UNIVERSITI TUNKU ABDUL RAHMAN

FACULTY OF ENGINEERING AND SCIENCE

UEME3223 Computer Aided Design and Manufacture

Preliminary report

Group Members:

GROUP NO. 7

NAME ID. & COURSE

KHOO SIN YAU 1903765 MH

ER KAI SHENG 2000934 MH

PHANG YI 1902323 MH

LAU LOK BIN 1902064 MH

CHAI JIA YEE 1903978 MH

Introduction:

Introduction of Flywheel Cam, Jig and Fixture

A flywheel is a mechanical device that employs angular velocity conservation to store

rotational torque, which is proportional to the product of its moment of inertia and the square of

its rotating speed. In particular, if the flywheel's moment of inertia remains constant, the stored

(rotational) energy is proportional to the square of its rotational speed. Because a flywheel stores

mechanical work for later use, it is reasonable to think of it as a kinetic energy equivalent of an

electrical inductor. This common principle of energy storage, once abstracted, is described in the

generalized idea of an accumulator. A flywheel, like other forms of accumulators, intrinsically

smooths sufficiently tiny variations in a system's power output, effectively acting as a low-pass

filter with regard to the mechanical velocity (angular or otherwise) of the system. More

specifically, the stored energy in a flywheel will provide a burst in power output in response to a

dip in power input and will absorb any hydroelectricity input (system-generated power) in the

form of rotary motion.

The fundamental aim of a jig is to ensure repeatability, precision, and interchangeability

in product manufacture. When a key is copied, the original is used as a jig so that the new key

has the same route as the old one. Jigs are no longer necessary with the introduction of

automation and computer numerically controlled (CNC) machines since the tool path is digitally

set and kept in memory. Plastic reforming jigs can be created. Long well before the industrial

period, jigs or templates were used. There are numerous different sorts of jigs, and each one is

specially designed to perform a certain task. Plus, jigs are special in that they cause the tool to

become immobile as they move.

 In the industrial business, a fixture is a task-holding or support device. Fixtures are used

to firmly place (position in a certain position or alignment) and support the work, guaranteeing

that all components produced using the fixture are conformant and interchangeable. Using a

fixture increases production economics by allowing for smooth operation and rapid transition

from part to part, lowering the need for specialized personnel by minimizing how workpieces are

installed, and boosting uniformity across a product cycle. A fixture varies from a jig in that the

tools must move relative to the workpiece while using a fixture; a jig lifts the piece while the tool

stays stationary. The primary function of a fixture is to provide a stable mounting point for a

workpiece, providing for support during operation as well as greater accuracy, precision,

dependability, and interchangeability in completed products. It also helps to cut down on

working time by enabling for rapid set-up and smooth transitions from part to component. It

typically simplifies a process's complexity, allowing untrained employees to undertake it and

essentially passing the tool maker's competence to the unskilled labor. Fixtures also improve

operator safety by lowering the focus and work necessary to keep a piece stable. The most

beneficial economic purpose of a fixture is to lower labor expenses. Operating a device or

process without a fixture may necessitate several or more operators; utilizing a fixture can

minimize one of the operators by anchoring the workpiece.

 Figure 1.0: Hand sketch of the fixture.

Working principle of the fixture:

The fixture is designed in a way that it is easy to use and provides firm support for the

workpiece during the milling process. The workpiece is supported with a 3-point fix as

highlighted in the figure below.

Figure 2.0: Top view of the fixture and the flywheel.

 Point 1 and 2 are fixed bumps casted with the outer rim that acts as support points while

the 3rd point is a bolt which will be screwed into the rim after the workpiece is placed to ensure

the workpiece is secured firmly to the fixture for the milling process. Points 1 and 2 also doubles

as reference points for the whole system. After the top face is machined, the 4 securing bolts will

be removed and the whole rim will be flipped 180 degrees horizontally and secured back to the

base aligning with the 4 bolting points so the second face of the workpiece could be machined

without losing its reference points.

Figure 3.0: The bottom part of the fixture.

At the bottom side of the fixture, an arc shaped drain (labeled 1) and a cylinder (labeled

2) is bored from the fixture, these are clearance holes for the machining tool to move without

damaging the structure of the fixture during the milling process, as the tool could pass through

the fixture via the drain and cylinder during the machining process. The base of the fixture is

designed as a square shape so it could be easily placed and secured on the milling table.
Fabrication plan of fixture:

1. Fabricate a disc with a diameter of 270mm and a height of 15mm into a ring with
reference bumps. The two reference bumps are shown in the figure below.

Figure 4.0: The “ring” part of the fixture (Top View).

2. Drill 4 bolt through holes with a diameter of 10mm. The four holes are shown in the
figure above.
3. Drill a through hole with a diameter of 10mm at the side of the ring. This hole is on the
opposite side of the reference bump. The hole is shown in the figure below.

Figure 5.0: The “ring” part of the fixture.

4. Drill 4 bolt through holes with a diameter of 10mm in a square base with a length of
360mm and a height of 10mm.
5. Drill a 50mm diameter hole and cut an opening as shown in the figure below.
 Figure 6.0: The base part of the fixture (Top View).

6. The ring and base are bolted together to form a fixture.

Fabrication plan of flywheel:

1. The fixture is first clamp and fixed on the working table of the CNC milling machine.

2. An Aluminum disc is placed into the ring of the fixture and fixed by a bolt, the position

of the 5 mm through hole must be placed at the center of two reference curves as marked

on the figure below.

Figure 7.0: Fixture and Flywheel (Top View).

3. The milling tool is set and placed at the position 10 mm above the workpiece and a 10

mm through hole which is placed in the center of the disc is drilled.

4. After the drilling process, a finishing process is required to ensure the unwanted part is

fully removed and the surface of the workpiece is smooth.

5. The four through holes with diameter of 4 mm are drilled by the machine with the

sequence as shown below.

Figure 8.0: Flywheel (Top View).

6. The 4 mm diameter holes are finished by the machine after the drilling process is done.

7. Then, the 5 mm diameter hole that is placed on 0 degree of the flywheel is milling and

the finishing process is undergoing after the milling process is done.

8. Next, the blind slot which has arcs with radius of 56 mm, radius of 46 mm, and width of

12 mm is milling until depth of 6 mm.

9. After the milling process, the finishing process is required to ensure the surface of the

workpiece is smooth and all unwanted parts are removed.

10. Take out the workpiece from the fixture by screwing out the screws (as marked in the

figure below) and flip the ring of the fixture together with the workpiece 180°, reinstall

the ring of the fixture and workpiece onto the base of the fixture with screws.
 Figure 9.0: Fixture and Flywheel (Top View).

11. Ensure the screws are screw tight and the position of the ring of fixture with the

workpiece is not running.

12. Then, the blind slot which has arcs with radius 51 mm and radius of 41 mm, and with

width of 12 mm is milling until depth of 6 mm.

13. After the milling process is done, the finishing process is undertaken to remove the

remaining unwanted part on the workpiece and ensure the surface of the workpiece is

smooth.

14. The workpiece becomes unbalanced after the milling process is done, therefore, a through

hole with diameter of 8 mm is milling in the 90 degrees clockwise direction from the

diameter of 5 mm through and 90 mm above the 10 mm through hole. 1. After that, the

finishing process of the hole is operated.

 Figure 10.0: Flywheel (Top View).

15. Then, a blind hole with diameter of 24.60 mm and depth of 12 mm is milling at the

position of 56.57 mm above and 57 mm to the left of the diameter of 10 mm center

through hole. Finishing process is undergoing after the milling process.

Figure 11.0: Flywheel (Top View).

16. Take out the flywheel cam from the fixture. The flywheel is done and becomes balanced.