is 0.0137 hour and it take 0.0127 hour to load the part and another 0.0127 hour to unload it. P= 1/s P= 1/ 0.0137 +0.0127 + 0.0127 P= 1/0.0391 P= 25.57 parts per hour. 8.3 Calculating labor expense

Labor is the single most expensive factor in manufacturing. If labor expenses can be reduced, so can overall production cost jigs and fixture reduced machining. 8.4 Calculating the cost per part

A comparison of tool costs or labor expenses cannot give the tool designer enough information to determine the true economic potential of a design. For accuracy, he must calculate how much the design is worth in terms of total production and cost per part. The formula for finding this value is

CP = cp+ L/ LS

where Cp = cost per part Tc = Tool cost L = Cost of labor Ls = Lot size

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8.5

Formula sheet

Production Ph= Parts per hour S = Single part time Includes load time and unload time Labor Expense L = Cost of labor LS = lot size Ph = Parts per hour W = Wage rate L = Ls/ Ph X W Cost per Part Cp = Cost per part Tc =Tool cost L =Cost of labor Ls= Lot size CP = TC+ L / Ls Total savings Economical Production Ts = Total savings Ls = Lot size Cp1 = Cost per part First tool Cp2 = Cost per part second tool Ts= Ls x (Cp1-cp2)

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Production alternative Ts = Total savings Ls = Lot size Cp1 = Cost per part First tool Cp2 = Cost per part second tool Tc = Tool cost Ts= Ls x (Cp1-cp2)- Tc Break even point Bp = Break even point Tc = Tool cost Cp1= First cost per part Cp2 = Second cost per part BP = TC/ (Cp1-Cp2)

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Summary This project is aimed to provide the machining repeatability and high productivity with out distortion due to clamping and machining forces. After introduced the Jig & Fixture the productivity of the both component has been increased. The main goal is design a tool which will support to increase the productivity with a simple material and pieces and no complication design and manufacturing process. Simple to manufacturing Simple to maintenance High reliability High Performance Safety Keep all designs simple and uncomplicated Use performed materials where possible Always use standard components Reduce or eliminate secondary operation Do not use overly light tolerances Simplify tool drawings Performing an economic analysis helps the designer consider a variety of tool alternative to find the most efficient and cost effective design. Estimating the tool cost and productivity Calculating the values necessary to determine the best tooling alternatives Preparing a comparative analysis of the tooling alternatives

The project is fully supported by Al Jaber Precision Engineering management and Production and Design Department. I have used my concepts, ideas and technical knowledge during design, manufacturing, assembly and trail testing. Finally its

satisfied the all aspects of indented purpose. I hope that we have done a good job in a professional manner.

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Conclusions & Recommendations Conclusions: Use of jigs and fixture directly influence the quality of performance of the operation. It improves efficiency of work by eliminating production of poor quality products and reducing the product cycle time. Design of jigs and fixtures truly depends on the type of operation and machine tool to be used for that operation. The use of jig and fixture involve locating the workpiece is right position on the machine tool. The meaning of location is determining the points on the work where it should be supported to restrain all the motions so that the work can be done without any problem. Along with the fixtures jigs are used to guide the tool movement during an operation. These are made of hardened steel, wear resistant and corrosion resistant steel. Different types are jigs are used for different types of operations. I could say that this project will help to improve production rate and fulfil the intention of Jig & Fixture function and satisfying the requirements. The tool is performing well with unique features along with many tangible and intangible benefits. I have advised to measure and monitor the performance for continuous improvements. I sincerely thankful to the management, staff for their support and the guidance I got from my managers and colleagues who have helped me to complete the project with in time.

Recommendations: This project is just an example of a small and simple tool how helpful for manufacturing process. I would like to recommend that it is possible to apply improvements in order to increase the performance and productivity, as well as decrease the costs. The same way design a tool for material handling and storage process which will give remarkable improvement. Currently, for loading and offloading being carried out by with the help of over head crane and fork lifter which is to be eliminated. Loading and offloading method must be replaced by an easy, simple and fast mechanism. If required I shall give a proposal for the same.

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REFERENCES

Jigs and Fixtures by ALBERT A.DOWD and FRANK W.CURTIS McGraw-hill book Company. Inc

Jig And Fixture Design by Franklin D.Jones, The Industrial Press

ABBREVIATIONS: CAD CAM CNC AWS L.L.C = = = = = Computer Aided Design Computer Aided Manufacturing Computerized Numerical Control American Welding Society Limited Liability Company

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Checklist of items for the Final Project Work Report

This checklist is to be duly completed, verified and signed by the student. Is the final report properly hard bound? (Spiral bound or Soft bound or Perfect 1 2 3 4 bound reports are not acceptable.) Is the Cover page in proper format as given in Annexure A? Is the Title page (Inner cover page) in proper format? (a) Is the Certificate from the Supervisor in proper format? (b) Has it been signed by the Supervisor? Is the Abstract included in the report properly written within one page? Have the technical keywords been specified properly? Is the title of your report appropriate? The title should be adequately descriptive, precise and must reflect scope of the actual work done. Have you included the List of abbreviations / Acronyms? Uncommon abbreviations / Acronyms should not be used in the title. Does the Report contain a summary of the literature survey? Does the Table of Contents include page numbers? (i). (ii). 9 Are the Pages numbered properly? (Ch. 1 should start on Page # 1) Are the Figures numbered properly? (Figure Numbers and Figure Titles should be at the bottom of the figures) (iii). Are the Tables numbered properly? (Table Numbers and Table Titles should be at the top of the tables) (iv). (v). 10 Are the Captions for the Figures and Tables proper? Are the Appendices numbered properly? Are their titles appropriate Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

6 7 8

Yes Yes

Is the conclusion of the Report based on discussion of the work? Are References or Bibliography given at the end of the Report?

11

Have the References been cited properly inside the text of the Report? Is the citation of References in proper format? Is the report format and content according to the guidelines? The report should not be a

12

mere printout of a Power Point Presentation, or a user manual. Source code of software need not be included in the report.

Declaration by Student: I certify that I have properly verified all the items in this checklist and ensure that the report is in proper format as specified in the course handout.

---------------------------------

Place: ABU DHABI Date: 26/03/2012

Signature of the Student Name: ANBUSELVAN.R ID NO: 200918TS010

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