Tool Design (Repaired)1

DESIGN AND FABRICATION OF FIXTURE TO TORQUE AND ASSEMBLY THE DIFFERENTIAL CAGE

Industrial & Production engineering department P.E.S.C.E

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COMPANY PROFILE



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ABOUT THE COMPANY

Es t ab l i shed i n 1981 , Au t o mot i ve Ax l e s L imi t ed ( AAL) i s a j o i n t

ven t u r e o f Ar v i n Mer i t o r Inc . , USA ( fo r mer l y t he au to mot i ve d i v i s i on

o f Rock we l l I n t e r na t i ona l Co r po r a t i on ) , a Fo r t une 500 company , and

t he Ka l yan i Gr oup . Wi t h manu fac t u r i ng f ac i l i t i e s l oca t ed a t Myso r e ,

t he company i s cu r r en t l y t he l a r ge s t i ndependen t manufac t u r e r o f Rea r

Dr i ve Ax l e Assembl i e s i n t he coun t r y . Ove r t he yea r s , AAL ha s

deve l oped an i mp r e s s i ve do mes t i c OEM c l i en t e l e t ha t i nc l udes Ashok

Ley l and , Te l co , Veh i c l e Fac t o r y , J aba l pur , Mah i nd r a & Mah i nd r a ,

Vo l vo and Bha r a t Ea r t h Move r s . AAL expo r t s ax l e pa r t s t o USA, and

I t a l y .

T h e i n f r a s t r u c t u r e a t A A L s p a n s h i g h l y s p e c i a l i z e d m a n u f a c t u r i n g p r o c e s s e s

i n v o l v i n g F r i c t i o n W e l d i n g , C o 2 W e l d i n g , C N C M a c h i n i n g , F l e x i b l e M a c h i n e



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C e n t r e ’ s a n d a r a n g e o f s p e c i a l l y b u i l t m a c h i n e s f o r p r o d u c t i o n o f A x l e s a n d

B r a k e s . T h e f a c i l i t i e s a l s o c o m p r i s e G l e a s o n G e a r M a n u f a c t u r i n g E q u i p m e n t

b a c k e d b y a m o d e r n H e a t T r e a t m e n t S h o p i n c l u d i n g C o n t i n u o u s C a r b u r i z i n g

a n d S e a l e d Q u e n c h F u r n a c e . W i d e r a n g e o f R e a r D r i v e A x l e s c a t e r i n g t o

c o m m e r c i a l v e h i c l e s r a n g i n g f r o m 6 T o n s t o 3 5 T o n s G C W , S - C a m A c t u a t e d

Q u i c k C h a n g e A i r B r a k e s f o r c o m m e r c i a l v e h i c l e s , a n d T r a i l e r A x l e s f o r 1 0

T o n s t o 1 3 T o n s G V W .

AAL has a Qua l i t y Managemen t Sy s t em t ha t i s c e r t i f i ed t o I SO/ TS

16949 : 2002 s t anda r d and a l so Env i r on men t a l Managemen t Sys t em t ha t

i s c e r t i f i ed t o I SO 14001 : 2004 s t anda r d

HISTORY

1981 - Foundation Stone laid

1981 - Incorporation and commencement of business

1982 - First Annual General meeting of Members

1983 - First Public Issue of equity shares

1984 - Commercial production of Rear Axle Housing

1986 - Commercial production of Brake Assembly

1988 - Commercial production of Axle Assembly for LCV manufacturers

1991 - Entered Export market by exporting prototypes to MB-Germany

1995 - Rights issue in the ratio of 1:4

1996 - Sales cross Rs. 1 billion

1998 - Quality Management System certified to ISO 9001

2000 - Quality System certified to QS 9000

2003 - Sales cross Rs. 2 Billion

2005 - Quality System certified to TS16949

2005 - Sales cross Rs. 3.5 Billion

2005 - Foundation Stone laid for 'Kalyani Nagar' colony of Employees

2006 - Environment Management System Certified to IS14001

2006 - Silver Jubilee year - Sales Cross Rs. 4.5 Billion

2011 - 30th Anniversary



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DEFINING MOMENTS REFERENCE TO BIFR IN 1989

The company brought in Rockwell's state-of-the-art manufactureing technology to India way

ahead of its time expecting it would be able to penetrate a market segment in which CV

manufacturers were making their own axles. Due to unforeseen delays caused due to various

factors, it took us several years to achieve this objective. We had therefore to be content with

the business of contract manufacturing in which we could barely recover variable costs

resulting in the accumulation of significant losses with interest and depreciation burden

contributing to the erosion of over 50% of the company's net worth which led to its reference

to BIFR.

COMPANY VISION

Be a world class quality supplier of cost competitive products

Retain leadership in Indian markets for Rear Axles

Enhance exports business with ArvinMeritor & Others to 20% of Total Sales

PRODUCTS

P r o d u c t s m a n u f a c t u r e d a t A A L a r e b a s e d o n t e c h n o l o g y p r o v i d e d b y A r v i n

M e r i t o r I n c . , U S A , t h r o u g h M e r i t o r H V S ( I n d i a ) L t d , I n d i a a n d i n c l u d e t h e

f o l l o w i n g ,

W i t h m a n u f a c t u r i n g f a c i l i t i e s l o c a t e d a t M y s o r e , t h e c o m p a n y i s c u r r e n t l y

o n e o f t h e l a r g e s t i n d e p e n d e n t m a n u f a c t u r e r o f R e a r D r i v e A x l e A s s e m b l i e s

i n t h e c o u n t r y a n d w i t h m o r e t h a n 2 0 y e a r s o f a x l e - p r o d u c i n g e x p e r i e n c e

a n d a d v a n c e d g e a r i n g t e c h n o l o g y f r o m M e r i t o r H V S ( I n d i a ) L t d , h a s b e e n

m a n u f a c t u r i n g r e l i a b l e , l o n g - l i f e h e a v y d u t y d r i v e a x l e s . T h i s c a p a b i l i t y

a l l o w s t h e c o m p a n y t o m e e t t h e s t e e r , d r i v e a n d t r a i l e r a x l e r e q u i r e m e n t s

o f c u s t o m e r s i n t h e a d d r e s s e d m a r k e t s . T h e M a r k e t i n g & F i e l d S e r v i c e

S u p p o r t i s p r o v i d e d b y M e r i t o r H V S ( I n d i a ) L t d .



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TYPES OF PRODUCTS

S i n g l e d r i v e a x l e s

T a n d e m d r i v e a x l e s

N o n D r i v e a x l e s

SINGLE DRIVE AXLES

A A L o f f e r s a b r o a d s e l e c t i o n o f s i n g l e r e a r d r i v e a x l e s r a n g i n g f r o m 6 0 0 0 k g

t o 1 4 0 0 0 k g G A W R f o r T r u c k , B u s , T r a c t o r & c o n s t r u c t i o n v o c a t i o n s .

TANDEM DRIVE AXLES

V e h i c l e s u s e d i n t h e m i n i n g & T r a c t o r a p p l i c a t i o n s a r e o f t e n r e q u i r e d t o

c a r r y e x t r e m e l y h e a v y l o a d s , A A L o f f e r s t h e f o l l o w i n g v a r i e t y o f s i n g l e -

r e d u c t i o n t a n d e m d r i v e a x l e s w i t h G A W R c a p a c i t i e s f r o m 1 9 0 0 0 k g t o 2 8 0 0 0

k g f o r s u c h v e h i c l e s .

NON DRIVE AXLES

T h i s a x l e d o e s n o t h a v e d r i v e b u t u s e d a l o n g w i t h d r i v e a x l e s i n o r d e r t o

i n c r e a s e t h e v e h i c l e l o a d b e a r i n g c a p a c i t y



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QUALITY OBJECTIVES

CUSTOMER SATISFACTION:

Supply state of the art Products/Services to Customers that meet their expectations for

Quality, Technology, Time, and Responsiveness.

QUALITY:

Continually improve Effectiveness and Efficiency of Quality Management Systems to

maintain a distinguishable competitive Edge as viewed by Customers.

HUMAN RESOURCES DEVELOPMENT:

Establish and Implement leading edge Human Resource Systems and Practices to meet the

business objective through Training, Empowerment, and Motivation in achieving Total

Employee Involvement.

COMPETITION:

(Neutralize) Out Perform Competitors strategies by developing Customer Loyalty with

differentiated products, superior service and competitive Pricing.

FINANCIAL PERFORMANCE:

Exceed our financial and growth objectives through aggressive implementation of our

Business Plan.

ENVIRONMENT & SAFETY:

Establish and implement suitable environment and safety practices/ systems to fulfill our

social objectives.



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FEATURES

High efficiency gearing

Integral brake to axle design and manufacturing capability.

Wide ratio availability

Weight optionised designs

Driver operated differential locks

Worldwide availability

CUSTOMERS

T h e c u s t o m e r b a s e f o r A u t o m o t i v e A x l e s L i m i t e d i n c l u d e s c o m p a n i e s l i k e

V o l v o

E i c h e r

T a t a M o t o r s

A s h o k L e y l a n d

E s s a r

D a i m l e r C h r y s l e r

A r v i n M e r i t o r

M a h i n d r a & M a h i n d r a

B a j a j T e m p o

V F J ( A r m y )



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CHAPTER 1

INTRODUCTION TO

TOOL DESIGN



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1.TOOL DESIGN

Tool design is the process of designing and developing the tools, methods and

techniques necessary to improve manufacturing efficiency and productivity. It gives industry

the machines and special tooling needed for today’s high-speed, high-volume production. It

does this at a level of quality and economy that will ensure that the cost of the product is

competitive. Since no single tool or process can serve all forms of manufacturing, tool design

is an ever-changing, growing process of creative problem solving.

1.1 TOOL DESIGN OBJECTIVES

The main objective of tool design is to lower manufacturing costs while maintaining

quality costs while maintaining quality and increased production. To accomplish this, the tool

designer must satisfy the following objective

Provides simple, easy-to-operate tools for maximum efficiency.

Reduce manufacturing expenses by producing parts at the lowest possible

cost.

Design tools that consistently produce parts of high quality.

Increase the rate of production with existing machine tools.

Design the tool so to make it foolproof and to prevent improper use.

Select materials that will give adequate tool life.

Provide protection in the design of the tools for maximum safety of the

operator.

1.2TOOL DESIGN IN MANUFACTURING

Manufacturing for global competitiveness clearly requires the success of concurrent

engineering. Concurrent engineering is a process that allows the design team to be involved

in a comprehensive plan for product design and production. Concurrent engineering allows

the design team member to be involved in product design and production where their

knowledge of fixtures and manufacturing processes will result in fewer design errors.

Concurrent engineering teams consists of product designers, process planning engineers, tool



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designers, quality control engineers, production management, and machining technicians.

Companies may vary job titles and team compositions to suit their internal company

structure.

Team members contribute based on their area of expertise. The product, a method for

manufacturing, tooling concepts, and a quality plan are developed that suits the selected

manufacturing facility. In this way, problems are not discovered on the production floor, but

are corrected early in the concurrent process. This ultimately saves time and money while

speeding up the process of getting product to market earlier. Concurrent engineering allows a

company to have a distinct economic advantage in a global market.

The tool designer develops a plan for maintaining the concepts developed by the team

with respect to economic guidelines. Expert computer systems are now part of the design

environment. And they support an integrated approach for tracking time and money allocated

for the project and provides immediate information at any point in the concurrent process.

1.3 PLANNING THE DESIGN

The designer is responsible for managing information resource that impacts the tool

design. Product design changes are continuously reviewed to determine tooling changes are

continuously reviewed to determine tooling changes that might be necessary. Last-minute

costly changes are eliminated or minimized. The team meets regularly to provide any

necessary updates or changes in the production plan. This is time wisely spent and results in

an efficient and cost effective tool design. The design process is not as linear as it used to be.

Communication models between team members include e-mail and electronic transfer of

materials and may use of sophisticated technology such as teleconferencing. Team members

may consist of customers, designers, and builders in different locations that may take them

halfway around the world.

1.4 PART DRAWINGS

The tool designer receives a duplicate of the part geometry that will be used to make

the part many part prints are transmitted electronically and may include a solid model. The

solid model allows the designer to view the three-dimensional part geometry. The task of tool

design begins with a more complete understanding of part. A prototype, or a single

manufactured part used for evaluation purposes, can be made available. A prototype goes one



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more step beyond the solid computer model. The prototype, a single physical part provided

prior to formal production, is a valuable tool for understanding more complex part

geometrics. Prototypes are manufactured using conventional computer numerical control

(CNC) machine tools or some of the newer technologies such as stereo lithography and LOM

develop the part geometry using a system of layering the medium and solidifying or cutting

out that layer with a laser. The result is a solid object made one layer at a time where the

layers may be no more than .003 thick. Whether analyzing the prototype and part drawing or

just the part drawing, the designer must consider the following factors that directly influence

the design choices. These factors are:

Overall size and shape of the part

Type and condition of the material used for the part

Type of machining operation to be performed

Degree of accuracy

Number of pieces to be made

Locating and clamping surfaces

1.5 PRODUCTION PLAN

The production plan is an itemized list of the manufacturing operation and the

sequence of the operation chosen by process planning engineers. The production plan can

take many forms, depending on the needs of each company. At the least, it should include a

brief description of each machining operation and the machine tool designated for these

operations.

The tool designer also uses this plan to assist in the design. The production plan can

include the following:

Type and size of machine tool specified for each operation

Type and size of cutters specified for each operation.

Sequence of operations

Previous machining operations performed on the part



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In addition to the part drawing and production plan, the tool designer is informed

of the amount of time and money that is available to spend on design. Using this

information and a little creativity and experience, the tool designer begins to

study the design alternatives.

1.6 ALTERNATIVES

One of the first steps in problem solving is determining the alternative solutions. The

same process is used in tool design to ensure that the best method is chosen. During this

phase of design, tool designer must analyze all important information in order to answer the

following questions:

Should special tooling be used or existing equipment modified?

Should multiple-spindle or single –spindle machines be used?

Should the tool be single purpose or multipurpose?

Will the saving justify the cost of the tool?

What type of gauge, if any, should be used to check each operation?

Answering these question and others related to the specific task, the tool designer

develops alternative solution. From these alternative solutions, the most efficient,

dependable, and cost effective design is chosen.

1.7 REQUIREMENTS TO BECOME A TOOL DESIGNER

To perform the function of a tool designer, an individual must have the following

skills:

The ability to make mechanical drawings and sketches

An understanding of modern manufacturing methods, tools and techniques

A creative mechanical ability

An understanding of basic tool making methods

A knowledge of technical mathematics through practical trigonometry



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CAD drafting skills

File management

Electronic communication skills

Geometric dimensioning and tolerancing



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CHAPTER 2

JIGS AND FIXTURE



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2. JIGS AND FIXTURES

Jigs and fixture are production-work holding devices used to manufacture duplicate

parts accurately. The correct relationship and alignment between the cutter, or other tool and

the workpiece must be maintained. To do this, a jig or fixture is designed and built to hold,

support, and locate every part to ensure that each is drilled or machined within the specified

limits.

Jigs and fixtures are so closely related that the terms are sometimes confused or used

interchangeably. The terms are sometimes confused or used interchangeably. The difference

is in the way the tool is guided to the work piece.

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

As a rule, small jigs are not fastened to the drill press table. If, however, holes above

.25 inch in diameter are to be drilled, it is usually necessary to fasten the jig to the table

securely.

A fixture is a production tool that locates, holds, and supports the work securely so

the required machining operation can be performed. Set blocks and feeler or thickness gauges

are used with fixtures to references the cutter to be work piece. A fixture should be securely

fastened to the table of 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.



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2.1 DIFFERENCES BETWEEN JIGS AND FIXTURES

JIGS FIXTURE

It holds, locates and guides the tool It holds and positions the work piece but does

not guide the tool.

Jigs are designed for quicker handling

therefore they are lighter and clamping with

the table is not required.

They are meant for constraining motion and

heavier in construction and bolted rigidly on

machine tools

They have reference surfaces and points for

accurate alignment of parts and tools

They are generally designed for specific

purposes and they are shapes usually replicas

of work piece.

TABLE 2.1.1

2.2 ADVANTAGE OF JIGS AND FIXTURES

They eliminate the marking out, measuring and other setting tasks before

machining.

They save time and effort.

It reduces overall manufacturing cost by fully or partially automating the

process.

It increases machining accuracy.

They enable the production of identical parts which are interchangeable.

They enable the use of semi skilled workers.

They reduce expenditure on quality and finished goods.

It reduces operation labor.

It increase productivity.

2.3 APPLICATION AND CLASSIFICATION OF JIGS AND

FIXTURE

The obvious place for jigs and fixture is in mass production, where large quantity

output offers ample opportunity for recovery of the necessary investment. However, the



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advantage in the use of jigs and fixture are so great, and so varied, that these devices have

also naturally found their way into the production of parts in limited quantities as well as into

manufacturing process outside of the metalworking industry. The many problems of

geometry and dimensions encountered within the aircraft and missile industry have greatly

accelerated the expanded use of jigs and fixtures.

Within the machine shop, jigs and fixtures are used for the following operation:

boring, Broaching, Drilling, Grinding, Honing, Lapping, Milling, Planing, profiling, reaming,

Sawing, shaping, slotting, spot facing, tapping, and turning. A systematic master

classification of machining fixtures according to the characteristics of the operation is shown

in table 2.3.1

SURFACE MACHINING

Rotary motion Straight-line motion

Single-point cutter

lathe fixture Planing, Shaping and Slotting fixtures

Multiple-point cutter

Milling fixtures for circular feed

fixtures for circular Grinding

Milling fixtures for straight line feed

Broaching fixtures

Surface –Grinding fixtures

Sawing fixtures

HOLE MACHINING

Single-point cutter Multiple-point cutter

Boring jigs Drill jigs

Tapping jigs

Reaming jigs

Honing and lapping jigs

TABLE2.3.1

Outside of the machine shop, jigs and fixtures may be applied to advantage for:

Assembling, Bending, Brazing, Heat treating, Inspecting, Riveting, Soldering, Testing, and

Welding. Such fixtures can be characterized as manual work fixture and may be classified as

shown in table 2.3.2



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PURPOSE TYPE

Preparatory operations Layout fixtures

Metallurgical operations Heat-treating fixtures

Annealing fixtures

Joining operations Welding fixtures

Soldering and brazing fixtures

Riveting fixtures

Wire-stitching fixtures

Crimping fixtures

Assembly fixtures

Quality control inspection fixtures

measuring fixtures

pressure testing fixtures

TABLE 2.3.2

2.4 CLASSIFICATION OF FIXTURES

Machining fixtures

Manual fixtures

Machining fixture

They are used during product processing stage. It depends on the type of machining

operation that is being performed on work piece.

Lathe fixture

Milling fixture

Grinding fixture

Boring fixture

Sawing fixture

Broaching fixture



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Manual work fixture

The names used to describe various types of fixtures are determined mainly by the

structure of the tool.

PLATE FIXTURE

These fixtures are made on plate with clamps.

ANGLE PLATE FIXTURE

Using these kinds of fixtures machining is done at the right angles to the

locators.

VICE JAW

With the help of these fixtures machining of small parts can be done.

INDEXING FIXTURE

These fixture are used for operations spaced evenly.

MULTISTATION FIXTURE

These fixture are especially used when machining is done with high speed and

production.

2.5 CLASSIFICATION OF JIGS

Boring jigs

Drilling jigs

Jigs can be further classified as:

OPEN JIGS

These jigs are used when machining is needed for more than one side of the work.

CLOSED JIGS

These jigs are used when machining is needed for one side of the work.



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Some specific jigs are:

TEMPLATE JIGS

These jigs are used when accuracy is needed.

PLATE JIGS

These jigs are used when accuracy is needed.

SANDWICH JIGS

Parts which are very thin and fragile are machined using sandwich jigs.

ANGLE PLATE JIGS

These jigs are used when machining is done at right angles to the locator.

BOX OR TUMBLE JIGS

This jig totally surrounds the part and it looks as a box

CHANNEL JIGS

These jigs are held on two sides and for machining third side.

LEAF JIGS

These jigs are provided with top cast for easier loading.



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INDEXING JIGS

These jigs are used to space the holes accurately.

MULTISTATION JIGS

They are used multiple speeds for more than one job.



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CHAPTER 3

HYDRAULIC SYSTEM



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Fluid power systems are made up of component groups containing parts

designed to perform Specific tasks. These component groups acts together to perform the

work desired by the system designer. The work may involve simple or complex tasks, but

the component groups perform specific system functions that are basic to all fluid power

systems.

3.1HYDRAULIC ACTUATING SYSTEM

FIG 3.1.0.1 BASIC COMPONENT OF HYDRAULIC SYSTEM

3.1a) ACTUATORS

Actuators are the components that convert the energy in the system fluid to

mechanical movement to perform the work for the system was designed. Cylinder and motors

are the two basic type of actuators used in fluid power systems. Cylinders provide linear

motion, while motors provide rotary movement. A variety of specially designed actuators

provide combination of these motions for specific applications.



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CYLINDER

A basic cylinder consists of a cylinder body, cylinder end caps, piston, piston rod, ports, and

seals, A closed chamber is produced in the cylinder body when the end caps are attached to

the body. The piston rod is attached to the piston and this assembly is located in the chamber

with the rod extending through one of the end caps. The closed chamber is divided into two

parts by the piston. Ports are located in each of the end caps. Appropriate seals are located

between the end caps and cylinder, piston and cylinder, and piston rod and end cap.

Forcing fluid into the cylinder through a port causes the piston rod to move out of the

cylinder on the extension stroke and back into the cylinder on the retraction stroke. This

produces linear motion for use in a machine.

FIG 3.1a.0.1

3.1b) MOTORS

Fluid power motors have many of the same basic design characteristics as pumps.

There are several different motor designs, ranging from simple to very complex. A basic

motor consists of housing, rotating elements, power output shaft, ports, and seals. The

housing provides a closed chamber to retain system fluid. The rotating elements divide the

housing chamber into intake and Outlet sections. The power output shaft is attached to the

rotating elements. Ports are provided in both the intake and outlet sections of the housing

chamber. Seals are provided to prevent leakage of fluid between the housing and rotating

elements and between the housing and the power output shaft.



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Forcing fluid into the motor causes the rotating elements to turn the power output

shaft. This produces rotary motion for use in a machine.

3.1c) RESERVOIR

The reservoir is the storage area for oil in a hydraulic system. The unit may be a

simple box like container or it may be a cavity in the base of a machine that serves to store

system fluid. A pneumatic system uses a receiver to store compressed air. This unit is usually

a cylindrical tank. The reservoir or receiver also plays other important roles in system

operation, such as contributing to system temperature control and fluid cleaning.

3.1c) CONDUCTORS

Conductors confine the system fluid as it is distributed throughout the system. Pipes,

tubes, and hoses are the three general types of conductors used in fluid power systems.

Special manifolds consisting of multiple passageways are used in systems where space and

weight are important Factors. The type of conductor used depends on the type of fluid,

system pressure, required component movement, and the environment in which the system

operates. This group of components also includes a variety of fittings and adapters to allow

easy assembly while assuring a system free from leaks.

Pipes are rigid conductors commonly used in stationary fluid power installations.

Piping is lower in cost than most other conductors with comparable specifications. The pipe

designed for use in fluid power systems is made from mild steel. It is manufactured as

seamless.

Tubes are similar to pipes, but are considered to be semi-rigid. Tubing for use as a

conductor in fluid power installations is made from thin steel. Tubing is lightweight, easy to

install, has a good appearance, and develops few leaks during system operation, Figure



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FIG 3.1c.0.1

Hoses are flexible conductors made from layers of materials. They contain system

fluid while withstanding system pressure and allowing easy movement of system

components. Hose construction includes an inner tube to contain the fluid, a middle section of

braided fabric or wire to withstand pressure, and an outer layer of material for protection

from dirt and abrasion, Figure

Hydraulic hose is made using multiple layers of FIG 3.1C.0.2

Synthetic rubber, braided fabric, and wire to provide a

Flexible high pressure conductor.

Fittings and adapters are needed to assemble conductors and other system

components. Fittings are considered the parts needed to assemble similar conductors, while

adapters are required when connecting different types of conductors or when attaching

conductors to system components.

3.1d) DIRECTION CONTROL VALVES

Directional control valves regulate the direction of actuator movement by creating

flow pathsto and from the actuator. A basic control valve consists of a valve body, internal



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elements that open and close fluid flow paths through the valve, an external device for

shifting the internal elements, ports to connect the valve to the system, and sealing devices to

prevent fluid leakage,

FIG 3.1d.0.1

When a directional control valve is used in a fluid power system, it directs fluid to one

side of the internal elements of an actuator, causing the actuator to move in one direction.

Fluid from the other side of the actuator’s internal elements flows through the valve and is

returned to the system (or atmosphere). Shifting the valve creates a flow path to the opposite

side of the internal elements of the actuator, causing the actuator to move in the opposite

direction.

3.1e) PRESSURE CONTROL VALVES

Pressure control valves regulate pressure in the system or a part of the system. These

components are used to control maximum system pressure, limit pressure in a part of the

system, or delay the movement of an actuator until a desired pressure is reached. A basic

pressure control valve consists of a valve body, internal elements that control fluid flow

through the valve, an external device to allow adjustment of the valve, ports to connect the

valve to the system, and appropriate sealing devices.

FIG 3.1e.0.1



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In a hydraulic system, the basic pressure control device is a closed valve that does not

open to allow fluid to flow through it until a desired pressure is reached, When the system

reaches the desired pressure, the internal elements of the valve move opening a passageway

through the valve. Fluid that is not needed to maintain the desired system pressure then

passes through the valve to a lower-pressure section of the system. The amount of fluid that

passes through the valve varies according to the amount of fluid needed to maintain the

desired system pressure. The smaller the amount of fluid needed to maintain the desired

system pressure, the higher the flow through the valve to the low-pressure section of the

system.

3.1f) FLOW CONTROL VALVE

Flow control valves regulate fluid flow in the, system or a part of the system. These

valves control the volume of flow by varying the size of an orifice in the passageway through

which the system fluid flows. A basic flow control valve consists of a valve body, internal

elements to control flow through the valve, an external mechanism to allow adjustment of the

valve, ports to connect the valve into the system, and appropriate seals to prevent fluid

leakage.

The passageway in a basic flow control valve provides an open route for fluid flow

through the valve. The volume of fluid flow through the valve is controlled by the size of the

passageway opening. Adjusting the size of the passageway varies the flow volume, which

controls the speed of system actuator(s). The larger the opening, the higher the volume of

flow through the valve and the higher the speed of the actuator(s).

3.1f.0.1



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CHAPTER 4

DESIGN



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4. DESIGN OF FIXTURE

Outline of fixture planning process

fig 4.1

Part details

Operation

classification

Equipment

selection

Operator

criteria

Select

pertinent

items

Select

pertinent

items

Select

pertinent

items

Select

pertinent

items

Initial design concepts

Discarded

ideas

Preliminary fixture

design

Cost analysis and

evaluation

Primary fixture

design

Alternate 1

fixture design

Alternate 2

fixture design

Evaluate and final decision

completion of design, execution of shop drawings



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4.1 PRINCIPLE OF FIXTURE DESIGN

LOCATION

It should ensure that work is given in the desire constraint and proper location of

the part should be ensured.

CLAMPING

The clamper should be positioned to give the best resistance to cutting forces.

CLEARANCE

The clamper should be positioned to give the best resistance to cutting forces.

HANDLING

For easier movements of the fixture, it should be made as light as possible.

GENERAL

To avoid complications in the design it should be kept simple to minimize the

cost.

The fixture should provide space for coolant circulation.

The fixture should have enough stability and rigidity.

4.2 LOCATORS

Location refers to the establishment of the desired relationship between the work

pieces and jigs and fixture. Correct location influences the accuracy of finished products. Jigs

and fixture are so designed that all possible movements of the components must be restricted.

The determination of the location points and clamping of the work piece serves to

restrict the movement of the components in any directions while setting it alt the correct

position relative to the jig. The location points are first determined by finding out possible

degree of freedom of work piece which is then restricted by suitable arrangement, which

serves as locations.



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4.3TYPES OF LOCATORS

FLAT LOCATOR.

They are used for locating flat machined faces of the component. The component

is directly placed on the machine surface of the jig body and undercut provided help in swarf

removal.

CYLINDERICAL LOCATOR.

This is used for locating the components having drilled holes. The cylindrical

locators fitted on the jig body are inserted in the drilled hole of component to locate in

position.

4.4 CLAMPING

It serves the purpose of holding the work piece securely on jigs and fixtures

against the cutting forces to achieve efficient clamping.

FACTORS TO BE CONSIDERED IN CLAMPING

The clamping pressure should not be too much.

The clamping pressure should be exerted on the solid support of the work to avoid

distortion.

The movement of work must be limited.

The clamps must be simple.

The design must be as so as to enable the clamp to be completely lifted out of

work while unloading.

It should prevent the wear of the clamping faces.

TYPES OF CLAMPING ‘

SCREW CLAMP

These types of clamps are used to grip the work on its edges. This type of

clamping arrangement enables the top surfaces of work to be machined without any



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difficulty. But longer time is required for clamping and unclamping the work. Also the

clamping force changes from component to component.

FLAT CLAMP

This type of clamp supports work by clamp face which is pressured against the

work by tightening the work piece.

PIVOTED CLAMP

This type of clamp is eliminates the use of spanner for clamping purpose. The

work can be gripped quickly by rotating the screw which actuates the pivoted clamp on the

face of the work.

EQUALIZING CLAMP

This type of clamp is employed to exert equal pressure on the two faces of work

by two legs of the clamp.

LATCH CLAMP

It is employed to clamp a work by a latch and pivoted leaf. The leaf is closed on

the work and keeps its position by latch. The clamping pressure is not high but loading and

unloading arrangement is quick.

SWING PLATE CLAMP

It is used for quick loading and unloading purpose for light jobs. The clamp is

operated by swing the swing the plate in the position and locking it by turning.

WEDGE CLAMP

It is employed to grip the work by a wedge block. The wedge block grips the work

against the fixed bottom fitted on the other end of the jig.

MAGNETIC CLAMP

It is employed to grip the work by using magnetic field. It can only be used clamp

magnetic materials. Ferro-magnetic materials can be easily clamped and held in position.



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4.5 DESIGN

The successful design of fixture is the result of designer’s ability to analyze all the

milling operation to perform on the component to incorporate design features in the fixture

that offset or eliminate the difficulties or problem associated with such operations.

4.5.1 GENERAL CONSIDERATION IN DESIGN

TYPE OF LOAD AND STRESSES CAUSED BY THE LOAD

The load on the component may act in several ways due to which internal stresses

are developed. Based on these stresses one has to fix the dimensions of components

so as to withstand the stresses.

SELECTION OF MATERIAL

It is essential to have a thorough knowledge of the properties of the material and

behavior under working condition. Some of the important characteristics of material

are strength, durability, resistance to heat corrosion and so on.

FROM AND SIZE OF THE PARTS

Form and size of the parts are based on our judgment. The stresses induced on the

parts must be within the availability and its assembly with its meeting parts.

CONVENIENCE AND ECONOMICAL FEATURES

The operation which the component has to perform is studied carefully and cost

for manufacturing is optimized.

USE OF STANDARDS PARTS

The use of standard parts is closely related to cost because the cost of standard or

stock parts is only a fraction of cost of similar parts made to order.



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4.5.2 MAIN CONSIDERATION IN DESIGN

The primary function of the fixture is to establish proper relative position of the

parts being milled and maintain it through the process.

The fixture should produce parts within the specified tolerance with little or no

distortion.

The fixture should have adequate clearance between the work pieces without

jamming the fixture,

The fixture should be comfortable for the worker to operate it in the height and

length etc.

4.5.3 DESIGN APPROACH

First the overall design of fixture is decided based on the peripheral geometry of

the component being machined. As there are no formula to determine the various

design parameters i.e., height and shape of the fixture, economic analysis is done to

find out these parameters ergonomically analysis is a means of fitting a worker to a

job to find out how much he is comfortable with the job.

When machining operation is being carried out on the fixture, considerable amount of

stresses are developed due to thermal expansion and contribution of the work piece

on the fixture. The clamp should be designed taking thermal stresses into account.

However the magnitude of thermal stresses is negligible compared to the stress

induced due to impact load considered.



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CHAPTER 5

PROJECT DESCRIPTION



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PROJECT DESCRIPTION

CURRENT OPERATING PRODECURE

the initial assembly is made in one fixture and transporting for torque the bolts

The assembled part is placed on ring gear which is placed on another fixture



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By clamping to the fixture the torquing operation is carried out.

The assembled differential is transporting for further operation



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TIME ESTIMATION OF OPERATION USING CURRENT FIXTURE

operation time

Lifting flange form stored area to fixture 1 30sec

Placing on the fixture 1 30sec

Assembly the differential gears 480sec

Transporting the diff. case to fixture 1 30sec

Placing it on flange part 30sec

To torque bolts (8nos.) 10min

Transporting assembled in F1 to fixture 2 240sec

Lifting and placing gear on fixture 2 from store

area 2

60sec

Placing the assembly part on gear at f2 30sec

Clamping and unclamping time 5 min

To torque the bolts (26nos) 20 min

Total time 50.5+4=54.5 min

Number of worker involved in work 3



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DATA COLLECT FOR DESIGN OF FIXTURE



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COST OF MATERIALS:

Materials Cost in (Rs)

Mild steel 60/kg

EN8 75/kg

EN24 90/kg

EN19 80/kg

EN353 100/kg

EN36 125/kg

Aluminum 280/kg

Copper 750/kg

Brass 600/kg

EN31 90/kg

OHNS 90/kg



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COST OF OPERATIONS:

Operations Cost in (Rs)

Lathe 75/hr

Milling 100/hr

Drilling 50/hr

Heat treatment 30/kg

Stress relieving 10/kg

Blackening 8/kg

EDM Wire cut 250/hr

Grinding 60/hr



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PROPOSED DESIGN

We have design a single fixture for both to torque and to assemble differential gear cage.

The below show the estimated time of operation in our proposed fixture design.

Time estimation of operation in proposed fixture.

operation time

Lifting flange form stored area to fixture 30sec

Placing on the fixture 30sec

Assembly the differential gears 480sec

Transporting the diff. case to fixture 30sec

Placing it on flange part 30sec

To torque bolts (8nos.) 5min

Transporting assembled in F1 to fixture 2 0

Lifting and placing gear on fixture from store

area

60sec

Placing the assembly part on gear at fixture 0

Clamping and unclamping time 3

To torque the bolts (26nos) 15 min

Total time 34+3=37min

Number of worker involved work 2



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PROPOSED FIXTURE

+



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SECTION VIEW OF PROPOSED FIXTURE



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FREE BODY DIAGRAM

The figure show free body diagram, here we get clearly picture of which part

share/bear the load on it from the main forces.

Clamping force on production = 8000N

Force on the power screw = 12500N (i.e. 8000+4500)

Force on the bottom beam of frame ≈ 15000N (8000+4500+wgt power screw)

Force on shaft on each ≈ 12500N (wgt of whole frame of fixture

including product )

The power screw is subjected = 900bl-ft torque

4kN each

Clamping force exert

by hydraulic cylinder

4.5kN of product

weight.

i.e

450kg×9.81=4.5KN

Total force on the

beam ≈ 15KN



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STRESS ANALYSIS OF PARTS



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DESIGN OF HYDRAULIC CIRCUIT

In our proposed design we two identical cylinder to clamp the work piece it should be

actuates at same time interval and with same velocity, so it must synchronized using parallel

hydraulic synchronization circuit as shown below.

The above figure show hydraulic circuit for proposed

fixture which contain two cylinder which synchronized by

connecting it in parallel it is control by 4/3 DCV operated

by solenoid control. The cylinder locking is done by pilot

operated check value and pump unloading done

using check value as show in fig.

P M



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CALCULATION

FORCE REQUIRED (F) = 4KN

LENGTH OF WORK STROKE (L) = 90mm

SPEED OF PISTON AND ROD ASSEMBLY= 30mm/sec

F=PA

BORE OF PISTON SELECTED=63mm (from STD size)

ROD DIAMETER=28mm

TYPE OF PISTON: double acting welded head end rectangular flange cylinder

P=F/A =4000/∏×31.52

=1.283N/mm2 =12.83bar

Extension force,

Fest=P×AP

=1.283×∏×31.52

=4000N

Input flow rate,

Qin = Vest×Ap

= 30×∏×31.52

= 93517.35mm3/sec = .093ltr/sec

Output flow rate

Qout= Vext×Ar

= 30×∏×(31.52-14

2)

= 75044.794mm3/sec =.075ltr/sec

PUMP SELECTION

Type: GEAR PUMP

Displacement: 100cc

Motor speed : 1000rpm



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Motor efficiency =85%

Load pressure = 30bar

Torque on shaft= pump displacement × load pressure /20×∏=471Nmm

Power in=motor speed × pump displacement × load pressure/(600×motor efficiency)=

5.8kw

Power out= motor speed× pump displacement × load pressure /600=5kw



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CHAPTER 6

MATERIAL SELECTION



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Material selection:

When selecting materials for manufacturing a component. The following factors are

to be considered.

Mechanical properties like density, specific heat, thermal expansion and conductivity,

melting point.

Physical properties like density, specific heat, thermal expansion and conductivity,

melting point.

Chemical properties like oxidation, corrosion, general degradation of properties and

flammability of materials.

Cost and availability of raw and processed materials are major manufacturing.

Reliability of supply and demand also affects cost.

Time and service depended factors like wear, fatigue, creep and dimension

considered. friction and corrosion can shorten a products life.

Engineering steels

Steel is an alloy of carbon and iron, with carbon dictating the hardness and grade of

engineering steel. Carbon has consistently proved itself to be the most cost effective alloying

material for iron; however, other materials such as tungsten or manganese can also be used to

bring certain properties. Varying the amount of alloying elements in engineering steel

controls properties such as it’s hardness, ductility and tensile strength.

EN8 Medium carbon engineering steel

EN9 Medium carbon engineering steel (high carbon than EN8)

EN19 Chromium molybdenum high tensile engineering steel. Usually supplied in ‘T’

condition

EN24 Nickel chromium molybdenum high tensile steel. Usually supplied in ‘T’

condition.

EN30B 4¼ nickel steel.



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EN31 High carbon alloy steel.

EN32 Low case hardening engineering steel.

EN36 Nickel chromium carburizing engineering steel.

EN40B 3% chromium molybdenum nitriding steel.

EN41 Chromium aluminum nitriding steel.

EN43 Medium carbon spring steel specification.

EN45 silicon manganese alloy spring steel.

EN47 Chromium vanadium spring steel.



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BILL OF MATERIAL



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ITEM NO. PART NUMBER MATERIAL QTY.

1 support pillar STD 2 RT

12”×8”

2 base plate MS 2

3 support block MS 2

4 shaft EN19 1

5 outside side channel

STD 2 C 7 × 9.8

6 inside side

channel STD 2

C 7 × 9.8

7 outside bottom channel

STD 1 C 7 × 9.8

8 inside bottom channel

STD 1 C 7 × 9.8

9 shaft2 EN19 1

10 bottom bush EN8 1

11 power screw EN8 1

12 nut EN19 4

13 locator cum clamp

jaws EN8 1

14 bolt EN19 1

15 upper frame EN8 1

16 hycylinder

2

17 M12-1.75 x 45 STD 8

18 piston

2

19 sideangle plate MS 4

20 product

1

21 clamp bolt EN19 1

22 ring EN8 1

23 Pu pad PU 2



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CHAPTER 7

FABRICATION



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FABRICATION

Fabrication is defined as the process of converting raw material into finished products.

PROCESS CHART FOR FABRICATION

RAW MATERIAL

FABRICATION

FINISHED PRODUCTS

OBJECTIVE

The main objective of fabrication is to maintain all design consideration and

specification as per design and drawing.

FABRICATION OF FIXTURE

COLLECTION OF MATERIALS

FABRICATION OF STRUCTURE

FABRICATION OF PLATES, PINS AND LOCATORS

ASSEMBLY OF STRUCTURE TO FROM FIXTURE



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Operation involved in fabrication

1. Flame cutting

2. Deburring

3. Face milling

4. Welding

5. Drilling and boring

6. Turning and facing

7. Tapping

FLAME CUTTING

flame cutting uses an oxyacetylene flame to cut the metal plates. The required shape

is pre programmed using CNC machine. The shape of the profile is cut on the metal plate

with 1.5mm allowance around the perimeter for nozzle width.

DEBURRING

It is operation performed to remove the burrs. Burr is the extra unwanted material

which is formed when the metal surface is cut by flame cutting or machining. These burrs are

to be removed for proper surface finish on metal parts. The de-burring tool is a cylindrical

grinding wheel type, which rotates at high speed and removes the burr.

FACE MILLING

It is the operation performed by milling cutter to produce a flat machined surface

perpendicular to the axes of rotation of the cutter. Face milling is performed on faces of

those parts of the plastic fixture that belt with the component and table. A vertical milling

machine with cutter diameter 160mm having 8 teeth is used, the teeth are the inserts that can

be replaced when damaged or worn out. The peripheral cutting edges of the cutter do the

actual cutting, where as the cutting edges finish up the work by removing small amount of

material. The vertical milling machine used is so called because of the vertical positioning of

cutter spindle. The table movements are horizontal, transverse and vertical. The spindle can

be moved up and down to perform various operations.

WELDING

Welding is done in order to join two or more similar or dissimilar metal to that they

would be fixed firmly without breakage. The CO2 MIG welding all parts of the fixture. These

are welding process uses a consumable wire feeder. The CO2 gas which is used to prevent

the welds from oxidation is ejected from the welding gun.

DRILLING AND BORING

Drilling is the operation to produce cylindrical hole by removing metal by the edge of

the rotating cutting tool called drill. Radial drilling operation is performed on brackets and



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the channel of the fixture. Also the drilling operation is performed to produce slots in these

parts by the chain drilling operation which would serve for end milling operation to be easier.

Chain is a process by which a series of inline holes with a gap of 1mm between them is

produced. By performing this, the amount of material to be removed by end mill cutter to

produce a slot is very much reduced.

Boring is the process of enlarging the hole to get required dimension. The drilling

process cannot process cannot be used to drill holes of required dimensions. Therefore exiting

hole is enlarged to the diameter by boring.

TURNING AND FACING

Facing is the operation of machining the ends of work to produce the flat surface

square with the axis. This is also used to cut the work to the required length. The operation

involves feeding the tool perpendicular to the axis of rotation of work piece. A properly

ground facing tool is mounted in the tool holder in the post. A regular turning too may be

used for facing a large work piece.

TAPPING

It is a process of creating helical ridges. It is similar to thread cutting but the

difference between them is that in thread cutting helical ridges are formed on the outer side of

cylinder or conical rod whereas in tapping helical ridges are formed on the inner side of a

pre-bored hole of the component.



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CHAPTER 8

COST ESTIMATION



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Material cost

Total cost for material ≈ 74,000rs

ITEM

NO. PART NUMBER Material QTY.

Mass of

item

Cost for material

1 support pillar STD 2 68kg 68×2×70=9520rs

2 base plate MS 2 30kg 30×2×60=3600rs

3 support block MS 2 105kg 105×2×60=12600

4 shaft EN19 1 106kg 106×1×80=8480

5 outside side channel

STD 2 8kg 8×2×70=1120

6 inside side

channel STD 2

6.5kg 6.5×2×70=910

7 outside bottom channel

STD 1 14kg 14×1×70=980

8 inside bottom channel

STD 1 12.5kg 12.5×1×70=875

9 shaft2 EN19 1 112kg 112×1×80=8960

10 bottombush EN8 1 10kg 10×1×75=750

11 power screw EN8 1 38.5kg 38.5×1×75=2888

12 nut EN19 4 6.7kg 6.7×4×80=2144

13

locator cum

clamp jaws

EN8 1

52kg 52×1×75=3900

14 bolt EN19 1 25kg 25×1×80=2000

15 upper frame EN8 1 132kg 132×1×75=9900

16 hycylinder std 2 - -

17 M12-1.75 x 45 STD 8 400

18 piston std 2 - -

19 side angle plate MS 4 7kg 7×4×60=1680

20 product

1

21 clamp bolt EN19 1 20kg 20×1×80=1600

22 ring EN8 1 3.7kg 3.7×1×75=278

23 Pu pad PU 2 600×2=1200



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FRABRICATION COST

FLAME CUTTING COST

item

NO

DESCRIPTION DIMENSION TIME QUATITY TOTAL

TIME(min)

1 SUPPORT

PILLAR

12”×8”×36” 6min 2 12

2 BASE PLATE 10”×30”×.5” 5min 2 10

5 to 8 Frame channel

cutting

ref - 6 48

15 upper frame ref 20 min 1 20

19 Side angle plate ref 5min 4 20

Total flame cutting time 110≈2hrs

Cost per man hour for cutting is 350

Total man-hour cost =2×350=700rs

HACKSAW CUTTING COST

Total Hacksaw Cutting Hours = 7hrs

Cost per man hour for cutting = 200

Total man- hour cost for hack saw cutting=7×200=1400rs

Total cost for cutting =700+1400=2100



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TURNING COST

SL NO DESCRIPTION DIMENSION TIME QUATITY TOTAL

TIME

1 SHAFT REF 90min 2 180min

2 Power screw ref 150min 1 150min

3 nuts ref 20min 4 80min

4 Bottom bush ref 50min 1 50min

5 Clamping bolts ref 70 min 2 140min

6 Others ref 120min - 120min

Total turning time 12hrs

Cost per man-hour = Rs75/hr

Total man-hour cost= 12×75=900rs

THREAD CUTTING

SL NO DESCRIPTION TIME QUATITY TOTAL TIME

1 Power screw 80min 1 80min

2 bolt 50min 2 100min

Total thread cutting time 180min

Cost per man hour = Rs 75/hr

Total man hour cost= 3×75=225



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BORING COST


1 Bottom bush 15min 1 15min

2 Upper frame

clamping part

15min 2 30min

3 ring 5min 1 5min

4 nuts 10min 4 40min

5 Jaws cum locator

part

30min 1 30min

6 Supporting block 30min 2 60min

Total boring time 180min

Cost per man- hour for boring = 100

Total man-hour cost = 3×100=300

TAPPING COST


1 nuts 20min 4 80min


3 Upper frame

clamping part

30min 2 60min

Total time for tapping 170min≈3hrs

Cost per man-hour for tapping =100

Total man-hour cost = 100×3=300Rs



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DRILLING COST



2 ring 5min 1 5min

3 Upper frame 60min 1 60min

4 Supporting block 30min 2 60min

5 nuts 5min 4 20min

6 other 30min 30min

Total drilling time 190min≈3.25hrs

Cost per man-hour for drilling= 50

Total man-hour cost =3.25×50≈170

MILLING COST

Cost per man-hour for milling=100

Total man-hour cost=2×100=200

WELDING COST

Cost per man-hour for welding=Rs.150

Total man-hour cost=20hrs×150=3000

COST FOR ASSEMBLY

Cost per man/day =200

Total cost for assemble it =2×200=400

Total cost for fabrication of proposed fixture is 7595rs



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TOTAL COST ESTIMATION

particulars description COST(Rs)

Material cost 74000

Fabrication cost 7595

Motor cost 1pcs 4000

Hydraulic system 12000

Gear reducer 1pcs 3000

Total Cost in Rs 100595



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CONCLUSION • It reduces production time by 47% compared to current fixture.

• It reduces the number of workers involved in production

process.

• It saves floor space of about 50% compared to current fixture.

• It’s eliminates movement of part during assembly.



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DETAIL DRAWINGS



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BIBILOGRAPHY Jig and Fixture Design Manual by ERIK KARL HENRIKSEN.

Jig and Fixture Design by EDWARD G. HOFFMAN

http://www.g-w.com/PDF/SampChap/60525_0816_Ch02.pdf

A Textbook of Machine Design by R.S KHURMI AND J K GUPTA

Hydraul ic AND Pneumat ic Cy l inders by D.J .DUNN

http://www.westyorkssteel.com

http://www.precisehydraulic.com/Hydrodynamics-Welded-

cylinders.pdf

http://www.g-w.com/PDF/SampChap/60525_0816_Ch02.pdf

http://www.westyorkssteel.com/

http://www.precisehydraulic.com/Hydrodynamics-Welded-cylinders.pdf

http://www.precisehydraulic.com/Hydrodynamics-Welded-cylinders.pdf



Contents COMPANY PROFILE ........................................................................................................................... 1

ABOUT THE COMPANY ........................................................................................................................ 2

HISTORY .............................................................................................................................................. 3

COMPANY VISION ............................................................................................................................... 4

PRODUCTS ........................................................................................................................................... 4

TYPES OF PRODUCTS ........................................................................................................................... 5

SINGLE DRIVE AXLES ............................................................................................................... 5

TANDEM DRIVE AXLES ............................................................................................................ 5

NON DRIVE AXLES ..................................................................................................................... 5

QUALITY OBJECTIVES .......................................................................................................................... 6

QUALITY: ...................................................................................................................................... 6

HUMAN RESOURCES DEVELOPMENT: .................................................................................. 6

COMPETITION: ............................................................................................................................ 6

FINANCIAL PERFORMANCE: ................................................................................................... 6

ENVIRONMENT & SAFETY: ...................................................................................................... 6

FEATURES ............................................................................................................................................ 7

CUSTOMERS ........................................................................................................................................ 7

CHAPTER 1 ........................................................................................................................................... 8

INTRODUCTION TO TOOL DESIGN1.TOOL DESIGN ........................................................................ 8

1.TOOL DESIGN ....................................................................................................................................... 9

1.1 TOOL DESIGN OBJECTIVES ............................................................................................................ 9

1.2TOOL DESIGN IN MANUFACTURING .............................................................................................. 9

1.3 PLANNING THE DESIGN ............................................................................................................... 10

1.4 PART DRAWINGS ......................................................................................................................... 10

1.5 PRODUCTION PLAN ..................................................................................................................... 11

1.6 ALTERNATIVES ............................................................................................................................. 12

1.7 REQUIREMENTS TO BECOME A TOOL DESIGNER ....................................................................... 12



CHAPTER 2 ......................................................................................................................................... 14

JIGS AND FIXTURE ........................................................................................................................... 14

2.1 DIFFERENCES BETWEEN JIGS AND FIXTURES .............................................................................. 16

2.2 ADVANTAGE OF JIGS AND FIXTURES ........................................................................................... 16

2.3 APPLICATION AND CLASSIFICATION OF JIGS AND FIXTURE ........................................................ 16

2.4 CLASSIFICATION OF FIXTURES ..................................................................................................... 18

Machining fixture .......................................................................................................................... 18

Manual work fixture ..................................................................................................................... 19

2.5 CLASSIFICATION OF JIGS ............................................................................................................. 19

CHAPTER 3 ......................................................................................................................................... 22

3.1HYDRAULIC ACTUATING SYSTEM ................................................................................................. 23

3.1a) ACTUATORS ..................................................................................................................... 23

3.1b) MOTORS ............................................................................................................................. 24

3.1c) RESERVOIR ....................................................................................................................... 25

3.1c) CONDUCTORS .................................................................................................................. 25

3.1d) DIRECTION CONTROL VALVES ................................................................................... 26

3.1e) PRESSURE CONTROL VALVES ..................................................................................... 27

3.1f) FLOW CONTROL VALVE ................................................................................................ 28

CHAPTER 4 ......................................................................................................................................... 29

DESIGN4. DESIGN OF FIXTURE ............................................................................................................ 29

4. DESIGN OF FIXTURE .......................................................................................................................... 30

4.1 PRINCIPLE OF FIXTURE DESIGN ................................................................................................... 31

LOCATION .................................................................................................................................. 31

CLAMPING .................................................................................................................................. 31

CLEARANCE ............................................................................................................................... 31

HANDLING ................................................................................................................................. 31

GENERAL .................................................................................................................................... 31

4.2 LOCATORS ................................................................................................................................... 31

4.3TYPES OF LOCATORS .................................................................................................................... 32

4.4 CLAMPING ................................................................................................................................... 32

FACTORS TO BE CONSIDERED IN CLAMPING ................................................................... 32

4.5 DESIGN ........................................................................................................................................ 34



4.5.3 DESIGN APPROACH ......................................................................................................... 35

CHAPTER 5 ......................................................................................................................................... 36

PROJECT DESCRIPTION ................................................................................................................... 36

CURRENT OPERATING PRODECURE .................................................................................................. 37

TIME ESTIMATION OF OPERATION USING CURRENT FIXTURE ................................... 39

DATA COLLECT FOR DESIGN OF FIXTURE ........................................................................ 40

PROPOSED DESIGN ........................................................................................................................... 43

PROPOSED FIXTURE ................................................................................................................ 44

SECTION VIEW OF PROPOSED FIXTURE ............................................................................. 45

STRESS ANALYSIS OF PARTS ................................................................................................ 47

DESIGN OF HYDRAULIC CIRCUIT ........................................................................................ 50

CALCULATION .................................................................................................................................... 51

CHAPTER 6 ......................................................................................................................................... 53

MATERIAL SELECTION ................................................................................................................... 53

Material selection: ............................................................................................................................ 54

Engineering steels ............................................................................................................................. 54

BILL OF MATERIAL ............................................................................................................................. 56

CHAPTER 7 FABRICATION ............................................................................................................. 58

FABRICATION .................................................................................................................................... 59

OBJECTIVE ......................................................................................................................................... 59

FABRICATION OF FIXTURE ................................................................................................................. 59

Operation involved in fabrication ..................................................................................................... 60

FLAME CUTTING ...................................................................................................................... 60

DEBURRING ............................................................................................................................... 60

FACE MILLING .......................................................................................................................... 60

WELDING .................................................................................................................................... 60

DRILLING AND BORING .......................................................................................................... 60

TURNING AND FACING ........................................................................................................... 61

TAPPING ...................................................................................................................................... 61

CHAPTER 8 ......................................................................................................................................... 62

COST ESTIMATION ........................................................................................................................... 62

FLAME CUTTING COST ........................................................................................................... 64



HACKSAW CUTTING COST ..................................................................................................... 64

TURNING COST ......................................................................................................................... 65

THREAD CUTTING .................................................................................................................... 65

BORING COST ............................................................................................................................ 66

TAPPING COST .......................................................................................................................... 66

DRILLING COST ........................................................................................................................ 67

MILLING COST .......................................................................................................................... 67

WELDING COST ......................................................................................................................... 67

COST FOR ASSEMBLY ............................................................................................................. 67

TOTAL COST ESTIMATION ................................................................................................................. 68

CONCLUSION ..................................................................................................................................... 69

DETAIL DRAWINGS .......................................................................................................................... 70

BIBILOGRAPHY ................................................................................................................................. 80

Tool Design (Repaired)1

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