TABLE OF CONTENTS

CHAPTER NO.

TITLE
Abstract List of tables List of figures

PAGE No.
i ii iii

1 2 2.1 2.2 2.3 3 3.1 3.2 4 4.1 4.2 4.3 4.4

Introduction Research methodology Survey Report Objective Methodology Design and cost estimation Design calculation Cost estimation Modular fixture Components Merits Cost expenditure References

ABSTRACT

In the existing fixtures, there are various limitations in terms of work holding, stress bearing and mounting. This has given raise to a situation where we have started using a number of fixtures, which has increased the expenditure and complexity in machining. Though universal fixtures are available, they mostly meet only with a single demand and they are relatively expensive. In our project we have reduced both the expenditure and complications of a universal fixture and have developed a simple, effective fixture which is easy to fabricate and use. As the name indicates, the modular fixture has separate units which can be rearranged to hold work pieces of any complex geometry.

LIST OF TABLES

S. No 1 2 3

Table Cost Estimation Material Machining

Page No.

LIST OF FIGURES

S. No 1

Figure General layout of the fixture

Page No.

2 3 4 5 6

Slide Clamps Studs Fixtuing examples Nut and bolts

CHAPTER 1 INTRODUCTION

Throughout the history of manufacturing, fixtures have played an important role in increasing productivity. Two stellar categories of work holding devices/tools that have provided their mettle are:

General Purpose Work holders [G.P.W] Special Purpose Work holders [S.P.W]

Although these fulfill all tooling requirement; neither of them is economically viable. For this reason, a third type of fixturing, namely, Modular fixturing has evolved to fill the gap between general and special purpose fixturing. Modular fixturing is a work holding system that uses a set of reusable standard components to build a wide variety of special purpose work holding devices. Modular fixtures are assembled with a variety of standards of tooling plates, supports, locating elements, clamps and similar units.

CHAPTER 2 RESEACH METHODOLOGY

2.1 SURVEY REPORT

It has been observed that in machining there are lots of complications associated with the use of the right fixture for work holding. And as a consequence, a number of fixtures are being used to hold a specific type of work piece. Universal fixtures developed to hold a wide set of work piece specifications are costly and require skilled labor.

2.2 OBJECTIVES
PRIMARY OBJECTIVE:
To design a fixture to effectively hold work pieces of any complex geometry, capable of being mounted on most of the machines.

SECONDARY OBJECTIVE:
To reduce the expenditure on using a number of fixtures and to minimize their complexity.

2.3 METHODOLOGY
The various methods followed in the fabrication of the modular fixture are:

Process planning Designing Machining Milling Slotting Drilling Reaming Tapping Fastening

CHAPTER 3
DESIGN AND COST ESTIMATION

3.1

Design Calculation: Let us assume that we are cutting a slot with 3X3 mm depth and width of

cut, on a component 100X30 mm dimension, in a vertical milling machine. Selection of clamping stud: A inch stud is selected for clamping the work. Cutting force = 4.5Kfbd Cs

Assuming feed f = 100m/min Material constant for mild steel = 8.5 Assuming cutting speed Cs = 15m/min fc = 4.5X8.5X100X5X5 15 Since the work piece is held throughout the process we arrive at a conclusion that, the clamping force is greater than the cutting force. So, let us assume it as 10KN, which means each bolt has the clamping force of 2.5 KN = 6375N

Selecting the range 1863 N 2545.46 N, the diameter of bolt is arrived at (db) = 7/16 inch <

inch

Hence the design is safe.

Calculating bearing area:

For C45 steel And

yield stress = 600 N/m2 Yield stress = Cutting force Bearing area

Bearing area = 1721.25 = 2.86 mm2 600

But Available area = 50.06 mm2 < calculated area

Hence the design is safe

3.2

COST ESTIMATION Table 1: Material: The materials used are tabulated as follows

S.No
1 2 3

Component
Polished steel bar Allen screw 6X16 Stud [1/2]

Quantity
20 kg 4 6

Rate
62 3 11

Cost
1240 12 66

Table 2: Machining: The machining costs involved are tabulated as follows

Total cost: S.No. 1 2 3 Process Slotting Drilling Miscellaneous Component Frame/Slides Frame/Slides Cost 200 100 100

Total cost = material cost + machining cost 1318 + 400 = Rs.1718/-

CHAPTER 4

MODULAR FIXTURE 4.1 Components

The modular fixture to be fabricated is to have the three main components 1. Frame 2. Slide 3. Holding system 4.1.1 Frame: The frame is the base part of the fixture; its purpose is to support other components and to hold the fixture on the table. 4.1.2 Slide There are two slides moving over the frame in the slots provided. They can be adjusted and fixed as per requirement in a convenient position. 4.1.3 Holding system Holding system components are those which hold the work in a position convenient for machining. They are fastened to the slides in a required pattern. They can be studs, clamps, supports, locating elements or whatever, based on requirement of the operation and are discussed here. Locating and supporting elements are those modular elements which aid in machining. They are use for accurate positioning of the tool in the required position and to support the work properly during machining.

Clamps:

Clamps are elements commonly and most widely used in modular fixtures. The different types of clamps used are High rise clamps, Up-thrust clamps, Screw edge clamps, Pivot edge clamps, Cam edge clamp and Ball element clamps. High raise clamps: The high raise clamp is composed of a series of assembled parts, however the major elements are the strap, the contact and extensions. It aids in clamping of the work piece in an elevated platform to provide better height. Up-thrust clamps: The up-thrust clamp possesses a unique design that holds the work piece with pressure from below. This design is well suited for elevated platforms. Screw edge clamps: They combine the work of a screw clamp and a locator in a single unit. They are available in both fixed and adjustable configurations. Pivoting edge clamps: The pivoting clamps use a pivoting leaver to apply holding forces. These clamps are used with a matching backstop unit to hold work piece between two jaws. Cam edge clamps: The cam edge clamps use a flat spiral cam design to generate holding forces against the work piece.

Ball element clamps:

The design of ball element clamp permits the contact surface of the locators, supports and clamps to conform to the shape of work piece eliminating all chances of component distortion.

Studs: Studs are simple but efficient holding elements. They combine both cost and work efficiency. In the designed modular fixture, studs are used as holding elements.

4.2 MERITS

1. Has a wide range of features and components which can greatly reduce tooling area and save money and material 2. The fixture has less lead time. Savings of 80%are common. And its well established that each hour of lead time of modular fixture equals two to six hours of conventional jig/fixture 3. Reusable 4. Can be dismantled and rejoined in desired form 5. Versatility of application

4.3. COST ESTIMATE

Table 1: Material: The materials used are tabulated as follows

S.No
1 2 3 4

Component
Polished steel bar Grub screw 12X70 Allen screw 6X16 Stud [1/2]

Quantity
20 kg 4 4 6

Rate
62 16 3 11

Cost
1240 64 12 66

Table 2: Machining: The machining costs involved are tabulated as follows

S.No. 1 2 3

Process Slotting Drilling Labor

Component Frame/Slides Frame/Slides -

Cost 200 100 150

Total cost:

Total cost = material cost + machining cost 1382 + 450 = Rs.1832/-

REFERENCES

Book references:
Hajra Choudry (2005) Elements of workshop technology Elanchezian.C Sunder Selwyn.T Vijaya Ramnath.B Design of Jigs, Fixtures and Press tools

Web references:

http://www.invert-a-bolt.com/lean.shtml

http://riot.ieor.berkeley.edu/riot/Applications/Fix tureNet/index.html