Design and Fabrication of Turning Fixture and Drilling Jig for Exhaust Manifold (original) (raw)
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The Design and Need for Jigs and Fixtures in Manufacturing
The paper gave a detailed definition of jigs and fixtures, and also identified the numerous advantages that are associated with the use of jigs and fixtures in manufacturing to include: production increase, cost reduction, interchangeability and high accuracy of parts, reduction of the need for inspection and quality control expenses, reduction of accident as safety is improved, automation of machine tool to an appreciable extent, easy machining of complex and heavy components, as well as low variability in dimension which leads to consistent quality of manufactured products. The work also explained that since the design is dependent on numerous factors which are analyzed to achieve an optimum output, that jigs and fixtures should be made of rigid light materials to facilitate easy handling. For adequate strength and rigidity, a mild steel with 16 millimeters diameter was chosen for the design of a sample jig and fixture. Mild steel which contain about 0.29% of carbon are very cheap, and because of their easy availability are often the choicest material for the making of jigs of fixtures.With 1.5 as the material factor ‘k’ for mild steel, a feed rate of 0.17 millimeter per revolution, and a drill diameter of 16 millimeters, the Thrust/Drilling force was calculated as 3094.2 N. The Force acting on each of the lips was calculated as 1700 N, the Torque (M) was gotten as 1360N-mm, while the value of the Clamping Force was also calculated as 4080N. The calculated values confirmed that a 16 millimeter diameter mild will lead to the construction of a rigid and strong jigs and fixtures that will guarantee high machining accuracy, consistent quality of products, and interchangeability. Finall, the paper advocated that jigs and fixtures must be provided with adequate clearance which should allow for variations in size of components especially during forging, milling, and casting operations.
Jigs and Fixtures in Manufacturing
Standard machine tools can be converted into speciality machine tools with the help of jigs and fixtures. Jigs and fixtures continue to be employed, either alone or in conjunction with other technologies, despite the general trend toward higher quality production. Although several writers have provided valuable details on some aspects of fixture design, there is still a need for a unified approach to creating jigs and fixtures. This paper examines the fundamentals of fixture and jig design. These principles of location, clamping, and automation in fixture design form the heart of effective jigs and fixture design, which evolves irrespective of the rapid evolution of machine tools and manufacturing technologies. The ideal fixture would solve the workpiece distortion brought on by clamping and cutting force, in addition to the high productivity and machining repeatability it would otherwise provide.
Journal of Advanced Research in Applied Sciences and Engineering Technology
Jigs and fixtures were brought to the world of machining, bringing a variety of practical purposes. The concept enables rapid mass production of the same product. Thus, the company will streamline the manufacturing process for each component and boost productivity. At times, the machining operation was carried out entirely by the machine, without jigs and fixtures. As a result, jigs and fixtures were created to expedite the drilling process. The project's objectives are to design a jig and fixture, fabricate it, and analyze the performance on a square block of wood. The structural model for drilling jigs and fixtures was created using the Inventor Professional 2019 Computer-Aided Design Software. The fabrication process used were milling, surface grinding, CNC wire-cut, and drilling machines. Aluminium 1065 was utilized because it is less expensive, lighter than other materials, and easy to process. The result demonstrates that a hole can be drilled quickly using the jigs and fi...
IJERT-An Advanced Treatise on Jigs and Fixture Design
International Journal of Engineering Research and Technology (IJERT), 2013
https://www.ijert.org/an-advanced-treatise-on-jigs-and-fixture-design https://www.ijert.org/research/an-advanced-treatise-on-jigs-and-fixture-design-IJERTV2IS80370.pdf Jigs and fixtures are special production tools which make the standard machine tool, more versatile to work as specialized machine tools. Even with the advancement of manufacturing industries, there is a continued use of jigs and fixture either in some form or other, either independently or combination with other systems. Various areas related to design of fixtures are already well described by various authors but there is a need of basic approach to design these jigs and fixtures. This paper gives a brief introduction to the general and classic principles of jigs and fixtures design. These principles are still very applicable and form the basis of good of jigs and fixtures design, despite the rapid advancement of machine tools and manufacturing technology, principle of location, clamping, automation in fixtures design and this will continue to evolve in the future. An ideal fixture should not only provide the machining repeatability and high productivity, it should also offer a solution which reduces work piece distortion due to clamping and machining force. Key words: Jigs and fixtures design importance of location and clamping, manufacturing considerations and need of automation of jigs and fixtures.
International Journal for Research in Applied Science and Engineering Technology IJRASET, 2020
This final year paper report is about the design and Fabrication of jigs and fixtures for manufacturing process. For this project, it is focus on the perspective of the job handling to produce the part. Improvement that is trying to do is by replace the manual handling for the process by designing the jigs and fixture for this process. The objectives of this project are to investigate the collected data and analyse the design of jig and fixture to ease work handling. The methodology adopted for problem identification in connecting rod line are Root cause analysis for quality-related problems is a key and necessary step in the operations of manufacturing processes, especially in high-throughput automated processes. The design of jig and fixtures is using CATIA V5 software. Jigs and fixtures are specially designed so that large numbers of components can be machined and to ensure interchangeability of components. To reducing the setup, loading, unloading and machining time during drilling, reaming, Tapping and chamfering operation. The jigs and Fixture is successfully designed and implemented for the radial drilling machine for line balancing of existing connecting production line and it help to ease the handling of the job. It will make easy, quick and consistently accurate locating, supporting and clamping the blank in alignment of the cutting tool. Guidance to the cutting tool like drill, reamer, tap etc. Increase in productivity and maintain product quality consistently. It will reduce operator's labour and skill requirement, Also reduce measurement and its cost. After the implementation of jigs and fixture on Radial drilling machine the non-productive time (loading and unloading) was reduced from 78 seconds to 52 Seconds and machine setup time reduced to 120 to 96 seconds also machining time reduced to 38 to 30 seconds due to increase in spindle speed where the difference of 58 seconds is converted as the productive time and this will help to overcome the problem of bottleneck in existing connecting rod production line, productivity will be improved and this also helps to good will of the company.
Flexible Fixtures for Parts Machining in Automobile Industry
Proceedings of the 2nd EAI International Conference on Management of Manufacturing Systems, 2018
Fixtures play an essential role in production of high-quality and competitive products, especially under conditions of multiproduct manufacturing, which requires quickly re-equipment while transferring to the machining of parts of other nomenclature. Nowadays, the multiproduct manufacturing is the basic form of organization in the manufacturing and automobile industries. The article describes the ways of increasing of machining efficiency of parts of automobile industry at the contracting organizations, which are parts of automakers or work closely with them. For increasing the machining efficiency through the use of approaches to intensification of production, and also for performed analysis of locating charts for the majority of parts, which are included to the construction of machines, the principally new constructions of functional modules of modular adjustable fixtures for locating and clamping of parts are used. Use of the proposed construction with the possibility of automatized adjustment ensures the spreading of technological possibilities of metal-cutting equipment, decreasing of preparatory time and setup time, and therefore, assists improving of the efficiency of production planning.
" DESIGN AND MANUFACTURING OF MODIFIED ANGLE JIG TOOL "
To face challenges industries needs to increase their production rate with good quality product, achieving production in time. This project is proposed method to design modified angle jig for the drilling holes on given component. Thus the time required for the production of component should be decreased to as small as possible with the help of these jig. The marking time, loading and unloading time can be get minimise with reduction in rejection, and cost effectiveness tool. In this paper we starts from basic conseptual design of jig and comes up with this model which can satisfy theoretical concepts of jig design.The 3D model design done on Solidworks & 2D drafting carried on using AutoCAD.
Design and Fabrication Jig and Fixture for Pin Component in Vehicle Component Parts
2016
In manufacturing industry especially automotive industry there are rising issues concerning the need to save labour energy, time as well as providing a lower cost industry. This paper presents the capability of 3D software to assist in generating and improving innovative product. This project helps the mechanics to remove pin component; distributor pin and piston pin. The issue here is with conventional method where the pin is removed by a punch method is too big of a risk on distributors or piston to accept the load from hammer. This project also hopes to avoid human injuries and reduce human energy when knocking the pin. Overall this project through three main phases, first design the jig and fixture using pro engineer software (Pro/E), second is in the fabrication process via machining process and finally analysis process by comparing outcome the distributor and piston in conventional method and using jig. The result shows that the function of jig and fixture reduces the damage o...
Computer-Aided Design of Traditional Jigs and Fixtures
Computer-Aided Design of Traditional Jigs and Fixtures, 2021
Conventional design of jigs and fixtures has become unsuitable given the requirements of modern technology and complexity and diversity in the production with the rapid update of products. Computer-aided design (CAD) of jigs and fixtures is an effective solution in this direction. The current paper focuses on a computer-aided design of the traditional jigs and fixtures and developed a system containing tailor-made software, created using the Visual Basic programming language and installed on it the viewer screen to show the part. The developed system has been built by connecting Visual Basic programming language to the SolidWorks software on which the part is drawn and saved as STEP AP-203 file format, and the system reads and extracts the data from the STEP AP-203 file. Heuristic rules of feature recognition are pre-prepared for checking the extracted geometric data and deciding which data shape will represent the machining feature; then, the system provides the optimum design of the traditional jigs and fixtures for a group of hollow cylindrical parts that contain a group of cross-holes on the cylinder body, whether perpendicular or offset from the cylinder’s axis, (inclined or inclined offset, or blind or through, by applying pre-prepared heuristic rules for the design of traditional jigs and fixtures.