The fixture is a collection of working holdings
that holds, supports, and locates the workpiece.
Depending on their application, the fixture is needed in
different industries. The locating pin is used to restrict
the panel's degree of freedom. The panel will affect the
loading and unloading of the panel due to a fixed
position pin, so we have to configure the shift tool to
change the positioning pin during loading and unloading
of the panel. In this project we will create a CAD model
with a jig and welding fixture. The change unit or the
position unit will be designed as compact as possible,
depending on the need for the jig and the welding
fixture. This project is designed to move the positioning
pin between the locating pin and the panel to avoid
interference during loading and unloading.
FAST stands for “FUNCTIONAL ANALYSIS SYSTEMS TECHNIQUE”
The FAST technique has long been used in Value Engineering to analyze costs. Function Analysis System Technique (FAST) is a tool that has mainstay of the value management profession since its introduction In 1965.
Product Design and Development 20ME43P C-20 Lab Manual.pdfTHANMAY JS
Product Development and Design:
1. Explain Product Development-Stages of Product Development-Need and Feasibility study
2. Explain Development of design-Selection of Materials and Process
3. Explain Protype –launching of product –Product life cycle
General consideration in design Based on:
• Functional requirement
• Effect on environment
• Life, Reliability, Safety
• Principles of Standardization
• Assembly Feasibility
• Maintenance-Cost-Quantity
• Legal issues and Patents
• Aesthetic and Ergonomic factors
• Choice of Materials
• Feasibility of Manufacturing Processes
Aesthetic and Ergonomic consideration in Design:
• Explain Aesthetic considerations-Basic types of product forms, designing for appearance, shape, Design features, Materials, Finishes, proportions, Symmetry Contrast etc.
• Morgan’s color code.
• Ergonomic considerations-Relation between man, machine and environmental factors.
• Design of displays and controls.
“Case Study on Ergonomics and Aesthetic design principles”.
Torsion of Shaft:
1. Assumptions in Shear stress in a shaft subjected to torsion –Strength and Rigidity (Solid and Hollow shaft)
2. Power Transmitted by Solid and Hollow shaft - ASME and BIS Code for power Transmission
3. Problems on Shafts subjected to only Shear based on Rigidity and Strength
Validate the Problems on Shafts for Strength and Rigidity using Ansys (One each on Strength and Rigidity)
1. Problems on Shafts subjected to only Shear based on Rigidity and Strength
2. Problems on Shaft subjected to only Bending
3. Problems on Shaft subjected to only Bending
Practice on Section of Solids
a) Prisms
b) Pyramid
1. Problems on Shaft subjected to combined Shear and Bending.
2. Problems on Shaft subjected to combined Shear and Bending
3. Problems on Shaft subjected to combined Shear and Bending
Practice on Section of Solids
a) Cylinder
b) Cone
Springs:
1. Classification of springs- Application of springs- Leaf springs –Application
2. Terminology of Helical spring-Materials and Specification of springs
3. Design of helical spring
Sections on Simple Machine Elements (CAD)
a) Sectional front view, Front view with Right half in Section, Front view with Left half in Section
b) Sectional Top View
c) Sectional Side View
Coupling:
i. Design of Muff coupling
ii. Design of Protected type Flange Coupling
iii. Design of Knuckle Joint
Using CAD, prepare Part Models for Muff coupling based on designed parameter and assemble the same.
Extract the Sectional views for the above machine element indicating Surface Texture and Bill of Materials
3D Printing
1. Introduction, Process, Classifications, Advantages of additive over conventional Manufacturing, Applications, Modeling for Additive Manufacturing
2. Additive Manufacturing Techniques, 3D Printing Materials and its forms, Post Processing Requirement and Techniques.
3. Product Quality, Inspection and Testing, Defects and their causes, Additive Manufacturing Application Domains
Preparation of 3D Printer for printing – Modeling, S
FAST stands for “FUNCTIONAL ANALYSIS SYSTEMS TECHNIQUE”
The FAST technique has long been used in Value Engineering to analyze costs. Function Analysis System Technique (FAST) is a tool that has mainstay of the value management profession since its introduction In 1965.
Product Design and Development 20ME43P C-20 Lab Manual.pdfTHANMAY JS
Product Development and Design:
1. Explain Product Development-Stages of Product Development-Need and Feasibility study
2. Explain Development of design-Selection of Materials and Process
3. Explain Protype –launching of product –Product life cycle
General consideration in design Based on:
• Functional requirement
• Effect on environment
• Life, Reliability, Safety
• Principles of Standardization
• Assembly Feasibility
• Maintenance-Cost-Quantity
• Legal issues and Patents
• Aesthetic and Ergonomic factors
• Choice of Materials
• Feasibility of Manufacturing Processes
Aesthetic and Ergonomic consideration in Design:
• Explain Aesthetic considerations-Basic types of product forms, designing for appearance, shape, Design features, Materials, Finishes, proportions, Symmetry Contrast etc.
• Morgan’s color code.
• Ergonomic considerations-Relation between man, machine and environmental factors.
• Design of displays and controls.
“Case Study on Ergonomics and Aesthetic design principles”.
Torsion of Shaft:
1. Assumptions in Shear stress in a shaft subjected to torsion –Strength and Rigidity (Solid and Hollow shaft)
2. Power Transmitted by Solid and Hollow shaft - ASME and BIS Code for power Transmission
3. Problems on Shafts subjected to only Shear based on Rigidity and Strength
Validate the Problems on Shafts for Strength and Rigidity using Ansys (One each on Strength and Rigidity)
1. Problems on Shafts subjected to only Shear based on Rigidity and Strength
2. Problems on Shaft subjected to only Bending
3. Problems on Shaft subjected to only Bending
Practice on Section of Solids
a) Prisms
b) Pyramid
1. Problems on Shaft subjected to combined Shear and Bending.
2. Problems on Shaft subjected to combined Shear and Bending
3. Problems on Shaft subjected to combined Shear and Bending
Practice on Section of Solids
a) Cylinder
b) Cone
Springs:
1. Classification of springs- Application of springs- Leaf springs –Application
2. Terminology of Helical spring-Materials and Specification of springs
3. Design of helical spring
Sections on Simple Machine Elements (CAD)
a) Sectional front view, Front view with Right half in Section, Front view with Left half in Section
b) Sectional Top View
c) Sectional Side View
Coupling:
i. Design of Muff coupling
ii. Design of Protected type Flange Coupling
iii. Design of Knuckle Joint
Using CAD, prepare Part Models for Muff coupling based on designed parameter and assemble the same.
Extract the Sectional views for the above machine element indicating Surface Texture and Bill of Materials
3D Printing
1. Introduction, Process, Classifications, Advantages of additive over conventional Manufacturing, Applications, Modeling for Additive Manufacturing
2. Additive Manufacturing Techniques, 3D Printing Materials and its forms, Post Processing Requirement and Techniques.
3. Product Quality, Inspection and Testing, Defects and their causes, Additive Manufacturing Application Domains
Preparation of 3D Printer for printing – Modeling, S
This presentation focuses on basics of solid state processes and its processes including the applications of specific processes. It also covers the advantages and disadvantages of the discussed processes.
DESIGN FOR MANUFACTURING AND ASSEMBLY.A really good insight of DFA and DFM. Also includes a very precise and appealing caste study on aimplemention of DFMA on a motor drive assembly.
GD&T is an international way of describing a part accurately. It is used widely in all manufacturing sectors for part dimensioning. This ppt contains basic overview of GD&T. The detailed version will be uploaded soon.
Introduction to hydraulics and pneumatic by Varun Pratap SinghVarun Pratap Singh
Download Link (Copy URL):
https://sites.google.com/view/varunpratapsingh/teaching-engagements
This file contains basic information about hydraulics and pneumatic systems.
Purpose Statement:
To provide an overview of Design for Manufacturing and Assembly (DFMA) techniques, which are used to minimize product cost through design and process improvements.
Mechanical Drafting welding joint, piping and duct layoutGaurav Mistry
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Computer aided fixture design for machining of key waysLaukik Raut
Eccentric shaft play an important role in application of
ginning machine. Machining of keyways on eccentric
shaft is a important task. Machining on simple shaft is
easy as compare to eccentric shaft by conventional
process. machining of keyways on eccentric shaft is a
time consuming process, so reducing this time is a main
aim.
The job having a cylindrical shape and number of
keyways are required on it at an different position. This
is a challenging task for design engineer and hence
Computer Aided Fixture Design (CAFD) is incorporated
in manufacturing industry. It deals with the integration
of CAD and CNC programming in CAM systems using
software’s for fixture design. Except V block, no other
option is available to hold cylindrical object and hence
special type of fixture is designed for this case, which can
be used for machining of keyway on eccentric shaft.
Fixtures reduce operation time and increases
productivity and high quality of operation is possible.
DESIGN OF FIXTURE OF CONNECTING ROD FOR BORING OPERATIONijsrd.com
Connecting rod is very important part of engine. It should be accurately machined with the acceptable tolerance. Also the fluctuations of dimensions in work-piece to work piece should be minimum so that it will be easier to assemble in engine. But it has been observed that the required dimensions for the bolt diameter and smaller end diameter for the connecting rod are not continuously achievable by using the existing fixture. The diameters required of the bolts and the smaller end of the said connecting rod are 10±0.05 mm and 24±0.01 mm respectively The aim of this project is to design and development of a new fixture for machining (Boring) operation using designing software's i.e. Pro E and analysis using ANSYS ,which can eliminate the said problems. And the production rate will also increase up to 15% which is quite objective. So for that, a new hydraulic fixture is designed and observed that dimensional accuracy, increased production rate up to 15% and more output per day with boring operation. Which defines process is satisfactory enough and validates the project.
This presentation focuses on basics of solid state processes and its processes including the applications of specific processes. It also covers the advantages and disadvantages of the discussed processes.
DESIGN FOR MANUFACTURING AND ASSEMBLY.A really good insight of DFA and DFM. Also includes a very precise and appealing caste study on aimplemention of DFMA on a motor drive assembly.
GD&T is an international way of describing a part accurately. It is used widely in all manufacturing sectors for part dimensioning. This ppt contains basic overview of GD&T. The detailed version will be uploaded soon.
Introduction to hydraulics and pneumatic by Varun Pratap SinghVarun Pratap Singh
Download Link (Copy URL):
https://sites.google.com/view/varunpratapsingh/teaching-engagements
This file contains basic information about hydraulics and pneumatic systems.
Purpose Statement:
To provide an overview of Design for Manufacturing and Assembly (DFMA) techniques, which are used to minimize product cost through design and process improvements.
Mechanical Drafting welding joint, piping and duct layoutGaurav Mistry
Theory of welding joint, types, advantages, disadvantages, symbols, arrow symbol, interpretation of symbol of welding in drawing, piping layout, types, duct layout
Computer aided fixture design for machining of key waysLaukik Raut
Eccentric shaft play an important role in application of
ginning machine. Machining of keyways on eccentric
shaft is a important task. Machining on simple shaft is
easy as compare to eccentric shaft by conventional
process. machining of keyways on eccentric shaft is a
time consuming process, so reducing this time is a main
aim.
The job having a cylindrical shape and number of
keyways are required on it at an different position. This
is a challenging task for design engineer and hence
Computer Aided Fixture Design (CAFD) is incorporated
in manufacturing industry. It deals with the integration
of CAD and CNC programming in CAM systems using
software’s for fixture design. Except V block, no other
option is available to hold cylindrical object and hence
special type of fixture is designed for this case, which can
be used for machining of keyway on eccentric shaft.
Fixtures reduce operation time and increases
productivity and high quality of operation is possible.
DESIGN OF FIXTURE OF CONNECTING ROD FOR BORING OPERATIONijsrd.com
Connecting rod is very important part of engine. It should be accurately machined with the acceptable tolerance. Also the fluctuations of dimensions in work-piece to work piece should be minimum so that it will be easier to assemble in engine. But it has been observed that the required dimensions for the bolt diameter and smaller end diameter for the connecting rod are not continuously achievable by using the existing fixture. The diameters required of the bolts and the smaller end of the said connecting rod are 10±0.05 mm and 24±0.01 mm respectively The aim of this project is to design and development of a new fixture for machining (Boring) operation using designing software's i.e. Pro E and analysis using ANSYS ,which can eliminate the said problems. And the production rate will also increase up to 15% which is quite objective. So for that, a new hydraulic fixture is designed and observed that dimensional accuracy, increased production rate up to 15% and more output per day with boring operation. Which defines process is satisfactory enough and validates the project.
An Advanced Exploration on Fixture DesignIJERA Editor
Widely used in manufacturing, fixtures have a direct impact upon product manufacturing quality, productivity and cost, so much attention has already been paid to the research fixture design and many achievements in this field have been reported. In this paper, a literature survey of fixture design and automation over the past decade is proposed. First, an introduction is given on the fixture applications in industry. Then, significant works done in the design field, including their approaches, requirements and working principles are discussed. Finally, some prospective research trends are also discussed.
Design and development of hydraulic fixtureLaukik Raut
In machining fixtures, minimizing workpiece deformation due to clamping and cutting forces is
essential to maintain the machining accuracy. The recent trends in industry are towards adopting
the hydraulic techniques, because it save time generates accuracy and it is having some flexibility.
Hydraulic Fixture is major application in the field of designing, where in several software’s are
available for the purpose of design. Hydraulic lift housing is engine part of an agricultural tractor
which plays an important role in application of lifting trolley of tractor and machining of hydraulic
lift housing is a important task. Loading and unloading of workpiece in manual clamping is time
consuming process, so reducing machining time, set up time etc is a main aim of process. The
job having cylindrical shape, this is a challenging task for design engineer, hence hydraulic
fixture design is incorporated in manufacturing industry. Except toggle clamp, no other option is
available to hold cylindrical object, hence special type of fixture is design for this case, which
can be used for machining of hydraulic lift housing, Fixture reduces operation time, increases
productivity, and best quality of operation is possible. The project deals with the designing of
different parts of fixture assembly, 3D modeling by using Pro-E WILDFIRE 5.0, finite element
analysis of hydraulic lift housing by using ANSYS software.
DESIGN AND DEVELOPMENT OF MACHINING FIXTURE FOR BD65 FINAL DRIVE CASE ON HORI...IAEME Publication
A machining fixture is a device used to hold or support work in the manufacturing
industry. By using the specifications of the horizontal machining center, we designed
and analyzed the 3D model of the fixture in the software. For the final drive case, this
machining fixture on LH & RH is used for Bharath dozers 65 ton capacity. This
horizontal machining center will increase production rates, reduce demand for labor,
save time. This machine will be performed after production hours, after operations
such as drilling, boring, tapping, reaming, threading. Using a fixture improves the
economy of production by enabling smooth operation and rapid transition from part
to part, reducing the skilled labor requirement to simplify set-up and use of fixtures,
and increasing compliance across a production run
Design and development of fixture for eccentric shaft a reviewLaukik Raut
of eccentric shaft for ginning machine..
Fixture is required in various industries
according to their application. Designer design
fixture according to dimension required by
industry to fulfill our production tar gate. In
traditional manufacturing process performing
operation on eccentric shaft is critical. so holding
a work piece in proper position during a
manufacturing operation fixture is very
necessary and important. Because the shaft is
eccentric so for this requirement of
manufacturing process Designer design proper
fixture for eccentric shaft.
Fixtures reduce operation time and increases
productivity and high quality of operation is
possible.
Similar to Design and analysis of jig and welding fixture (20)
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Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
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About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
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Design and analysis of jig and welding fixture
1. Impact Factor Value 5.856 e-ISSN: 2456-3463
International Journal of Innovations in Engineering and Science, Vol 5, No.10, 2020
www.ijies.net
1
Design and Analysis of Jig and Welding Fixture
for Car Panel to Shift the Locate Pin
Diksha R. Bahadure 1, Dr. Subhash N. Waghmare 2
1
M.Tech. a student in Mechanical Engineering Design, Priyadarshini College of Engineering, Nagpur, India, 440022
2
Assistant Professor in Mechanical Engineering Department, Priyadarshini College of Engineering,Nagpur, India, 440022
DOI: 10.46335/IJIES.2020.5.10.1
Abstract – The fixture is a collection of working holdings
that holds, supports, and locates the workpiece.
Depending on their application, the fixture is needed in
different industries. The locating pin is used to restrict
the panel's degree of freedom. The panel will affect the
loading and unloading of the panel due to a fixed
position pin, so we have to configure the shift tool to
change the positioning pin during loading and unloading
of the panel. In this project we will create a CAD model
with a jig and welding fixture. The change unit or the
position unit will be designed as compact as possible,
depending on the need for the jig and the welding
fixture. This project is designed to move the positioning
pin between the locating pin and the panel to avoid
interference during loading and unloading.
Keywords- Locating pin, panel, CAD model, welding
fixture, jig
I- INTRODUCTION
The jigs and fixtures are an economical way to mass-
produce a part. Thus jigs and fixtures are used and are
one of the most critical installations of the mass
production system. These are special work holding and
tool guiding device. The output quality of a process
primarily determined by the quality of the jigs and
fittings used for this purpose. What makes a fixture
special is that everyone is designed to match a particular
part or shape. A fixture has the main function of locating
and retaining a work piece during service. In addition to
locating and supporting the work piece, a jig differs from
a fixture in the sense that it directs the tool to its correct
location or movement during operation. Fixture required
Specialization to accurately hold the work-piece during
the welding operation. The Fixture designed hold job
and rotate the job at required Speed. The reduced cycle
time and operator labor while increasing functionality
[1],[2], [3].
Depending on their application, the fixture is needed in
different industries. Due to some drawbacks the
configuration of a new fixture is changed over the current
fixture. The part fixture is installed manually so loading
and unloading of the material take more cycle time [4] ,
[5], [6], [7]. .
Work-holding methods have also changed considerably;
the core principles of clamping and position are still
identical. Mass production methods require a simple and
easy way to put work on them for various operations. To
address this issue we designed the welding fixture with
enhanced mobility [8], [9], [10], [11].
In general, clamping is necessary to hold the job in the
jig. Much as in the automotive market, jigs may also be
concept guides or templates. Special cramping jigs to
ensure that the panel is placed in the right position. The
fixture is a strong and rigid mechanical device that
attaches to a machine and allows the stock to slide while
holding firmly, allowing for simple, easy and reliable
accuracy of position, support, and clamping. A fixture is
a device for locating, holding, and supporting a work-
piece during a manufacturing operation. This consists of
locators, clamps, supports, and fixture body [12], [13],
[14], [15].
The unit's contents describe jigs and fixtures as a work
piece clamping device and guiding device for the
2. Impact Factor Value 5.856 e-ISSN: 2456-3463
International Journal of Innovations in Engineering and Science, Vol 5, No.10, 2020
www.ijies.net
2
machine. The use of jigs and fittings directly impacts the
output level of the operation. It increases work efficiency
by eliminating the manufacture of low-quality goods and
reducing product cycle times. Jigs and fixtures design
always depends on the type of operation and the machine
tool to be used for that operation. Using jig and fixture
means placing the work piece in the appropriate location
on the machine tool. The purpose of the position is to
decide the points on the work where all the movements
should be restricted so that the work can be completed
without any problems [16], [17], [18], [19]. For this
reason, other position principles are followed, such as 3-
2-1 position theory, flat locator, cylindrical and conical
locator, and jack pin locator. The key aim of the position
theory is to curb the rigidity of the clamping. At the same
time all of this leaves the production area open and ready
for production. The unit also defines different types of
clamping devices and the characteristics of a successful
clamping system along with the attachments, jigs are
used to direct the movement of the tool during service.
They are made of steel that is hardy, wear-resistant, and
corrosion-resistant. It also defines the widely used
fixtures in the room [20], [21], [22], [23].
II- METHOLOGY
Design Selection
Design selection is the process of selecting the concept
that has been evaluated according to the requirement and
the appropriate criteria. When comparing the relative
strengths and limitations of the model, choose the best
definition to be used for further analysis. Generally
speaking, idea selection is the method of narrowing up
the alternative definition considered [24], [25], [26], [27].
The screening form was chosen for the final design for
the jig. This approach will help designers determine
which concept is best.
Fig. 1- Location of pin damaging panel (before
modifications)
Final Concept
The final design of the semi-auto insertion jig is much
better than the second design, which for this design is the
assembly component, which is also simple.
Basic Design Principle for Jig and Fixture
The basic concept when designing the jig and the
fixture is to help, locate, clamp, and keep the job. This
concept originates from the final design of semi-auto
insertion [28], [29]. The support of the part should be
rigid. From this semi-auto insertion jig, make sure that
the supporting design is robust enough to ensure accuracy
when inserting the e-ring into the main lever portion. The
fool proofing tool used for these parts is pins which
clearly can position parts correctly and prevent parts from
entering this jig incorrectly. Using screw clamps, this
semi-auto inserter jig [30], [31]. The torque is used by the
base screw clamp to hold a part in places by direct
pressure on another part. The retaining power for this jig
uses the screws and nuts. The bolts and nuts are simple to
use and can be mounted from any component [32], [33].
Design for safety
The design of the product is safe and easy to use when
designing jig and fixtures. Sharp corners should be
avoided on the jig or fixture body. When designing the
semi-auto insertion jig in this project, each design
component uses chamfers in each corner to ensure that
there is no sharp corner that can damage the operator
when using the jig Bolt and groove should be inside the
body and should not protrude the surface [34], [35]. The
surface of this semi-auto insertion is well built as
something bold is placed inside the jig which makes the
work surface clear and can prevent injury and obstacles
while doing the job.
III- DESIGN
Force Calculation and Analysis of Clamp-
CLAMPING FORCE CALCULATION (BEFORE
MODIFICATION)
B
F
A
F 2
1
Where F1= Clamping force
F2= Cylinder force
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3
Fig. 2: Clamp dimensions of A and B
Given,
The bore diameter of cylinder = Φ50
F2 = Cylinder force = 78 kgf
A = 60 mm
B = 239.5 mm
Therefore,
5
.
239
60
*
78
1
F
kgf
F 54
.
19
1
81
.
9
*
54
.
19
1
F
N
F 192
1
The clamping force is 192 N
CLAMPING FORCE CALCULATION (AFTER
MODIFICATION)
B
F
A
F 2
1
Where F1= Clamping force
F2= Cylinder force
B
A
F
F *
2
1
Given,
Bore diameter of cylinder = Φ63
F2 = Cylinder force = 124 kgf
A = 60 mm
B = 239.5 mm
Therefore,
5
.
239
60
*
124
1
F
kgf
F 06
.
31
1
81
.
9
*
06
.
31
1
F
N
F 305
1
The clamping force is 305 N
Table 1- According to Japanese Industrial Standards
(JIS) bore diameter and force of cylinder is given below
Sr.no The bore diameter
of the cylinder
Cylinder force
1 Φ 40 78 kgf
2 Φ 50 78 kgf
3 Φ 63 124 kgf
4 Φ 80 201 kgf
Table 2- Mechanical Properties of Steel (SS400)
Sr.no Stress Safety factor Allowable
stress (MPa)
1 Tensile 1.67 140
2 Compression 1.67 140
3 Bending 3.0 80
4 Shear 1.67 140
Table 3- Maximum allowable deflection (mm)
Sr.no Parts Allowable deflection
(mm)
1 Stool 0.5199
2 Bracket 0.306
3 Stopper 0.391
4 Clamp 0.203
Table 4- Thermal Properties of Steel (SS400)
Sr.no Temperature
(0
C)
Young
Modulus(GPa)
Poisson’s
ratio
1 50 209.05 0.3
2 100 205.74 0.3
3 200 198.90 0.3
4 300 192.14 0.3
5 400 183.65 0.3
6 500 174.52 0.3
Table 5- According to Japanese Industrial Standards
(JIS) flat steel sizes are given below
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Sr.no Sectional Dimension Break
area
(cm2
)
Unit
weight
(Kg/m)
Thickness
(mm)
Width(mm)
1 100 12 9.42
12 125 15 11.8
150 18 14.1
180 21.6 17
200 24 18.8
230 27.6 21.7
250 30 23.6
280 33.6 26.4
300 36 28.3
32 5.12 4.02
38 6.08 4.77
44 7.04 5.53
2 16 50 8 6.28
65 10.4 6.16
75 12 8.16
90 14.4 9.42
100 16 11.3
125 20 12.6
150 24 15.7
180 28.8 18.8
200 32 22.6
230 36.8 25.1
250 40 28.9
280 44.8 31.4
300 48 35.2
The finite element analysis of the parts of the jig is given
below:
To shift the locating pin, the shift cylinder arrangement is
designed because of that stresses are developed in the
following parts.
Fig. 3: Model showing stresses in SS400
The maximum stress develops in the above part is
5.46e+005, which is 54.6 MPa. This is less than
maximum allowable stresses as shown in table 2.
Therefore, the design is safe.
Fig. 4: Model (Stool) showing deflection in SS400
The maximum deflection develops in the above part is
0.000283 mm, which is less than the maximum allowable
deflection as shown in table 3. Therefore, the design is
safe.
Fig. 5: Model showing stresses in SS400
The maximum stress develops in the above part is
6.72+005, which is 0.672 MPa. This is less than
maximum allowable stresses as shown in table 2.
Therefore, the design is safe.
Fig. 6: Model (Bracket) showing deflection in SS400
The maximum deflection develops in the above part is
0.000345 mm, which is less than the maximum allowable
deflection as shown in table 3. Therefore, the design is
safe.
5. Impact Factor Value 5.856 e-ISSN: 2456-3463
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5
Fig. 7: Model (Stopper) showing stresses in SS400
The maximum stress develops in the above part is
5.46e+007, which is 54.6 MPa. This is less than
maximum allowable stresses as shown in table 2.
Therefore, the design is safe.
Fig. 8: Model (Stopper) showing deflection in SS400
The maximum deflection develops in the above part is
0.0763 mm, which is less than the maximum allowable
deflection as shown in table 3. Therefore, the design is
safe.
Fig. 9: Model (Clamp) showing stresses in SS400
The maximum stress develops in the above part is
8.24e+007, which is 82.4 MPa. This is less than
maximum allowable stresses as shown in table 2.
Therefore, the design is safe.
Fig. 10: Model (Clamp) showing deflection in SS400
The maximum deflection develops in the above part is
0.159 mm, which is less than the maximum allowable
deflection as shown in table 3. Therefore, the design is
safe.
The engineering design process is one of the steps
required for product creation. Phase in the design of a jig
and fixture is to find the right combination of design
characteristics at a fair cost by assessing its functional
requirements. At this point, the tool design process will
clearly state the problem that needs to be solved and
accomplished. The design process also included research
involving the product, such as the clamping location, load
distribution, selection of materials, and more research and
design details. This method will also clarify how to build
the semi-auto e-ring insertion jig and how to carry out the
study. The software CATIA CAD is used for the design.
These values are very necessary to decide if the design of
the component is acceptable and complies with the
requirement.
Fig. 11: Jig with Shift cylinder arrangement
The shift unit is shifted 70mm below as the shift
cylinder is of 75mm stroke length. 5mm clearance is
maintained.
By using these flat bar sizes the parts of the jig
and welding fixture has designed. All parts of the jig are
shown in figure 11.
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6
IV- CONCLUSION
In this research work, the shift unit in the jig is made as
compact as possible according to the necessity of the jig
and the welding fixture. This project has planned to shift
the locating pin to prevent interference during the
landing and takeoff of the panel. To make this kind of
arrangement some parts of the jig have to modify. By
using Japanese Industrial Standards (JIS) parts get
modified in CATIA. By using the same, parts get drafted
in Auto CAD; with the modifications in design the
objective is achieved.
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