proto copy finale draete

8/2/2019 Proto Copy Finale Draete

1/60

v


2/60


3/60

HYDRAULIC CLAMPING ARRANGEMENT FOR

CONNECTING ROD MILLING FIXTURE

SUBMITTED BY:AJINKYA VIJAY MORE(11MCD0013)

GUIDED BY:DR.K ANNAMALAI.

School of Mechanical and Building Sciences, VIT University, Vellore - 632014, TamilNadu,

India

ABSTRACT

Now a days all manufacturing industries are attempts to bring down themanufacturing time and resources. For that purpose they have in search of various types of

specific manufacturing systems. Fixtures are one of the mean that it accomplish this need

effectively.

We design and manufacture the Connecting Rod Milling Fixture With Hydraulic

Clamping Arrangement, which can potentially reduce the process time and almost

eliminates setup time.


4/60

. This need of fixture for following purposes

1. It works as work holding device.

2. It is base to machining theory.

NEED OF PROJECT:-

For milling of five components i.e. Split Type Connecting Rods. They need for

Vertical Machining Centre (V.M.C.) with precise accuracy and reduced time of machining.

Present method of machining makes use of stoppers and clamps only which

require long processing time. Maximum time of worker is wasted in setting of work piece on

the machine. Also accuracy is not so precise. Therefore to get the precise accuracy company

needs this fixture.

Hydraulic clamping arrangement provides perfect clamping action & reduces time

of adjusting connecting rods on fixture.

At a time 4 connecting rods can be milled on this fixture. Due to this setting time

can be reduced.. It is robust structure.


5/60

COMPONENTS USED FOR HYDRAULIC CLAMPING

1) Hydro line 32:-Anti corrosion, anti oxidation, anti wear, anti foam additives speciallyselected to maintain good air- release properties. Theses oils are recommended for use in generalhydraulic systems,

2) Hydraulic cylinder

Hydraulic cylinders get their power from pressurized hydraulic fluid, which is typically

oil. The hydraulic cylinder consists of a cylinder barrel, in which a piston connected to a

piston rod moves back and forth. The barrel is closed on each end by the cylinder bottom

(also called the cap end) and by the cylinder head where the piston rod comes out of the

cylinder. The piston has sliding rings and seals. The piston divides the inside of the

cylinder in two chambers, the bottom chamber (cap end) and the piston rod side chamber

(rod end). The hydraulic pressure acts on the piston to do linear workand motion.

Flanges, trunnions, and/or clevisses are mounted to the cylinder body. The piston rod also

has mounting attachments to connect the cylinder to the object or machine componentthat it is pushing.
http://wapedia.mobi/en/Hydraulichttp://wapedia.mobi/en/Hydraulic_fluidhttp://wapedia.mobi/en/Barrelhttp://wapedia.mobi/en/Pistonhttp://wapedia.mobi/en/Piston_rodhttp://wapedia.mobi/en/Mechanical_workhttp://wapedia.mobi/en/Flangehttp://wapedia.mobi/en/Trunnionhttp://wapedia.mobi/en/Clevis_pinhttp://wapedia.mobi/en/Clevis_pinhttp://wapedia.mobi/en/Trunnionhttp://wapedia.mobi/en/Flangehttp://wapedia.mobi/en/Mechanical_workhttp://wapedia.mobi/en/Piston_rodhttp://wapedia.mobi/en/Pistonhttp://wapedia.mobi/en/Barrelhttp://wapedia.mobi/en/Hydraulic_fluidhttp://wapedia.mobi/en/Hydraulic


6/60

3) Hydraulic accumulator:-

A hydraulic accumulator is an energy storage device. It is a pressure storage reservoir in

which a non-compressible hydraulic fluid is held under pressure by an external source.

That external source can be a spring, a raised weight, or a compressed gas. The main

reasons that an accumulatoris used in a hydraulic system are so that the pump doesn'tneed to be so large to cope with extremes of demand, so that the supply circuit can

respond more quickly to any temporary demand and to smooth pulsations.

In modern, often mobile, hydraulic systems the preferred item is a gas charged

accumulator, but simple systems may be spring-loaded. There may be more than one

accumulator in a system. The exact type and placement of each may be a compromise

due to its effects and the costs of manufacture.

An accumulator is placed close to the pump with a non-return valve preventing flow back

to it. In the case of piston-type pumps this accumulator is placed in the best place to

absorb pulsations of energy from the multi-piston pump. It also helps protect the systemfrom fluid hammer. This protects system components, particularly pipework, from both

potentially destructive forces. An additional benefit is the additional energy that can be

stored while the pump is subject to low demand. The designer can use a smaller-capacity

pump. The large excursions of system components, such as landing gear on a large

aircraft, that require a considerable volume of fluid can also benefit from one or more

accumulators. These are often placed close to the demand to help overcome restrictions

and drag from long pipe work. The outflow of energy from a discharging accumulator is

much greater, for a short time, than even large pumps could generate.

An accumulator can maintain the pressure in a system for periods when there are slight

leaks without the pump being cycled on and off constantly. When temperature changes

cause pressure excursions the accumulator helps absorb them. Its size helps absorb fluid

that might otherwise be locked in a small fixed system with no room for expansion due to

valve arrangement.

The gas precharge in an accumulator is set so that the separating bladder, diaphragm or

piston does not reach or strike either end of the operating cylinder. The design precharge

normally ensures that the moving parts do not foul the ends or block fluid passages. Poor

maintenance of precharge can destroy an operating accumulator. A properly designed and

maintained accumulator should operate trouble-free FOR YEARS

JUSTIFICATION OF FIXTURE:

1. To reduce the cost of production and setting up costs.

2. To increase production.

3. To assure high accuracy of part.

4. To increase versatility of the machine.

5. Saving of labour.

6. To reduce the quality control expenses.
http://wapedia.mobi/en/Energy_storagehttp://wapedia.mobi/en/Pressurehttp://wapedia.mobi/en/Hydraulic_fluidhttp://wapedia.mobi/en/Spring_(device)http://wapedia.mobi/en/Weighthttp://wapedia.mobi/en/Gashttp://wapedia.mobi/en/Axial_piston_pumphttp://wapedia.mobi/en/Water_hammerhttp://wapedia.mobi/en/Water_hammerhttp://wapedia.mobi/en/Axial_piston_pumphttp://wapedia.mobi/en/Gashttp://wapedia.mobi/en/Weighthttp://wapedia.mobi/en/Spring_(device)http://wapedia.mobi/en/Hydraulic_fluidhttp://wapedia.mobi/en/Pressurehttp://wapedia.mobi/en/Energy_storage


7/60

7. To use less skilled labour.

8. To improve safety at the work and thereby reduce rate of accidents

DESIGN PRINCIPLE FOR FIXTURE

Locating:-

Locating refers establishment of a proper relation between the work piece and the fixture.

Let us consider a work piece in a space. The work piece is assumed to have true and flat

faces. In a state of freedom, it moves in either of the two apposed directions along three

mutually perpendicular axes, XX, YY, and ZZ. These six movements are called

movement of translation. Also the work piece can rotate in either of two opposed


8/60

directions around each axis, clockwise and roundwise. These movements are called

rotational movements.

The sum of these two types of movements gives the twelve degree of freedom of work

piece

in space. To confine the work of piece accurately and positively in another fixed body ,the

movements of work piece in any of the twelve degree of freedom must be restricted

.

.

PROCESS SHEET


9/60

1) PART NAME: - CASTING BASE

Raw Material Size: - 500X 340X 195

Material: - C.I.

Sr.

No

.

Operation Machine Tool

Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

( MIN)

1 Milling HOR

Boring

Machine

CBH 100

T-Max

cutter

0.05

mm

650

rpm

2mm Vernier

calliper and

steel rule

240

2 Drilling HOR

Boring

Machine

CBH 100

Various

sizes of

drills Dia

67.5,13.5,

6Reamer

dia. 14

3

mm

625

rpm

2mm Vernier

calliper

300

3 Boring HOR

Boring

Machine

CBH 100

Size 50

boring

tool

0.05

mm

1000

rpm

2mm Vernier

caliper,

Micrometer

600

4 Spot

facing

HOR

Boring

Machine

CBH 100

SS Slot

drill

0.01

mm

800

rpm

1mm 90

5 Surface

Grinding

ELB

Surface

Grinding

Machine

inch

bsp

Micrometer 240


10/60

6 Fitter

work

including

dia. 8

extra long

drills,

tapping

ELB

Surface

Grinding

Machine

Vernier

calliper

and steel

rule

120

7 Slots of 14

mm

Dekel

Milling

Machine,

Jig/ Boring

Machine

(Double

column)

End Mill

cutter

dia.12

mm

dia 6 X

16,

6H7

dia. 55

finish

bore,

dia.12H7

(3 holes),

dia 18H7

(4 holes)

0.05

mm

650

rpm

2mm Vernier

calliper

and steel

rule

180

8 CMM

Inspection

Inspection 3- D Co-

ordinate

Inspectio

n

240

2) PART NAME: - FIXED BLOCK


Material:- EN353


11/60

Sr.

No.


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)

1 Blank and

Step Milling

BFW

VF2

Milling

Machine

Tmax &

End Mill

cutter

0.05

mm

650

rpm

3mm Vernier

calliper and

steel rule

350

2 Fitter work

(Marking,

Drilling,

Tapping)

No.6 tap,

Drill of

7&11

Vernier

calliper and

steel rule

330

3 Heat

Treatment

Case

Hardening

Dynamic

Hardness

Tester

FANSE

60

4 Surface

Grinding

PRAGA

451

Surface

Grinding

Machine

Grinding

Wheel

Micrometer 240

5 Slots Dekel

Milling

Machine

FP4M.

1549

End Mill

Cutter

0.05

mm

650

rpm

2mm Vernier

calliper and

steel rule

180

6 7H7, 6H7

Dowel

Jig

Boring

Machine

(Double

Column)

Jig

Boring

Tool

0.05

mm

650

rpm

3mm Vernier

calliper and

Micrometer

210


12/60

7 Dia. 18

Wire Cut

CNC

Spark

Errosion

EDM

Machine

Copper

Electrode

Vernier

calliper

180

3) PART NAME: - ORIENTATION BLOCK

Raw Material Size: - 70 X 35X 20

Material: - EN353

Sr.

No.


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)

1 Turning LB17 Turning 0.1m 1000 2mm Vernier 60


13/60

4) PART NAME: - SUPPORT PLATE

Raw Material Size: -55X 65X 15

Lathe

Machine

&

Facing

Tool

m rpm caliper

2 Step Milling BFW

HF2 091

Milling

Machine

Tmax &

End

Mill

Cutter

0.05

mm

600

rpm

3mm Vernier

calliper

180

3 Fitter

Marking &

Drilling

Vernier

calliper and

steel rule

150

4 Heat

Treatment

Case

Hardening

Dynamic

Hardness

Tester

FANSE

60

5 Surface

Grinding

CNC

Arc

Milling

Machine

Micrometer 240


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)


14/60

Material: - M.S.

5) PART NAME: - RESTING PAD


Material: -O.H.N.S.: - SUPPORT PIN


1 Blank

Milling

BFW

VF2

Milling

Machine

Tmax

& End

Mill

cutter

0.05

mm

600

rpm

3mm Vernier

calliper and

steel rule

210

2 Fitter

Marking &

Drilling

Vernier

calliper and

steel rule

60

3 Surface

Grinding

451P

PRAGA

Surface

Grinding

Machine

Grindin

g

Wheel

Micrometer 120

4 Jig Boring

dia.6H7(4

holes)

Jig

Boring

Machine

(CBH

100)

Jig

Boring

Tool

0.05

mm

800

rpm

2mm Vernier

calliper

and

Micrometer

90


15/60

Material: - O.H.N.S.

6) PART NAME: - LOCATING PIN

Raw Material Size: - 24 X 42L

Material: O.H.N.S

Sr.

No.


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)

1 Blank

Milling

BFW

HF2 091

Milling

Machine

Tmax &

End Mill

cutter

0.05

mm

900

rpm

2mm Vernier

calliper

90

2 Fitter

Marking &

Drilling

Vernier

calliper and

steel rule

90

3 HeatTreatment

Dielectric

Hardening

DynamicHardness

Tester

FANSE

60

4 Surface

Grinding

452P

PRAGA

Surface

Grinding

Machine

Grinding

Wheel

Micrometer 90

5 Dia. 20

Wire Cut

Wire Cut

EDM

Machine

Vernier

calliper and

Micrometer

240

Sr.

No.


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)

1 Turning LB17

Lathe

Machine

Single

point

cutting tool

0.01

mm

900

rpm

2mm Vernier

calliper and

steel rule

90


16/60

7) PART NAME: - GUIDE ROD

Raw Material Size: - 10X 80L

Material: - EN353

Sr.

No.

Operation Machine Tool Used Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)

1 Turning LB 17

Lathe

Single

point

cutting tool

0.01

mm

900

rpm

1mm Vernier

calliper and

steel rule

60

2 Heat

Treatment

Hardening

Dynamic

Hardness

Tester

FANSE

60

3 Milling BFW VF2

Milling

Machine

Tmax &

End Mill

cutter

0.05

mm

800

rpm

2mm Vernier

calliper and

steel rule

120

4 Cylindrical

Grinding

Cylindrical

Grinding

Machine

GCU 250

PARISHU

DH

Cylindrical

Grinder

Micrometer 150


17/60

2 Heat

Treatment

Case

Hardening

Dynamic

Hardness

Tester

FANSE

60

3 Cylindrical

Grinding

Cylindrical

Grinding

Machine

GCU 250

PARISHU

DH

Cylindrical

Grinder

Micrometer 90


18/60

8) PART NAME: - GUIDE PLATE

Raw Material Size: - 50 X 30 X 20

Material: - M.S.

9) PART NAME: - GUIDE PIN

Raw Material Size:- 22X 105L

Sr.

No.


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)

1 Milling BFW

VF2

Milling

Machine

Tmax &

End Mill

cutter

0.05

mm

800

rpm

2mm Vernier

calliper and

steel rule

120

2 Fitter

Marking &

Drilling

Vernier

calliper and

steel rule

60

3 Surface

Grinding

451P

PRAGA

Surface

Grinding

Machine

Grinding

Wheel

Micrometer 90

4 Jig Boring Jig

Boring

Machine

(Double

Column)

Jig

Boring

Tool

0.05

mm

1000

rpm

2mm Vernier

calliper and

Micrometer

180


19/60

Material: - M.S.

Sr.

No.


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)

1 Turning LB 17

Lathe

Machine

Single

point

cutting

tool

0.05

mm

900

rpm

2mm Vernier

calliper and

steel rule

150

2 Milling FN3V 1482

BFW

Milling

Machine

End

Mill

cutter

0.05

mm

600

rpm

3mm Vernier

calliper and

steel rule

120

3 Driling Radial

Drilling

Machine

RM62 6410

Drill of

Dia.4

0.05

mm

625

rpm

2mm Vernier

calliper

60

4 Cylindrical

Grinding

Cylindrical

Grinding

Machine

GCU 250

PARISHU

DH

Cylindri

cal

Grinder

Micrometer 210

10) PART NAME: - CYLINDER MOUNTING BLOCK


Material: - EN8


20/60

Sr.

No.


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)

1 Turning LB 17

Lathe

Machine

Single

point

cutting

tool

0.05

mm

1000

rpm

2mm Vernier

calliper and

steel rule

120

2 Heat

Treatment

Toughning

Dynamic

Hardness

Tester

FANSE

60

3 Surface

Grinding

451P

PRAGA

Surface

Grinding

Machine

Grinding

Wheel

Micrometer 60


21/60

11)PART NAME: - SUPPORT PIN


Material: - EN8

Sr.

No.


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)

1 Turning LB 17

Lathe

Machine

Single

point

cutting

tool

0.05

mm

1000

rpm

2mm Vernier

calliper and

steel rule

60

2 Milling BFW

HF2 091

Milling

Machine

End

Mill

cutter

0.05

mm

800

rpm

2mm Vernier

calliper and

steel rule

90

3 Surface

Grinding

451P

PRAGASurface

Grinding

Machine

Grindin

g Wheel

Micrometer 90

12) PART NAME: - SUPPORT BLOCK


22/60


Material: - M.S.

Sr.

No.


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)

1 Turning LB 17

Lathe

Machine

Single

point

cutting

tool

0.05

mm

1000

rpm

2mm Vernier

calliper and

steel rule

180

2 Fitter

Marking &

Drilling

Vernier

calliper and

steel rule

240

3 Milling BFW

VF2

Milling

Machine

End

Mill

cutter

0.05

mm

800

rpm

2mm Vernier

calliper and

steel rule

120

4 Heat

Treatment

Case

Hardening

Dynamic

Hardness

Tester

FANSE

60

5 Surface

Grinding

451P

PRAGA

Surface

Grindin

g

Machine

Grindin

g Wheel

Micrometer 120

13) PART NAME: - FIXED BLOCK


23/60

Raw Material Size: - 98 X 65 X 45

Material:- EN353

5 Slots Dekel

Milling

MachineFP4M.

1549

End Mill

Cutter

0.05

mm

650

rpm

2mm Vernier

calliper and

steel rule

180

7H7, 6H7

Dowel

Jig

Boring

Machine

(Double

Jig

Boring

Tool

0.05

mm

650

rpm

3mm Vernier

calliper and

Micrometer

210

Sr.

No.


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)

1 Blank and

Step Milling

BFW

VF2

Milling

Machine

Tmax &

End Mill

cutter

0.05

mm

650

rpm

3mm Vernier

calliper and

steel rule

330

2 Fitter work

(Marking,

Drilling,

Tapping)

No.6 tap,

Drill of

7&11

Vernier

calliper and

steel rule

330

3 Heat

Treatment

Case

Hardening

Dynamic

Hardness

Tester

FANSE

60

4 Surface

Grinding

PRAGA

451

Surface

Grinding

Machine

Grinding

Wheel

Micrometer 240


24/60

Column)

7 Dia. 18

Wire Cut

CNC

Spark

Errosion

EDM

Machine

Copper

Electrode

Vernier

calliper

120

14) PART NAME: - ORIENTATION BLOCK


Material: - EN353

Sr.

No.


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)

1 Turning LB17

Lathe

Machine

Turning

&

FacingTool

0.1

mm

1000

rpm

2mm Vernier

calliper

60

2 Step Milling BFW

HF2 091

Milling

Machine

Tmax &

End

Mill

Cutter

0.05

mm

600

rpm

3mm Vernier

calliper

180

3 Fitter

Marking &Drilling

Vernier

calliper andsteel rule

150

4 Heat

Treatment

Case

Hardening

Dynamic

Hardness

Tester

FANSE

60

5 Surface CNC Micrometer 240


25/60

Grinding Arc

Milling

Machine

15) PART NAME: - SUPPORT PLATE


Material: - M.S.

Sr.

No.


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)

1 Blank

Milling

BFW

VF2

Milling

Machine

Tmax &

End Mill

cutter

0.05

mm

600

rpm

3mm Vernier

calliper and

steel rule

210

2 Fitter

Marking &

Drilling

Vernier

calliper and

steel rule

90

3 Surface

Grinding

451P

PRAGA

Surface

Grinding

Machine

Grinding

Wheel

Micrometer 120

4 Jig Boring

dia.6H7(4holes)

Jig

BoringMachine

(CBH

100)

Jig

BoringTool

0.05

mm

800

rpm

2mm Vernier

calliperand

Micrometer

90

16) PART NAME: - GUIDE ROD


26/60

Raw Material Size: - 15 X 85

Material: - EN353

Sr.

No.


of cut

Inspection

Instruments

TIME

(MIN)

1 Turning LB 17

Lathe

Single

point

cutting tool

0.01

mm

900

rpm

1mm Vernier

calliper and

steel rule

60

2 Heat

Treatment

Case

Hardening

Dynamic

Hardness

Tester

FANSE

30

3 Cylindrical

Grinding

Cylindrical

Grinding

Machine

GCU 250

PARISHU

DH

Cylindrical

Grinder

Micrometer 90

17) PART NAME: - GUIDE PLATE

Raw Material Size: - 65 X 50X50

Material: - M.S.

Sr.

No.

Operation Machine Tool Used Feed Speed Dept

h of

cut

Inspection

Instruments

TIME

(MIN)


27/60

1 Milling BFW

VF2

Milling

Machine

Tmax &

End Mill

cutter

0.05

mm

800

rpm

2mm Vernier

calliper and

steel rule

120

2 Fitter

Marking &

Drilling

Vernier

calliper and

steel rule

60

3 Surface

Grinding

451P

PRAGA

Surface

Grinding

Machine

Grinding

Wheel

Micrometer 90

4 Jig Boring Jig

Boring

Machine

(Double

Column)

Jig Boring

Tool

0.05

mm

1000

rpm

2mm Vernier

calliper and

Micrometer

180

18) PART NAME: -PIN

Raw Material Size: - 20X 65

Material: - EN8

Sr.

No.


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)

1 Turning LB 17

Lathe

Machine

Single

point

cutting

0.05

mm

1000

rpm

2mm Vernier

calliper and

steel rule

150


28/60

tool

2 Heat

Treatment

Toughening

Dynamic

Hardness

Tester

FANSE

60

3 Cylindrical

Grinding

Cylindrical

Grinding

Machine

GCU 250

PARISHU

DH

Cylindri

cal

Grinder

Micrometer 210

19) PART NAME: - CLAMPING PAD


Material: - O.H.N.S.

Sr.

No.


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)

1 Blank and

Step Milling

BFW

HF2 091

Milling

Machine

Tmax &

End Mill

cutter

0.05

mm

700

rpm

2mm Vernier

calliper and

steel rule

180

2 Fitter

Marking &

Vernier

calliper and

60


29/60

Milling steel rule

3 Surface

Grinding

451P

PRAGA

Surface

Grinding

Machine

Grinding

Wheel

Micrometer 210

4 Drilling Jig

Boring

Machine

(Double

Column)

0.05

mm

800

rpm

3mm Vernier

calliper

60

20) PART NAME: - SWING ARM


Material: - EN8

Sr.

No.


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)1 Milling BFW

FN3V

1482

Milling

Machine

End Mill

cutter

0.05

mm

600

rpm

3mm Vernier

calliper and

steel rule

300

2 Drilling Drilling

Machine

0.12

mm

900

rpm

2mm Vernier

calliper

210


30/60

BVR3

3 Heat

Treatment

Toughning

Dynamic

Hardness

Tester

FANSE

60

4 Surface

Grinding

451P

PRAGA

Surface

Grinding

Machine

Grinding

Wheel

Micrometer 180

5 Wire Cut CNC

Spark

Errosion

Machine

Vernier

calliper and

Micrometer

300

21) PART NAME: -CYLINDRICAL MOUNTING PLAE


Material: - M.S.

Sr.

No.


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)

1 Milling BFW

VF2

Milling

Machine

End Mill

cutter

0.05

mm

800

rpm

2mm Vernier

calliper and

steel rule

240

2 Fitter

Marking &

Chamfering

Vernier

calliper and

steel rule

60

3 Drilling Drilling

Machine

0.12

mm

900

rpm

2mm Vernier

calliper

120


31/60

BVR3

4 Surface

Grinding

451P

PRAGA

Surface

Grinding

Machine

Grinding

Wheel

Micrometer 180

5 Jig Boring HOR Jig

Boring

Machine

CBH 100

Jig

Boring

Tool

0.05

mm

800

rpm

3mm Vernier

calliper and

Micrometer

90

22) PART NAME: - CYLINDRICAL STOPPER

Raw Material Size:- 110 X 55X 20

Material: - M.S.

Sr.

No.


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)

1 Milling BFW

HF2 091

Milling

Machine

End

Mill

Cutter

0.05

mm

800

rpm

2mm Vernier

calliper and

steel rule

300

2 Fitter

Marking

Vernier

calliper and

steel rule

30

3 Welding Welding

Machine

60

4 Slot Milling Deckel

Milling

End

Mill

0.05

mm

650

rpm

2mm Vernier

calliper and

150


32/60

Machine

FP4M

1589

Cutter steel rule



Material: - EN8

Sr.

No.


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)

1 Blank

Milling

BFW

FNV

1482

Milling

Machine

Tmax &

End Mill

cutter

0.1.

mm

800

rpm

2 mm Vernier

calliper and

steel rule

240

2 Fitter

Marking

Vernier

calliper and

steel rule

40


Milling

Machine

End Mill

Cutter

0.05

mm

650

rpm

2mm Vernier

calliper and

Micrometer

240


33/60

FP4M

1589

4 Drilling Drilling

Machine

BVR3

Drill 0.12

mm

900

rpm

2mm Vernier

calliper

60

5 Heat

Treatment

Toughning

Dynamic

Hardness

Tester

FANSE

60



Material: - EN8

Sr.

No.


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)

1 Blank

Milling

BFW

FNV

1482

Tmax &

End Mill

cutter

0.1.

mm

800

rpm

2 mm Vernier

calliper and

steel rule

240

Surface

Grinding

451P

PRAGA

Surface

Grinding

Machine

Grinding

Wheel

Micrometer 240

EDM Slot CNC

Spark

Errosion

Machine

Copper

Electrode

300


34/60

Milling

Machine

2 Fitter

Marking

Vernier

calliper and

steel rule

40


Milling

Machine

FP4M

1589

End Mill

Cutter

0.05

mm

650

rpm

2mm Vernier

calliper and

steel rule

240

4 Drilling Drilling

Machine

BVR3

Drill 0.12

mm

900

rpm

2mm Vernier

calliper

60

5 Heat

Treatment

Toughning

Dynamic

Hardness

Tester

FANSE

30

6 Surface

Grinding

451P

PRAGA

Surface

Grinding

Machine

Grinding

Wheel

Micrometer 240

7 EDM Slot CNC

Spark

Errosion

Machine

Copper

Electrode

300



Material: - EN8


35/60

Sr.N

o.


of cut

Inspection

Instruments

TIME

(MIN)

1 Blank

Milling

BFW

FN3V

1482

Milling

Machine

Tmax &

End Mill

cutter

0.1.

mm

800

rpm

2 mm Vernier

calliper and

steel rule

240

2 Fitter

Marking

Vernier

calliper and

steel rule

60


Milling

Machine

FP4M

1589

End Mill

Cutter

0.05

mm

650

rpm

2mm Vernier

calliper and

steel rule

240

4 Drilling Drilling

Machine

BVR3

Drill 0.12

mm

900

rpm

2mm Vernier

calliper

45

5 Heat

Treatment

Toughning

Dynamic

Hardness

Tester

FANSE

60

6 Surface

Grinding

451P

PRAGA

Surface

Grinding

Machine

Grinding

Wheel

Micrometer 240

7 EDM Slot CNC

Spark

Errosion

Machine

Copper

Electrode

Vernier

calliper

300


36/60



Material: - EN8

Sr.N

o.


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)

1 Blank

Milling

BFW

FN3V

1482

Milling

Machine

Tmax &

End Mill

cutter

0.1.

mm

800

rpm

2 mm Vernier

calliper and

steel rule

240

2 Fitter

Marking

Vernier

calliper and

steel rule

60


Milling

Machine

FP4M

1589

End Mill

Cutter

0.05

mm

650

rpm

2mm Vernier

calliper and

steel rule

240

4 Drilling Drilling

Machine

BVR3

Drill 0.12

mm

900

rpm

2mm Vernier

calliper

45

5 Heat

Treatment

Toughning

Dynamic

Hardness

Tester

FANSE

60


37/60

6 Surface

Grinding

451P

PRAGA

Surface

Grinding

Machine

Grinding

Wheel

Micrometer 240

7 EDM Slot CNC

Spark

Errosion

Machine

Copper

Electrode

Vernier

calliper

300



Material: - EN8

Sr.N

o.


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)

1 Blank

Milling

BFW

FNV

1482

Milling

Machine

Tmax &

End Mill

cutter

0.1.

mm

800

rpm

2 mm Vernier

calliper and

steel rule

240

2 Fitter

Marking

Vernier

calliper and

steel rule

60


Milling

Machine

FP4M

1589

End Mill

Cutter

0.05

mm

650

rpm

2mm Vernier

calliper and

steel rule

240


38/60

4 Drilling Drilling

Machine

BVR3

Drill 0.12

mm

900

rpm

2mm Vernier

calliper

45

5 Heat

Treatment

Toughning

Dynamic

Hardness

Tester

FANSE

30

6 Surface

Grinding

451P

PRAGA

Surface

Grinding

Machine

Grinding

Wheel

Micrometer 240

7 EDM Slot CNC

Spark

Errosion

Machine

Copper

Electrode

Vernier

calliper

300



Material: - EN8

Sr.N

o.


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)

1 Blank

Milling

BFW

FN3V

1482

Milling

Machine

Tmax

& End

Mill

cutter

0.1.

mm

800

rpm

2 mm Vernier

calliper and

steel rule

240

2 Fitter

Marking

Vernier

calliper and

60


39/60

steel rule


Milling

Machine

FP4M

1589

End

Mill

Cutter

0.05

mm

650

rpm

2mm Vernier

calliper and

steel rule

240

4 Drilling Drilling

Machine

BVR3

Drill 0.12

mm

900

rpm

2mm Vernier

calliper

45

5 Heat

Treatment

Toughning

Dynamic

Hardness

Tester

FANSE

60

6 Surface

Grinding

451P

PRAGA

Surface

Grinding

Machine

Grindin

g

Wheel

Micrometer 240

EDM Slot CNC

Spark

Errosion

Machine

Copper

Electro

de

Vernier

caliper and

Steel rule

300

29) PART NAME: - SPACER PLATE

Raw Material Size: - 65 X 25X10

Material: -M.S.


40/60

Sr.

No.


Used

Feed Speed Depth

of cut

Inspection

Instruments

TIME

(MIN)

1 Blank

Milling

BFW

VF2

Milling

Machine

Tmax

& End

Mill

cutter

0.05

mm

900

rpm

2mm Vernier

calliper and

steel rule

180

2 Fitter

Marking

Vernier

calliper and

steel rule

60

3 Drilling BVR3

Drilling

Machine

Drill

Dia.

7mm

0.12

mm

900

rpm

2mm Vernier

calliper

30

30) PART NAME: - PROBING BUSH

Raw Material Size: - 25X 20

Material: -O.H.N.S.

Sr.

No.


of cut

Inspection

Instruments

TIME

(MIN)


41/60

1 Turning LB 17

Lathe

Machine

Single

point

cutting tool

0.1

mm

1000

rpm

2mm Vernier

calliper and

steel rule

90

2 Heat

Treatment

Case

Hardening

Dynamic

Hardness

Tester

FANSE

60

3 Internal

Grinding

Internal

Grinding

Machine

TGF

248800248

6

Internal

Grinding

Tool

Micrometer 60

4 O.D.

Grinding

Cylindrical

Grinding

Machine

GCU 250

PARISHU

DH

Cylindrical

Grinder

Micrometer 60


42/60

ASSEMBLY OF FIXTURE:-

Support plate & Spacer plate are fixed on casting base. Then probing bush is

attached to casting base. Fixed block is mounted on casting base. Then guide plate is

mounted on fixed block. Now guide rods are located.

Then resting pad is arranged on Guide plate. Then Orientation block is mounted on

fixed block. Then cylinder stopper is attached.

KOSMEK hydraulic cylinders are fixed at their appropriate position. Swing arm is

placed at the end of KOSMEK cylinder. Clamping pads are located on swing arm.

Then cylinder mounting block is attached to casting base. Then single acting

cylinder with 10mm stroke is fixed. Now support block is mounted on casting base with

respect to cylinder mounting block. Then guide pin is mounted on support block.

Again 7 times above procedure is repeated as there are 8 subassemblies which are

similar.

At the end, accumulator is mounted on casting base & hydraulic connection is do

WEIGHT CALCULATIONS:-

1) CASTING BASE

Specific weight of C.I.=7.85gm/cm cube

Raw Material Size: 500X 340X 195

Volume=33150000mm^3=33150.000cm^3

Weight =33150.000*7.85/1000=110 kg

Unit cost=Rs.55/kg

Cost=110*55=Rs.6050


43/60

2) FIXED BLOCK

Specific weight of M.S.=7.85gm/cm cube

Raw Material Size: 50X 60X 115

Volume=345000mm^3=345.000 cm^3

Weigh =345*7.85/1000=11kg

Unit cost=Rs.45/kg

Total cost=4*495= Rs.1980

3) ORIENTATION BLOCK

Specific weight of EN 353=7.85gm/cm cube

Raw Material Size: 70 X 35X20

Volume=49000mm^3=49.00cm^3

Weight =49.00*7.85/1000=9kg

Unit cost=Rs.100/kg

Cost=9*100=Rs.900


4) SPPORT PLATE

Raw Material Size: 55 X 65X15

Volume=55 X 65X15=53625 mm^3=53.625cm^3

Weight =53.625*7.85/1000=1.6kg

Unit cost=Rs.45/kg

Cost=1.6*45=Rs.72


5) RESTING PAD

Raw Material Size: 45X65X15

Volume=43875mm^3=43.875cm^3

Weight =43.875*7.85/1000=2.76kg


44/60

Unit cost=Rs.100/kg

Cost=2.76*100=Rs.276


6) LOCATING PIN

Raw Material Size: D24X42

Volume=3.14*12^2*42=19000.35mm^3=19.000m^3

Weight =19.000*7.85/1000=3.5kg

Unit cost=Rs.70/kg

Cost=3.5*70=Rs.245


1) GUIDE ROD

Raw Material Size

Volume=3.14*5^2*80=6283.185mm^3=6.283cm^3

weight=6.283*7.85/1000=0.4 kg

Total cost=8*24.4= Rs.195.2Unit cost=Rs.61/kg

Cost=0.4*61=Rs.24.4

8)GUIDE PLATE


Volume=50X30X20=30000mm^3=30.000cm^3

Weight =30.000*7.85/1000=1kg

Unit cost=Rs.45/kg

Cost=1*45=Rs.45


9) GUIDE PIN


Volume=3.14*11^2*105=39913.93mm^3

Weight =39913.93*7.85/1000=2.5kg

Unit cost=Rs.45/kg

Cost=2.5*45=Rs.112.5

Total cost=8*112.5= Rs.900


45/60

10) CYLINDER MOUNTING BLOCK


Volume=99549.21mm^3=99.549cm^3

Weight =99.549*7.85/1000=6.20kg

Unit cost= Rs. 55/kg

Cost=6.2*55=Rs.341


11) SUPPORT PIN


Volume=2356.19mm^3=2.356cm^3

Weight =2.356*7.85/1000=0.1kg

Unit cost=Rs. 55/kg

Cost=0.1*55=Rs.5.5


12) SUPPORT BLOCK


Volume=427256.60mm^3=427.256cm^3

Weight =427.256*7.85/1000=27kg

Unit cost=Rs.45/kg

Cost=27*45=Rs.1215


13) FIXED BLOCK


Volume=98X65X45=286650mm^3=286.650cm^3

Weight =286.650*7.85/1000=10kg

Unit cost=Rs.45/kg

Cost=10*45=Rs.450


14) ORIENTATION BLOCK


Volume=57720mm^3=57.720cm^3


46/60

Weight =57.720*7.85/1000=10.6kg

Unit cost=Rs.100/kg

Cost=10. 6*100=Rs.1060

Total cost=24*1060= Rs.25440

15) SUPPORT PLATE


Volume=48750mm^3= 48.75cm^3

Weight =48.75*7.85/1000=1.45kg

Unit cost=Rs.45/kg

Cost=1.45*45=Rs65.25


16) GUIDE ROD


Volume=15020.74mm^3= 15.02cm^3

Weight =15.02*7.85/1000=0.96kg

Unit cost=Rs.61/kg

Cost=0.96*61=Rs.58.56

Total cost=8*58.56= Rs.468.5

17) GUIDE PLATE


Volume=162500mm^3= 162.5cm^3

Weight =162.5*7.85/1000=5.4kg

Unit cost=Rs.45/kg

Cost=5.4*45=Rs.243


18) PIN


Volume=20420.35mm^3= 20.42cm^3

Weight =20.42*7.85/1000=1.28kg

Unit cost=Rs.45/kg

Cost=1.28*45=Rs57.6


47/60


19) CLAMP PAD


Volume=57200mm^3= 57.2cm^3

Weight =57.2*7.85/1000=3.5kg

Unit cost=Rs.100/kg

Cost=3.5*100=Rs.350


20) SWING ARM


Volume=218120mm^3= 218.12cm^3

Weight =218.12*7.85/1000=7kg

Unit cost=Rs.55/kg

Cost=7*55=Rs.385


21) CYLINDER MOUNTING PLATE


Volume=170625mm^3= 170.625cm^3

Weight =170.625*7.85/1000=5.44kg

Unit cost=Rs.45/kg

Cost=5.44*45=Rs.244.8

Total cost=4*244.8= Rs.979.2

22) CYLINDER STOPPER


Volume=121000mm^3= 121.00cm^3

Weight =121.00*7.85/1000=7.6kg

Unit cost=Rs.45/kg

Cost=7.6*45=Rs.342


23) RESTING PAD


48/60


Volume=81250mm^3= 81.25cm^3

Weight =81.25*7.85/1000=2.5kg

Unit cost=Rs.55kg

Cost=2.5*55=Rs.137.5


26) RESTING PAD


Volume=81250mm^3= 81.25cm^3

Weight =81.25*7.85/1000=2.5kg

Unit cost=Rs.55kg

Cost=2.5*55=Rs.137.5


27) RESTING PAD


Volume=81250mm^3= 81.25cm^3

Weight =81.25*7.85/1000=2.5kg

Unit cost=Rs.55kg

Cost=2.5*55=Rs.137.5


28) RESTING PAD


Volume=73125mm^3= 73.125cm^3

Weight =73.125*7.85/1000=2.25kg

Unit cost=Rs.55kg

Cost=2.25*55=Rs.123.75


29) SPACER PLATE


Volume=16250mm^3= 16.25cm^3

Weight =16.25*7.85/1000=0.5kg


49/60

Unit cost=Rs.45/kg


Cost=0.5*45=Rs.22.5

30) PROBING BUSH

Raw Material Size: 25X 20

Volume=9817.48mm^3= 9.817cm^3

Weight=9.817*7.85/1000=0.6kg

Unit cost=Rs.70/kg

Cost=0. 6*70=Rs.42


BOUGHT OUT COMPONENTS

Sr. No. Material Description Quantity Cost/Unit

In Rs.

Total Cost

In Rs.

LIST OF MATERIAL FOR

HYDRAULICARRANGEMENTFlat--End Pieces Plates-- 0.23 34 7.82

Flat--End Pieces Plates-- 0.56 34 19.245

Flat--End Pieces Plates-- 0.28 34 9.52

Tube Seamless 6X1mm 1 32.5 32.5

Ferrule L6 6 7.5 45

PMS Coupling CP6-LR 1/8 2 19 38

CX6-L/R bsp TTMSCO 1 22 22

Item Quick Coupler suitable for 200

bar

2 840 1680


50/60

Plug MS inch 2 5 10

Ball Valve inch bsp Heavy Duty 1 1260 1260

Accumulator VEKTEK make model

49-0116-02

1 10450 10450

Liner Bush EN353 ID 20mmX25mm

L Processed

2 50.01 100.02

HYD _CYL KOSMEK LV 0550-C-P

Clockwise

2 30352.005 60704.01

HYD _CYL KOSMEK LV 0550-C-P

Counter Clockwise

2 30352.005 60704.01

Wiper Rod ID 6,OD 12 Thick 3.5mm 10 67.5 675

Wiper Rod ID 12,OD 21 Thick 5mm 10 76.5 765

HYD _CYL 10mm Stroke Single

Acting No DP0

8 5485.96 43887.68

Valve Sequence Quicloc Make No.

V11101

1 6334.52 6334.52


51/60

:

SR

NO

DETAILS QNTY MATERIALS PURCHASE

PRICE INRS.

1 CASTING

BASE

1 C.I. 6050

2 FIXED BLOCK 4 M.S. 1980

3 ORIENTATION

BLOCK

24 EN353 21600

4 SPPORT

PLATE

4 M.S. 288

5 RESTING PAD 8 OHNS 2208

6 LOCATING

PIN

20 OHNS 490

7 GUIDE ROD 8 EN353 195.2

8 GUIDE PLATE 8 M.S. 180

9 GUIDE PIN 4 M.S. 900

10 CYLINDER

MOUNTING

BLOCK

8 EN8 2728

11 SUPPORT PIN 8 EN8 44

12 SUPPORT

BLOCK

8 M.S. 9720

13 FIXED BLOCK 4 M.S. 1800

14 ORIENTATION

BLOCK

24 EN353 25440

15 SUPPORT

PLATE

4 M.S. 261

16 GUIDE ROD 8 EN353 468.5

17 GUIDE PLATE 4 M.S. 972

18 PIN 8 EN8 460.8

19 CLAMPING

PAD

8 OHNS 2800

20 SWING ARM 4 EN8 1540

21 CYLINDER

MOUNTING

PLATE

4 4 M.S. 979.2


52/60

CONCLUSION:

We have developed fixture for vertical machining centre (VMC).

We have succeeded in designing of fixtures as per specifications..

We have done this with optimum cost of efficiency; the accuracy of work piece produce by

using the fixture is to the satisfaction.This has resulted in case of operation and handling

without affecting the accuracy of work piece.

This project work has given us experience about overall design and manufacturing

activities that take place in the Engineering Industry We have interacted with lot of people

during our project work.

Involving in this project was an exiting and learning experience for use. This project

work has broadened our horizons.

This experience will definitely help us in our future for developing ourselves as

good Engineers.


53/60

BIBLIOGRAPHY

1. Production Engineering- P. C. Sharma.

2. Production Technology- R. K. Jain.

3. An introduction to jig and Tool Design- M. H. A. Kempster ELBS.

4. Machine Design- R. S. Khurmi.

5. Production Technology- H. M. T. Handbook

6. Auto Cad- 2009

7. www.kosmek.com

8. www.enercap.mht.com

9. www.vektek.com
http://www.kosmek.com/http://www.kosmek.com/http://www.enercap.mht.com/http://www.enercap.mht.com/http://www.vektek.com/http://www.vektek.com/http://www.vektek.com/http://www.enercap.mht.com/http://www.kosmek.com/


54/60


55/60


56/60


57/60


58/60


59/60


60/60

proto copy finale draete

Documents