International Journal of Trend in Research and Development, Volume 5(1), ISSN: 2394-9333 www.ijtrd.com Design and Analysis of a Jig and Fixture for Drilling an inclined hole in a TEE Plain Adapter

1Shubham Misal, 2Kalpesh Tatar and3Amol Vyavahare, 1Design Engineer, Keon Designs, Pimpri-Chinchwad, Maharashtra, India 2Design Engineer, C G Power and Industrial Solutions Ltd. 3Graduate Apprentice Trainee, Mahindra Vehicles Manufacturers Ltd.,

Abstract: The target of the mass production is to increase the production. As we know the solution to this is by reducing the productivity and increase the accuracy. This is done by set up cost of the machine and also reducing the manual reducing the set up cost and manual fatigue. Thus mass fatigue. In this case the device that caters our needs is the use production can be achieved by the use of jigs and fixture. For of jigs. large scale production of different material, a lot of time is II. DESIGN PROCEDURE FOR JIG AND FIXTURE wasted in set up of the device and clamping the device. This paper work aims at design and analysis of a Jig and Fixture for In the design of a fixture, a definite sequence of design stages drilling an inclined hole at an angle of 45°. The thrust force is involved. They can be grouped into three broad stages of required for drilling operation is calculated. The 3D modelling design development. Stage one: It deals with information of workpiece, jig and fixture is done by Catia V5 software. The gathering and analysis. These include product analysis such as finite element analysis of the workpiece is carried out by the study of design specifications, process planning, examining Ansys workbench 16.0 software the outcome of the project the processing equipment and considering operator safety and involves development of jig and fixture which thus resulted in ease of use. In this stage, all the critical dimensions and increase of rate of production. feasible datum areas are examined in detail. Here study of workpiece, where hole is to be drilled, is conducted. Here we Keywords: Jig and Fixture, Catia, Finite element analysis. assessed different surfaces for clamping and locating purpose. I. INTRODUCTION Clamping and locating should be in such way that it should not hamper any surface or edge. Also it should be ensured that A fixture is a production tool which is mainly used to locate, there will be no unequal stress distribution. Also sensitive hold and support the work piece firmly to the table. Set blocks surfaces should be kept away from clamping devices. Stage and feeler are sometimes used to provide reference of the Two: It involves the consideration of clamping and locating cutter to the workpiece. The main concern is the fastening of schemes. A clamping scheme is devised in such a way that it the fixture. The fixture should be so chosen that the fastening will not interfere with the tools or cutters and are fully of the job to the table is done quickly. It is mainly used in compatible with proposed locating surfaces or areas. The milling operation. But nevertheless it can also be used locating scheme, using standard elements such as pins, pads, extensively in drilling machine also for holding the job during etc. is designed to be consistent with clamping and tool- the drilling operation and pressing operation. Size of the guiding arrangements. In this stage jig plate comes into fixture varies from being simple to expensive and complicated. picture. There thumb rule is, jig plate should remain stationary It largely depends on complication of workpiece. These as much as possible. It should not behave like C-plate. Because fixtures also help in simplifying the network operations which whole accuracy of configuration totally depends on how jig are performed on special equipment. Project work aim to plate is aligning axis of tool and drilling hole. Bush is used to design and fabricate a jig for drilling hole of 14 mm diameter guide tool through it smoothly. Also bush plays role as in mild steel material at inclined position 45. Due to vibration absorber which are induced in drilling tool. Stage unavailability of proper fixture, company personal uses Three: It is the design of the structure of the fixture body traditional methods for drilling hole by using just locator and frame. This is usually built around the workpiece as a single supporter. Due to this only 40-50 components are drilled every element which links all the other elements used for locating, day. Also there were number of inaccuracy while producing clamping tool-guiding, etc. into an integral frame work. The hole in workpiece. Hence mass production was not possible above procedures are quite general and can be modified with precision. Hence company asked us to design and depending on the relative importance of the various elements manufacture required drilling jig. Sponsored organization in providing for the required accuracy of the workpiece to be provided a design of workpiece. Accordingly, that we have located and secured into the fixturing device. With the popular designed same component using Catia parametric. After that adaptation of modular fixturing elements, the fixture body we studied different locating and clamping surfaces available frame is usually a standard block with fixed arrays of locating on work which could not be deformed easily. Here drilling tool and fixing holes or slots. It becomes a matter of selecting the cannot produce hole which is at 45 inclinations. Hence it is most suitable body frame to accommodate the various required to produce an arrangement or assembly to hold this elements, provide good support of the workpiece and access to workpiece horizontally. Workpiece does not have circular cutters and tools. cross sectional area, it is having rectangular cross sectional area. Hence to hold this work we need to produce V-slot in III. DESIGNED COMPONENTS OF FIXTURE supporting block. Also plate having v-slot in it. Care is taken Fig 3.1 represents the TEE Plain Adapter on which an inclined that, while supporting and clamping extra non uniform stresses should not be introduced in work. Also there should not be any hole is to be drilled at an angle of 45°. Fig 3.2 shows a Base deformation to workpiece. Material used for fixture is „Oil plate which supports whole assembly. M8 bolts are used to hardening non-shrinking steel‟ that is OHNS. Increasing the firmly fix the fixture with base plate. Dimensions of base plate productivity and accuracy are the two basic aims of mass are 150×150×15 mm. Material used for base plate and all other IJTRD | Jan - Feb 2018 Available [email protected] 72 International Journal of Trend in Research and Development, Volume 5(1), ISSN: 2394-9333 www.ijtrd.com components is OHNS. Fig 3.3 shows Holding block of OHNS mm so that effective width of bush will be 3mm. Jig plate is material which is used to hold workpiece firmly. Since also made from OHNS material. Fig 3.5 represents Clamping workpiece having V-shape, a slot of V is formed in this block Plate which constrain upward movement of workpiece. It is using Wire Cutting. Also V-slot is inclined at 45 because we also made up of OHNS material having V-slot in it. This have to drill hole at 45, so that workpiece become horizontal clamping plate is fixed to main holding block with the help of for drilling. Milling operation is performed at bottom of V- stud and wing screw arrangement, so that quick realise of block to avoid deterioration to edge of workpiece. Fig 3.4 workpiece is possible when drilling operation is completed. represents Jig Plate which is the very important part of fixture Fig 3.6 and Fig 3.7 represents Supporting blocks and Plates assembly. Purpose of jig plate is to guide tool, so that drilling respectively. Purpose of project is to drill hole at 45. Hence we can be done without any error. There is chance of dislocating need to make arrangement which can locate workpiece tool with respect to workpiece. Thus jig provides fix path to horizontally. So we designed supporting block in that manner. tool so that drill can be produced at desired location. A bush is Now it is imperative to hold that inclined block. So here come inserted in jig plate which has internal diameter equal to hole supporting blocks and plate comes into picture. They are fitted to be drilled which is 14 mm and outer diameter equal to 20 to work holding block using nut and bolt arrangement.

Fig. 3.1 Fig 3.2 Fig 3.3

Fig 3.4Fig 3.5 Fig3.6

Fig 3.7

Fig 3.7 Fig 3.8 Fig 3.7 represents the 3D Cad assembly while Fig 3.8 main component to be drilled is mounted on the fixture body represents the rendered form of the 3D Cad assembly. The (Pink). The Fixture body is sliced at an angle of 45 degrees to

IJTRD | Jan - Feb 2018 Available [email protected] 73 International Journal of Trend in Research and Development, Volume 5(1), ISSN: 2394-9333 www.ijtrd.com make the drilling position horizontal. A Jig plate is used with a 0.002503, thus the mesh quality has passed the orthogonality bush press fitted in it to guide the tool. To prevent the sliding test. of the component and hold it in position clamping plate and supporting plate is used. The Clamping Plate is clamped with the help of wing nut. The supporting plate is rested on supporting blocks. The supporting block, the supporting plate and the fixture body are bolted by 2 nut bolt arrangements. And the whole arrangement is clamped on base plate by using threaded bolts. IV. THEORETICAL CALCULATIONS FOR DRILLING FORCE Cutting speed = V (π × d × N) V = 60 (3.1415 × 14 × 500) = 60 Fig. 5.1 m = 22 min The Skewness quality of the discretized elements is expressed in terms of the percentage of volume /area of the total elements mm Feed rate (s) = 0.165 rev Fig 5.2. Total of 37.21% falls in excellent zone 25.17% in very good zone. 27.129% in good zone. 10.27% lies in acceptable Material Factor (k) = 1.07 region. Power of Spindle (P) 1.25 × d2 × k × N × (0.056 + 1.5 × s) = 105 = 1.31075 0.056 + 1.5 × 0.165 = 0.3978 kW Transmission efficiency (η) = 80% Power of motor (P‟) P P′ = η 0.3978 = 0.8 = 0.4972 kW 975 × P Torque T = N Fig 5.2 975 × 0.3978 The „Aspect Ratio‟ which measure how much stretched the = 500 elements are, is also quite significant. The aspect ratio tells us about how much elongated or skinny an element is. For the T = 775.7 Nm three dimensional elements we have used, aspect ratio is the ratio of the lengths of the largest and the smallest edge.The Thrust F = 1.16 × k × d × (100 × s)0.85 minimum value achieved is 1.0 while the maximum being F = 1846.49413 N 18824. The average value is 3.7687. The acceptance criteria call for aspect ratio < 100. Since, the average value of aspect V.FINITE ELEMENT MODEL DETAILS ratio is quite below the threshold, it indicates that nearly all the element has a good geometry. The model which was prepared external to ANSYS was imported. Engineering Data Manager was used for defining, VI. SIMULATION RESULTS AND DISCUSSIONS storing, and organizing material properties. A mesh with The finite element analysis is carried out by giving suitable quality metrics was generated. Of many metrics special boundary conditions and applying forces. Here in jig and attention was given to orthogonal quality, skewness, aspect fixture as the base plate remain fixed so it is given fixed ratio and jacobian. Statics for the orthogonal quality is given in boundary condition while as calculated from the equations the Fig. 5.1. A major of the total elements (approximately above, the thrust force of 1846.49413 N and a torque of 775.7 62%) lie in a „very good‟ zone followed by (approximately Nm was applied on the workpiece by the drill while 33%)in „good‟ zone and a very meagre amount (approximately performing drilling action. Using these boundary conditions, a 5%) in acceptable zone. A very negligible amount falls in simulation test was performed and the results obtained are „bad‟ zone i.e. 0.01-0.001. Since there are no elements in shown below. As shown in Fig 6.1 the maximum Von mises „unacceptable‟ zone of 0.001-0.00 minimum value obtained is IJTRD | Jan - Feb 2018 Available [email protected] 74 International Journal of Trend in Research and Development, Volume 5(1), ISSN: 2394-9333 www.ijtrd.com N stress developed in the Holding block is 13.819 mm2 and maximum deformation obtained is 0.000345 mm. Fig 6.2 shows the maximum von mises stress developed in clamping plate is 18.582 N and maximum deformation obtained is mm2 0.000342 mm. Fig 6.3 shows the maximum von mises stress N developed in supporting plate is 11.535 mm2 and maximum deformation obtained is 0.000348 mm.Fig 6.4 shows the maximum von mises stress developed in TEE Plain Adapter is N 25.163 mm2 and maximum deformation obtained is 0.00126 mm. It is found that torque and thrust applied during Fig 6.4 drilling is 7607 N/mm and 1846.4941 N respectively. The CONCLUSIONS overall stress value is 21.79 MPa and overall deformation is 0.0001396 mm. As the overall stress value and deformation is The amount of Von mises stress and total deformation in all much less, we can conclude that the design of fixture is safe. the components were obtained in the simulation.As per finite element analysis it is found that only nominal stresses and deformations are incurred in fixture body and workpiece which is within limit. Also stress distribution in the workpiece is uniform. So it is safe to assume that no deformation will be occurring in the Tee Plain adapter or the fixture. This not only increases the rate of production but also decreases the amount of work that was performed for adjusting the workpiece for drilling operation in conventional method. Also maximum accuracy and reliability is achieved which was not possible with the help of traditional methods.

References Fig. 6.1 [1] Anoop Mathew Kurian, Dr. Binu, C. Yeldose, Ernest Markose Mathew “Effect of Wire EDM Parameters on Surface Roughness of Stainless Steel 15-5 PH” [2] Nikhil. G. Lokhande, C.K. Tembhurkar“Advanced Fixture for Angular Drilling On Cylindrical Objects” [3] Smit Patel, Sahil Vasoya, Ankur Joshi “Design and Manufacturing of Jigs for Drilling Machine” [4] Hans-Christian Möhringa, Petra Wiederkehrb “Intelligent Fixtures for High Performance Machining” [5] Anand Raghu, Shreyes N. Melkote “Analysis of the effects of fixture clamping sequence on part location Fig 6.2 errors” International Journal of Machine Tools & Manufacture 44(2004) 373-382 PPI-3 [6] Jaime Camelio and S. Jack Hu “Diagnosis of multiple fixture faults in machining processes using designated component analysis” [7] Kulankara Krishnakumar, Shrwyes N. Melkote “Machining fixture layout optimization using the genetic algorithm” International Journal of Machine Tools & Manufacture 40(2000)579-58-98, P.P-2

Fig 6.3

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