TABLE OF CONTENTS CHAPTER.

NO TITLE PAGE NO

I II III 1.

ABSTRACT LIST OF FIGURES LIST OF TABLES INTRODUCTION 1.1. INTRODUCTION... 1.2. INTRODUCTION TO COMPONENT (PETROL BRACKET) 1.2.1. Drive shaft ...... 1.3. INTRODUCTION TO WORK HOLDING DEVICES 1.3.1 Jigs and Fixtures- Introduction.. 1.4. INTRODUCTION TO LOCATING AND CLAMPING DEVICES 1.4.1 PRINCIPLE OF LOCATION ... 1.4.1.1. Principle of Pin Location 1.4.1.2. Principle of Mutually Perpendicular Planes . 1.4.1.3 Principle of Extreme ... 1.4.2. LOCATING METHODS AND DEVICES .... 22 20 21 17 17 20 11 13 8 10 7

1.4.3. PINS AND BUTTON LOCATORS ... 1.4.3.1 Locating Pins . 1.4.3.2 Conical Locating Pins .... 1.4.3.3 Cylindrical Locating Pins .. 1.4.4. CLAMPING INTRODUCTION 1.4.4.1. Clamping device .. 1.4.4.1.1. Bridge Clamp . 1.5. INTRODUCTIONS TO SENSORS . 1.5.1. PROXIMITY SENSOR ... 1.5.2 PROXIMITY LIMIT SWITCH 2. METHODOLOGY . 2.1. WORKING 2.2. DESIGN OF ASSEMBLY FIXTURE.. 2.3. FIXTURE MANUFACTURING PROCESS 2.4. COST ESTIMATION .. 2.5. COMPARISON OF EXISTING FIXTURE AND NEW DESIGNED FIXTURE... 2.6. ADVANTAGES.

22 23 23 23 24 27 27 29 30 31 32 33 35 55 58

59 61

3. 4.

CONCLUSION

...

63 65

BIBLIOGRAPHY ..

LIST OF FIGURES FIG NO 1.1 ...... 1.2 DESCRIPTION PAGE NO

PETROL BRACKET..... 8 A SIMPLE DESIGN OF JIG AND FIXTURE 16

1.3

WORKPIECE IN SPACE ............... 18

1.4

WORKPIECE LOCATED IN A FIXED BODY 18

1.5

PRINCIPLE OF MUTUALLY PERPENDICULAR PLANES .... 21

1.6

LOCATING PINS .. 23

1.7

METHOD OF CLAMPING ... 25

1.8

POSITION OF CLAMP 26

1.9

BRIDGE CLAMP 28

3.1(A)

3D-BOTTOM BASE PLATE WITH SENSOR STAND .................... 35

3.1 (B)

2D-BOTTOMS BASE PLATES WITH

SENSOR STAND ....................... 3.2(A) 3D-BOTTOM BASE PLATE WITH LIMIT SWITCH 3.2 (B) 3D-BOTTOM BASE PLATES WITH LIMIT SWITCH 3.3(A) 3.3(B) 3.4(A) 3.4(B) 3.5(A) 3.5(B) 3.6(A) 3.6(B) 3.7(A) 3.7(B) 3.8(A) 3.8(B) 3.9(A) 3.9(B) 3.10(A) 3D-TOP BASE PLATE .. 2D-TOP BASE PLATE . 3D-SENSOR STAND 2D-SENSOR STAND . 3D-PLUNGER 2D-PLUNGER ... 3D-SPACER 2D-SPACER 3D-SENSOR PIN ... 2D-SENSOR PIN 3D-SLIDING CLAMP 2D-SLIDING CLAMP 3D-ANGULAR BLOCK 2D-ANGULAR BLOCK . 3D-FINAL ASSEMBLY OF A FIXTURE .
4

36

37

38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53

3.10(B) 3.11

2D-FINAL ASSEMBLY OF A FIXTURE PICTORIAL REPRESENTATION OF EXISTING FIXTURE AND NEW DESIGNED FIXTURE

54

59

LIST OF TABLES TABLE NO 2.1 2.2 DESCRIPTION PAGE NO

COST ESTIMATION.... 58 COMPARISION OF EXISTING FIXTURE AND NEW DESIGNED FIXTURE 60

CHAPTER-1 INTRODUCTION
1.1. INTRODUCTION: Fixture is one of the most important mechanical members which are used to hold the work piece. Fixtures are used to securely locate and support the work, ensuring that all parts produced using the fixture will maintain conformity and interchangeability. from part to part. The petrol brackets are used for mounting the drive shaft. The assembly of petrol bracket includes assembly of a stud which secures the petrol bracket to the engine bed. There are many cases by which the stud can be unscrewed. A large number of components are being rejected due to the mismatching of the stud in the petrol bracket. In order to overcome the errors in assembling and also to improve production, fixtures are used. A conventional fixture is used in assembly, but the errors during the assembly remains the same, so we came up with the idea of designing a new fixture in order to reduce the errors in assembling the bracket. Sensors are
7

Fixtures are used in order to improve

economy of the production by allowing smooth operation and quick transition

used in the new fixture in order to detect the errors committed during the assembly. When the stud is not related to the tapped hole, the sensor gives a warning to the operator regarding the stud position until the operator assembles the stud in proper position. This sensor equipped fixture helps in achieving zero error in assembly and also improves productivity by reducing the rejection of the brackets.

1.2.

INTRODUCTION TO COMPONENT (PETROL BRACKET):

Petrol bracket is also known as the coupling bracket for a petrol engine. The main application of the petrol bracket is to provide the bearing surface for the drive shaft which is used to connect the electric motor shaft and the engine shaft (vertical shaft to horizontal shaft) by using bevel gear. Installation of the drive shaft with coupling bracket is done as vertical drive shaft between motor-drive and bevel gear. Technically, horizontal is also possible. This petrol bracket is used for ford (figo) car. The component (petrol bracket) is made of cast iron.

FIG. 1.1 PETROL BRACKET

CAST IRON: Cast-iron is an alloy of iron and carbon, and is popular because of its low cost and ability to make complex structures. The carbon content in cast iron is 3% to 4.5% by weight. Silicon and small amounts of Manganese, Sulfur, and Phosphorus are also present in it. The products of cast iron exhibit reasonable resistance against corrosion. It is neither malleable nor ductile, and it cannot be hardened like steel. It melts at about 2100 F, and has either a crystalline or a granular fracture. The mechanical properties of cast iron are very much dependent on the morphology of its carbon content. Carbon is present in the form of plates in gray cast iron, whereas, it is incorporated in compound Fe3C (cementite) in white cast iron. Nodular cast iron, which show better tensile
9

strength and strain than gray cast iron, carry carbon in the form of sphere shaped graphite particles. COMPOSITION OF CAST IRON: 1. Cast iron is actually an iron-carbon-silicon alloy containing between 3 and 5.5 % carbon.1 to 3% silicon. 2. Other elements such as sulfur, magnesium and potassium totaling about 0.5 %.steels contain less than 2% carbon.

PROPERTIES OF CAST IRON: 1. Tensile strength 2. High compressive strength 3. Resistance to deformation 4. Resistance to oxidation 1.2.1. DRIVE SHAFT: The drive shaft is the mechanical connection between motor drive and on-load tap-changer head or off-circuit tap-changer head. The change from the vertical to the horizontal direction is performed by the bevel gear. Accordingly, the vertical drive shaft has to be mounted between motordrive and bevel gear and the horizontal drive shaft between bevel gear and onload tap-changer or off-circuit tap-changer.

10

The drive shaft is designed as a square tube and is coupled at both ends by two coupling brackets and one coupling bolt at the driving end of the drive shaft ends of the unit to be connected. An assembly fixture is made to assemble the stud in a petrol bracket with an alignment, thus preventing misalignment (error). The stud is designed in such a way that one side is longer and other side is shorter. The petrol bracket which is assembled here is used for ford car engine.

1.3.

INTRODUCTION TO WORK HOLDING DEVICES:

Holding or clamping the work piece is an important factor in the manufacturing process. The main objective of work holding is to position or locate a work piece in definite relation to the cutting tool, and to clamp it with a proper force in order to withstand the cutting forces while maintaining that precise position.

11

Work holding devices include all devices that hold, grip or chuck a work piece to perform a manufacturing operation. It includes clamps, vises, chucks, fixtures etc.., The holding force may be applied mechanically, electrically, hydraulically or pneumatically. Parts are clamped, relative to their datum planes, for machining, assembly, welding, and inspection Production devices are generally work holding devices such as work holders with or without tool guiding or setting arrangement, used to locate and hold the work piece.

Basic functions of a work holding device: Locate - Refers to positioning a part with respect to its datum(s) for manufacturing purposes Clamp - Refers to holding the part for manufacturing purpose

DESIGN CONSIDERATION OF WORKHOLDERS: 1. RELIABILITY Must maintain the clamping force during operation Must be easy to maintain and lubricate 2. RUGGEDNESS Must be able to withstand impact force during operation
12

Must resist abrasion Easy to maintain and replace worn parts 3. DESIGN AND CONSTRUCTION EASE Use standard parts whenever possible If possible use modular fixture ADVANTAGES: 1) PRODUCTIVITY: Eliminate individual markings, positioning, etc. 2) INTERCHANGEABILITY Facilitate uniform quality. No need for selective assembly 3) SKILL REDUCTION Simply locating and clamping of the Workpiece 4) COST REDUCTION Scrap, easy assembly, saving labor cost. 1.3.1. JIGS AND FIXTURES-INTRODUCTION : Jigs and fixtures are special purpose tools which are used to facilitate production (machining, assembling and inspection operations) when workpieces are to be produced on a mass scale. The mass production of workpieces is based on the concept of interchangeability according to which every part will be produced within an established tolerance. Jigs and fixtures provide a means of manufacturing interchangeable parts since they establish a relation, with predetermined tolerances, between the work and the cutting tool. They eliminate the necessity of a special setup for each individual part. Once a jig or fixture is
13

properly set up, any number of duplicate parts may be readily produced without additional set up. HENCE JIGS AND FIXTURES ARE USED: 1. To reduce the cost of production, as their use eliminates the laying out of work and setting up of tools. 2. To increase the production. 3. To assure high accuracy of the parts. 4. To provide for interchangeability. 5. To enable heavy and complex-shaped parts to be machined by being held rigidly 6. Reduced quality control expenses. 7. Increased versatility of machine tool. 8. Less skilled labour. 9. Saving labour. 10. Their use partially automates the machine tool. 11. Their use improves the safety at work, thereby lowering the rate of accidents. JIG: A jig may be defined as a device which holds and positions the work, locates or guides the cutting tool relative to the workpiece and usually is not fixed to the machine table. It is usually lighter in construction. FIXTURE: A fixture is a work holding device which only holds and positions the work, but does not in itself guide, locate or position the cutting tool. The setting of the tool is done by machine adjustment and a setting block or by using slips gauges. A

14

fixture is bolted or clamped to the machine table. It is usually heavy in construction. Jigs are used on drilling, reaming, tapping and counter boring operations, while fixtures are used in connection with turning, milling, grinding, shaping, planning and boring operations. To fulfill their basic functions, both jigs and fixtures should possess the following Components or elements: 1. A sufficiently rigid body (plate, box or frame structure) into which the workpieces are loaded 2. Locating elements. 3. Clamping elements. 4. Tool guiding elements (for jigs) or tool setting elements (for fixtures). 5. Elements for positioning or fastening the jig or fixture on the machine on which it is used.

Locating pins are stops or pins which are inserted in the body of jig or fixture, against which the workpieces pushed to establish the desired relationship between the workpiece and the jig or fixture. To assure interchangeability, the locating elements are made from hardened steel. The purpose of clamping elements is to exert a force to press a workpiece against the locating elements and hold it there in opposition to the action of the cutting forces. In the case of a jig, a hardened bushing is fastened on one or more sides of the jig, to guide the tool to its proper location in the work. However, in the case of a fixture, a target or set block is used to set the location of the tool with respect to the workpiece within the fixture.
15

Most jigs use standard parts such as drill bushings, screws, jig bodies and many other parts. Fixtures are made from grey cast iron or steel by welding or bolting. Fixtures are usually massive bodies because they have to withstand large dynamic forces. Because the fixtures are in between the machine and the workpiece, their rigidity and the rigidity of their fastening to the machine table are most important. Jigs are positioned or supported on the machine table with the help of feet which slide or rest on the machine table. If the drill size is quite large, either stops are provided or the jig is clamped to the machine table to withstand the high drilling torque. Fixtures are clamped or bolted to the machine table.

FIG.1.2. A Simple Design of Jig and Fixture According to the degree of mechanization and automation, jigs and fixtures are classified as: (a) hand operated (b) power (c) semi-automatic (d) automatic.

USES OF JIG AND FIXTURE: Reduce cost of production.

16

Increase the production. To assure high accuracy of parts Provide for interchangeability Enable heavy and complex parts to machine Reduced quality control expenses. Less skilled labor. Partially automates the machine tools Use improve the safety, accidents low 1.4. INTRODUCTION TO LOCATING AND CLAMPING:

The question of properly locating, supporting, and clamping the work is important since the overall accuracy is dependent primarily on the accuracy with which the workpiece is consistently located within the jig or fixture. There must be no movement of the work during machining. Locating refers to the establishment of a proper relationship between the workpiece and the jig or fixture. The function of clamping is to exert a force to press the workpiece against the locating surfaces and hold it there against the action of cutting forces.

1.4.1. PRINCIPLE OF LOCATION:

In order to study the complete location of a workpiece within jig or fixture, let us consider a workpiece in space .The workpiece is assumed to have true and flat faces. In a state of freedom, it may move in either of the two opposed directions along three mutually perpendicular axes, XX, YY and ZZ. These SIX
17

movements are called "movements of translation. Also, the Workpiece rotate in either of two opposed directions around each axis, clockwise and anticlockwise. . These six movements are called "rotational movements". The sum of these two types of movements gives the twelve degrees of freedom of a workpiece in space. To confine the workpiece accurately and positively in another fixed body (Jig or fixture), the movement of the workpiece in any of the twelve degrees of freedom must be restricted

FIG.1. 3 Workpiece in Space

18

FIG.1.4 Workpiece Located in a Fixed Body. 1. The workpiece is resting on three pins A, Band C which are inserted in the base of the fixed body. The workpiece cannot rotate about the axes XX and YY and also it cannot move downward. 2. Two more pins D and E are inserted in the fixed body, in a plane perpendicular to the plane containing the pins A. Band C. Now the workpiece cannot rotate about the Z- axis and also it cannot move towards the left. Hence, the addition of pins D and E restrict three more degrees of freedom, namely 6, 7 and 8. 3. Another pin F in the second vertical face of the fixed body, arrests degree of freedom 9.

19

Thus, six locating pins, three in the base of the fixed body, two in a vertical plane and one in another vertical plane, the three planes being perpendicular to one another, restrict nine degrees of freedom. Three degrees of freedom, namely, 10, 11 and 12 are still free. To restrict these, three more pins, one for each of these degrees of freedom are needed. But this will completely enclose the workpiece making its loading and unloading into the jig or fixture impossible. Due to this, these remaining three degrees of freedom may be arrested by means of a clamping device. The above method of locating a workpiece in a jig or a fixture is called the "3-2-1"principle or "six point location" principle. Some of the principles to be followed for location of a workpiece are explained below.

1.4.1.1. PRINCIPLE OF PIN LOCATION:

The principle of minimum locating points. According to this principle, only the minimum locating points" should be used to secure location of the workpiece in anyone plane. Considering the "3-2-1 principle, these pins are used to the base of the fixed body. This is due to the reason that this is the minimum number of locating points through which a plane can be drawn on which the workpiece will seat. The workpiece may rock and get strained if more than three locating points are provided. Now considering the second plane, It is clear that if one locating point is provided, the workpiece will swivel about this point, but not if there are two such location points, these two locating points establish a line parallel to the
20

first plane. With the workpiece located against a plane and a line, it has only one direction of movement in third plane. Therefore, one locating point is sufficient in the third plane to prevent this movement. 1.4.1.2. PRINCIPLE OF MUTUALLY PERPENDICULAR PLANES: 1. The "3-2-1" principle can also be put as a workpiece may be fully located by supporting it against three points in one plane, two points in second plane and one point in a third plane. These three planes are not parallel and are preferably perpendicular to one another. If the locating surfaces are not perpendicular to one another, the following two difficulties will arise: 2. The workpiece will tend to lift due to the wedging action between the two locating surfaces. 3. A large error in the movement of the workpiece introduced due to the displacement of a locating point or a particle (chip or dirt) adhering to it. 4. The difference of resulting error and introduced error, which is the projection factor is zero when the locating surfaces are normal and increases as the angle between them becomes more acute.

21

FIG.1.5 Principles of Mutually Perpendicular Planes

1.4.1.3. PRINCIPLE OF EXTERME: The locating points should be placed as far away from one another possible, to achieve the greatest accuracy in location.

1.4.2. LOCATING METHODS AND DEVICES: Locators are those parts of a jig or fixture which helps a workpiece to seat in proper position in it. Depending on the type of work, locators are designed. There is a large variety of locating devices or locators and methods of locating elements available to a jig and fixture design. The majority of workpiece can be located with these methods. The various locating devices and methods are as follows:
22

Pins of various designs and made of hardened steel are the most common locating devices used to locate a workpiece in a jig or fixture. The shank of the pin is press fitted or driven into the body of the jig or fixture. The locating diameter of the pin is made larger than the shank to prevent it from being forced into the jig or fixture body due to the weight of the workpiece or the cutting forces. 1.4.3. PINS AND BUTTON LOCATORS: This is one of the common methods of location. A round pin or button is used to support the job firmly and hold it in position. The main difference between pins and buttons are length. Buttons are generally shorter in length than pins and are generally used for vertical locations. Pins are generally used for horizontal locations. Larger sizes are sometimes referred to as plugs. Depending upon the mutual relation between the workpiece and pin, the pins may be classified as: 1. Locating pins 2. Support pins 3. Jack pins

1.4.3.1. LOCATING PINS:

When reamed or finely finished holes are available in the workpiece, these can be used for locating purposes in the manner shown in Fig. Depending upon their form, the locating pins are classified as: 1.4.3.2. CONICAL LOCATING PINS.

23

These pins are used to locate a workpiece which is cylindrical and with or without a hole as shown in Fig. (a) (b) .Any variation in the hole size will be easily accommodated due to the conical shape of the pin. 1.4.3.3. CYLINDRICAL LOCATING PINS: In these pins, the locating diameter of the pin is made a push fit with the hole in the workpiece, with which it has to engage. The top portion of these pins is given a sufficient lead either by chamfering [Fig. (c) and (d)] or by means of radius [Fig (e)] to facilitate the loading of the workpiece.

FIG1.6 LOCATING PINS

1.4.4. CLAMPING INTRODUCTION:

If the workpiece cannot be restrained by the locating elements, it becomes necessary to clamp the workpiece in jig or fixture body. As already noted, the purpose of clamping is to exert a pressure to press a workpiece against the locating surfaces and hold it there in opposition to the cutting forces i.e. to
24

secure a re1iable (positive) contact of the elements and prevent the work m the fixture from displacement and vibration In machining. The most common example of a clamp is the bench vise, where the movable jaw of the vise exerts Force on the workpiece thereby holding it in the correct position of location in the fixed jaw of the vise.

PRINCIPLES FOR CLAMPING PURPOSES: Since the proper and adequate clamping of a workpiece is very important, the following design and operational factors should be taken care of: 1. The clamping pressures applied against the workpiece must counteract the tool forces. 2. The clamping pressures should not be directed towards the cutting operation. Whenever possible, it should be directed parallel to it, Fig

FIG 1.7 METHOD OF CLAMPING

25

3. The clamping pressure must only hold the workpiece and should never be great enough so as to damage, deform or change any dimensions of the workpiece. 4. The clamping and cutting forces should be directed towards the locating pins, otherwise the workpiece may get bent or forced away from the locating pins during machining. 5. Clamping should be simple, quick and fool proof. Complicated clamps lose their effectiveness as they wear. 6. The movement of a clamp should be strictly limited and if possible it should be positively guided. 7. Whenever possible, the lifting of the clamp by hand should be avoided if it can be done by means of a spring fitted to it. 8. Clamps should never be relied upon for holding the workpiece against the cutting force. The cutting force should be arranged against a fixed stop or a substantial part of the fixture body. 9. The clamps should always be arranged directly above the points supporting the work; otherwise the distortion of the work can occur, as illustrated in Fig. 10. Fibre pads should be riveted to the clamp faces, otherwise soft and fragile workpiece can get damaged. 11. A clamp should be designed to deliver the required clamping force when operated by the smallest force expected. 12.A clamp should be strong enough to withstand the reaction imposed upon it when the largest expected operating force is applied. 13. Clamping pressure should be directed towards the points of support, otherwise work will tend to rise from its support, Fig.

26

FIG 1.8 POSITION OF CLAMP

1.4.4.1. CLAMPING DEVICE:

1.4.4.1.1. BRIDGE CLAMP. It is very simple and reliable clamping device. The clamping force is applied by the spring loaded nut Fig , The relative positions of the nut, the point of contact of the clamp with the work and with outer support should be carefully considered, since the compressive force of the nut is shared between the

27

workpiece and the clamp support inversely as the ratio of their distances from the nut.

The distance 'x' is less than or equal to but never greater than the distance 'y'. The spring is fitted with the clamp for its automatic lifting when the nut is loosened to remove the workpiece from the jig or fixture. To avoid the complete removal of the nut every time a workpiece is changed the clamp may be slotted to draw it back as shown in Fig. A two way clamping can be obtained by the bridge clamp as shown in Fig.

28

FIG.1.9 BRIDGE CLAMP

1.5.

INTRODUCTION TO SENSORS: Sensors are devices which produces a proportional output signal

(mechanical, electrical, magnetic, etc.) when exposed to a physical phenomenon (pressure, temperature, displacement, force, etc.). Many devices require sensors for accurate measurement of pressure, position, speed, acceleration or volume. Transducers are devices which convert an input of one form of energy in to an output of another form of energy. The term transducer is often used synonymously with sensors. However, ideally, the word transducer is used for the sensing element plus any associated
29

signal conditioning circuitry. Typically, a transducer may include diaphragm which moves or vibrates in response to some form of energy, such as sound. Some common examples of transducers with diaphragms are

microphones, loudspeakers, thermometers, position and pressure sensors. Sensors are transducers when they sense one form of input energy and produce output in a different form of energy.

TYPES OF SENSORS: Passive and Active sensors Analog and digital sensors

1.5.1. PROXIMITY SENSOR: A Proximity sensor can detect objects without physical contact. A proximity sensor often emits an electromagnetic field or beam and look for changes in the field. The object being sensed is often referred to as the proximity sensor's target. Different proximity sensor targets demand different sensors. For example, a capacitive or photoelectric sensor might be suitable for a plastic target; an inductive proximity sensor requires a metal target.

30

A proximity sensor that measures current flow between the sensing electrode and the target provides readouts in appropriate engineering units. Usually, one side of the voltage source or oscillator connects to the sensing electrode, and the other side connects through a current-measuring circuit to the target, which generally is a metal part at earth or ground potential. Proximity sensor selection depends on the material to be sensed. Proximity sensor probes for sensing no conducting surfaces or insulators vary slightly from those for conducting surfaces. No conducting probe signals are also more difficult to linearize. TYPES: Hall Effect sensor Capacitive sensors Eddy current proximity sensors Inductive proximity sensors Pneumatic proximity sensor Proximity switches 1.5.1.1. PROXIMITY LIMIT SWITCH: Proximity switches are used to detect the presence of an object. These can be achieved by the presences of an object in order to give output which is either on or off. These can be classified in two types: Non contact type Contact type
31

The non-contact type switches detect the presence of an object without a physical contact. Examples: magnetic reed switch, photoelectric sensors, inductive proximity sensor. The contact type switches detect the presence of an object with a physical contact. The function of a limit switch is to produce electrical signal corresponding to the position of the mechanical member to be detected. Limit switches have operating heads which incorporate some types of lever arm or plunger mechanism, the selection of which is application dependent. When a limit switch has the positive opening of the normally closed contact, it is typically suitable for use in machine safety application. PROXIMITY SWITCH APPLICATIONS: 1. Don't use the limit switch as a mechanical stop (use another component) 2. Use cam surfaces to allow gradual actuation 3. Don't apply side forces to the switch roller or lever (will wear Bearings quickly) 4. Use appropriate switch actuator for type of force/motion applied 5. Dont switch excessive currents through the switch contacts

32

CHAPTER-2 METHODOLOGY
2.1. WORKING: Work holding is one of the efficient methods. The main purpose of using fixtures is to reduce the setting time of the workpiece. The fixture is designed in such a way that the loading and unloading of the workpiece is done easily and quickly. Work holding devices play a major role in manufacturing as they ensure smooth and efficient operation of the component. Fixtures are used for holding the work piece during machining.

33

Petrol brackets are used to mount the drive shaft in automobiles. The petrol bracket is casted from cast iron into the required shape and further machining processes are carried out to achieve good precision component with good surface finish. A stud is used in the petrol bracket in order to hold the drive shaft with the petrol bracket. The Stud is provided with a neck such that the length of thread is longer on one side and shorter on the other side. During assembly of the stud into the petrol bracket, the thread with the shorter side should be inserted first, if the longer side is inserted the entire component is rejected. screwened through torque wrench. Here the sliding element is used for clamping the work piece efficiently. The cylindrical locator are used for setting the workpiece in the fixture easily in which both clamping and locators arrest six degrees of freedom efficiently. Human error occurs during screwing the stud as the operator inserts the longer side of the stud into the petrol bracket. Due to lack of concentration or continuous work, human error occurs which results in rejection of the component. Hence we came up with the idea of introducing fixtures in the assembly. A sensor (proximity limit switch) equipped fixture is designed in order to eliminate the chances of error. An assembly fixture is used to assemble the stud in a petrol bracket and is manufactured using mild steel. As we know that mild steel has good load bearing capacity and corrosion resistance, mild steel is chosen. Wear and tear occurs in the petrol bracket during clamping, so brass is used for clamping in order to reduce the wear and tear.
34

The stud is

When the stud is misassembled in wrong position (i.e.) instead of inserting the shorter side, longer side is inserted, the limit switch warn the operator through alarm sounds when the stud is assembled wrongly. This assembly fixture can be easily operated, so even a semiskilled labor can operate the fixture with ease. This reduces the manpower, labor cost and also the manufacturing cost. Due to implementation of the sensor equipped fixture, zero error is achieved, assembling time is reduced and rejection of components is eliminated. Hence due to the above mentioned factors the production rate can be increased.

2.2. DESIGN OF ASSEMBLY FIXTURE: BOTTOM BASE PLATE WITH SENSOR STAND: 3D-DIAGRAM

35

FIG.3.1 (A) BOTTOM BASE PLATE WITH SENSOR STAND The bottom base plate holds all the component of the fixture such as sensor kit, angle plate, clamping device, locating pins in an efficient way. The pillars are provided in order to connect the top and bottom base plate by using bolt. The bottom base plate is made of mild steel.

BOTTOM BASE PLATE WITH SENSOR STAND 2D-DIAGRAM

36

FIG.3.1 (B) BOTTOM BASE PLATE WITH SENSOR STAND

BOTTOM BASE PLATE WITH LIMIT SWITCH: 3D-DIAGRAM

37

FIG.3.2 (A) BOTTOM BASE PLATE WITH LIMIT SWITCH

BOTTOM BASE PLATE WITH LIMIT SWITCH 2D-DIAGRAM

38

FIG.3.2 (B) BOTTOM BASE PLATE WITH LIMIT SWITCH:

TOP BASE PLATE 3D-DIAGRAM

39

FIG 3.3 (A) TOP BASE PLATE The top base plate is fixed above the bottom base plate by using spacer. The angular block and clamping device is placed above top base plate. The hole is provided to the sensor pin in order to indicate the error during assembly. It is made of mild steel.

TOP BASE PLATE 2D-DIAGRAM

40

FIG 3.3 (B) TOP BASE PLATE

SENSOR STAND: 3D-DIAGRAM

41

FIG.3.4 (A) SENSOR STAND

The design shown above is a sensor stand. The sensor stand is used to hold the proximity limit switch. Hence the sensor stand is fixed to the bottom base plate of the fixture. The two bottom holes in the sensor stand are used to fix with the base plate of the fixture. The holes provided at the top are used to hold the limit switch using bolt and nut. The sensor stand is made of mild steel.

SENSOR STAND

42

2D-DIAGRAM

43

FIG.3.4 (B) SENSOR STAND

PLUNGER: 3D-DIAGRAM

FIG.3.5 (A) PLUNGER

The plunger consists of a spring loaded roller which is attached to the limit switch. It is located below the sensor pin. The sensor pin will push the plunger when a stud is misassembled and gives indication to the sensor. It is made of mild steel (EN-8).

44

PLUNGER 2D-DIAGRAM

45

46

FIG.3.5 (B) PLUNGER

SPACER: 3D-DIAGRAM

FIG.3.6 (A) SPACER:

47

The top base plate is supported by the Spacer. The limit switch is placed in between the top and bottom base plate in order to operate the sensor easily. The Spacer is made of mild steel.

SPACER 2D-DIAGRAM

48

FIG.3.6 (B) SPACER:

SENSOR PIN: 3D-DIAGRAM

FIG.3.7 (A) SENSOR PIN:

49

The sensor pin is placed above the limit switch. When a stud is misassembled it pushes the sensor pin down and gives indication to the sensor. It is made of mild steel (EN-36).

SENSOR PIN 2D-DIAGRAM

50

FIG.3.7 (B) SENSOR PIN:

SLIDING CLAMP: 3D-DIAGRAM

FIG.3.8 (A) SLIDING CLAMP

51

The sliding clamp is used while clamping and removing the workpiece in the fixture. The clamp pad is provided in the sliding clamp. The clamp pad is made of brass material, because it eliminates wear and tear to the component.

SLIDING CLAMP 2D-DIAGRAM

52

FIG.3.8 (B) SLIDING CLAMP:

ANGULAR BLOCK 3D-DIAGRAM

53

FIG 3.9 (A) ANGULAR BLOCK

ANGULAR BLOCK 2D-DIAGRAM

54

FIG 3.9 (B) ANGULAR BLOCK

FINAL ASSEMBLY OF A FIXTURE: 3D-DIAGRAM

55

FIG.3.10. (A) FINAL ASSEMBLY OF A FIXTURE

FINAL ASSEMBLY OF A FIXTURE 2D-DIAGRAM

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FIG.3.10. (B) FINAL ASSEMBLY OF A FIXTURE 2.3. FIXTURE MANUFACTURING PROCESS:

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1. RAW MATERIAL 2. SIZING

-MS, EN-8, EN-36, EN-24. -SHAPER, CONVENTIONAL, TURNING, MILLING

3. HEAT TREATMENT -HRC (e.g. 60-62) 4. GRINDING 5. BLACKENING 6. INSPECTION 7. ASSEMBLING -SURFACE OR CYLINDRICAL GRINDING -BLACK OXIDE COATING

RAW MATERIAL: The fixture is manufactured using the above processes. Initially raw material is collected which consists of properties such as MS, EN-8, EN-36, and EN-24. EN8 is grade of through-hardening medium carbon steel, which can be readily machined in any condition. EN8 is suitable for the manufacture of parts such as general-purpose axles and shafts, gears, bolts and studs.

SIZING: The raw material is converted in to required shape by using a casting. After that the machining operation is carried out such as shaping, turning and milling.
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Machining is any of various processes in which a piece of raw material is cut into a desired final shape and size by a controlled material-removal process. The traditional machining processes are turning, boring, drilling, milling, broaching, shaping, planing, reaming and tapping. Turning operations are operations that rotate the workpiece as the primary method of moving metal against the cutting tool. Milling operations are operations in which the cutting tool rotates to bring cutting edges to bear against the workpiece. Drilling operations are operations in which holes are produced or refined by bringing a rotating cutter with cutting edges at the lower extremity into contact with the workpiece. Drilling operations are done primarily in drill press but sometimes on lathes or mills. HEAT TREATMENT: Heat treating is a group of industrial and metalworking processes used to alter the physical, and sometimes chemical, properties of a material. Heat treatment involves the use of heating or chilling, normally to extreme temperatures, to achieve a desired result such as hardening or softening of a material. Heat treatment techniques include annealing, case hardening, precipitation strengthening, tempering and quenching. It can be further surface-hardened typically to 60-62 HRC by induction processes, producing components with enhanced wear resistance. The Rockwell scale is a hardness scale based on indentation hardness of a material. The Rockwell test determines the hardness by measuring the depth of penetration of an indenter under a large load compared to the penetration made by a preload.
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GRINDING: Grinding is one of the methods of surface finishing. There are two types of grinding such as cylindrical and surface grinding. Cylindrical grinding is used for finishing the flat surface and surface grinding is used for finishing the cylindrical surface. BLACK OXIDE COATING: Black oxide is a conversion oxide coating formed on the metal surface as a result of a chemical reaction of the metal atoms with an oxidizing agent (air, aqueous solution, molten salts). Black oxide coating is used mostly for Carbon steels, Alloy steels, Tool and die steels and Cast irons. Stainless steels and Copper alloys may also be black oxide coating. INSPECTION: Most high precision parts and components need to be inspected either visually or mechanically in order to confirm dimensions. This is an efficient method which improves productivity.

ASSEMBLING: Finally the components of the fixture are assembled in an efficient way by using bolt, nut, welding, which is designed in such a way to increase productivity. 1.6. COST ESTIMATION:

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S.NO

EQUIPMENT

MATERIAL

QUANTITY

COST

I. 1 2 3 4 5 6 Angular block Clamping device(sliding block) Clamp pad Top base plate Bottom base plate Spacer

FIXTURE COST Mild steel Mild steel Brass Mild steel Mild steel Mild steel 1 1 1 1 1 4 4000 1500 500 1500 1500 1000

II.

ELECTRICAL SPARES COST Electrical spares (limit

switch 2no,control box 1no,Cable and others) TYPE-OMRON 3332 D4C-

----

------

7000

III.

TOTAL COST TABLE NO 2.1COST ESTIMATION

17000

2.5. COMPARISION OF EXISTING FIXTURE AND NEW DESIGNED FIXTURE:

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EXISTING FIXTURE:

NEW DESIGNED FIXTURE:

FIG. NO 3.11 PICTORIAL REPRESENTATION OF FIXTURE CHARACTERISTICS EXISTING FIXTURE NEW DESIGNED

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FIXTURE Operation Sensor Difficult to operate Does not indicate the error, due to absence of sensor. Setting time Assembling time for the component is up to 90 seconds. Productivity Productivity is less compared to designed fixture. Labour availability Skilled labour is required. Clamp usage Two clamping is used, so makes more time. Semi skilled labour can operate. Single clamping is used, so assembling time is reduced. Component rejection There is a chance of misalignment of stud, so component is rejected. There is no chance of misalignment of stud. So component rejection is eliminated. Assembling time for the component is reduced to 65 seconds. Productivity is more. Easy to operate Indicate the error, due to the presence of sensor.

TABLE 2.2 COMPARISION OF EXISTING FIXTURE AND NEW DESIGNED FIXTURE 2.6. ADVANTAGES: 1. It reduces or eliminates the efforts of setting the work piece and maintains the accuracy of performance.

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2. Assembling time is reduced when comparing the conventional fixture due to single clamping device instead of using two clamping devices which is also an efficient method. 3. It reduces the production cycle time so increases production capacity. 4. Semi-skilled labour can assemble the workpiece using fixture with ease. 5. Operators working become comfortable as his efforts in setting the work piece can be eliminated.

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CHAPTER-3 CONCLUSION
CONCLUSION: The design of fixture is effective and efficient in assembly of the petrol bracket there by reducing the assembling time and increasing the productivity. Due to
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implementation of the sensor equipped fixture, zero error is achieved, and rejection of components is eliminated. The assembling time of existing fixture for a petrol bracket is 90 seconds and the assembling time of new designed fixture for a petrol bracket is 70 seconds. It reduces the assembling time of each component by 20 seconds comparing the conventional fixture. This meets the major advantages which increases the productivity. Even a semi-skilled operator can handle this fixture in assembly with ease which reduces the manpower, labor cost resulting in a minimized manufacturing cost.

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CHAPTER-4 BIBLIOGRAPHY
BIBLIOGRAPHY: 1. AMERICAN SOCIETY OF TOOL AND MANUFACTURING ENGG HAND BOOK 2. PRODUCTION TOOLING EQUIPMENT PARSONS
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3. ENGINEERING PRODUCTIVITY-WALKER 4. JIGS AND FIXTURES INTRODUCTION -HASTLEHURST 5. ADVANCED FIXTURE DESIGN FOR FMS -ANDREW YEH CHRIS NEE, KENNETH WHY BREW, A.SENTHIL KUMAR 1995. 6. A FUNCTIONAL APPROACH FOR THE FORMALIZATION OF THE FIXTURE DESIGN- R.HUNTER, J.RIOS, J.M.PEREZ, A.VIZAN 2006. 7. COLVIN, FRED HERBERT 1867-MACHINE TOOLS. 8. HAAS, LUCIAN LEVANT 1881-MACHINE TOOLS.
9.

JIGS AND FIXTURES-INTRODUCTION -PRAKASH HIRALAL JOSHI-2010.

10.

JIG

AND

FIXTURE

DESIGN

MANUAL-ERIK

KARL

HENRIKSEN 1973.

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