Process optimization, design and analysis of horizontal...

International Journal of Science, Engineering and Technology Research (IJSETR), Volume 4, Issue 9, September 2015

3276

ISSN: 2278 – 7798 All Rights Reserved © 2015 IJSETR

Abstract— Project gives feasible solution to move and rotary

indexing the component with full proofing fixture for special

purpose operations like drilling, Tapping, debarring, washing,

drying involve in manufacturing and assembly. Rotary

indexing type structure is made for handling the crank case

inside the cleaning machine use for making fully ready

component before assembly operation .System is useful to save

time manpower and deliver perfect cleaned and dry component

.system involved all the mechanical components along with the

sensors used to restrict the rotating operations, stop and go

operations etc. Mechanical structure and possible loading

conditions are studied and calculated to validate the bending

and deformation effects while it take indexing at different

angle. Structure will rotate 360 degree with multiple stoppages

and inside the structure cylinder block will be fixed

automatically, stress values need to be calculated on multiple

stoppages/ indexing angles.

Index Terms— Rotary indexing, Roller Wheel, Fixture,

Strain, Stress, Deformation.

INTRODUCTION

Design of automated Rotary indexing Type Fixture For

crank case is taken from the special purpose machine in

which component crank case) is to be machined, cleaned

,dry, and proceed towards assembly section in continuous

production line of Automobile company The arrangement of

said project will be process wise well defined sequence and

operation for the decided cycle time where the rotary Fixture

along with component will be get stoppage at every angular

position with the used sensors .Operation cycle will be run

through PLC Programme.

Problem Identification

Rotation of crank case is not possible manually; in automated

drilling and other operations component need to be rotate

indexing mode so that robotic drill can be face the drilling

surface with precision. Rotary cage is to be made to give

feasible solution .deformation may occur while rotation

.stress may be increase at multiple angles as the load is

coming directly on cage.

Fig. 1 Layout shows Need of indexing

Present Theories and Practices

Without rotating component it can be operated by keeping

operating face open toward tool it can be operated with only

single process multiple processes can’t be handle

simultaneously , since ,face wise operation can be changed.

After operating with tools component need to be clean before

reaching to assembly section again another station

component is transfers by moving fixture, here manual

handling and manual air blow for cleaning ,cavities, holes,

oil, coolant, dirt etc. It takes more time to complete all these

processes,

It will have been good if rotary indexing is provided in a

single station with common fixturing with allowing face

indexing only tools will change on same place and

component will take rotation.

Fig. 2 Design of Existing Cage

Process optimization, design and analysis of

horizontal Indexing cage fixture

Vishal Kumar, Prof. Dr. S.G. Taji, Prof. Baban P. Londhe

Shree Ramchandra College of Engineering, Lonikand, Pune, India

MIT Academy of Engineering, Alandi, Pune, India

Shree Ramchandra College of Engineering, Lonikand, Pune, India


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Fig 3 Initial Cage Design

Design Input :

• Total set of Fixtures Trolley required to be

Mounted- 1Nos

• Total Weight Of components: 300 Kg

• Maximum Available Area: 2Mtr x 3Mtr

• Loading Height: 1000 mm from ground.

• Degree of rotation for cage -360 degree

• material for construction- AISI 304, non-metal

-UHMW

• 3D model of crank case

• Trolley Fixture model already available

• Indexing structure to be designed for this assembly.

Fig 4 Trolley

II. LITERATURE REVIEW

1) Thomas and Ghadhi

(1986) Worked on Fixtures which are important in

both traditional manufacturing and modern flexible

manufacturing system (FMS), which directly affect

machining quality, productivity and cost of

products. The time spent on designing and

fabrication fixtures significantly contributes to the

production cycle in improving current product and

developing new products [5].

2)

2) Nee & Kumar (1991) also developed a rule-based

automated fixture design. In addition to the functionality

offered by Nnaji et al. Nee & Kumar performed a limited

check on the displacement likely at each locating point as a

result of the machining forces and also implemented a simple

justification module that employed heuristic rules to

determine whether a modular (comprised from a set of

standard components) or dedicated (custom) fixture design

should be generated [6].

3) Jeng and Gill (1997) formulated a fixture design problem

in hierarchical design structure. Mervyn et al. (2003)

presented an internet-enabled fixture design system by the

use of XML file format. Rios et al. (2005) and Alarcon et al.

(2010) developed and presented KBE (knowledge based

engineering) application for, modular fixture design. Hunter

et al. (2006) presented a functional design approach in which

the functional requirements and constraints are considered as

an input to the fixture design process. Taufif Bin Zakaria &

Wang and Rong (2008) and Sun and Chen (2007) presented

the case based reasoning method to provide a computer aided

fixture design solution. Perremans (1996) developed an

expert system for automatic fixture design [8].

4) Wu et al (1997) developed an automated customized

fixture design system. Based upon a fixture structure

analysis, fixtures are divided into functional components

(locators and clamps), fixture bases, and supports. The inputs

to the approach are the work piece geometry together with

the locating and clamping coordinates. A geometry-element

generator generates fixture components with dimensions

according to work piece geometry and operational

information. Once individual locators and clamps have been

designed individually, the support units can then be

generated to connect the locators/clamps to the base plate,

resulting in a complete fixture unit. Rules are used to select

components [7].

III. DERIVED UNIT DESIGN & CALCULATIONS

Fig 5 Cage design followed by taking component dimensions for

fitment


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Material Data

Grade

Design

strength

(N/mm2)

Ultimate

tensile

strength

(N/mm2)

Young's

Modulus

(N/mm2)

Elongation

(%)

Stainless steel

304 210 520 200 000 25

316 220 520 200 000 22

Considering round cage as fixturing element to mount object

fitted while rotating, Rotating parameters considering by full

proof fitting of this heavy object.

Fig 6 Crank case easy mounting in cage

Fig 7 First Drilling Guide in Cage

Two locations are to be covered for drilling 8 numbers of

holes.

Component is slide 100 mm left side to make opening for tool

entering.

Fig 8 Second Drilling Guide in Cage

Drilling face is to be opened to make machined here in

previous design

Drilling face was covering by cage plat, now its resolved by

giving simple cut to the cage side.

Fig 9 Guiding wheel to hold cage fixture

Fig 10 Bottom roller wheel for loading & unloading

Multiple wheels will allow component to enter inside and

unload by simple sliding by pushing and pulling operation by

cylinder stroke

Drive unit made for the transmission of rotary motion into

cage which is holding fixture cum component is made by

considering the input parameters like speed and cycle time

require for the process inside the machine.

Fig 11 Assembly of Driven unit

Calculations for selection and finalized the parameters:

Total CAGE weight = 110 kg

Per component weight =300kg

Maximum number of components at a time = 1


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For rolling applications, generally preferred value the

coefficient of friction is 0.3.

Total pulling weight = Total cage weight

+ (Per component weight × Maximum

No. of components at a time)

Hence,

1) Total pulling weight = 110 + (300×1)

=410kg.

Maximum Pull = Total Pulling weight × Coefficient of

Friction

= 410 × 0.3

=123 kg

= 1230 N …………………… where,

Consider g =10m/s2

2) For PCD of Drive sprocket,

Chain pitch (P) = 25.4 mm

Number of teeth on sprockets (z) = 17

Time to travel pitch (t) = 60 sec.

Pitch Circle Diameter of Drive Sprocket, (PCD) = Pitch (P) /

sin (180/z) (π/180)

Hence,

PCD of Sprocket = 25.4 / sin (180/17) (π/180)

= 138.17 mm

= 0.138m

Since the driving sprocket is a ring bonded by chain of pitch

25.4 mm

Ring dia d =725 mm

Perimeter of ring =2 л d = 4553

No. of pitch will be on ring (z) = 4553 / 25.4 = 179.25

Chain pitch (P) = 25.4 mm

Number of teeth on drive sprockets (z) = 17

Pitch between rotation components (Pc) = 4553

mm(considered after every rotation fresh cycle)

Time to travel pitch (t) = 60 sec.

3) Centre distance between two Shafts

= (PCD of Drive Sprocket + PCD of driven Ring) / 2

= (1384+725) /2

= 431.5 mm

= 0.431 m

4) Torque Calculation For Drive Unit

Required torque = Maximum pull × (PCD of Sprocket / 2)

= 1230 × (0.138 / 2)

= 85 Nm

Required RPM = Pc × (t / 60) × (z / P)

= 4553 × (60 / 60) × (17 / 25.4)

= 10.544

= 10.5 RPM

5) Final Result

Consider the service factor for the conveyor chain is 1.7

Hence,

Final output Torque, (T)

= required torque × Service factor

= 85 × 1.7

=144.5 Nm

Final Output RPM, (n) = 10.5 rpm

Final Output HP = (2 × л × n × T) / 45000

= (2 × л × 10.5 × 144.5) / 45000

= 0.212 HP

Track rod assessment

Total load 94 kg = 940 N (74 kg of cylinder block + 19.6 kg

of fixture trolley.)

Trolley loaded on two track rod by four wheels, point

loading acting 235 N each point.

Fig 12 Loading on Rod (Simply supported)

Fig 13 SFD & BMD for Rod

IV.FINITE ELEMENT ANALYSIS

The controls in this group set the basic size defaults for the

initial mesh. Local controls (described later), can be used to

override these values in specific regions of the model.


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• These settings assume the “Use Advanced Size Function” is

set to “Off”.

• Relevance Canter: sets the midpoint of the “Relevance”

slider control.

• Element Size: defines element size used for the entire

model.

• Initial Size seed: Initial mesh size is based either on the

entire assembly or on each individual part.

• Smoothing: Attempts to improve element quality by

moving nodes. Number of smoothing iterations can be

controlled (Low, Medium and High).

• Transition: Controls the rate at which adjacent elements

will grow (Slow, Fast).

Drum cage forming ring analysis

Fig 14 Force on Cage Ring

Fig 15 Elastic Strain on Cage Ring

Track Rod Weldment Assessment

Fig 16 Force on Rod


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Fig 17 Shear Stress on Rod

Fig 18 Equivalent Elastic Strain on Rod

Fig 19 Deformation of Rod

Fig 20 Directional Deformation on Rod

Stresses and deformation seen in the drum fixture structure:

Loading distribution in drum rotor:

Total load 94 kg = 940 N

Fig 21 FBD of cage with external load

Fig 22 FE Model of Cage


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Fig 23 Deformation of Fixture

Fig 24 Strain of Fixture

Fig 25 Force on Fixture

Fig 26 Maximum Shear Stress

Fig 27 Directional Deformation

V. CONCLUSION

Total deformation 0.0214 mm found in drum as per FEA &

But 0.02 mm found in physical validation, Stress level also

2.92 Mpa which reflect very safe working in structural

behavior as per material

It has been concluded that round structured drum type

horizontal fixture is possible to make indexing for heavy

components in SPM.


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Acknowledgment

It gives me great pleasure to submit my Dissertation on

“Process optimization, design and analysis on horizontal

Indexing cage fixture for cylinder block” to partial

fulfillment of my ME Design Engineering. I take this

opportunity to thank my Project guide Prof. Dr. S.G. Taji &

Co-Guide Prof. Baban P. Londhe for his valuable guidance

and his deep interest throughout the study and completion of

the Project.

It would be befitting to mention a word of thanks to Prof.

A.B. Verma, HOD, Department of Mechanical Engineering,

SRCOE, Pune.

They have helped me through their expertise in their fields

along with their invaluable advice helped me understand the

basics of dynamics and its applications in the real life

problems. I would also like to take this opportunity to express

my gratitude towards the staff members of the department for

their continuous support.

REFERENCES

[1] Structural analysis on tippler structure, University of

Pretoria by Petrus Johannes adriaans vanzyl

[2] Building Better Products with Finite Element Analysis,

1999, 587 pages, Vince Adams, Abraham Askenazi,

156690160X, 9781566901604, OnWord Press, 1999

[3]http://www.technicaljournalsonline.com/ijeat/VOL%20II

/IJAET%20VOL%20II%20ISSUE%20IV%20%20OCTBE

R%20DECEMBER%202011/ARTICLE%206%20IJAET%

20VOLII%20ISSUE%20IV%20OCT%20DEC%202011.pd

f

[4] http://eprints.nmlindia.org/2384/1/057.pdf

Parag Malode, Ravindra Chhangani, Amlan Datta and

Biswajit Basu Aditya Birla Science and Technology Co. Ltd.,

MIDC Taloja, Panvel, Maharashtra-410208

[5]Gandhi M.V. and B. S. Thompson, “Automated design of

Modular fixture for flexible manufacturing systems”, Journal

of Manufacturing system, 5(4), pp 243- 254, 1986

[6] Nee & Kumar “Assembly with automatically

reconfigurable fixture”, IEEE journal of robotics and

Automation, 1985-1991.

[7] Wu, Y., Rong, Y., and Chu, T.C., .Automated generation

of dedicated fixture designs..International Journal of

Computer Applications in Technology, Vol. 10(3/4), pp.

213-235, 1997.

[8] Taufif Bin Zakaria, “Dedicated fixture design for

polishing of silicon”, University of Malaysia Pahang,

November 2008.

First Author – This is Vishal Kumar , I have done B.E. in Mechanical

engineering from Amravati university , now I am doing M.E. (Design)from

S.R.C.O.E. Lonikand Pune

Second Author – This is Dr. S.G. Taji Prof. of MIT College of engineering

pune.

Third Author –This is Prof. Baban P. Londhe Prof. of S.R.C.O.E.

Lonikand Pune

http://www.technicaljournalsonline.com/ijeat/VOL%20II/IJAET%20VOL%20II%20ISSUE%20IV%20%20OCTBER%20DECEMBER%202011/ARTICLE%206%20IJAET%20VOLII%20ISSUE%20IV%20OCT%20DEC%202011.pdf






http://eprints.nmlindia.org/2384/1/057.pdf

Process optimization, design and analysis of horizontal...

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