AUTOMATION OF FIXTURE OF VERTICAL MILLING CENTER(VMC)

PROJECT GUIDEA.S.PATIL

FORTUNA ENGG PVT LTD.

ABOUT PROJECT:PHASES OF PROJECT:1. Determination of current manufacturing line problems: More cycle time for machining of Connecting Rod(C.R.) in all of machining of the VMC’s. Deposition of chip(in bulk) in the various fixtures of the VMC’s, thereby increasing the cycle time for the job. Manual measurement of the weights of C.R. Manual drilling & press fit operation of the C.R.

2. Analysis of the problems & respective solution to the problems: Reducing the cycle time by Automation of the fixture of VMC’s. In cooperating proper chip disposal mechanism. Partial Automation of the weighing system grades. Automation of the Press fit m/c thereby decreasing the manpower to only 1 worker per m/c as per 2 workers.

WHAT’S INNOVATIVE IN THE PROJECT??

NOTHING MUCH INNOVATIVE IN THE PROJECT!!!!!!

BUT JUST FEW POINTS WE BELIVE IS INNOVATIVE……

Current clamping/de-clamping of the job is 15 sec manually.

Automation reduces the time to nearly 3 sec.

Reduction of cycle time by nearly 70%!!!

SIGNIFICANCE OF THE PROJECT:

There are total of 6 VMC’s in the manufacturing line• Our project is only on one m/c• If successful our project will be implemented on the rest of the m/c

The present fixture can handle only 2 C.R• Have designed fixture which can handle 4 C.R• Firstly trial of hydraulic mechanism will be on the present fixture then to the

designed fixture

The next phase is Automation of the Bush Press m/c• 2 workers are required for the operation.• Automation will only require 1 worker at the m/c

PHASE 1 OF PROJECT:DESIGNING OF FIXTURE IN COORPORETING 4 C.R.

WHAT’S THERE IN THE PRESENT FIXTURE????Current fixture is a manual fixture in sense that operator has to clamp/de-clamp the fixture manually.The operator has to clamp/de-clamp the C.R manually with the help of spanner , then he has to fastened the side threaded screws on both sides. The whole operation takes about nearly 15 sec. .

DRAWBACKS OF PRESENT FIXTURE

1) Improper fitting of C.R in the small end center due to chip deposition.

2) Chip deposition in the lower inner side of the fixture.

3) Improper clamping of the C.R at the side ends.

THE 4 C.R DESIGN:

ADVANTAGES OF THE 4 C.R FIXTURE:ISOM

ETRIC VIE

W

• 4 C.R can be accommodated

• Compact structure

FRONT

VIE

W

• A hydraulic mechanism housed in the fixture for automation

• The cylinder is double acting cylinder which can be used for making chip disposal mechanism as well.

TOP VI

EW

• A spring mechanism is placed in the side instead of threaded screw to avoid clamping by spanner & for more proper holding.

• A two way spring block makes design compact.

WHAT HAVE WE DONE AS A DESIGN ENGG???Designing of the hydraulic mechanism.Designing of the spring.

Designing of the

Hydraulic

mechanism:

Phases of hydraulic mechanism design;• Determination of the

torques required for clamping/de-clamping of the nut in present fixture using Torque meter.

• Computation of force from torques using;• Standard method• Long formula

method• Designing of

hydraulic cylinder using forces obtained from the above results.

• Comparing with the standard cylinder in the market & selecting suitable cylinder.

THE POWER PACK UNIT:The power pack used is in the scraps of the company , using it all the system will be designed.

DESIGNING OF THE SPRING:The spring will be designed according to the forces obtained from actual placement of the C.R in the fixture & accordingly standard springs would be selected.

CURRENT STATUS OF THE PROJECT:

The Project has been completed 50% of the 1st phase.

The fixture designing incorporating the hydraulic cylinder is completed.

An order has been placed for the hydraulic cylinder to a Vendor.

After cylinder is received in 2-3 days , a trial will be taken on 2 C.R.

The results will be analyzed & will be implemented on the 4 C.R.