CONTENTS

Sr. No. Title Page No.

1. Profile of ThyssenKrupp Industries India

1
2. Description of Lathe Machine

1
2.1. Headstock

1
2.2. Tailstock

1
2.3. Tool Post

2
3. Description of Work Piece

6
4. Problem Statement 8
5. Slide Specifications

8
6. Design Approach

9
6.1. Approach 1: Varying the Tool Angle

9
6.2. Approach 2: Varying the Tool Height

17
6.2.1. Tool Angle = 25

17
6.2.2. Tool Angle = 30

26
7. Design of Fixture

35
7.1. Force Analysis

35
8 Manufacture of Fixture 40
8.1. Inspection 49
9. Cost Analysis

50
10. Design and Manufacture of Added Bases

53
11. Trials and Testing

54
12. Conclusion

55
13. References 56


1
1. Profile of ThyssenKrupp Industries India

ThyssenKrupp Industries India in the last four decades has grown to become
one of the most trusted names in the fields of Sugar Plant & Machinery, Open
Cast Mining & Bulk Material Handling Systems, Cement Plants & Machinery
and Steam Generating Plants. Today with strong foundations and access to
world class technology ThyssenKrupp Industries India's plantmaking
capabilities are helping the industry become competitive world over.
ThyssenKrupp Industries India's strategic vision as an EPC Contractor to
execute turnkey projects is derived from its core strength of integrated
engineering expertise & automation in manufacturing backed by an excellent
team of project executives.

The company firmly believes in delivering total customer satisfaction spanning
from concept to commissioning to after sales service.

ThyssenKrupp Industries India's highly competent project management
capabilities are a result of its tradition of anticipating and fulfilling specific
customer requirements. A highly qualified team of engineers and technicians,
supported by the most modern IT infrastructure ensures the brand of quality,
ThyssenKrupp is known for worldwide. The emergence of a true market
leader speaks volumes about the world class technology inherent in the
company's products. The company's nationwide branch network along with
the support of ThyssenKrupps global establishments enables it to meet the
needs of customers on time.

2. Description of Lathe Machine

2.1. Headstock

The headstock of the lathe machine is shown in fig 3.1. It has a cement
concrete foundation. The main chuck has eight T-slotted arms. A clamping
jaw is bolted to each independent arm. These jaws are used to clamp the
inner surface of the shell. The arms are bolted onto a gear which may be
meshed with a pinion. The power to rotate the work piece may be obtained
directly from a motor that drives the gear or from the pinion to achieve
appropriate speed reduction. The headstock details are illustrated in Fig 2.1.

2.2. Tailstock

Similar to the headstock, the tailstock of the lathe has eight arms with T-slots
on which jaws are mounted. The tailstock is given axial motion with the help of
a hydraulic piston mechanism.



2
2.3. Tool Post

The lathe has a T-slotted bed as shown in fig 3.1. The tool posts are bolted on
this bed. The tool post structures employed were welded structures
comprising of mild plates. There also was a ladder welded onto the structure
to enable the machine operator to reach the operating height, which was
3.36metres from the ground level. These are illustrated in the photos below.





HEADSTOCK AND TOOL POST





3


HEADSTOCK, EXISTING TOOL POST AND BED



4


EXISTING TOOL POST


5


Fig 2.1: Headstock of Lathe Machine with Existing Tool Post


6
3. Description of the Work piece

The lathe machine described above is employed for performing turning, facing
and polishing operations on shells used in rotary cement mills. Depending on
the requirements of the customer, i.e. mill capacity and quality of clinker, the
diameter of the mill may vary from 2.8metres to 6.2metres.

The work piece is mounted on the lathe by the help of overhead cranes, and
the independent jaws on the arms of the headstock and tailstock are clamped
on to the inner surface of the hollow cylinder. The mounting of the work piece
on the lathe machine and the surfaces to be machined are shown in fig 3.1
below.

After the job is mounted, truing is performed prior to commencement of
machining to ensure that the axial and radial run-out of the job is within
permissible limits. The photograph below shows a rotary cement mill.




ROTARY CEMENT MILL


7



Fig 3.1: Mounting of Work Piece on Head Stock and Tail Stock


8
4. Problem Statement

Initially, there were two of the existing tool posts that were in use. These tool
posts would initially carry out the machining operations on the tyres for
bearing support and on completion of these machining operations, the
machining of the girth gear flange was carried out. It was planned to design
and manufacture a third fixture that would enable the machining of the girth
gear flange to be carried out simultaneously with machining of the tyres for
bearing support, by an operator standing on the ground level. Such a fixture
would save machining time as simultaneous machining would take place on
all three areas of the work piece to be machined. Also operation from the
ground level would ensure greater safety and ease of operation. The design
approaches employed to design the fixture are discussed bellow.

5. Slide Specifications

The slide that was to be mounted on the fixture is shown in the photograph
below. The slide is powered by a D.C. motor manufactured by Advani-
Oerlikon Ltd. The motor generates 2.25Kw (3hp) with a maximum rpm of
1500. The output shaft of the motor is coupled to a worm gearbox that has a
reduction ratio 25:1. The output shaft from the gearbox is coupled with a feed
rod. As shown below, there is one longitudinal slide and two cross slides. The
single point cutting tool used has a shank of 32mm by 32mm and is mounted
on the slide by employing a tool holder (not shown in photo).


MACHINING SLIDE


9
6. Design Approach

Although the lathe machine was used for machining rotary cement kiln shells
ranging from 2.8metres to 6.2metres in diameter, a majority of the work
pieces had diameters ranging from 4metres to 5.8metres. Hence for the sake
of comparison of various design approaches, work pieces ranging from
4metres to 5.8metres were considered.

After study of the machine, it was proposed that the reduction in operating
height be achieved by inclining the tool at a suitable angle to enable operation
from the ground. Throughout the design stage, it was kept in mind that the
single point must always be radial with respect to the cylindrical work piece,
i.e. the direction of the tool must always be passing through the axis of the
cylindrical work piece. The basic idea was to use a fixture in the form of an
inclined table on which the slide housing the tool holder and cutting tool will be
bolted. Machining work pieces of varying diameters by inclining the tool could
be achieved by the following two methods:
i. Varying the tool angle and keeping the tool height constant.
ii. Varying the tool height and keeping the tool angle constant.

6.1. Approach 1: Varying the Tool Angle

The first approach that was considered was to vary the angle of inclination of
the tool as per the variation in work piece diameter and keeping the height of
the tool tip constant. It was evident that for comfortable operation of the lathe
hand wheels by a person who is 1750mm in height, the hand wheels must be
situated at a height of 1200mm form the ground. Therefore the height of the
tool tip to be kept constant was so selected that the height of the hand wheel
be 1200mm from the ground. It was learnt that facing of the girth gear flange
on the shell was to be performed up to a maximum of 250mm depth of cut.
Hence to provide for this, the cross slide was taken back by 250mm while
preparing the layout drawings. Also an effort was made to keep the overhang
of the tool holder as small as possible to minimize vibrations and increase the
rigidity of the tool. The various dimensions were obtained and layouts were
prepared are as follows.




10

Fig 6.1 (a): Layout for Varying Tool Angle for 4000mm Work Piece



11

Fig 6.1 (b): Layout for Varying Tool Angle for 4200mm Work Piece


12

Fig 6.1 (c): Layout for Varying Tool Angle for 4400mm Work Piece


13

Fig 6.1 (d): Layout for Varying Tool Angle for 4600mm Work Piece


14

Fig 6.1 (e): Layout for Varying Tool Angle for 4800mm Work Piece


15

Fig 6.1 (f): Layout for Varying Tool Angle for 5100mm Work Piece


16

Fig 6.1 (g): Layout for Varying Tool Angle for 5200mm Work Piece


17
The layouts shown above prove that although this method may seem to be
convenient initially, it does pose some major problems. The machining of a
particular diameter work piece demands a specific value of tool angle. For
work pieces having 4metres to 5metres, the range of tool angles is from 23 to
29. Hence it follows that in order to accommodate the said range of work
piece diameters, a number of inclined tables giving various angles of
inclination to the slide, will have to be manufactured. Manufacturing so many
fixtures is not economical.

With the ever increasing variation in customer requirements now-a-days, it is
possible that work piece diameters smaller than 4metres or larger than
5.8metres be required to be machined. In such cases the tool angle may be
lesser than 20 or greater than 30. Needless to say for achieving these
values of tool angle, greater number fixtures must be manufactured.

Another interesting fact to be noted is that for work piece diameters lesser
than 3.5metres, the tool angle rises to above 40. At such high values of tool
angle there is a possibility of the slide overturning. In addition to this, for such
small work piece diameters, there will be a large overhang of the fixture over
the T-slotted bed, making the mounting unstable.

Hence, it is clear that variation in tool angle not only proves to be
uneconomical, but also does not show much scope for expansion and lacks
versatility.

6.2. Approach 2: Varying the Tool Height

After realizing the shortcomings of approach 1, it was decided to study the
case where the tool angle is to be kept constant. After taking the slide
dimension into consideration, analysis was carried out by keeping the tool
angle at 25 and 30.

6.2.1. Tool Angle = 25

The angle made by the cutting tool with respect to the horizontal was kept
constant at 25 and the height of the tool was varied. However, several
considerations were to be taken note of. The operating height from the
ground, though variable, had to lie between 800mm to 1400 to ensure
comfortable operation from ground level.

It was also required that the overhang of the fixture over the T-slotted base
Be kept minimal. As in the previous case, the cross slide was taken aback by
250mm to carry out facing operation on the girth gear flange. Lastly, the tool
holder must not be given too large an overhang, so as to keep vibrations in
check. Fig 5.2 below shows the layout diagrams for 25 constant tool angle


18

Fig 6.2 (a): Layout for Constant Tool Angle (25) for 4000mm Work Piece



19

Fig 6.2 (b): Layout for Constant Tool Angle (25) for 4200mm Work Piece


20


Fig 6.2 (c): Layout for Constant Tool Angle (25) for 4400mm Work Piece


21


Fig 6.2 (d): Layout for Constant Tool Angle (25) for 4600mm Work Piece


22

Fig 6.2 (e): Layout for Constant Tool Angle (25) for 4800mm Work Piece



23

Fig 6.2 (f): Layout for Constant Tool Angle (25) for 5100mm Work Piece


24

Fig 6.2 (g): Layout for Constant Tool Angle (25) for 5400mm Work Piece


25

Fig 6.2 (h): Layout for Constant Tool Angle (25) for 5800mm Work Piece


26
Due to the fact that the angle is kept constant at 25, only one fixture having
an inclination of 25 is sufficient. But additional packing (shown by hatched
lines) will have to be manufactured to raise the fixture and slide to the
required height. However, as shown in the layout, it was made possible to use
the same packing for machining two different diameters by adjusting the cross
slide position and the tool holder overhang. For a majority of the work piece
diameters, the operating height lies between comfortable limits. It is also
noteworthy that by keeping the angle at 25, the possibility of the slide
overturning is eliminated.

6.2.2. Tool Angle = 30

The design considerations similar to 6.1.1. were noted and layout diagrams
were prepared as shown in following fig 6.3.





27

Fig 6.3 (a): Layout for Constant Tool Angle (30) for 4000mm Work Piece


28

Fig 6.3 (b): Layout for Constant Tool Angle (30) for 4200mm Work Piece



29

Fig 6.3 (c): Layout for Constant Tool Angle (30) for 4400mm Work Piece



30

Fig 6.3 (d): Layout for Constant Tool Angle (30) for 4600mm Work Piece


31

Fig 6.3 (e): Layout for Constant Tool Angle (30) for 4800mm Work Piece


32

Fig 6.3 (f): Layout for Constant Tool Angle (30) for 5100mm Work Piece


33

Fig 6.3 (g): Layout for Constant Tool Angle (30) for 5400mm Work Piece


34

Fig 6.3 (h): Layout for Constant Tool Angle (30) for 5800mm Work Piece


35
Similar to case 6.1.1, due to the tool angle being equal to 30, only one fixture
having an inclination of 30 is required to be manufactured. Also the tool tip
height is lesser at 30 than at 25. This reduces the chances of vibrations.
However the larger angle compromises this advantage by lacking the stability
achieved at lower tool angles. Also, the operating heights for a considerable
number of work piece diameters lie outside the comfortable limits.

Therefore, after comparing the advantages and disadvantages of the three
possibilities discussed in above, it was concluded that best performance and
comfort of operation could be achieved by keeping the angle constant at 25
and varying the tool tip height.

7. Design of Fixture

The inclined table was to be used to act as a base to the tool slide and give
the required inclination to the tool. It was decided to manufacture this table as
welded assembly. Before beginning the assembly, the thickness of the Mild
Steel (M.S.) pates that were available in the inventory, were found out. Using
available metal plates, the manufacturing drawings were prepared. The
material for the plates used was IS 2062 Grade A steel and the weld size
chosen was 8mm by 8mm fillet welds.

7.1. Force Analysis

The tangential cutting force for turning operation is given calculated as
P
z
= 6120N/v (Table 257, Machine Tool Design Handbook, C.M.T.I.)
Where N = Power at the spindle (kW)
v = Cutting speed (m/min)
N = UK
h
K

Q... (Table 257, Machine Tool Design Handbook, C.M.T.I.)

Where U = Unit power (kW/cm
3
/min)
K
h
= Correction factor for flank wear
K

= Correction factor for rake angle

Q = Metal removal rate (cm
3
/ min)

Work piece material: Mild Steel (hardness 125 B.H.N.)
Average Chip thickness = 1mm
Assume:
Rake angle = 0
Therefore,
U = 28kW/cm
3
/min (Table 269, Machine Tool Design Handbook, C.M.T.I.)
K
h
= 1.06 (Table 270, Machine Tool Design Handbook, C.M.T.I.)
Due to large diameter of work piece flank wear is ignored and hence,
K

= 1




36

Now metal removal rate is calculated by the formula:
Q = stv
Where, s = Feed per revolution
t = Depth of cut
v = Cutting speed

s = 0.4mm/rev for roughing and 0.1mm/rev for finishing
We will consider s = 0.4mm/rev for calculation purposes.

t = 3mm

v = Dn/1000
Where, D = Diameter of work piece
n = rpm

4000 < D < 5800
For calculation purposes we will consider maximum work piece diameter of
5800mm.
n = 4rpm
v = x 5800 x 4 / 1000
v = 72.88m/min

Therefore,
Q = 0.4 x 3 x 72.88
Q = 87.45cm
3
/min

N = UK
h
K

Q
N = 28 x 1.06 x 1 x 87.45
N = 2595.51kW

Therefore,
P
z
= 6120 x 2595.51 / 72.88
P
z
= 217954.46kgf
P
z
= 2137.4kN

Assuming nose radius of single point cutting tool to lie between 0.4mm to
0.8mm and approach angle x = 90, we have the relat ions:
P
y
/ P
z
= 0.3... (Table 274, Machine Tool Design Handbook, C.M.T.I.)
Where, P
y
= Thrust force
Therefore,
P
y
= 0.3 x P
z

P
y
= 0.3 x 2137.4
P
y
= 641.22kN



37

P
x
/ P
z
= 0.7... (Table 274, Machine Tool Design Handbook, C.M.T.I.)
Where, P
x
= Axial Force
Therefore,
P
x
= 0.7 x P
z

P
x
= 0.7 x 2137.4
P
x
= 1496.18kN

In addition to these cutting forces, the fixture must also withstand the weight
of the slide. The weight of the slide is approximately equal to 1ton.
The weight of the slide can be resolved in two directions: one in the direction
of the tangential force, and the other in the direction of the thrust force. Let
these two components of the weight be W
z
and W
y
respectively.
Therefore,
W
z
= Wsin65
W
z
= 1000 x 9.81 x sin 65
W
z
= 8890.88N or 8.89kN

W
y
= Wcos65
W
y
= 1000 x 9.81 x cos65
W
y
= 4145.88N or 4.15kN

Therefore the total force acting on the fixture in the tangential, radial and axial
directions can be calculated as:
F
z
= P
z
+ W
z

F
z
= 2137.4 + 8.89
F
z
= 2146.3kN

F
y
= P
y
+ W
y

F
y
= 641.22 + 4.15
F
y
= 645.37kN

F
x
= P
x
= 1496.18kN

Now, the radial force F
x
will act upon the support plate and will be resisted by
the welds highlighted in Fig. 7.1. Now the shear stress acting on a fillet weld is
given by the following formula:
= P / 0.707hl
Where, P = tensile force on plates = F
y
= 645.37kN = 645370N
h = leg of the weld (mm) = 8mm
l = total length of the weld
= 1980mm
= 645370 / (0.707 x 8 x 1980)
= 57.63MPa


38
Now the maximum yield strength of IS 2062 Grade A steel is 240MPa >
57.63Mpa. Hence the design of the welds on the support plate ribs is safe.

Fig 7.1





The radial and tangential forces can be resolved in the horizontal and vertical
directions as shown in Fig 7.2. Now the horizontal force will act upon the
welds on the rear plate ribs as shown in Fig 7.3. The shear stress acting on
the welds is calculated as:






Fig 7.2


39





Fig 7.3

= P / 0.707hl
Where, P = tensile force on plates = F
h
= 1672.46kN = 1672460N
h = leg of the weld (mm) = 8mm
l = total length of the weld = 1600mm
= 1672460 / (0.707 x 8 x 1600)
= 184.81Mpa
Now the maximum yield strength of IS 2062 Grade A steel is 240MPa >
184.81Mpa. Hence the design of the welds on the rear plate ribs is safe.












40


8. Manufacture of Fixture

The detailed drawing (Sheet No. 2) was first submitted to the metal cutting
section, where the required sizes of M.S. plates were cut by CNC flame
cutting. The cutting was completed on 14 November 2009.


CNC Flame Cutting

On preparing the metal plates, the assembly was fit up according to the
assembly drawing (Sheet No. 1). The plates were attached by welding spots
at the joints by carbon arc welding. As the structure was a closed structure, it
was not possible to fit the whole structure and then weld it. After considering
ease of welding, the optimum process was decided. The entire process of
assembly of the fixture is illustrated in Process sheet

Once the entire welding of the assembly was completed, machining
operations were performed on the top and bottom surfaces of the fixture, M30
holes were machined in the top plate and 24 holes were machined in the
bottom plate.

The thickness of the top plate used was 32mm. It was seen that a single pass
weld was inadequate for the joint between the 32mm thick top plate and the
25mm thick rear plate. Hence a multi pass weld was employed for this
particular joint. The weld was made in 5 passes. Hence in order to prevent
localized heating and distortion of the plate as well as to remove the moisture
from the joint, this area was preheated prior to the weld. Preheating was
carried out using L.P.G. torch that was mounted on stand. The entire fit up
and welding of the fixture was completed on 17
th
November 2009. The
preheating and welding is shown in the photographs below. Table 8.1 below
shows the process sheet for the assembly of the fixture.


41
Table 8.1
ThyssenKrupp Industries India
ASSEMBLY PROCESS SHEET
Name: Turning, Facing and Polishing Fixture for Lathe Raw Material: IS 2062 Grade A
Quantity: 1 Sheet 1 of 6
Opn.
No.
Process Picture
Description Equipment
Process
Parameters
Measuring
Instrument
Remarks
10 -
Marking on
bottom plate
Chalk
powder and
string
- Metal scale
Refer SHEET NO.
1
20

Positioning and
fitting of two
rear plate ribs
by welding
spots
Carbon arc
welding and
safety
equipment
-
Metal scale
and tri square
Ribs to be fitted at
extreme positions
30

Locating and
fitting rear plate
by welding
spots
Carbon arc
welding and
safety
equipment
-
Metal scale
and tri square
Rear plate to be
located using
support of ribs and
prior markings
40

Locating and
fitting side
plates by
welding spots
Carbon arc
welding and
safety
equipment
-
Metal scale
and tri square
Check
perpendicularity of
side plates w.r.t.
bottom plate


42
ThyssenKrupp Industries India
ASSEMBLY PROCESS SHEET
Name: Turning, Facing and Polishing Fixture for Lathe Raw Material: IS 2062 Grade A
Quantity: 1 Sheet 2 of 6
Opn.
No.
Process Picture
Description Equipment
Process
Parameters
Measuring
Instrument
Remarks
50

Fitting
remaining rear
plate ribs by
welding spots
Carbon arc
welding and safety
equipment
-
Metal scale
and tri
square
Check
perpendiculari
ty of ribs w.r.t.
bottom plate
60

Placing top
plate over the
side plates and
fitting by
welding spots
Overhead crane,
Carbon arc
welding and safety
equipment
-
Metal scale,
tri square
and spirit
level
Check
whether angle
of top plate is
25
70 -
Removing burrs
and protrusions
from the surface
of top plate
Hand Grinder and
safety equipment
- -
Ensure
smooth
enough
surface for
subsequent
fitting of
support plate


43
ThyssenKrupp Industries India
ASSEMBLY PROCESS SHEET
Name: Turning, Facing and Polishing Fixture for Lathe Raw Material: IS 2062 Grade A
Quantity: 1 Sheet 3 of 6
Opn.
No.
Process Picture Description Equipment
Process
Parameters
Measuring
Instrument
Remarks
80


Welding multi-
pass weld on
joint between
rear plate and
top plate
CO
2
welding and
safety equipment,
LPG cylinder and
torch
5 Passes
Voltage = 220V
Current = 30A
Wire Feed Rate
= 9m/min
Preheat Time=
15min per pass
- -
90

Welding 8mm x
8mm fillet welds
on all joints on
internal joints on
side plates
CO
2
welding and
safety equipment
Voltage = 220V
Current = 30A
Wire Feed Rate
= 9m/min
- -
100

Fitting and
welding of front
plate and ribs
CO
2
welding and
safety equipment
Voltage = 220V
Current = 30A
Wire Feed Rate
= 9m/min
Metal scale
and tri
square
-


44
ThyssenKrupp Industries India
ASSEMBLY PROCESS SHEET
Name: Turning, Facing and Polishing Fixture for Lathe Raw Material: IS 2062 Grade A
Quantity: 1 Sheet 4 of 6
Opn.
No.
Process Picture Description Equipment
Process
Parameters
Measuring
Instrument
Remarks
110

Welding of
plates for
facilitating
transport of
fixture
CO
2
welding and
safety equipment
Voltage = 220V
Current = 30A
Wire Feed Rate
= 9m/min
- -
120

Machining of
M30 holes in top
plates
Boring machine,
Taps
Speed =
150rpm
Feed =
0.3mm/rev
Vernier
Calipers
Refer SHEET
NO. 1
130

Machining of
24mm holes in
bottom plate
Boring machine
Speed =
150rpm
Feed =
0.3mm/rev
Vernier
Calipers
Refer SHEET
NO. 1


45
ThyssenKrupp Industries India
ASSEMBLY PROCESS SHEET
Name: Turning, Facing and Polishing Fixture for Lathe Raw Material: IS 2062 Grade A
Quantity: 1 Sheet 5 of 6
Opn.
No.
Process Picture Description Equipment
Process
Parameters
Measuring
Instrument
Remarks
140

Machining top
contact surface
Boring machine
with vertical face
milling attachment
Speed =
150rpm
Feed =
1200mm/min
Depth of Cut =
3mm
roughing(2pass
es)
0.2mm finishing
(1pass)
Vernier
Calipers
-
150

Machining
support plate
Boring machine
with vertical face
milling attachment
Speed =
150rpm
Feed =
1200mm/min
Depth of Cut =
3mm
roughing(2pass
es)
0.2mm finishing
(1pass)
Vernier
Calipers
-


46
ThyssenKrupp Industries India
ASSEMBLY PROCESS SHEET
Name: Turning, Facing and Polishing Fixture for Lathe Raw Material: IS 2062 Grade A
Quantity: 1 Sheet 6 of 6
Opn.
No.
Process Picture Description Equipment
Process
Parameters
Measuring
Instrument
Remarks
`160

Machining
bottom contact
surface
Boring machine
with vertical face
milling attachment
Speed =
150rpm
Feed =
1200mm/min
Depth of Cut =
3mm
roughing(2pass
es)
0.2mm finishing
(1pass)
Vernier
Calipers
-


.


47

PREHEATING PRIOR TO MULTI-PASS WELDING


MULTI-PASS WELDING OF FIXTURE


48

WELDING OF FIXTURE


COMPLETION OF FILLET WELDS ON INNER JOINTS



49
8.1 Inspection:

Inspection results are tabulated in Table 8.2 below

Table 8.2
ThyssenKrupp Industries India
QUALITY ASSURANCE
FINAL INSPECTION REPORT
Job Description: Turning fixture for Lathe Machine Quantity: 1
Page 1 of 1
Date: 7-12-2009
The item was inspected and the following are the observations
Sr. No.
Required
Dimensions
Observed
Dimensions
Remarks
1.
Angle of the top
plate = 25
25
2.
Distance of top
plate location
point from front
edge of bottom
plate = 462 mm
462 mm
3.
Height for top
plate location
point = 526 mm
526 mm
4.
Distance of
support plate
from top plate
location point =
280 mm
280 mm
5.
Distance of M30
holes from top
plate location
point = 245 mm
245 mm







50
9. Cost Analysis:

The approximate weight of the fixture was calculated using the weights of the
plates used and the total weight of the filler material used. Now the total
volume of metal plates used was calculated to be 204999.41cm
3
. The plates
used were M.S. plates and the density of mild steel is = 7.86g/cm
3
.
V
1
= 204999.41cm
3

Therefore, the weight of the metal plates used was calculated as:
M
1
= V
1
x
M
1
= 204999.41 x 7.86
M
1
= 1611295.363g
M
1
= 1611.29Kg
The cost of IS 2062 Grade A steel is Rs 52 per Kg
Hence the raw material cost can be calculated as
C
1
= 52 x 1611.29
C
1
= Rs 83,787

Weld specifications:
CO
2
Welding at 220A 28V,
8 x 8 mm fillet welds
Filler Material: 1.2 mm FCAW wire fed at 9m/min

The total welded length in the fixture was calculated to be 53362mm.
The weld cross sectional area is
A = x 8 x 8 = 32mm
2

Total volume of filler material used is
V
2
= Total weld length x Weld cross section area
V
2
= 53362 x 32
V
2
= 1707584mm
3


The filler material used was M.S. wire coated with anti-oxidant coating. Hence
the weight of the filler material can be calculated as
M
2
= V
2
x
M
2
= 1707.584 x 7.86
M
2
= 13421.61g
M
2
= 13.42Kg
The cost of 1.2 mm FCAW wire is approximately Rs 90 per Kg
Therefore the total cost of filler material can be calculated as:
C
2
= 13.42 x 90
C
2
= Rs 1207.8

The total time taken for the fit up of the fixture was approximately 3hrs.
T
1
= 3hrs




51
Wire feed rate = 9m/min = 150mm/sec
Wire cross section area = /4 x 1.2
2
Wire feed rate in terms of volume of filler material per second is
F = 150 x /4 x 1.2
2
F = 170mm
3
/sec

Weld time can be calculated as
T
2
= V/F
T
2
= 1707584/170
T
2
= 10044.61sec
T
2
= 173.3min or 2hrs 53min

Based on timings recorded during the welding, it was found that on an
average, 50% of the weld time was required for slag removal and cooling of
the welded area.
Hence, Weld cooling and slag removal time
T
3
= 0.5 x T
1
T
3
= 0.5 x 173.3
T
3
= 86.65min or 1hr 27min

For welding the multi-pass weld, preheating was carried out for a period of
15min/pass. Therefore the time required for preheating is calculated as
T
4
= 15 x 5
T
4
= 75min or 1hr 15min

Taking into account the various stoppages in work such as replacement of
wire spool as well as relaxation of the worker, the contingency and relaxation
allowance must also be considered. This allowance is assumed to be 10% of
the weld time.

Therefore,
T
5
= 0.1 x 173.3
T
5
= 17min

The total time required to weld the fixture can be calculated as
T
w
= T
1
+ T
2
+ T
3
+ T
4
+ T
5

T
w
= 9hrs 52min

The wage rate of a welder is Rs 350 per day for an 8hour shift.
Therefore the total labour cost associated with the welding of the fixture can
be calculated as :
C
3
= 9.866 x 350/8
C
3
= Rs 432




52
The time required for drilling 30mm holes in top plate can be calculated as :
T
6
= d x N / s
r
x n
Where s
r
= Feed per revolution
n = rpm
d = depth of hole = 32mm
N = No. Of holes to be drilled
Therefore,
T
6
= 32 x 12 / 0.3 x 150
T
6
= 8.53min

Similarly, the time required for drilling 24mm holes in bottom plate can be
calculated as:
T
7
= d x N / s
r
x n
Where s
r
= Feed per revolution
n = rpm
d = depth of hole = 32mm
N = No. Of holes to be drilled
Therefore,
T
7
= 32 x 10 / 0.3 x 150
T
7
= 7.11min

Time required for milling top plate can be calculated as:
T
8
= L
m
/ s
Where L
m
= Length of machining
s = Feed per min
L
m
= 22050mm
s = 1200mm/min
T
8
= 22050/1200
T
8
= 18.375min

Similarly, Time required for milling support plate can be calculated as:
T
9
= L
m
/ s
Where L
m
= Length of machining
s = Feed per min
L
m
= 4800mm
s = 1200mm/min
T
9
= 4800/1200
T
9
= 4min

Similarly, Time required for milling bottom plate can be calculated as:
T
10
= L
m
/ s
Where L
m
= Length of machining
s = Feed per min
L
m
= 38700mm
s = 1200mm/min


53
T
10
= 38700/1200
T
10
= 32.25min

The total time required to machine the fixture is calculated as :
T
m
= T
6
+ T
7
+ T
8
+ T
9
+ T
10
T
m
= 70.265min or 1hr 10min or 1.17hrs
Cost operating the machine tool is Rs 1500 per hour
Hence, total machining cost is calculated as :
C
4
= 1.17 x 1500
C
4
= Rs 1,755

Therefore the total cost of the fixture is
C = C
1
+ C
2
+ C
3
+ C
4

C = Rs 87182

10. Design of Added Bases

In order to achieve the varying tool heights, the fixture must be placed at
suitable heights above the bed for machining smaller diameters. In order to
impart the required height to the tool, several added bases had to be
designed. The base heights required for machining various diameters are
given in Table 9.1.

Diameter to be Machined Required Height of Base
4000 393
4200 393
4400 303
4600 303
4800 197
5100 197
5400 106
5800 0
Table 9.1

For machining the 5400mm diameter work piece, the height of 106mm can be
achieved by placing blocks underneath the fixture and clamping. Hence three
bases had to be manufactured having heights 393mm, 303mm and 197mm.
The assembly and detailed drawings of the added bases have been shown in
Sheet Nos. 3 to 8.







54
11. Trials and Testing

On completion of manufacture of fixture trial run was conducted on 15
December 2009. It was observed that the speed reduction in the existing
system was not sufficient to obtain the required feed rate. As a result further
speed reduction was required and an additional speed reduction gearbox was
to be added.


TRIAL RUN

It was found that with the existing system, a feed of 8mm/min was obtained
when motor rpm was 350.
As the speed reduction is 25:1,

Feed rod rpm = Motor rpm / 25
= 350 / 25
= 14rpm
Hence, when feed rod rpm is 14, feed obtained is 8mm/min.
Now, the required feed rate was 0.4mm/rev for rough turning and 0.1mm/rev
for finishing.
Work piece rpm = 4
Therefore, required feed rate = 0.4 x 4 = 1.6mm/min




55
The gearbox used was a worm gearbox having reduction ratio of 15:1.
Now according to the new system when motor rpm is 350,
Feed rod rpm = 350 / 25 / 15 = 0.933
When feed rod rpm is 14, feed rate obtained is 8mm/min
Hence when feed rod rpm is 0.933, feed rate obtained will be
= 8 x 0.933 / 14
=0.533mm/min
= 0.133mm/rev
Therefore with the help of the additional gearbox, a feed rate of 0.133mm/rev
can be obtained. The additional gearbox used is shown is shown below.


ADDITIONAL GEARBOX

12. Conclusion

After addition of second gearbox the required feed rate was achieved
resulting in satisfactory performance of the fixture. The addition of the third
fixture enabled simultaneous machining operations to be carried out at both
the bearing support tyres as well as the girth gear flange. Such an integration
of the third machining process led to machining time reduction. Also the new
fixture was lighter in weight than its previous counterparts. As a result, there
was greater ease in setting up the operation and time required for non-value-
added activities was greatly reduced.


56


13. References

Production Technology, H.M.T.
An Introduction to Workshop Technology, W. Chapman
Westermann Tables for the Metal trade
Work Study, I.L.O.
Machine Tool Design and Numerical Control, N.K. Mehta
Process Engineering for Manufacturing, Eary and Johnson
Machine Tool Design Handbook, Central Machine Tool Institute