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A PROJECTREPORT
ON
MULTIPURPOSE ANGULAR GRINDING
FIXTURE
A Dissertation Submitted By,
ARUNKUMAR N
(1554/DTC/2014)
For the award of,
TRAINEE OFFICER IN GRADUATE ENGINEERING TRAINING
Under the valuable guidance of
Mr. A SHANKAR
ANISO9001:2008CERTIFIEDTRAININGINSTITUTION
CERTIFICATE
THIS IS TO CERTIFY THAT PROJECT TITLED
MULTIPURPOSE ANGULAR GRINDING
FIXTURE
It is a bona fide record of the project work done
by, ARUNKUMAR N
This is
to
Certify
that
PROJECT GUIDE
PRINCIPAL
(A SHANKAR)
(A SHANKAR)
PREFACE:
I am submitting this project report as a part of fulfillment of the course,
GRADUATE ENGINEER TRAINEE at NETTUR TECHNICAL TRAINING
FOUNDATION, BENGALURU, KARNATAKA during the year AUGUST 2014-2015.
The main aim of this project is to reduce cost of the fixture and used for training purpose.
The main purpose of a fixture is to locate and in the cases hold a work piece during an
operation.
The main aim of this project is to reduce cost of the fixture and used for training purpose.
CONTENTS:
SL.NO
CONTENTS
PAGE NO
INTRODUCTION TO FIXTURES
13-16
DESIGN CONSIDERATIONS
16-20
TYPES OF FIXTURES
21-26
27
ADVANTAGES OF FIXTURES
28
29-30
30-42
COST ESTIMATION
43-50
INSPECTION
51-59
10
11
12
13
3D DESIGN OF FIXTURE
PHOTOGRAPHIC IMAGE OF FIXTURE
CONCLUSION
REFERENCES
58-65
66-73
74
76
INTRODUCTION:
Over the past century, manufacturing has made considerable progress. New machine
tools, high-performance cutting tools, and modern manufacturing processes enable today's
industries to make parts faster and better than ever before. Although work holding methods have
also advanced considerably, the basic principles of clamping and locating are still the same.
The fixture is a special tool for holding a work piece in proper position during manufacturing
operation. For supporting and clamping the work piece, device is provided. Frequent checking,
positioning, individual marking and non-uniform quality in manufacturing process is eliminated
by fixture. This increase productivity and reduce operation time. Fixture is widely used in the
Industry practical production because of feature and advantages.
To locate and immobilize work pieces for machining, inspection, assembly and other operations
fixtures are used. A fixture consists of a set of locators and clamps. Locators are used to
determine the position and orientation of a work piece, whereas clamps exert clamping forces so
that the work piece is pressed firmly against locators. Clamping has to be appropriately planned
at the stage of machining fixture design. The design of a fixture is a highly complex and
intuitive process, which require knowledge. Fixture design plays an important role at the setup
planning phase. Proper fixture design is crucial for developing product quality in different terms
of accuracy, surface finish and precision of the machined parts In existing design the fixture set
up is done manually, so the aim of this project is to replace with hydraulic fixture to save time
for loading and unloading of component. Hydraulic fixture provides the manufacturer for
flexibility in holding forces and to optimize design for machine operation as well as process
function ability.
HISTORY
The first manufactured products were made one at a time. Early artisans started with little
more than raw materials and a rough idea of the finished product. They produced each product
piece by piece, making each part individually and fitting the parts into the finished product. This
process took time. Moreover, the quality and consistency of products varied from one artisan to
the next. As they worked, early manufacturing pioneers realized the need for better methods and
developed new ideas.
Eventually, they found the secret of mass production: standardized parts. Standard parts
not only speeded production, they also ensured the interchangeability of parts. The idea may be
obvious today, but in its time, it was revolutionary.
These standard parts were the key to enabling less-skilled workers to replicate the skill of
the craftsman on a repetitive basis. The original method of achieving consistent part
configuration was the template. Templates for layout, sawing, and filing permitted each worker
to make parts to a standard design. While early templates were crude, they at least gave skilled
workers a standard form to follow for the part. Building on the template idea, workers
constructed other guides and work holders to make their jobs easier and the results more
predictable. These guides and work holders were the ancestors of today's jigs and fixtures.
[NETTUR TECHNICAL TRAINING FOUNDATION, KUMBAKONAM]Page 13
A fixture references the cutting tool, in this case with a set block.
DESIGN CONSIDERATIONS
The principal considerations when choosing among work holder varieties fall into three
general categories: tooling cost, tooling details, and tooling operation. Although each of these
categories is separated here, in practice they are interdependent. The following are some design
differences and considerations for permanent, general-purpose, and modular work holders.
Tooling Costs
The total cost of any jig or fixture is frequently the major area of consideration in many
work holder designs. Although initial cost is a major element, it should not be the basis for
accepting or rejecting any tooling option.
A more-proper economic evaluation of the work holder design takes into consideration
many other factors. As discussed previously, permanent fixtures have distinct advantages in the
production of high-volume and high-precision parts. They also typically reduce machine setup
[NETTUR TECHNICAL TRAINING FOUNDATION, KUMBAKONAM]Page 16
. A combination drill jig/milling fixture used for both types of operations on the same part.
INTERNAL-MACHINING APPLICATIONS:
Cylindrical- and Irregular-Hole Machining
Drill jigs
Boring jigs
Electrical-discharge-machining fixtures
Punching fixtures
Internal-broaching fixtures
NON-MACHINING APPLICATIONS:
Assembly
Welding fixtures
Mechanical-assembly fixtures
(Riveting, stapling, stitching, pinning, etc.)
Soldering fixtures
Inspection
Mechanical-inspection fixtures
Optical-inspection fixtures
Electronic-inspection fixtures
Finishing
Painting fixtures
Plating fixtures
Polishing fixtures
Lapping fixtures
Honing fixtures
Miscellaneous
Layout templates
Testing fixtures
Heat-treating fixtures
TYPES OF FIXTURES:
The following is a partial list of production operations that use fixtures:
Assembling
Lapping
Boring
Milling
Broaching
Planning
Drilling
Sawing
[NETTUR TECHNICAL TRAINING FOUNDATION, KUMBAKONAM]Page 20
Shaping
Stamping
Tapping
Testing
Turning
Welding
The names used to describe the various types of fixtures are determined mainly by
how the tool is built. Jigs and fixtures are made basically the same way as far as locators
and positioners are concerned. The main construction difference is mass. Because of the
increased tool forces, fixtures are built stronger and heavier than a jig would be for the
same part.
Plate fixtures
Plate fixtures are the simplest form of fixture. The basic fixture is made from a Flat plate that
has a variety of clamps and locators to hold and locate the part. The simplicity of this fixture
makes it useful for most machining operations. Its adaptability makes it popular.
Angle-plate fixture
The angle-plate fixture is a variation of the plate fixture. With this tool, the part is
Normally machined at a right angle to its locator.
[NETTUR TECHNICAL TRAINING FOUNDATION, KUMBAKONAM]Page 21
Duplex fixtures
Profiling fixtures
Profiling fixtures are used to guide tools for machining contours that the machine
cannot normally follow. These contours can be either internal or external. Since the
fixture continuously contacts the tool, an incorrectly cut shape is almost impossible. The
operation in Figure shows how the cam is accurately cut by maintaining contact
between the fixture and the bearing on the milling cutter. This bearing is an important
part of the tool and must always be used.
.
MILLING FIXTURE
Milling Fixtures
Milling fixtures are the most common type of fixture in general use today.
The simplest type of milling fixture is a milling vise mounted on the machine table.
However, as the work piece size, shape, or complexity becomes more sophisticated, so
too must the fixture.
The design should permit as many surfaces of the part to be machined as possible.
Without removing the part.
Whenever possible, the tool should be changed to suit the part. Moving the part to
accommodate one cutter for several operations is not as accurate or as efficient as
changing cutters.
Locators must be designed to resist all tool forces and thrusts. Clamps should not be
used to resist tool forces.
Clearance space or sufficient room must be allotted to provide adequate space to change
cutters or to load and unload the part.
Milling fixtures should be designed and built with a low profile to prevent unnecessary
twisting or springing while in operation.
The entire work piece must be located within the area of support of the fixture. In those
cases where this is either impossible or impractical, additional supports, or jacks, must
be provided.
Chip removal and coolant drainage must be considered in the design of the fixture.
Sufficient space should be permitted to allow the chips to be easily removed with a
brush.
Set blocks or cutter setting gages must be provided in the fixture design to aid the
operator in properly setting up the tool in production.
Lathe Fixtures
Similar to the design of milling fixtures.
In milling, the work piece is stationary and the cutting tool revolves. In turning
operations, the work piece revolves and the cutting tool is stationary.
Tool designer must deal with-centrifugal force. The complete fixture must be designed
and constructed to resist the effects of the rotational, or centrifugal, forces present in the
turning.
Since lathe fixtures are designed to rotate, they should be as lightweight as possible.
Lathe fixtures must be balanced. While perfect balance is not normally required for
slow-speed turning operations, high rotational speeds require the fixture to be wellbalanced.
Projections and sharp corners should be avoided since these areas will become almost
invisible as the tool rotates and they could cause serious Injury
The part should be positioned in the fixture so that most of the machine operation can be
performed in the first fixturing.
Clamps should be positioned on surfaces, or areas, which are rigid before and after
machining.
As with other fixtures, some means of cutter setting should also be incorporated into the
design. However, since the work holder will be rotating, this setting device should be
removed.
Whenever possible, standard lathe accessories should be adapted in the design of turning
fixtures. Lathe faceplates are an ideal method to mount large fixtures. Likewise, a
standard lathe chuck, or collets, can and should be modified for many fixturing
applications.
Surface grinding fixtures are similar in design to milling fixtures, but made to much
closer tolerances. Whenever practical, use magnetic chucks to hold the work piece.
Provide adequate room or slots to permit the escape of coolant and to allow easy
removal of built-up grinding sludge.
Provide coolant containment devices or splash guards to keep the fixture from spilling
coolant on the floor around the machine. Fixture elements which are in contact with the
magnetic chuck should be made from ferrous materials. Include provisions for rapid
wheel dressing and truing in the design of the fixture, if not built into the machine. All
locators must be accurately and positively positioned.
Boring Fixtures
These fixtures differ from boring normally used for large parts with large holes where
the boring bar is rigid enough to provide additional support. A pilot bushing is not
needed.
[NETTUR TECHNICAL TRAINING FOUNDATION, KUMBAKONAM]Page 26
DOWEL PIN
Dowel pins are often used as precise locating devices in machinery. Steel dowel pins
are machined to tight tolerances, as are the Corresponding holes, Which are typically reamed.
A dowel pin may have a smaller diameter than its hole so that it freely slips in or a larger
diameter so that it must be pressed into its hole (interference fit).
FULCRUM PIN
A Lever is a rigid rod or bar capable of turning about a fixed point called fulcrum. or A shaft or
pin on which something turns.
ALLEN SCREW
A screw with a hexagonal hole in the head with a tapered threaded shank and slotted head.
It is turned by an axial hexagonal hole in its head.
BEVEL EDGE
[NETTUR TECHNICAL TRAINING FOUNDATION, KUMBAKONAM]Page 28
PROJECTSUMMARY:
STEPS INVOLVING IN MANUFACTURING PROCESS:
FLOW CHART:
CADD
drawing
AUTO
CAD
drawing
Process planning
Purchasing
Machining
Milling
Turning
Surface
grinding
Bench work
Drilling
Bench
work
Reject
Rework
Inspection
OK
Bench
work
Assemb
ly
Trial
Approva
l
PROJECT BOUNDARY
DESCRIPTION
TARGET DATE
Selection Of fixture
24-06-2015
24-07-2015
26-07-2015
26-07-2015
18-08-2015
22-08-2015
24-08-2015
Project Report
10-09-2015
Approval
JOB DETAILS:
NAME
: TRI SQUARE
MATERIAL
: MILD STEEL
THICKENESS
: 5mm
SCALE
: 1:1
(d) Allowances:
In additions to the elements of time described above, the total time to perform an
operation includes a number of allowances like time for personal needs of the
operator, time for checking, time for tool sharpening etc.
Lathe:
The factors that govern machining time will be understood from a simple case of
machining. A steel rod has to be reduced in diameter from D1to D2 overall length L by
straight turning in a centre lathe.
TC= (Lc ( Ns0))xnp
Where
L=required length of cut
TC= cutting time
LC= actual length of cut
=L+A+O
A, O= approach and over run
Milling:
Milling time TC= (l+a) / F
Where
l is the length of work piece in the direction of feed
a is the approach length a=d (D -d)
d depth of cut in mm
D Diameter of milling cutter in mm (18mm carbide insert cutter)
F Table feed in mm/min (~100 mm/min)
Surface grinding:
Machining time t m = 2xLxBxi
V x1000xS
L=l+ (2 x over travel)
Where,
L=grinding length in mm l
= length of work piece
i = number of cuts
V=Speed of table in m/min
S=lateral feed in mm/stroke
B=Width of work piece
Drilling:
Ex: For 18mm,
V= d n/1000m/min
N=1000X25/18
=442.09 rpm.
Feed=0.5mm/rev
Machining time:
Tm=L/Sr XN
Tm=machining time
L =Length of the tool travel
Sr =feed
N =speed in rpm.
FEED:
Fm=Ft X Z X N
=0.1X6X318.31 [Ft=feed/tooth]
=190.98mm/min
DEPTH OF CUT:
0.5mm/pass
Machining time:
Tm =L+a/f
a=d (D-d)
=0.5(15-10)
=3.535mm
Tm =115+10.94/160
=0.7783min
=46.68secper pass
=46.68x2.5
= 10.12min
Other side,
=46.68X2=93.36sec/side
Breadth wise,
Tm=46.68x2
=93.36 sec/side
Tm=46.68x1.5
=70.02sec/side
Feed=0.5mm/rev
N=1000XV/D
=1000X20/ X18
=353.677rpm
Machining time,
Tm=18/0.5x2000
=1.08min
For =6mm
N=1000x20/ X6
=1061.0rpm
Tm=18/0.5X550
=3.5min.
For =8.5mm
N=1000x20/ X8.5
Tm=20/0.5X994.71
=748.96rpm
=2.5min
Feed=0.5mm/rev
For =4mm
N=1000XV/D
=1000X20/ X4
=1591.54rpm
For =8.5mm
N=1000x20/ X8.5
=748.96rpm
For =13mmN=20000/ X13 =489.70rpm
Machining time,
Tm=20/0.5x2122.00
=1.18min
Tm=20/0.5X994.71
=2.5min.
Tm=20/0.5X544
=3min.
Tm=8/0.5X578
=1.6min.
Feed=0.5mm/rev
Tm =8/0.5X1224.2
=0.78min.
Tm=8/0.5X1500
=0.64min.
Tm=4/0.5X578
=0.87min.
Weight of MS flat
WEIGHT = VOLUME (m3) X DENSITY OF A PARTICULAR MATERIAL (Kg/m3)
Surface
Grinding
(hr)
Total
(hr)
(hr)
(hr)
(hr)
Fixed Plate
2:00
2:00
1:00
2:00
7:00
Sliding Plate
2:00
2:00
1.00
2:00
7:00
Top Plate
2:50
2:00
1:00
2:00
7:50
Base Plate
3:50
3:00
1:00
2:00
9:50
Fulcrum Pin
0.5
2:50
Clamp plate
Total (hr)
2:00
10:00
1:00
0.25
2:00
3:25
10:00
2:00
4:25
10:50
36:75
COST ESTIMATION:
Estimation is the art of determining the cost which is likely to be incurred on the
manufacturer of article, before it is actually manufactured.
Actually estimation is necessary to complete in the market and be sure if the manufactured
article is profitable or not .Here we have considered the approximate value of the following
1. Machine hour rate
2. Machining time
3. Cost of material
Machine
Machine
Description
Utilization
Machining
rate/hour
Milling
10:00
80/hr
800.0
Surface grinding
10:00
90/hr
900.0
Lathe
2:00
50/hr
100.0
Drilling
4:00
120/hr
360.0
Bench work
10:50
70/hr
735.0
SL
NO
(Rs)
2895/-
SL.NO
Material description
Quantity
(Rs)
Total
Amount
(Rs)
Rate
MS Flat
20.224Kg
60
1214
MS Round rod
105
562.0
Allen screw
20
10
196
Dowel pin
2 Nos
10
20
Total Cost(Rs)
1992.0/-
Rs =4887
Description
Material
Quantity
Fixed Plate
M.S
Sliding Plate
M.S
Top Plate
M.S
Base Plate
M.S
Fulcrum Pin
M.S
Dowel pin
STD
Clamp plate
M.S
Remarks
Process
Interpretation of diagram
Tools used
Machine
2
3
4
5
6
7
8
Vernier caliper,
Micrometers, vernierheight
gauge.
Radial Drilling
Machine.
Countersink tool.
Drilling machine.
6 flat file.
Bench vice.
Tools used
Machine
Milling machine,
Surface Grinding
Machine.
Surface table and
Anvil.
Process
Interpretation of diagram
Vernier caliper,
micrometres,vernierheight
gauge.
Radial Drilling
Machine.
Countersink tool.
Drilling machine.
6 flat file.
Bench vice.
3
4
5
6
7
8
Milling machine,
Surface Grinding
Machine.
Surface table and
Anvil.
Process
Interpretation of diagram
3
4
Tools used
Vernier
calliper,
micrometres,vernierheight
gauge.
Clamp the work piece in milling vice Vernier Caliper, 20 end
remove the excess stock and
mill cutter, fly mill cutter.
machined the references in SG.
Vernier height gauge, dot
Marking and Punching.
punch, ball peen hammer.
Machine
Milling machine,
Surface Grinding
Machine.
Surface table and
Anvil.
Sensitive and Radial
drilling machine.
Lathe machine.
Bench vice.
Countersink tool.
Drilling machine.
6 flat file.
Bench vice.
Tools used
Machine
8
9
Process
Interpretation of diagram
Vernier caliper,
Micro meters, vernier
height gauge.
6
7
Milling machine,
Surface Grinding
Machine.
Surface table and
Anvil.
Drilling machine.
Countersink tool.
Drilling machine.
6flat file.
Bench vice.
Process
Interpretation of diagram
Vernier
caliper,
micrometres, vernierheight
gauge.
Lathe
Marking
Lathe
Lathe
Cutting tool.
Lathe
Cutting tool
Lathe.
4
5
Tools used
Machine
Planning the sequence of operations for all the positions. The operations, which can be done
at our tool room.
Tool manufacturing:
Manufacturing of tool was started after receiving the material as per the operation sequence.
was centrally inspected after visual inspection near the machine itself.
MACHINES UTILISED:
LATHE
MILLING MACHINE
DRILLING
SURFACE GRINDING
LATHE
The main function of lathe is to remove metal from a piece of work to give it the requires
shape and size. This is accomplished by holding the work securely and rigidly on the machine
and then turning it against cutting tool which will remove metal in the form of chips.
Operations involved:
Turning
Facing
Chamfering
Threading.
MILLING:
Milling machine is used for removing excess material from a work piece with a
Rotating cutting tool. The rotating cutting tool is called the milling cutter. The cutter rotates
at a high speed and because of the multipoint cutting edge it removes metal at a very fast rate.
The machine can also hold number of cutters at a time.
Milling process is used for producing flat, contoured or helical surfaces, for cutting
thread and tooth edges and for making helical grooves.
Operations involved
Face milling
End milling
DRILLING:
Drilling machine is used to originate or cut a hole where none previously existed.
This is an extensively used machine for through or blind holes. The hole is produced by
axially feedingtherotatingdrillintotheworkpiecewhichisheldonthetableofthedrilling machine.
Operation involved
Drilling
Chamfering
GRINDING:
Grinding operation is a method of machining work pieces by use of rotary abrasive
Tool, called grinding wheel. The grinding operation can be rough
Grinding or finishing grinding (precision grinding).Rough grinding is a commonly used
method for removing excess material from castings, forgings etc.
Precision grinding is the principal production method of cutting materials that are too
hard to be machined by other conventional tools and a finer surface finish as compared to
other manufacturing method.
Inspection report:
NETTUR TECHNICAL TRAINING FOUNDATION
INSPECTION REPORT
DRG.SIZE
149.0
97.0
48.5
80.6
50.6
80.6
16.4
18H7
9H7
10
5X45
11
2X45
12
18
13
14
16.0
15
Surface finish
16
Flatness
17
Parallelism
18
Perpendicularity
DRG NO:1
ACTUALSIZE
QTY:2
REMARKS
ACCEPTED:YES
REJECTED:
INSPECTION:
SECTION HEAD:
REWORK:
F/COM/7526
Inspection report:
NETTURTECHNICAL TRAINING FOUNDATION
INSPECTIONREPORT
DRG.SIZE
190
109
27.0
49.0
55.3
53.7
31.5
19.5
77.5
10
79.0
11
16.0
12
18H7
13
9H7
14
2X45
DRG NO:2
ACTUALSIZE
QTY:2
REMARKS
15
5X45
16
17
18
18
Surface finish
19
Flatness
20
Parallelism
21
Perpendicularity
ACCEPTED:YES
REJECTED:
REWORK:
F/COM/7526
INSPECTION:
SECTION HEAD:
Inspection report:
NETTUR TECHNICAL TRAINING FOUNDATION
INSPECTION REPORT
DRG.SIZE
197.0
148.0
16.5
47.2
82.2
98.0
114.5
145.2
180.2
10
10
11
12
13
34.5
14
60.5
15
98.0
16
2X45
17
5X45
18
133
19
7.0
20
10.0
DRGNO:3
ACTUALSIZE
QTY:1
REMARKS
21
8.0
22
Surface finish
22
Flatness
23
Parallelism
24
Perpendicularity
ACCEPTED:YES
REJECTED:
INSPECTION:
SECTION HEAD:
REWORK:
F/COM/7526
Inspection report:
NETTUR TECHNICAL TRAINING FOUNDATION
INSPECTION REPORT
DRG.SIZE
200
181.0
72.5
107.0
143.5
179.5
8.5
13
2X45
DRGNO:4
ACTUALSIZE
QTY:1
REMARKS
10
5X45
11
Surface finish
12
Flatness
13
Parallelism
14
Perpendicularity
ACCEPTED:YES
REJECTED:
REWORK:
F/COM/7526
INSPECTION:
SECTION HEAD:
Inspection report:
NETTURTECHNICAL TRAINING FOUNDATION
INSPECTION REPORT
DESCRIPTION:FULCRUM PIN
S.NO
DRG.SIZE
22.4
182.0
204.4
216.4
12.0
24.3
18.4
M8
Filing finish
10
Surface finish
11
flatness
12
parallelism
13
perpendicularity
ACCEPTED:YES
REJECTED:
REWORK:
F/COM/7526
3D DESIGN OF FIXTURE
DRGNO:5
ACTUALSIZE
QTY:1
REMARKS
INSPECTION:
SECTION HEAD:
BOTTOM PLATE
FIXED PLATE
SLIDING PLATE
TOP PLATE
CLAMP PLATE
DOWEL PIN
TRI SQUARE
FULCRUM PIN
NUT
SIDE VIEW
REAR VIEW
TOP VIEW
ANGLE 450
ANGLE 600
WORK PIECE
about
design
software such
as AUTOCAD.
CONCLUSION:
The grinding fixture was successfully completed and assembled on. It
took three months for completion of the tool. All that was involved in the
project is good design, systematic work and the co-operation and coordination
from all staff members to me, which fetched outstanding result at the end.
Though we have taken all care to complete the project to the best of our
ability, some errors may have crept in due to over sight or ignorance or trial and
error methods .There is definitely scope for improvement in the different
aspects of this project.
It really persuades me to do more & more, perhaps in better ways in my
future. I take this opportunity to thank everyone, who contributed directly or
Indirectly to the success of my project.
REFERENCES:
Production Technology
PG School
WESTERMANN TABLES
Hermann Jutz
Heinrich Gerling