The document describes the design and development of a rotary fixture for a CNC turning center. The fixture is intended to machine a flow TEE body from a petroleum refinery. Operations include facing, turning, grooving, boring, and back facing. A four-quadrant computer aided mass balancing method is used to predict and balance any mass imbalance before manufacturing. Mass properties are calculated for each quadrant and summed to find the total imbalance. A counterweight is then added to balance the fixture about the two axes perpendicular to the rotation axis. The method allows imbalance to be addressed during the design phase to reduce material waste and improve productivity compared to traditional post-manufacturing balancing approaches.
This document summarizes a research paper that proposes a computer-aided mass balancing method for rotary fixtures on CNC machines. The method uses CAD software to divide the fixture into four quadrants and calculate the mass properties of each quadrant. It then analyzes the mass distribution to determine any imbalances and calculates the necessary counterweights to balance the fixture. This approach allows imbalances to be predicted and addressed during the design phase before manufacturing, which can save costs and improve productivity compared to traditional post-manufacturing balancing methods. The paper presents this proposed computer-aided mass balancing method as applied to the specific case of designing a rotary fixture for machining a TEE body component on a CNC turning center.
Sand casting conventional and rapid prototyping manufacturing approacheseSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Manufacturing Process Simulation Based Geometrical Design for Complicated PartsLiu PeiLing
More than ever, it is critical that products are designed and manufactured right the first time. Design for Manufacturing (DFM) methodology has been recognized as one of the most effective ways to short product lifecycle time and reduce manufacturing cost. The main function of DFM in the detailed design stage is analyzing the manufacturability of the part. Various existing manufacturability evaluation methods have their limitations. In this paper, a new approach to DFM for the complicated parts is proposed. Instead of checking the manufacturability following the design, the in-process model resulting from the manufacturing process simulation is used to generate process dependent geometry surfaces at the design stage. The definition of the manufacturing process dependent geometry is given, and the methodology for creation of in-process model is presented in details.
Structural optimization of a powered industrial lift truck frameIAEME Publication
This document summarizes the structural optimization of a powered industrial lift truck frame. Topology and size optimization techniques were used to redesign the frame in Altair Engineering's OptiStruct software. Up to 15% weight reduction was achieved in the frame without compromising functional requirements or assembly fitments. Considerable cost savings of Rs. 10,000 per vehicle were realized through this optimization process. The optimized design was verified using an alternate solver and showed only marginal increases in stress and deflection compared to the original design.
DESIGN MODIFICATION AND ANALYSIS OF FIXTURE TO ACCOMMODATE DIFFERENT STEAM TU...Journal For Research
This document discusses the design modification and analysis of a fixture to accommodate different steam turbine casings. The existing fixture design is modeled and analyzed using finite element analysis, which shows high vibration and stresses. The fixture design is then modified by increasing the number of truss members, adding horizontal support members, and relocating control points. Analysis of the modified design shows reduced stresses, deformation, and vibration compared to the existing design. Specifically, the modified design increases natural frequency by up to 138% while reducing equivalent stress by up to 94% and deformation by up to 94%. In conclusion, the modified universal fixture design improves handling of different steam turbine casings with less vibration and stress.
IRJET- Taguchi Optimization of Cutting Parameters for Surface Roughness and M...IRJET Journal
This document summarizes a study that used the Taguchi method to optimize cutting parameters (cutting speed, feed rate, and depth of cut) for surface roughness and material removal rate during turning operations. Experiments were conducted using a CNC lathe machine and 25Cr-12 Ni TP309 steel workpiece material. An L9 orthogonal array was used to collect data on the response variables (surface roughness and material removal rate) based on variations in the cutting parameters. The data was analyzed using signal-to-noise ratios and ANOVA to determine the optimal cutting parameter settings that minimized surface roughness and maximized material removal rate.
Abstract: This Project presents the Design of Machining Fixture for Support Bracket for Machining on VTC (Vertical Turning Centre). Fixture Design consists of High product rate, low manufacturing operation cost. The fixture should be designed in such-a-way that part/product change overtime is very less. The report consists of study of input data from customers like Part drawing and Assembly drawing. The fixture design begins with part modeling, Machining and Analysis of various parts in the fixture assembly using AutoCAD and Solid works, for a analysis ANSYS Software package is used. The actual design begins with study details of project proposal summary from customer. After that machining fixture concept is done. Locating and clamping points are decided. This also includes accessibility, loading and unloading sequence of parts, required material for this fixture is selected, and Fixture is designed at HMT MACHINE TOOL, KALAMASSERY using Industrial application standards. Locating accuracy and machined part quality tested and found that the fixture is as good as any dedicated fixture in production.
The document discusses the design of a forging die for a planetary gear blank. It begins with an introduction to forging as a metalworking process and advantages it provides over other manufacturing methods. It then outlines the objectives and methodology for the die design project. The methodology involves designing the final gear part geometry, determining stock size requirements, and designing the forging die. Key die design considerations discussed include parting line selection, drafting angles, fillet and corner radii, flash and gutter design, and shrinkage allowance. The document concludes with CAD drawings of the designed forging die.
This document summarizes a research paper that proposes a computer-aided mass balancing method for rotary fixtures on CNC machines. The method uses CAD software to divide the fixture into four quadrants and calculate the mass properties of each quadrant. It then analyzes the mass distribution to determine any imbalances and calculates the necessary counterweights to balance the fixture. This approach allows imbalances to be predicted and addressed during the design phase before manufacturing, which can save costs and improve productivity compared to traditional post-manufacturing balancing methods. The paper presents this proposed computer-aided mass balancing method as applied to the specific case of designing a rotary fixture for machining a TEE body component on a CNC turning center.
Sand casting conventional and rapid prototyping manufacturing approacheseSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Manufacturing Process Simulation Based Geometrical Design for Complicated PartsLiu PeiLing
More than ever, it is critical that products are designed and manufactured right the first time. Design for Manufacturing (DFM) methodology has been recognized as one of the most effective ways to short product lifecycle time and reduce manufacturing cost. The main function of DFM in the detailed design stage is analyzing the manufacturability of the part. Various existing manufacturability evaluation methods have their limitations. In this paper, a new approach to DFM for the complicated parts is proposed. Instead of checking the manufacturability following the design, the in-process model resulting from the manufacturing process simulation is used to generate process dependent geometry surfaces at the design stage. The definition of the manufacturing process dependent geometry is given, and the methodology for creation of in-process model is presented in details.
Structural optimization of a powered industrial lift truck frameIAEME Publication
This document summarizes the structural optimization of a powered industrial lift truck frame. Topology and size optimization techniques were used to redesign the frame in Altair Engineering's OptiStruct software. Up to 15% weight reduction was achieved in the frame without compromising functional requirements or assembly fitments. Considerable cost savings of Rs. 10,000 per vehicle were realized through this optimization process. The optimized design was verified using an alternate solver and showed only marginal increases in stress and deflection compared to the original design.
DESIGN MODIFICATION AND ANALYSIS OF FIXTURE TO ACCOMMODATE DIFFERENT STEAM TU...Journal For Research
This document discusses the design modification and analysis of a fixture to accommodate different steam turbine casings. The existing fixture design is modeled and analyzed using finite element analysis, which shows high vibration and stresses. The fixture design is then modified by increasing the number of truss members, adding horizontal support members, and relocating control points. Analysis of the modified design shows reduced stresses, deformation, and vibration compared to the existing design. Specifically, the modified design increases natural frequency by up to 138% while reducing equivalent stress by up to 94% and deformation by up to 94%. In conclusion, the modified universal fixture design improves handling of different steam turbine casings with less vibration and stress.
IRJET- Taguchi Optimization of Cutting Parameters for Surface Roughness and M...IRJET Journal
This document summarizes a study that used the Taguchi method to optimize cutting parameters (cutting speed, feed rate, and depth of cut) for surface roughness and material removal rate during turning operations. Experiments were conducted using a CNC lathe machine and 25Cr-12 Ni TP309 steel workpiece material. An L9 orthogonal array was used to collect data on the response variables (surface roughness and material removal rate) based on variations in the cutting parameters. The data was analyzed using signal-to-noise ratios and ANOVA to determine the optimal cutting parameter settings that minimized surface roughness and maximized material removal rate.
Abstract: This Project presents the Design of Machining Fixture for Support Bracket for Machining on VTC (Vertical Turning Centre). Fixture Design consists of High product rate, low manufacturing operation cost. The fixture should be designed in such-a-way that part/product change overtime is very less. The report consists of study of input data from customers like Part drawing and Assembly drawing. The fixture design begins with part modeling, Machining and Analysis of various parts in the fixture assembly using AutoCAD and Solid works, for a analysis ANSYS Software package is used. The actual design begins with study details of project proposal summary from customer. After that machining fixture concept is done. Locating and clamping points are decided. This also includes accessibility, loading and unloading sequence of parts, required material for this fixture is selected, and Fixture is designed at HMT MACHINE TOOL, KALAMASSERY using Industrial application standards. Locating accuracy and machined part quality tested and found that the fixture is as good as any dedicated fixture in production.
The document discusses the design of a forging die for a planetary gear blank. It begins with an introduction to forging as a metalworking process and advantages it provides over other manufacturing methods. It then outlines the objectives and methodology for the die design project. The methodology involves designing the final gear part geometry, determining stock size requirements, and designing the forging die. Key die design considerations discussed include parting line selection, drafting angles, fillet and corner radii, flash and gutter design, and shrinkage allowance. The document concludes with CAD drawings of the designed forging die.
IRJET- Design AIDS for Beam-Column Design as per IS 800:2007IRJET Journal
This document presents design aids in the form of graphs to help structural designers efficiently design beam-columns according to IS800:2007. The authors developed excel spreadsheets to generate graphs of factored load versus factored moment for various steel sections and effective lengths. Fourteen graphs were presented for different Indian standard hollow beam sections (ISHB). The graphs allow designers to directly select a section based on the required factored load and moment capacity. An example problem demonstrates how to use the graphs to select a section meeting design requirements for a beam-column with a factored load of 1520kN and factored moment of 36kN-m. The graphs save designers time over manual calculations and reduce complexity, helping ensure structural safety in
IRJET- A Critical Review on Bellow Part Removal FixtureIRJET Journal
This document provides a review of bellow removal fixtures. It begins with an abstract that describes bellows as flexible elements in expansion joints that absorb dimensional changes from forces and thermal expansion. It also describes fixtures as work holding devices that impact manufacturing quality, productivity and cost.
The document then reviews the design of bellow removal fixtures. It discusses key parameters like the fixture frame needing to be rigid to minimize deflection, fast clamping, and locating the workpiece with at least three fixed support points. It also reviews the "3-2-1" locating principle for prismatic parts. Finally, it concludes that fixtures are used for locating and holding workpieces, and that they are fixed to machines to aid mass production and reduce operator
IRJET- Optimization Design and CFD Thermal Analysis of the 72/48 Switched Rel...IRJET Journal
This document describes the optimization design and computational fluid dynamics (CFD) thermal analysis of a 72/48 switched reluctance motor (SRM) for a mining application. A multi-objective optimization framework is proposed using surrogate modeling to reduce computational time. Key steps include design of experiments to collect data, sensitivity analysis to reduce design variables, constructing Kriging surrogate models, and using particle swarm optimization on the models. Thermal analysis using CFD is also performed to evaluate different water jacket configurations and reduce motor temperatures. The optimization results are validated using finite element analysis and show the 72/48 SRM is suitable for high-torque low-speed direct-drive in mining.
The document discusses the manufacturing process planning for a crankshaft using CAM software. It describes creating a 3D CAD model of the crankshaft from 2D drawings, including steps like sketching, revolving, extruding, and using instance geometry. It then covers the CAM process, including selecting a 5-axis DMG milling machine, choosing tools, and generating tool paths to manufacture the crankshaft. The document emphasizes how CAD/CAM allows integrating design and manufacturing to efficiently produce complex components like crankshafts.
1) The document describes two case studies of retrofitting damaged industrial buildings. The first case study involves retrofitting a steel structure damaged by faulty design through two strategies - welding additional members or adding another truss. The second case study modifies a structure by removing a column and adding a beam to support the trusses.
2) Both case studies are modeled and analyzed using STAAD-Pro software to determine load capacities and member sizes. For the first case, adding another truss is more economical but reducing ceiling height, so welding additional members is recommended. For the second case, analysis shows the added beam and existing columns can support the modified loads.
3) In conclusion, retrofitting existing structures is a
IRJET- Design and Structural Analysis of an Off Road VehicleIRJET Journal
This document describes the iterative design and structural analysis of an off-road vehicle frame. The frame was modeled in CATIA and analyzed in ANSYS to minimize stress concentrations through thickness and geometry modifications. Several impact tests were simulated, and the frame design was iteratively optimized to reduce stresses below safety thresholds. The final optimized frame design demonstrated reduced weight and stresses within allowable limits for all impact scenarios tested.
Design evaluation and optimization of steering yoke of an automobileeSAT Journals
Abstract The purpose of a steering system is to control the direction of the vehicle by operating the steering wheel of the steering system. The steering columns in a steering system are one of the main devices of an automobile. It is a very important part to attain stability and steady movement of the vehicle. The steering yoke consists of two forged-steel yokes or forks joined to the two shafts being coupled and situated at right angles to each other. A spider hinges these two yokes together. Since the arms of the spider are at right angles the spider arm rocks backwards and forward between four extreme positions. Motion transmission system of vehicles consist several components which sometimes encounter unfortunate failures. Some common reasons for the failures may be manufacturing, design faults, maintenance faults, raw material faults, material processing faults as well as the user originated faults. In this paper structural optimization of the steering yoke is carried out. For modeling of the component, CATIA V5 R17 software is used. It has been found that there are essentially in two stages of the design process that structural optimization can be applied. In the early stage of concept generation, topology optimization should be used to develop an efficient structure from the beginning. At this level an automatized variation of optimization parameters was proven useful to and the best feasible design possible. In the later stage, shape and size optimization should be used to fine-tune the structure realized from the topology optimization and carried out physical experimentation to validate the model. Keywords: Steering Yoke, Structural optimization, CATIA V5, Hyperworks
Design evaluation and optimization of steering yoke of an automobileeSAT Publishing House
This document describes research conducted to optimize the design of an automobile steering yoke through finite element analysis and experimental testing. The researchers created 3D models of the steering yoke in CATIA software and applied topology, shape, and size optimization techniques. They then conducted finite element analysis in HyperWorks to analyze von Mises stresses, displacement, and mass. Experimental testing was also performed on the steering yoke using a universal testing machine and strain gauges. The optimized design was found to have lower stresses, displacement, and mass than the original design, validating the finite element analysis model.
Large assembly management is a burgeoning problem which is encountered in
all the automotive industries. As the vehicle assemblies of projects moves
towards the fruition stage its size becomes more than 50GB. It thus becomes
very monolithic to manage, making easy tasks such as making minor changes
in the assembly or performing analysis extremely difficult to perform,
moreover the huge assembly size alone is not the only problem but even the
presence of several other components in the assembly tend to hinder any task
that is to be performed.
This document summarizes research on 3D printing hollow compounds of different shapes. It discusses how 3D printing allows for more optimized geometries compared to traditional manufacturing and can produce hollow turbine blades, gears, and disc brakes with properties similar to solid compounds. Finite element analysis was performed on hollow and solid shapes of different cross-sections, finding equivalent stresses were approximately the same. 3D printing reduces material costs and makes manufacturing hollow compounds easier compared to traditional methods. The document concludes 3D printing technologies provide design flexibility while creating parts with layer-by-layer printing instead of traditional manufacturing approaches.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
This document provides an overview of machine design. It defines machine design as designing machine elements and arranging them to obtain useful work. It discusses different types of design such as adaptive, developmental, and new design. It outlines key factors to consider in machine design like materials, forces, size, manufacturability, reliability, and cost. The goal of machine design is to safely transmit forces while allowing the machine to perform its task.
IRJET-Split Casing Open Differential without Cross Pin and it’s Comparison wi...IRJET Journal
This document summarizes the design optimization of work roll chocks and backup roll chocks in a cold rolling mill. The current chocks were failing prematurely, resulting in production stoppages and costs. A 3D model of the chocks was created and analyzed using ANSYS software to determine stress distributions and critical areas under load. The design was iteratively optimized to reduce weight and material costs while maintaining structural integrity. The optimized design was found to reduce chock weight by over 10% and save $9,154.50 per chock based on material and production costs. Modal analysis confirmed the natural frequencies of the optimized design would not cause resonance issues. This new optimized chock design was concluded to provide improved life and cost
The document discusses research on integrating geometric and mechanistic models for cutting process simulation and feedrate optimization in five-axis milling of free-form surfaces. It presents a method for extracting cutter-workpiece engagement geometry from CAD/CAM toolpaths to be used as input for a discrete mechanistic force prediction model. Experimental validation showed good agreement between simulated and measured cutting forces. The integrated modeling approach uses geometric simulation to dynamically update the workpiece model and determine cutter contact areas, while the mechanistic model estimates forces to calculate optimal feedrates within constraints of part quality, tool life, and machine limitations.
IRJET- Tensile and Shear Strength Approximate Prediction of Friction Surf...IRJET Journal
This document discusses using artificial neural networks (ANN) to predict the tensile and shear strength of tool steel coatings deposited through friction surfacing. Friction surfacing is used to deposit coatings on materials and has various industrial applications. An experiment was conducted to deposit tool steel coatings on low carbon steel using different levels of friction pressure, rotational speed, and welding speed. Tensile and shear strength tests were performed on the coatings. ANN models using a feedforward neural network (FFNN) structure were developed and trained on the experimental data to predict coating tensile and shear strength based on the friction surfacing process parameters. The ANN models provide a way to understand and optimize the relationship between mechanical properties and processing
IRJET - Design & Manufacturing of 20 Ton Horizontal Hydraulic Press Machine f...IRJET Journal
This document describes the design and manufacturing of a 20-ton horizontal hydraulic press machine for pipe squeezing and flaring operations. It discusses the need for such a machine to perform these operations for automotive and sheet metal applications. The key components of the machine, including the frame, cylinder, and piston, are modeled in UG NX-11 software. Detailed calculations are shown for selecting materials, estimating forces and stresses, sizing the cylinder, determining system pressures and flow rates, and selecting the appropriate motor power. 3D models and drawings of the frame, pillars, punch and die are presented. Finally, the hydraulic circuit diagram and concluding remarks discuss how the designed machine is intended to efficiently perform flaring and squeezing operations
This document outlines the syllabus for a course on Design of Machine Elements - I. It includes information on textbooks, reference books, modules, and topics to be covered. The course will cover the design process, analysis of forces on machine components, design for static strength, failure theories, stress concentration, and fundamentals of mechanical engineering design. It will consist of 3 hours of lectures and 2 hours of tutorials per week over 10 weeks. The first module will cover the introduction to design process, phases of design, engineering materials and properties, manufacturing processes, codes and standards, loading conditions, stresses, and design for static strength.
IRJET- Multi-Response Parametric Optimization During Turning of En-31 Bar usi...IRJET Journal
The document discusses using the Grey Relational Analysis (GRA) method to optimize multiple responses during turning of EN-31 steel bar. GRA was used to determine the best process parameters to simultaneously maximize material removal rate and minimize surface roughness. An experiment was conducted using a CNC lathe with varying cutting speed, feed rate, and depth of cut. Response values for material removal rate and surface roughness were measured and a GRA coefficient was calculated for each experimental condition. The condition with the highest GRA coefficient ranking would provide the optimal settings to meet the goals of high productivity and quality.
This document provides an introduction to machine design. It defines machine design as using scientific principles, technical information, and imagination to describe a machine to perform specific functions with maximum economy and efficiency. The document then outlines the basic principles of mechanical design, including the design process and considerations for static and fatigue loads. It also discusses standards and material selection in machine design.
DESIGN AND FABRICATION OF WELDING FIXTURES AND POSITIONERSvivatechijri
The document describes the design and fabrication of welding fixtures and positioners. It discusses how welding fixtures are used to accurately position components during welding in mass production. The document outlines the methodology used, including modeling fixtures in CAD software, calculating forces, and analyzing precision placement of circular components. It also discusses other aspects of welding automation like manipulators and positioners. The goal is to develop a new fixture design that can accurately position components within 0.1mm for mass production welding without using robots.
IRJET- Design, Development and Manufacturing of Dedicated Fixture for the...IRJET Journal
This document describes the design and development of a dedicated fixture for drilling and tapping operations on an NRV body component using a 4th axis rotary table VMC machine. It involves studying the component features, conceptualizing and detailing the fixture layout in Solidworks. Each fixturing component is designed and analyzed in ANSYS for deflections and stresses. The objectives are to design a fixture for drilling 4 holes of 11mm diameter and tapping 5 holes of M6x1 to a depth of 10mm in a single setup. The methodology involves component study, fixture planning, individual element design, assembly, manufacturing, and finite element analysis verification. Literature review discusses approaches like using genetic algorithms to optimize locator and clamp positions, reducing cycle times
International Journal of Engineering Research and DevelopmentIJERD Editor
Electrical, Electronics and Computer Engineering,
Information Engineering and Technology,
Mechanical, Industrial and Manufacturing Engineering,
Automation and Mechatronics Engineering,
Material and Chemical Engineering,
Civil and Architecture Engineering,
Biotechnology and Bio Engineering,
Environmental Engineering,
Petroleum and Mining Engineering,
Marine and Agriculture engineering,
Aerospace Engineering.
IRJET- Design AIDS for Beam-Column Design as per IS 800:2007IRJET Journal
This document presents design aids in the form of graphs to help structural designers efficiently design beam-columns according to IS800:2007. The authors developed excel spreadsheets to generate graphs of factored load versus factored moment for various steel sections and effective lengths. Fourteen graphs were presented for different Indian standard hollow beam sections (ISHB). The graphs allow designers to directly select a section based on the required factored load and moment capacity. An example problem demonstrates how to use the graphs to select a section meeting design requirements for a beam-column with a factored load of 1520kN and factored moment of 36kN-m. The graphs save designers time over manual calculations and reduce complexity, helping ensure structural safety in
IRJET- A Critical Review on Bellow Part Removal FixtureIRJET Journal
This document provides a review of bellow removal fixtures. It begins with an abstract that describes bellows as flexible elements in expansion joints that absorb dimensional changes from forces and thermal expansion. It also describes fixtures as work holding devices that impact manufacturing quality, productivity and cost.
The document then reviews the design of bellow removal fixtures. It discusses key parameters like the fixture frame needing to be rigid to minimize deflection, fast clamping, and locating the workpiece with at least three fixed support points. It also reviews the "3-2-1" locating principle for prismatic parts. Finally, it concludes that fixtures are used for locating and holding workpieces, and that they are fixed to machines to aid mass production and reduce operator
IRJET- Optimization Design and CFD Thermal Analysis of the 72/48 Switched Rel...IRJET Journal
This document describes the optimization design and computational fluid dynamics (CFD) thermal analysis of a 72/48 switched reluctance motor (SRM) for a mining application. A multi-objective optimization framework is proposed using surrogate modeling to reduce computational time. Key steps include design of experiments to collect data, sensitivity analysis to reduce design variables, constructing Kriging surrogate models, and using particle swarm optimization on the models. Thermal analysis using CFD is also performed to evaluate different water jacket configurations and reduce motor temperatures. The optimization results are validated using finite element analysis and show the 72/48 SRM is suitable for high-torque low-speed direct-drive in mining.
The document discusses the manufacturing process planning for a crankshaft using CAM software. It describes creating a 3D CAD model of the crankshaft from 2D drawings, including steps like sketching, revolving, extruding, and using instance geometry. It then covers the CAM process, including selecting a 5-axis DMG milling machine, choosing tools, and generating tool paths to manufacture the crankshaft. The document emphasizes how CAD/CAM allows integrating design and manufacturing to efficiently produce complex components like crankshafts.
1) The document describes two case studies of retrofitting damaged industrial buildings. The first case study involves retrofitting a steel structure damaged by faulty design through two strategies - welding additional members or adding another truss. The second case study modifies a structure by removing a column and adding a beam to support the trusses.
2) Both case studies are modeled and analyzed using STAAD-Pro software to determine load capacities and member sizes. For the first case, adding another truss is more economical but reducing ceiling height, so welding additional members is recommended. For the second case, analysis shows the added beam and existing columns can support the modified loads.
3) In conclusion, retrofitting existing structures is a
IRJET- Design and Structural Analysis of an Off Road VehicleIRJET Journal
This document describes the iterative design and structural analysis of an off-road vehicle frame. The frame was modeled in CATIA and analyzed in ANSYS to minimize stress concentrations through thickness and geometry modifications. Several impact tests were simulated, and the frame design was iteratively optimized to reduce stresses below safety thresholds. The final optimized frame design demonstrated reduced weight and stresses within allowable limits for all impact scenarios tested.
Design evaluation and optimization of steering yoke of an automobileeSAT Journals
Abstract The purpose of a steering system is to control the direction of the vehicle by operating the steering wheel of the steering system. The steering columns in a steering system are one of the main devices of an automobile. It is a very important part to attain stability and steady movement of the vehicle. The steering yoke consists of two forged-steel yokes or forks joined to the two shafts being coupled and situated at right angles to each other. A spider hinges these two yokes together. Since the arms of the spider are at right angles the spider arm rocks backwards and forward between four extreme positions. Motion transmission system of vehicles consist several components which sometimes encounter unfortunate failures. Some common reasons for the failures may be manufacturing, design faults, maintenance faults, raw material faults, material processing faults as well as the user originated faults. In this paper structural optimization of the steering yoke is carried out. For modeling of the component, CATIA V5 R17 software is used. It has been found that there are essentially in two stages of the design process that structural optimization can be applied. In the early stage of concept generation, topology optimization should be used to develop an efficient structure from the beginning. At this level an automatized variation of optimization parameters was proven useful to and the best feasible design possible. In the later stage, shape and size optimization should be used to fine-tune the structure realized from the topology optimization and carried out physical experimentation to validate the model. Keywords: Steering Yoke, Structural optimization, CATIA V5, Hyperworks
Design evaluation and optimization of steering yoke of an automobileeSAT Publishing House
This document describes research conducted to optimize the design of an automobile steering yoke through finite element analysis and experimental testing. The researchers created 3D models of the steering yoke in CATIA software and applied topology, shape, and size optimization techniques. They then conducted finite element analysis in HyperWorks to analyze von Mises stresses, displacement, and mass. Experimental testing was also performed on the steering yoke using a universal testing machine and strain gauges. The optimized design was found to have lower stresses, displacement, and mass than the original design, validating the finite element analysis model.
Large assembly management is a burgeoning problem which is encountered in
all the automotive industries. As the vehicle assemblies of projects moves
towards the fruition stage its size becomes more than 50GB. It thus becomes
very monolithic to manage, making easy tasks such as making minor changes
in the assembly or performing analysis extremely difficult to perform,
moreover the huge assembly size alone is not the only problem but even the
presence of several other components in the assembly tend to hinder any task
that is to be performed.
This document summarizes research on 3D printing hollow compounds of different shapes. It discusses how 3D printing allows for more optimized geometries compared to traditional manufacturing and can produce hollow turbine blades, gears, and disc brakes with properties similar to solid compounds. Finite element analysis was performed on hollow and solid shapes of different cross-sections, finding equivalent stresses were approximately the same. 3D printing reduces material costs and makes manufacturing hollow compounds easier compared to traditional methods. The document concludes 3D printing technologies provide design flexibility while creating parts with layer-by-layer printing instead of traditional manufacturing approaches.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
This document provides an overview of machine design. It defines machine design as designing machine elements and arranging them to obtain useful work. It discusses different types of design such as adaptive, developmental, and new design. It outlines key factors to consider in machine design like materials, forces, size, manufacturability, reliability, and cost. The goal of machine design is to safely transmit forces while allowing the machine to perform its task.
IRJET-Split Casing Open Differential without Cross Pin and it’s Comparison wi...IRJET Journal
This document summarizes the design optimization of work roll chocks and backup roll chocks in a cold rolling mill. The current chocks were failing prematurely, resulting in production stoppages and costs. A 3D model of the chocks was created and analyzed using ANSYS software to determine stress distributions and critical areas under load. The design was iteratively optimized to reduce weight and material costs while maintaining structural integrity. The optimized design was found to reduce chock weight by over 10% and save $9,154.50 per chock based on material and production costs. Modal analysis confirmed the natural frequencies of the optimized design would not cause resonance issues. This new optimized chock design was concluded to provide improved life and cost
The document discusses research on integrating geometric and mechanistic models for cutting process simulation and feedrate optimization in five-axis milling of free-form surfaces. It presents a method for extracting cutter-workpiece engagement geometry from CAD/CAM toolpaths to be used as input for a discrete mechanistic force prediction model. Experimental validation showed good agreement between simulated and measured cutting forces. The integrated modeling approach uses geometric simulation to dynamically update the workpiece model and determine cutter contact areas, while the mechanistic model estimates forces to calculate optimal feedrates within constraints of part quality, tool life, and machine limitations.
IRJET- Tensile and Shear Strength Approximate Prediction of Friction Surf...IRJET Journal
This document discusses using artificial neural networks (ANN) to predict the tensile and shear strength of tool steel coatings deposited through friction surfacing. Friction surfacing is used to deposit coatings on materials and has various industrial applications. An experiment was conducted to deposit tool steel coatings on low carbon steel using different levels of friction pressure, rotational speed, and welding speed. Tensile and shear strength tests were performed on the coatings. ANN models using a feedforward neural network (FFNN) structure were developed and trained on the experimental data to predict coating tensile and shear strength based on the friction surfacing process parameters. The ANN models provide a way to understand and optimize the relationship between mechanical properties and processing
IRJET - Design & Manufacturing of 20 Ton Horizontal Hydraulic Press Machine f...IRJET Journal
This document describes the design and manufacturing of a 20-ton horizontal hydraulic press machine for pipe squeezing and flaring operations. It discusses the need for such a machine to perform these operations for automotive and sheet metal applications. The key components of the machine, including the frame, cylinder, and piston, are modeled in UG NX-11 software. Detailed calculations are shown for selecting materials, estimating forces and stresses, sizing the cylinder, determining system pressures and flow rates, and selecting the appropriate motor power. 3D models and drawings of the frame, pillars, punch and die are presented. Finally, the hydraulic circuit diagram and concluding remarks discuss how the designed machine is intended to efficiently perform flaring and squeezing operations
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International Journal of Engineering Research and DevelopmentIJERD Editor
Electrical, Electronics and Computer Engineering,
Information Engineering and Technology,
Mechanical, Industrial and Manufacturing Engineering,
Automation and Mechatronics Engineering,
Material and Chemical Engineering,
Civil and Architecture Engineering,
Biotechnology and Bio Engineering,
Environmental Engineering,
Petroleum and Mining Engineering,
Marine and Agriculture engineering,
Aerospace Engineering.
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1. The document analyzes and summarizes the original design of a mechanical drill press. It details the design using diagrams and tables, identifying 34 individual parts.
2. Problems with the original design for mass production are identified, including a high number of small parts that slow assembly and the use of welding for some components.
3. Manufacturing processes, materials, costs and assembly time are estimated for the original design to serve as a baseline for redesign efforts aimed at reducing costs, waste and environmental impact.
Design, analysis and development of special purpose machine to carry heavy lo...eSAT Journals
Abstract
In the olden days very complicated thing is in the industry is to carry heavy loaded components and lifting from one place to another place, human effort needs lots of energy and it takes more time for same work, there are many huge and large amount of load lifting machine available, in that first started with gantry hoist and gantry cranes with which they carry heavy loads from one place to other, it works so far by the time but it can operate only in open place, in small scale industries it can’t work, during the period the need is new machine which works in small scale industries with good time, the changing the generation with the new technology industries are planned to develop the special purpose machine which is used to lift the heavy loads. Structural analysis of the “Gantry Structure” has been carried out to find the mechanical response of the structure, subjected to applied loads and boundary conditions. The results include deformed shape of the structure, displacements at required locations. Modal analysis done for checking the model, Gravity Loading Applied for different position and checked for the deformation of Solid Beam for different position. Optimization is done to reduce the cost of the structure. The response of the structure got by structural analysis using MSC Nastran.
Keywords: Gantry, Types of gantry, Structural analysis, optimization, modal analysis, HyperMesh, NASTRAN.
Design, analysis and development of special purpose machine to carry heavy lo...eSAT Journals
Abstract
In the olden days very complicated thing is in the industry is to carry heavy loaded components and lifting from one place to another place, human effort needs lots of energy and it takes more time for same work, there are many huge and large amount of load lifting machine available, in that first started with gantry hoist and gantry cranes with which they carry heavy loads from one place to other, it works so far by the time but it can operate only in open place, in small scale industries it can’t work, during the period the need is new machine which works in small scale industries with good time, the changing the generation with the new technology industries are planned to develop the special purpose machine which is used to lift the heavy loads. Structural analysis of the “Gantry Structure” has been carried out to find the mechanical response of the structure, subjected to applied loads and boundary conditions. The results include deformed shape of the structure, displacements at required locations. Modal analysis done for checking the model, Gravity Loading Applied for different position and checked for the deformation of Solid Beam for different position. Optimization is done to reduce the cost of the structure. The response of the structure got by structural analysis using MSC Nastran.
The inspiration driving CNC machining undertakings is to make explicit shapes or surface
characteristics for a thing. In view of math and surface completion determinations, conditions for machining
assignments have for the most part been chosen. Assembling ventures endeavor to make high phenomenal things
at decay cost to stay serious inside the market. This exploration zeroed in on growing the advantage of benefit
on PC mathematical control (CNC) by enhancing machining boundaries by processing activities. In this
exploration, the profundity of cut, cutting velocity and feed rate on the aluminum amalgam work piece by the
utilization of carbide unit, embed shaper, HSS were utilized to enhance the advantage of CNC processing
measures by advancing machining boundaries picked to be assessed in this investigation by utilizing Taguchi's
System approach including symmetrical exhibit. The Taguchi strategy is utilized to notice the impact of cycle
boundaries and to look at a portion of the decrease speed, feed and profundity with acknowledgment of the
essential machinability part, surface end. The surface completion has been portrayed as quality attributes and is
accepted to be straightforwardly identified with efficiency.
finite element analysis & design optimization of material handling equipmentINFOGAIN PUBLICATION
Material handling equipment is mechanical equipment used for the movement, storage, control products throughout the process of manufacturing, and disposal. The different types of material handling equipment can be classified into four major categories, transport equipment, positioning equipment, unit load formation equipment, and storage equipment. Excavator is used to excavate the material of the ground on which the machine rests and load it into trucks or tractor. In the severe working conditions, excavator parts are subjected to very high loads. The excavator mechanism must work reliably under random working conditions. Thus it is very much essential for the designers to evaluate not only a equipment of maximum reliability but also of minimum weight and cost, considering design safe under all loading conditions. It can be accomplished that, mechanical strength analysis is an important to step in the design of excavator parts. Finite Element Analysis (FEA) is the most appropriate technique in strength calculations of the structures working under known load and boundary conditions. In general, computer aided drawing model of the parts to be analyzed must to be set prior to the FEA. It is also promising to reduce the weight of the mechanism by performing optimization in FEA. This paper provides the platform for proceeding for the Modeling, FEA and optimization of backhoe excavator attachment, which was already carried out by other researchers for their related applications and it can be very helpful for development of any material handling equipment and new excavator attachment.
Finite element analysis of center pin and bracket of jig fixture assembly ijm...Dr.Vikas Deulgaonkar
The manufacturing industry caters the range of products to satisfy the ever changing market needs.
To overcome the increasing production demands, the industry implies various techniques. We need a technique for
increasing the production of drilling two holes on a Railway Pinion, improve the quality of product and reduce the
operation time. This project aims to design the Jig and Fixture for the same. The 3-dimensional Computer Aided Model
of the components is made using CATIA V5-R21 software. To study the behavior of component, simulation is carried out.
Preprocessing of the CAD model is carried in Hypermesh software. Boundary conditions are applied using physical
situations of the components. Finite element analysis of the components is done, and the results obtained are compared
with the theoretical analysis and also with the available literature. The stresses and deformations are found within desired limits. Using FE analysis, the parts are manufactured and assembled.
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.
Design and development of hydraulic fixtureLaukik Raut
The document describes the design and development of a hydraulic fixture for machining a hydraulic lift housing component. It discusses the advantages of hydraulic fixtures such as consistent clamping forces, repeatable clamp locations, elimination of human error, and increased productivity. It then describes the existing manual fixture and identifies problems with it like longer cycle times and potential defects from overtightening or loosening clamps manually. The development of a new hydraulic fixture is discussed, including material selection criteria, analytical design of fixture parts like the base plate and locating pins, and 3D modeling and analysis using Pro-E and ANSYS software. The hydraulic fixture aims to reduce setup times and improve quality for machining the cylindrical hydraulic lift housing.
IRJET- Review on Computer Aided Fixtre DesignIRJET Journal
This document summarizes a review on computer-aided fixture design. It discusses how fixtures play an important role in manufacturing to achieve interchangeability and accuracy. Traditionally, fixture design was done through trial and error, which was time-consuming. Computer-aided fixture design (CAFD) automates the process and allows designers to simulate virtual fixtures to identify deficiencies quicker. The document outlines the main steps in CAFD as setup planning, fixture planning, unit design, and verification. It also discusses various approaches researchers have proposed for setup planning and fixture optimization.
IRJET- Design and Thermal Analysis of Fixture Assembly and Base Plate for...IRJET Journal
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Mechanical design and taboos of mechanical designJasmineHL
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This document discusses how additive manufacturing (AM) and circular design principles can be merged to foster more sustainable production. It provides examples of how AM enables new repair, upgrade, and personalization strategies to prolong product lifetimes. Additionally, the document examines how computational design techniques like topology optimization and generative design can optimize parts for AM processes in ways that improve functionality while reducing material usage.
Design of machining fixture for turbine rotor bladeeSAT Journals
Abstract This Project presents the Design of Machining Fixture for Gas Turbine Rotor Blade for Machining on VMC (Vertical Machining Centre). Fixture Design consists of High product rate, low manufacturing operation cost. The fixture should be designed in such-a-way that part/product change overtime is very less. The report consists of study of input data from customers like Part drawing and Assembly drawing. The fixture design begins with part modeling, Machining and Analysis of various parts in the fixture assembly using AutoCAD and Solid works, for a analysis COSMOS Software package is used. The actual design begins with study details of project proposal summary from customer. After that machining fixture concept is done. Locating and clamping points are decided. This also includes accessibility, loading and unloading sequence of parts, required material for this fixture is selected, and Fixture is designed at SRI VENKATESWARA MECHANICAL AND ELECTRICALENGINEERING INDUSTRIES, Hyderabad using Industrial application standards. Locating accuracy and machined part quality tested and found that the fixture is as good as any dedicated fixture in production. Keywords: Vertical Machining Centre, AutoCAD and Solid works, COSMOS Software.
The document describes the design of a machining fixture for a gas turbine rotor blade. It discusses machining fixtures in general and their purposes. It then describes the specific rotor blade material, machining operations to be performed including milling, drilling and tapping. A conceptual layout of the fixture is presented including locating pins, rest pads and hydraulic clamps. Dimensions and tolerances of 50 microns are specified. Calculations are shown for material removal rates and cutting speeds for milling operations on the rotor blade. Main elements of the designed fixture are also listed and diagrams show the assembled fixture holding the rotor blade.
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F113243
1. International Journal of Engineering Science Invention
ISSN (Online): 2319 – 6734, ISSN (Print): 2319 – 6726
www.ijesi.org
Volume 1 Issue 1 ǁ December. 2012 ǁ PP.32- 43
www.ijesi.org 32 | P a g e
Design & Development of Rotary Fixture for CNC
N. P. Maniar1
, D. P. Vakharia2
1
Mechanical Engineering Department, Dharmsinh Desai University, India
2
Mechanical Engineering Department, Sardar Vallabhbhai National Institute of Technology, India
ABSTRACT : Various areas related to fixture are already been described by renowned authors, still there is
an urgent need to apply all these research works to an industrial application. This paper presents design and
development of rotary fixture for real industrial component. The component is Flow TEE body of petroleum
refinery. The operations to be performed are front facing, outside diameter turning, grooving, boring and back
facing. Actually HMC is the best solution for performing the required operations, but HMC costs around 12.5
million rupees whereas CNC turning centre costs only about 2.5 million rupees. A fixture is designed which can
be mounted on CNC turning centre and 10 million rupess are saved in installation cost as these operations can
now be performed on CNC turning centre using the designed fixture. Methodology for mass balance of rotary
fixture developed by investigators mostly act as post-mortem tool; calculating unbalanced mass after fixture is
manufactured. In the present work, a pre-mortem tool is developed to predict unbalanced mass well before
manufacturing. The present research also proposes alternate methods for mass balancing of rotary fixture. The
paper sets the classical example of integrated approach of design for manufacturing.
Keywords ––CNC (Computerized numerical control) turning centre, design, HMC (Horizontal machining
centre), mass balancing, rotary fixture
I. INTRODUCTION
The machine tool industry has undergone sufficient changes as the requirement of user engineering
systems changed; first it started with the manufacture of basic general purpose machine tools. These machines
though offered higher flexibility were not suitable for mass production owing to longer set up times and the
tedious adjustments of machine and tools besides requiring highly skilled operators. With growing need of fast
production to meet the requirements of industry, mass production machines are conceived. Hydraulic, tracer
control machine tool, special purpose automatic and semi-automatic machines were introduced with the
advancement of technology. These machines were highly specialized but inflexible. The use of these machines
was with a success for mass production and they have considerably reduced the production costs by way of
reduced machining times and labor costs.
Because of inflexibility these machine tools could not however be adopted by units involved in small
lot and piece production. Because of the above, great need is felt for tools that could bridge the gap between
highly flexible general purpose machine tools (which are not economical for mass production) and highly
specialized, but inflexible mass production machines. Numerical control machine tools with proper fixture set
up have to take up this role very well. And this has excited this research work on design and development of
rotary fixture for CNC.
The fixture designing and manufacturing is considered as complex process that demands the
knowledge of different areas, such as geometry, tolerances, dimensions, procedures and manufacturing
processes. While designing this work, a good number of literature and titles written on the subject by renowned
authors are referred. All findings and conclusions obtained from the literature review and the interaction with
fixture designers are used as guide to develop the present research work. As stated by Koji Teramoto, Masahiko
Anasoto and Kazuaki Iwata [1], Fixturing Plan (FP) and Machining Plan (MP) are mutually dependent. Implicit
to this conclusion, paper coordinates MP and FP by coupling a fixture design with manufacturing considerations
and mass balancing.
For this research, a relevant issue when considering requirements, taking this as a general concept, is to
make explicit the meaning of two main terms: Functional Requirement (FR) and Constraint (C) [2]. Functional
2. Design & Development of Rotary Fixture for CNC
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Requirement (FR), as it stated by different authors, „represents what the product has to or must do independently
of any possible solution‟. Constraint (C) can be defined as „a restriction that in general affects some kind of
requirement, and it limits the range of possible solutions while satisfying the requirements‟. Though some
contributions have been made in several areas related to design of fixture like knowledge model for fixture
design process, workpiece location, computer aided fixture design, fixture analysis under dynamic machining
etc. [3-8], but there is a great deal of urgency and importance to couple all these research works to an industrial
application. This paper reviews all these research works and transforms the theoretical knowledge of fixture
design to practical application.
The balancing of mechanisms is motivated by continuous interest machine designers express in the
solution of problems concerning prevention of noise, wear and fatigue generated by the transmission of
unbalanced shaking forces and shaking moments to the frames and foundations of machines. It generally
confines itself to the shaking force and shaking moment balancing, full or partial, by internal mass
redistribution or counterweight addition. However, the complete shaking force and shaking moment
balancing problem is very complicated. Often in practice, the problem of mass balancing is limited by
full force balancing and partial moment balancing [7].
Methodology for mass balance of rotary fixture developed by investigators mostly act as post-mortem
tool; calculating unbalanced mass after fixture is manufactured. In the present work, a pre-mortem tool is
developed to predict unbalanced mass well before manufacturing. Step by step procedure for mass balancing of
fixture is proposed with the innovative approach of use of Creo Elements/Pro 5.0. The present research proposes
alternate methods of IV Quadrant and VIII Quadrant Computer Aided Mass Balancing Method (CAMBM) for
mass balancing of rotary fixture.
The important details of the part and fixture are included in each fixture design section for clarifying
doubts in addition to component drawing & fixture drawing. The research work includes the 3D assembled &
exploded view of fixture using Creo Elements/Pro 5.0. Fixture is mass balanced using Pro/Mechanism. The
object of work presented here is to develop the study and to provide the optimum conditions of design
and development of rotary fixture for CNC.
II. DESIGN & DEVELOPMENT OF ROTARY FIXTURE
2.1 Statement of Problem
“Design & development of rotary fixture for machining flow TEE body on CNC turning centre. The
operations to be performed are front facing, outside diameter turning, grooving, boring and back facing. The
fixture being rotary in nature has to be mass balanced.”
2.2 Component details
The methodology proposed for design of a fixture includes the realization of two stages. The first stage
represents the knowledge of the objects like part geometry, machining process, functional and detailed fixture
design, and fixture resources. The second stage describes the inference process (design and interpretation rules)
needed to obtain a first solution for the machining fixture [3].
As a part of first stage, component geometry is discussed here [Fig. 1-3]. The component is Flow TEE
body, made up mild steel, weighing 46.5 kg and is one of the components of petroleum refinery. The component
is used as a joint or coupler for pipes through which petroleum liquid products flow and get mixed. The
component in raw material form is forged, proof machined with 3 mm machining allowance on conventional
lathe with 24 inch swing over diameter. The operations to be performed on component, using designed fixture
set up, are front facing, outside diameter turning, grooving, boring and back facing.
2.3 Locating and clamping
In machining, work holding is a key aspect, and fixtures are the elements responsible to satisfy this
general goal. Usually, a fixture solution is made of one or several physical elements, as a whole the designed
fixture solution must satisfy the entire FRs and the associated Cs.
3. Design & Development of Rotary Fixture for CNC
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Figure 1. Finished Component Drawing
Figure 2. 3D view of raw material of component
Figure 3. 3D view of finished part
Centering, locating, orientating, clamping, and supporting, can be considered the functional
requirements of fixtures. In terms of constraints, there are many factors to be considered, mainly dealing with:
shape and dimensions of the part to be machined, tolerances, sequence of operations, machining strategies,
cutting forces, number of set-ups, set-up times, volume of material to be removed, batch size, production rate,
machine morphology, machine capacity, cost, etc. At the end, the solution can be characterized by its:
simplicity, rigidity, accuracy, reliability, and economy [2]. Workpiece location in a fixture is significantly
influenced by localized elastic deformation of the workpiece at the fixturing points. These deformations are
caused by the clamping force(s) applied to the workpiece. For a relatively rigid workpiece, the localized elastic
deformations cause it to undergo rigid body translations and rotations which alter its location with respect to the
cutting tool. It is therefore important to minimize such effects through optimal design of the fixture layout [4].
S. K. Hargrove and A. Kusiak [5] recognize four general requirements of a fixture: (i) Accurate
location of the workpiece, (ii) Total restraint of the workpiece during machining, (iii) Limited deformation of
the workpiece, (iv) No machining interference. In addition, as set forth by R. T. Meyer and F. W. Liou [6],
dynamic machining conditions occur when a workpart is subject to machining forces that move through the
work part or along its surface. A viable fixture designed for a workpart experiencing dynamic machining must
ensure: the workpart is restrained for all time, the clamping forces are not too large or small, deterministic
positioning, accessibility, stability of the workpart in the fixture while under no external forces, and a positive
clamping sequence.
Workpiece motion arising from localized elastic deformation at the workpiece/fixture contacts due to
machining and clamping forces significantly affect the workpiece location accuracy and hence the machined
part quality. The tangential friction force plays an important role in fixture configuration design as it can be
utilized to reduce the number of fixture components, thereby the workpiece features accessibility to machining
operations and providing a damping mechanism to dissipate input energy from machining forces out of the
workpiece/fixture system. Contact problems with friction are generally complicated by the fact that the contact
surface can experience slipping, sliding, rolling or tension release depending on the magnitude of the normal
and tangential forces at the contact interface [8].
Considering all above mentioned facts, location & clamping is accomplished by using 3 V blocks and
latch clamp. The important parts of fixture used here are V block, latch clamp, base plate, vertical plate, adapter
plate, locator and rib [Fig. 4-7]. The fixture uses three V blocks to locate and a latch clamp to hold the
component. The latch clamp consists of two M 6 bolts to directly clamp the workpiece. The chuck of CNC
turning centre will be replaced with complete fixture set up using an adapter plate. The adapter plate holds the
same dimensions of chuck plate. The locator locates the vertical plate in correct position with adapter plate. The
base plate serves to hold the complete assembly of fixture. The ribs are clamped to base plate and provide the
holding arrangement for latch clamp. The fixture rotates with 550 rpm while performing operations on CNC
4. Design & Development of Rotary Fixture for CNC
www.ijesi.org 35 | P a g e
turning centre. The specification of spindle nose of CNC turning centre used in this work is A2-8, which can
carry a weight of 450 kg. The fixture is directly mounted on spindle nose.
Figure 4. 2D drawing of fixture
Figure 5. 3D view of fixture
5. Design & Development of Rotary Fixture for CNC
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Figure 6. 3D rear view of fixture
Figure 7. 3D exploded view of fixture
6. Design & Development of Rotary Fixture for CNC
www.ijesi.org 37 | P a g e
III. COMPUTER AIDED MASS BALANCING METHOD (CAMBM)
FOR ROTARY FIXTURE
Methodology developed by most of the researchers mostly act as post-mortem tool, calculating and
determining unbalanced mass after fixture is manufactured followed by unbalanced mass removal or
counterweight addition. A tool that could predict unbalanced mass during fixture design stage is not yet
developed. The present volume of this paper proposes the unique method of use of Creo Elements/Pro 5.0,
which would enable prediction of unbalanced mass during design stage well before manufacturing. This
approach would be highly useful in the shop floor, saving material cost, increasing the productivity and
decreasing the human labor. In this work, fixture is balanced by adding counterweight equal in magnitude and
opposite in direction as that of resultant unbalanced mass. The object of the work presented here is to
develop the study and to provide the optimum conditions of design, manufacturing, static analysis with
force & moment balancing of fixture. As the fixture is asymmetrical, it has to be mass balanced. The fixture
rotates around one axis; hence it has to be balanced about other two perpendicular axis. Here x - axis is the axis
of rotation. The results and outputs from Creo Elements/Pro 5.0 with solution of balancing are shown below.
3.1 IV Quadrant Computer Aided Mass Balancing Method
Step I: C. G., weight of fixture and offset distance of C. G. from axis of rotation are determined [Fig.
8]. The important results from the above output are as follows: weight of fixture with component, without
balancing mass = 233.12 kg. C.G. is offset from axis of rotation in x – axis by -130.56 mm, in y – axis by -1.11
mm and in z – axis by 2.38 mm.
Step II: Now the fixture is cut in 4 quadrants about 2 axis, perpendicular to each other and
perpendicular to axis of rotation below [Fig. 9].
Step III: The weight and C. G. of fixture in each quadrant are determined. [Fig. 10-13].
Step IV: The above outputs of weight of fixture and C. G. of each quadrant are summarized [Fig. 14,
Table 1].
Figure 8. Mechanical Analysis of Fixture
Quadrant II Quadrant I
Figure 12. Weight and C. G. of fixture in
Quadrant III
Figure 13. Weight and C. G. of fixture in
Quadrant IV
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Quadrant III Quadrant IV
Figure 9. 3D view of fixture in 4 Quadrants
Figure 10. Weight and C. G. of fixture in
Quadrant I
Figure 11. Weight and C. G. of fixture in
Quadrant II
Figure 14. 2D drawing showing summary of
weight and C. G. of fixture in all Quadrants
Table 1. Summary of C. G. of fixture in all
Quadrants
Quadran
t (i)
Co-ordinate of
C. G. (mm)
tan
θi
θi
(Degree)
xi yi
1 83.09 92.04 1.10 47.92
2 -103 80.78 -0.78 38.11
3
-
101.14
-
77.35 0.76 37.41
4 82.35
-
85.71 -1.04 46.14
Step V: According to principles of mechanics, ΣF = 0 and ΣM = 0 for mass balancing. The sums of
unbalanced mass in horizontal direction ΣFH and in vertical direction ΣFV are calculated [Table 2].
Step VI: Resultant unbalanced mass (R) and its line of action in terms of angle (α) with x-axis are
calculated using parallelogram law of forces [Table 3].
Step VII: Sum of moment of inertia about x – axis (Σmixi
2
) and that about y – axis (Σmiyi
2
) are
calculated [Table 4].
Step VIII: Resultant moment is calculated using principle of perpendicular axis theorem of moment of
inertia [Table 5].
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Table 2. Calculation of resultant mass in horizontal
direction (θFH) and in vertical direction(θFV)
Quadrant
(i)
mi
(kg)
FH=xi=miCos
θi
(kg)
FV=yi=miSin
θi
(kg)
1 38.5 25.79868396 28.57757698
2 48.09 -37.8405504 29.67727827
3 53.36 -42.38538755 -32.41555988
4 43.82 30.35986498 -31.59859171
θ -24.06738901 -5.75929635
Table 3. Calculation of Resultant Force, R
ΣFH
2
579.2392137 kg2
ΣFV
2
33.16949445 kg2
ΣFH
2
+ ΣFV
2
612.4087082 kg2
Resultant, R = √ (ΣFH
2
+
ΣFV
2
) 24.7468929 kg
tan α 0.23929876
α 13.45773737º
Table 4. Calculation of sum of moment of Inertia
about X – direction (θmixi
2
) and that of about Y –
direction (θmiyi
2
)
Quadra
nt
(i)
mi
(kg)
mixi
2
(kg mm2
)
miyi
2
(kg mm2
)
1 38.5
265802.001
9 326147.4216
2
48.0
9 510186.81 313806.89
3
53.3
6
545835.426
7 319254.0806
4
43.8
2 297166.316 321910.6637
θ
1618990.55
4 1281119.056
Table 5. Calculation of Resultant Moment, M
Ixx = Σ mixi
2
= 1618990.554 kg mm2
Iyy = Σ miyi
2
= 1281119.056 kg mm2
Izz = Ixx + Iyy
M = Σ mixi
2
+ Σ miyi
2
= 2900109.61 kg mm2
Step IX: Having M, R and α, the location of C. G. (rcm) of R is determined.
M = R rcm
2
rcm
2
= M / R
rcm = 342.33 mm
Thus the unbalanced mass is found to be 24.75 kg and its C. G. is situated at an angle of 13.45o
with x-
axis at a distance of 342.33 mm in quadrant III. Hence the fixture can be balanced by placing the counterweight
equal in magnitude and opposite in direction as that of unbalanced mass.
3.2 VIII Quadrant Computer Aided Mass Balancing Method
Step I: This step is same as in IV Quadrant Computer Aided Mass Balancing Method.
Step II: Now the fixture is cut in 8 quadrants around 4 axis at angle of 450
to each other and
perpendicular to axis of rotation.
Step III: The weight and C. G. of fixture in each quadrant are determined. [Fig. 15-22].
Step IV: The above outputs of weight of fixture and C. G. of each quadrant are summarized [Table 6].
Step V: According to principles of mechanics, ΣF = 0 and ΣM = 0 for mass balancing. The sum of
unbalanced mass in horizontal direction ΣFH and in vertical direction ΣFV is calculated [Table 7].
Step VI: Sum of moment of inertia about x – axis (Σmixi
2
) and that about y – axis (Σmiyi
2
) are
calculated [Table 8].
Step VII: Resultant unbalanced mass (R) and its line of action in terms of angle (α) with x-axis are
calculated using parallelogram law of forces [Table 9].
Step VIII: Resultant moment is calculated using principle of perpendicular axis theorem of moment of
inertia [Table 10].
Step IX: Having M, R and α, the location of C. G. (rcm) of R is determined.
M = R rcm
2
rcm
2
= M / R
rcm = 159.11mm
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Thus the unbalanced mass is found to be 59.78 kg and its C. G. is situated at an angle of 72.22o
with x-
axis at a distance of 159.11 mm in quadrant III. Hence the fixture can be balanced by placing the counterweight
equal in magnitude and opposite in direction as that of unbalanced mass.
Figure 15. Weight and C. G. of fixture in
Quadrant I
Figure 16. Weight and C. G. of fixture in
Quadrant II
Figure 22. Weight and C. G. of fixture in
Quadrant VIII
Table 6. Summary of C. G. of fixture in all
Quadrants
Quadrant
(i)
Co-ordinate of
C.G. (mm)
tan
θi
θi
(Degree)
xi yi
1 105.43 56.13 0.53 28.03
2 6.883 123.04 17.87 86.80
3 -63.16 122.57 -1.94 62.73
4 -133.13 49.29 -0.37 20.32
5 -132.09 -53.18 0.40 21.93
6 -59.39 -110.14 1.85 61.66
7 59.63 -110.11 -1.84 61.56
8 107.13 -59.26 -0.55 28.95
Table 7. Calculation of resultant mass in
horizontal direction (θFH) and in vertical
direction(θFV)
Quadrant
(i)
mass
mi
(kg)
FH=xi=miCosθi
(kg)
FV=yi=miSinθi
(kg)
1 17.82 15.72967885 8.374341968
2 20.70 1.156174297 20.6676864
3 20.67 -9.468080697 18.37401284
4 27.38 -25.67665437 9.506514638
5 30.61 -28.39510038 -11.43198908
6 22.60 -10.72639375 -19.89232207
7 22.77 10.84315128 -20.02246164
8 20.91 18.2972081 -10.12127837
θ -18.25888192 56.92255584
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Figure 17. Weight and C. G. of fixture in
Quadrant III
Figure 18. Weight and C. G. of fixture in
Quadrant IV
Figure 19. Weight and C. G. of fixture in
Quadrant V
Table 8. Calculation of sum of moment of Inertia about
X – direction (θ mixi
2
) and that of about Y – direction
(θ miyi
2
)
Quadrant
(i)
mi
(kg)
mixi
2
(kg mm2
)
miyi
2
(kg mm2
)
1 17.82 198077.9409 56143.28036
2 20.7 980.6767623 313374.0211
3 20.67 82456.46635 310533.7793
4 27.38 485272.0831 66519.82226
5 30.61 534076.1815 86568.52056
6 22.6 79714.08946 274156.523
7 22.77 80964.12921 276068.3095
8 20.91 239980.6596 73430.64232
Σ 766787.1672 746570.903
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Figure 20. Weight and C. G. of fixture in
Quadrant VI
Figure 21. Weight and C. G. of fixture in
Quadrant VII
Table 9. Calculation of Resultant Force, R
θFH
2
333.386769 kg2
θFV
2
3240.177364 kg2
θFH
2
+ θFV
2
3573.564133 kg2
Resultant, R = θ(θFH
2
+
θFV
2)
59.77929518 kg
tan θ -3.11752692
θ (degree) 72.21546938
Table 10. Calculation of Resultant Moment, M
Ixx = θmixi
2
766787.1672 kg mm2
Iyy = θmiyi
2
746570.903 kg mm2
Izz = Ixx + Iyy
M = θmixi
2
+ miyi
2
1513358.07 kg mm2
3.3 Comparison of Results obtained of two methods used for Mass Balancing
Table 11
Parameters Mass Balancing Method
4 Quadrant
Method
8 Quadrant
Method
Unbalanced Mass (kg) 24.75 59.78
Angle at which C.G. of unbalanced mass is situated (degree) 13.45 72.22
Distance at which C.G. of unbalanced mass is situated (mm) 342.33 159.11
Quadrant in which C.G. of unbalanced mass is situated III III
Mass of component (kg) 46.5 46.5
Mass of fixture including mass of component, excluding
unbalanced mass (kg)
183.46 183.46
Total mass of fixture including mass of component and
unbalanced mass (kg)
208.21 243.24
Actual mass of fixture including mass of component and
unbalanced mass (kg)
233.12 233.12
Absolute Error 24.91 10.12
Relative Error 0.10685 0.04341
Percentage Error 10.685 4.341
The above comparison shows that VIII Quadrant method gives more accurate results compared with 4
Quadrant Computer Aided Mass Balancing Method. Percentage error in VIII Quadrant method is reduced by
almost 6 % in comparison to IV Quadrant Computer Aided Mass Balancing Method.
IV. CONCLUSION
An integrated approach of design and mass balancing of rotary fixture has been adopted in this work.
This approach is of crucial importance in real manufacturing environment. Actually HMC is the best solution
for performing the required operations on part used in this work, but a designer cannot ask industry to replace
already existing set up of CNC turning centre with HMC as HMC costs around 12.5 million rupees whereas
CNC turning centre costs only about 2.5 million rupees. Here the research work of this paper is proved, 10
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million rupees are straight away saved in machine installation cost. In HMC, a tool rotates and component
remains stationary, vice versa for CNC turning centre. A designed fixture has the important novel characteristic
of performing all operations in a single set up with component rotating and tool stationary, satisfying the
essential requirement of CNC turning centre.
A simplified, analytical method of use of Creo Elements/Pro 5.0 is proposed to solve the balancing
problem. The approach of application of Creo Elements/Pro 5.0 to mass balance the fixture is very useful as it
opens the door not only to symmetrical part problems but also to a more general class of problem and difficult
tasks such as asymmetrical fixture as is the case in this work. The application of Creo Elements/Pro 5.0 and
principles of mechanics used in this work to overcome balancing problem is universal i.e. applicable for any
part. The findings of unbalanced mass and its location of C. G. are remarkably same as with experimental results
on dynamic balancing machine. This approach of solving the balancing problem is expected to have more
flexibility in its application, since it is not sensitive to dynamic conditions.
The present research work also proposes Computer Aided Mass Balancing Method (CAMBM) which
ease fixture designer from tedious and time consuming work of finding offset distance and C.G. of irregular
shape parts and also solving mass balancing problem. Two alternate methods of Computer Aided Mass
Balancing are presented and VIII Quadrant Computer Aided Mass Balancing Method is found more accurate
with the result of decrease in percentage error by almost 6 % in comparison to IV Quadrant Computer Aided
Mass Balancing Method.
ACKNOWLEDGEMENTS
The authors wish to acknowledge the support of Mr. Sudhir Thakar and Mr. Pradip Thanki, Trend
Enterprise, Rajkot, Gujarat, India for this research work. The authors also acknowledge the support of Mr.
Chetan M. Patel for his input to this research work.
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