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Introduction
In this project, product that had been chosen is brake disc. To manufacture break disc, there are
several process of machining that need to be done but only one machining process will be
choose. The critical part processing of brake disc is the surface finishing and to done this
process, grinding fixture is required to get the excellent thickness and accuracy of the surface
finishing. This surface finishing of break disc is important for the efficiency of the break disc to
functioning. Braking system in all vehicles must be works in good condition to make sure the
safety of passenger. All things that had been decided of the product, part, process, material and
others must be justify and have a reasonable reason. A brief concept taking from researching
about some of the jigs and fixtures that already exists today and a new design of jig and fixture
for the part product processing has been made where it is able to increase accuracy and precision
of the machining and also reduce the load and unload process time.
Objective
The objective of this assignment is to familiarize the student with process selection issues
related to the design of jig and fixture. Students also need to identify material of the product and
collect all the detail information about the manufacturing process from raw material until the part
becomes a product. Moreover, all the design consideration of jigs and fixtures must be state and
illustrate the method of locating, supporting, clamping and guidance of cutting tool in jigs and
fixture to simplify the machining process. Student also need to justify the crucial of the process
related with it actual performance and cost.
All type of vehicle must have braking system to complete the working system complete. This
report is going to discuss further on braking system of motorcycle. Disc brakes were invented in
1902 and patented by Birmingham car maker Frederick William Lanchester. His original design
had two discs which pressed against each other to generate friction and slow his car down. It
wasn't until 1949 that disc brakes appeared on a production car though. Basically, braking system
is disc brake system consists of a brake disc, a brake caliper and brake pads. A disc brake is a
type of brake that uses calipers to squeeze pairs of pads against a disc in order to create friction
that retards the rotation of a shaft, such as a vehicle axle, either to reduce its rotational speed or
to hold it stationary. The energy of motion is converted into waste heat which must be dispersed.
Disc brakes are most commonly used for vehicle braking but they are applicable to almost any
rotating shaft. The different between car and motorcycle brake disc is the surface which is car
brake disc have no drilled hole on the surface while motorcycle have the drilled hole. Despite it
has different figure but the mechanism of the braking system is just same which doesnt have any
much different.
Motorcycle brakes have a caliper, which squeezes the brake pads against the wheel. In a disc
brake, the brake pads squeeze the rotor instead of the wheel, and the force is transmitted
hydraulically instead of through a cable. Friction between the pads and the disc slows the disc
down. A moving motorcycle has a certain amount of kinetic energy, and the brakes have to
remove this energy from the motorcycle in order to stop it. Each time it stops, the brakes convert
the kinetic energy to heat generated by the friction between the pads and the disc.
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Raw
Material
Stamping
Process
Punching
Process
Skimming
Process
First
Quality
Inspection
Heat
Treatment
Quenching
Grinding
process
Final
Quality
inspection
Complete
Product
Stamping process.
Thick steel sheet rolled out from big coil is fed into stamping machine and the machine press out
the steel sheet with massive force into circular shape blank. The blank then transfer to another
stamping machine to punch out and produce the center shape of brake disc.
Punching process.
Punching machine punch all the brake disc holes with specific designed die. The function of hole
on the surface of brake discs are to remove heat during the braking to ensure the brake function
efficiently in high temperature. Punching machine also punch hole at the center of brakes disc to
make slot for screw to mounted it to motorcycle wheel hub.
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3.0 Tooling
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Suggest a
few
conceptual
Identifing areassketches for
to support,
the fixture.
locate and
Gathering clamp.
and analyze
the
information.
Identifiying and
define the
requirements .
Implementi
ng the
fixture
design.
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mass
mass
producti
producti
on.
Pevent
Pevent
workpiec
e from
bend.
repeatiti
ve
ve
process.
process.
ultrafine
surface
finish.
finish.
changea
changea
ble
ble
extensio
extensio
n for
front
front
and
and back
back
surface.
surface.
rotationa
rotationa
l force.
varius
type of
brake
disk.
reduce
reduce
time and
time
and
cost.
Hole for
locator
Clamping
and support
area.
d.
consideration. Every conceptual design has different locating, support and clamping mechanism.
After that, the concept will be select according to many other variables for example the ease of
manufacturability, ease of use, cost and many other variables that need to be considered taken.
The figures below show three of design that has been created.
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Support
Quick acting
knob
Slot for
Milling table
Locat
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Concept 2
Clamping
bolt
Locator
support
Spinning
fixture base
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Clampin
g nut
Locato
r pin
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Adjustable
Locator
pin
Adjustable
Magnetic clamp
Extension for
front and back
surface center
hub B.disc
Support
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From the figures given, three conceptual design are generated to describe the basic
concept under consideration for design surface grinding fixture to grind surface of brake discs.
All of the concepts have their own ability and function.
Concept 1 is the concept of turning grinding fixture consists of quick acting knob, locator
pin and support. The fixture will be mounted on cylindrical grinding chuck. The function of
locator pin is to guide the workpice accurately and precisely on the actual location. After locate
the workpiece at the actual location, quick acting knob is use to clamp the workpiece tightly. The
combinations of the support, locator and clamp are able to hold the part neatly.
Concept 2 is the concept of indexing fixture which consists of fixture that will spin
during surface grinding operation. The fixture will be attached on the surface grinding table
tightly. Adjustable locating nut and bolt clamp are used to locate and clamp the brake disc. Disc
brake are mounted on the flat support of the fixture itself for ease the surface grinding process
happen without the work ability slow.
Concept 3 is the combination concept of surface grinding fixture, magnetic clamp and
adjustable locator pin. Brake disc is attached on the support by aided by freely spinning
supporting center hub consist of two pin locator that align the center of brake disk respect to the
center fixture. Center hubs have an extension that can be replace to do front and back brake disk
surface grinding. Another two pin on the support table can be adjusted to meet the hole of variety
type of brake disc and hold form moving. Magnetic clamping component also can be adjusted to
clamp variety size of brake disc. Fixture is mounted on surface grinding spinning table.
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Concept
Description
Turning grinding
fixture.
2 locator pin.
Quick acting knob.
Mounted on machine.
Selection
Reject.
workpiece.
Quick acting
knob not
suitable and
can looses due
to vibration.
Indexing fixture.
Hold workpiece using
Reject.
Accuracy and
repeatability is
bolt clamp.
Attach on flat
low.
High vibration
machine table.
Spinning during
during process.
Lot of manual
grinding operation.
work.
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Combination of
Select.
surface grinding
unloading time.
High accuracy.
Ergonomic.
For variety
fixture, magnetic
clamp and adjustable
locator.
2 different type of
clamp
Extension center hub
securely.
can be replaced.
3.4 Justification
Type of fixture use:
Grinding fixture has been choosing as it suitable and fulfils the requirement of 3-2-1 principle to
do the surface finishing of the break disc. It widely used in industry to increase the mass
production as well as to get a higher quality by get the finish lengths and thickness of the
workpieces within precise tolerances.
Adjustable magnetic clamp:
Type of clamp use is magnetic clamp as it really suitable to use in the grinding surface machine.
It helps to clamp the workpiece for not moving during the machining process working. It is also
not give vibration to the workpiece while the process of machining runs.
Adjustable locating pins:
Locating position is made to bring the workpiece contact with the cutting tool prior to an
excellent alignment. This locating pins will help the stability and location accuracy of the
workpiece. Another two pin on the support table can be adjusted to meet the hole of variety type
of brake disc and hold form moving.
Extension for front and back surface center hub brake disc:
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The points that are taken into consideration for designing a product are as following:
a. Jig must be so strong that the deflection in the jig should be as less as possible.
The deflection that is mentioned includes the forces of cutting, clamping of
workpiece to the machine table. The frame of the fixture should have sufficient
mass to prevent vibrations during the machining of the job.
b. Another important design consideration is the clamping which should be fast
enough and require less amount of effort.
c. Arrangement of clamps should be such that they are easily available. They should
also have the arrangement for easy removal as well.
d. Is swinging of clamp system is provided for removal of workpiece the clamp
should swing as far as possible for unclamping the device.
e. There should also be provision for easy removal of chip. This will prevent the
interference of the chip with the operation on the workpiece i.e. cutting operation.
f. The clamps and support points which are to be adjusted in due course of time
should be preferred of same size. It will be better if the clamps and adjustable
support points can be operated from the front of the fixture.
g. If the surface area of clamping is more it damages the workpiece. This can be
avoided by making the surface area of clamping as small as possible.
h. As it is difficult to get spare parts during the operation so it is designed in such a
way that they can be easily replaced on failure.
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Conclusion
There are many elements in jig and fixture in order to make sure it is always in good condition
during used for machining processes. The definition and function of jig and fixture can describe
overall about the task that this equipment do to help the machinist for easier works. Jigs and
fixtures are manually or partially power operated devices. To fulfil their basic purposes, jigs and
fixtures are comprised of several elements as it need base and body or frame with clamping
features, locating elements for proper positioning and orientation of the blank, supporting
surfaces and base, the clamping elements, and tool guiding frame and bushes (for jig).
For the conclusion, the objective for this project are achieved and succeeded. The objective was
to establish and hold the proper position of the parts throughout the surface finishing, to identify
the related process, cutting tool and also machine tool of the part selected and lastly to improve
the productivity of the manufacturing process of excellent surface grinding. After do this project,
it give much benefit. Before this, some information and knowledge about jig and fixture are
gained but exactly this assignment help to learn and understand more deeply about jigs and
fixtures. This is because the jig and fixture is used widely in manufacturing field especially for
machining so it is very useful to gain the knowledge about jig and fixture. In order to finish this
assignment successfully, identifying the important thing about jigs and fixture have done. These
main elements are specified carefully that is suitable for the jig and fixture design.
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References
Journal
1) Brake disc and Process for producing the same (1978)
Hiroma Okunishi, Sayamasi. Brake disc and Process for producing the same. Journal of
Management.Vol 49(1), 1978.
2) Is Magnetic Workholding For You? Modern Machine Shop (2000)
Chris Koepfer. Is Magnetic Workholding For You? Modern Machine Shop. Article 2000
Internet
1)http://www.stoptech.com/about/factory-tour
Final quality control of brake disk
2)http://www.faqs.org/patents/app/20120125724#ixzz3XS9Qonit
Manufacturing process of brake disc
3) http://auto.howstuffworks.com/auto-parts/brakes/brake-types/disc-brake3.htm
How brake disc works
4) http://www.counterman.com/brake-rotors-when-to-resurface-and-when-to-replace/
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7) http://www.makeitfrom.com/material-data/?for=Cast-Iron.
Cast Iron - Material Properties Data :MakeItFrom.com. 2014. Cast Iron - Material Properties
Data :MakeItFrom.com.
8) http://ebcbrakes.com/articles/how-to-make-brakes/.
How to make brakes - EBC Brakes. 2014. How to make brakes - EBC Brakes
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