1

CHAPTER-1

INTRODUCTION 1.1 INTRODUCTION

Now days the development of industries has become the key area

for the engineers. In this dynamic cycle of industrial world they innovate

every machine for their purpose of their own needs.

1.2 HISTORY

The AMREP ltd group which is the leading industry with the

production of clutch plates for the heavy vechiles tie up with more

industries over the seas.

The group starts with the collaboration with Repco limited in

Australia at the year 1967.

In 1970 it results with the commercial production of clutch

assembly and components to automotives.

After this the company solved many complicated and more

potential problems to withstand the organisation with the fast moving

automotives industries in the world.

The organisation which has tendency to produce more than 3000

products/per day.

1.3 PRODUCTS

Clutch cover plate.

Clutch driven plate.

Clutch service kit.

Release lever kit.

Spring kit.

Lever plate kit.

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1.4 DEALERS

Passengers car :

Maruti car

Bajaj minidor

Hindustan trekker

Ambassador

Light commercial vehicle :

Tata sumo

Mahindra jeep

Bajaj tempo trax/traveller

Mahindra-EC150/FC160

Medium and commercial vehicles :

Tata 1210D/TMB

Tata 1210/SE/1312/1313/1510

Ashok Leyland comet/viking/tarus/hippo/beaver

Tractor

TAFE

Eicher

Swaraj

Mahindra

John deere

1.5 MANUFACTURING PROCESS

Press shop

Machine shop

Driven plate assembly

Cover assembly area

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1.6 TOOLS AND PRODUCT MAINTAINING AREA

Tool room

Rework area

Inspection of products.

1.7 IMPROVEMENT OF PRODUCTION

Total productivity management

Quality analyser

Design and development

FIGURE 1.1 : AMALGAMATION REPCO LIMITED

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CHAPTER-2

LITERATURE SURVEY

2.1 INTRODUCTION

In the existing process the organization which has to produce

clutch plates with the help of single riveting machine. The process which leads

to increase the operator fatigue and increases the production time. The project

which deals with the designing of the gang riveting fixture for the production of

driven plates assembly. The gang riveting fixture which helps to reduces the

process of individual riveting with main plate and segment riveting. The

specifications of the riveting machine and the hydraulic press machine are

explained below.

2.2 RIVETING MACHINE

The function of riveting machine is used to join together the two

products by using the rivets.

Pedestal riveting machines is used where the component length is

long & it has to hold vertically only. Also these machines can adjust

components with different lengths by adjusting moving fixtures up down.

2.3. FEATURES

Microsmatic Stroke adjustment

Head up & down movement arrangement

Operator Panel with auto/manual

Foot switch

Robust Base & Frame Construction

Advantages

Smooth & crack free surface finish

Smaller press can be used compared to impact pressure

Less noise during forming

Long tool life

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FIGURE 2.1 : RIVETING MACHINE

Setting facility for quality riveing

Different types of forming heads possible

Less maintenance

Cost saving

Easy to operate

Optional

Anti-tie 2 hand cycle start push button

Fixtures as per components

Job counter

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Input air pressure switch

PLC controlled Panel

Machine lamps

With extra shut height & throat depth

Possible Rivet Profiles

Conical

Flat

Crown

Eyelet

Semi-tubular

2.4 HYDRAULIC MACHINE PRESS

The hydraulic punching machine which is used to make the joints

of two components with the help of bottom and top die plates. In this machine

the punching process is done with the maximum load applicable for the product

and this must not causes any damages to the product.

Hydraulic punch presses, which power the ram with a hydraulic

cylinder rather than a flywheel, and are either valve controlled or valve and

feedback controlled. Valve controlled machines usually allow a one stroke

operation allowing the ram to stroke up and down when commanded.

Controlled feedback systems allow the ram to be proportionally controlled to

within fixed points as commanded. This allows greater control over the stroke

of the ram, and increases punching rates as the ram no longer has to complete

the traditional full stroke up and down but can operate within a very short

window of stroke.

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FIGURE 2.2 : HYDRAULIC MACHINE PRESS

Hydraulic presses are commonly used for

forging

clinching

moulding

blanking

punching

deep drawing

metal forming

The hydraulic punch which is used to make the rivets with a single stroke,which

has the following function

Time consumption

Operator fatigue

Increased productivity

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FIGUR 2.3 OUTLINE OF GANG RIVETING FIXTURE

TOP PAD

PUNCH HOLDER

STRIPPER PLATE

BOTTOM - DIE

STRIPPER PLATE

PUNCH HOLDER

BOTTOM PAD

TOP - DIE

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2.5 OBJECTIVE OF THE PROJECT

The main objective of this research is to design and develop jig and

fixture for riveting the clutch to be used in engine assembly. Among the

other objectives want to achieve are follows:

i. To identify current jigs and fixtures limitation and design technology

availability

ii. Carried out data collection based on need engine assembly used to

clutch rivet at machine press.

iii. To design and fabricate a jig and fixture press rivet based on data

collection.

iv. To validity the performance of jig and fixture at driven plate assembly

of clutch plate.

2.6 SCOPE OF STUDY

Scope of assumption for this research is to design and produce jig press

rivet clutch . These jigs and fixture are used at main assembly line to assemble

the components. The jig and fixture design based on data clutch

specification, the data from machine press also accounts to realize this study.

All the data collected based on references from the organisation.

2.7 PROBLEM STATEMENT

The description of common jig and fixture in use today suggests that jig

and fixture are currently designed for a specific task on specific part geometry.

There is only limited flexibility in using the same jig and fixture for different

part shapes and sizes. In order to comply with the needs of smaller batch sizes

of the future jig and fixture should also be redesigned with a view to make them

flexible and versatile to increase productivity. The goal of the jig and fixture

design today is to provide user some guidance so that these guides can be used

for a wide variety of part sizes, shapes, materials and weights. In this research, a

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subset of this problem has been addressed the jig and fixture press rivet for

clutch motorcycle engine assembly. Use a different jig and fixture for different

model can give effect to production when assemble the clutch at motorcycle

engine, which is takes a longer time when changing the jig and fixture. Based

on the problem has it, a study is carried out to develop a jig and fixture can be

used for all models in general to assemble clutch, however special focus is

given for 11054 models.Therefore the design this jig and fixture can be increase

a production and save cost,when jig and fixture established at assembly line

production.

2.8 IMPORTANT OF THE PROJECT

This project is important in order to generate the design that can be

improved a jig and fixture design assembly. Moreover the design also can

reduce the time to assemble clutch rivet and increase production. In addition it

also can encourage others to get some idea and knowledge to develop jig and

fixture for press base on this research. Study of suitable jig and fixture used for

press rivet operation to get the best design and can implement at real

environment.

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CHAPTER - 3

COMPONENTS DESCRIPTION

3.1 CLUTCH

A clutch is a mechanical device that provides for the transmission of

power (and therefore usually motion) from one component (the driving

member) to another (the driven member) when engaged, but can be disengaged.

3.2 MATERIALS

Various materials have been used for the disc-friction facings, including

asbestos in the past. Modern clutches typically use a compound organic resin

with copper wire facing or a ceramic material. A typical coefficient of friction

used on a friction disc surface is 0.35 for organic and 0.25 for ceramic. Ceramic

materials are typically used in heavy applications such as racing or heavy-duty

hauling, though the harder ceramic materials increase flywheel and pressure

plate wear.

3.3 PUSH/PULL

Friction-disc clutches generally are classified as push type or pull

type depending on the location of the pressure plate fulcrum points. In a pull-

type clutch, the action of pressing the pedal pulls the release bearing, pulling on

the diaphragm spring and disengaging the vehicle drive. The opposite is true

with a push type, the release bearing is pushed into the clutch disengaging the

vehicle drive. In this instance, the release bearing can be known as a thrust

bearing (as per the image above).

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3.4 DAMPERS

A clutch damper is a device that softens the response of the clutch

engagement/disengagement. In automotive applications, this is often provided

by a mechanism in the clutch disc centres. In addition to the damped disc

centres, which reduce driveline vibration, pre-dampers may be used to reduce

gear rattle at idle by changing the natural frequency of the disc. These weaker

springs are compressed solely by the radial vibrations of an idling engine. They

are fully compressed and no longer in use once the main damper springs take up

drive.

3.5 LOAD

Mercedes truck examples: A clamp load of 33 kN is normal for a single

plate 430. The 400 Twin application offers a clamp load of a mere 23 kN.

Bursts speeds are typically around 5,000 rpm with the weakest point being the

facing rivet.

3.6 MANUFACTURING

Modern clutch development focuses its attention on the simplification of

the overall assembly and/or manufacturing method. For example drive straps

are now commonly employed to transfer torque as well as lift the pressure plate

upon disengagement of vehicle drive. With regard to the manufacture of

diaphragm springs, heat treatment is crucial. Laser welding is becoming more

common as a method of attaching the drive plate to the disc ring with the laser

typically being between 2-3KW and a feed rate 1m/minute. Types are discussed

below.

3.6.1 MULTIPLE PLATE CLUTCH

This type of clutch has several driving members interleaved or "stacked"

with several driven members. It is used in race cars

including F1, IndyCar, World Rally and even most club

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racing,motorcycles, automatic transmissions and in some diesel

locomotives with mechanical transmissions. It is also used in some

electronically controlled all-wheel drive systems as well as in some transfer

cases.

3.6.2 WET & DRY

A wet clutch is immersed in a cooling lubricating fluid that also keeps

surfaces clean and provides smoother performance and longer life. Wet

clutches, however, tend to lose some energy to the liquid. Since the surfaces of

a wet clutch can be slippery (as with a motorcycle clutch bathed in engine oil),

stacking multiple clutch discs can compensate for the lower coefficient of

friction and so eliminate slippage under power when fully engaged. The Hele-

Shaw clutch was a wet clutch that relied entirely on viscous effects, rather than

on friction.

A dry clutch, as the name implies, is not bathed in liquid and should be,

literally, dry.

3.6.3 CENTRIFUGAL

A centrifugal clutch is used in some vehicles (e.g., mopeds) and also in

other applications where the speed of the engine defines the state of the clutch,

for example, in a chainsaw. This clutch system employs centrifugal force to

automatically engage the clutch when the engine rpm rises above a threshold

and to automatically disengage the clutch when the engine rpm falls low

enough. The system involves a clutch shoe or shoes attached to the driven shaft,

rotating inside a clutch bell attached to the output shaft. The shoe(s) are held

inwards by springs until centrifugal force overcomes the spring tension and the

shoe(s) make contact with the bell, driving the output. In the case of a chainsaw

this allows the chain to remain stationary whilst the engine is idling; once the

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throttle is pressed and the engine speed rises, the centrifugal clutch engages and

the cutting chain moves. See Saxomat and Variomatic.

3.6.4 CONE CLUTCH

As the name implies, a cone clutch has conical friction surfaces. The

cone's taper means that a given amount of movement of the actuator makes the

surfaces approach (or recede) much more slowly than in a disc clutch. As well,

a given amount of actuating force creates more pressure on the mating surfaces.

The best known example of a cone clutch is a synchronizer ring in a manual

transmission. The synchronizer ring is responsible for "synchronizing" the

speeds of the shift hub and the gear wheel to ensure a smooth gear change.

FIGURE 3.1 : CLUTCH

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3.7 ASSEMBLY PROCESS

The child parts which are gather around from some other organisation

and some of them are manufactured from here itself.

The process is carried with the following steps:

SPRING ASSEMBLY

STOP PIN RIVETING

MAIN PLATE FACING RIVETING

FACING SEGMENT SUB ASSEMBLY

DRIVEN PLATE ASSEMBLY

1. SPRING ASSEMBLY:

The drive function needs to be carefully reviewed to select the correct

clutch for an application. The spring assembly which helps to reduce the

damper ratio which carried out to release load applied to the clutch regain its

original shape.

FIGURE 3.2 SPRING ASSEMBLY

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The spring assembly which consist of the following :

Damper spring - 8 Nos

Cushion segment - 6 Nos

Shim/Friction washer - as required

Waved washer - 1

2.STOP PIN RIVETING:

The stop pin riveting process which helps to join the side plate and main

plate segments.

FIGURE 3.3 : SIDE PLATE

The above figure which is the side plate,in this process the side plate which is

get riveted wwith the spring assembled hub.

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3.MAIN PLATE FACING RIVETING:

The main plate facing segment riveting process,which is one part of the

clutch driven plate. It is the next process to the stop pin riveting process,it

consist of the rivet facing segment.

FIGURE 3.4 FACING SEGMENT

The main plate comes along with the facing segment in this the riveting consist

of 24 rivets along in it.

In this the rivet which is used as said to be 2 rivet (i.e., the size of rivet) of semi-

tubular rivets.

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4.FACING SEGMENT : SUB-ASSEMBLY:

In this process the facing segment and the sub assembly part which

undergoes to the riveting function. The process carried out with the use of

riveting machine.

FIGURE 3.5 : FACING SEGMENT AND SUB ASSEMBLY

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5.DRIVEN PLATE ASSEMBLY:

The driven plate assembly which is the last step to finish the product of

the clutch plate. In this process the assembled parts of main plate segment and

the facing segment sub assemblies are taken together to the final riveting

process to complete the assembly of the driven plate of clutch

FIGURE 3.6.DRIVEN PLATE ASSEMBLY

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3.8 PARAMETER OF MACHINE PRESS

The Machine which is controlled by using the hydraulic supply for the

attaining of proper punch with loads to be applied as required .

FIGURE 3.7. HYDRAULIC MACHINE PRESS

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3.9 INTODUCTION TO JIG AND FIXTURE

3.9.1 Jigs

A JIG is a type of custom-made tool used to control the location and/or

motion of another tool. A jig's primary purpose is to

provide repeatability, accuracy, and interchangeability in the manufacturing of

products.[1] A jig is often confused with a fixture; a fixture holds the work in a

fixed location. A device that does both functions (holding the work and guiding

a tool) is called a jig

3.9.2 Fixtures

A fixture is a work-holding or support device used in

the manufacturing industry. Fixtures are used to securely locate (position in a

specific location or orientation) and support the work, ensuring that all parts

produced using the fixture will maintain conformity and interchangeability.

Using a fixture improves the economy of production by allowing smooth

operation and quick transition from part to part, reducing the requirement for

skilled labour by simplifying how workpieces are mounted, and increasing

conformity across a production run.

A fixture differs from a jig in that when a fixture is used, the tool must move

relative to the workpiece, a jig moves the piece while the tool remains

stationary.

3.9.3 Objectives of jigs and fixtures

introduction of jigs and fixtures,

purpose and advantages of jigs and fixtures,

important considerations while designing jigs and fixtures,

know the meaning and principles of location,

describe the different types of locations,

explain the clamping and its different type,

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the requirements of a good clamping device,

know the different types of clamp,

explain the jigs and their different types, and

know about the milling fixtures.

3.9.4 PURPOSE AND ADVANTAGES OF JIGS AND FIXTURES

Following the purpose and advantages of jigs and fixtures :

(a) It reduces or sometimes eliminates the efforts of marking, measuring and

setting of workpiece on a machine and maintains the accuracy of performance.

(b) The workpiece and tool are relatively located at their exact positions before

the operation automatically within negligible time. So it reduces product cycle

time.

(c) Variability of dimension in mass production is very low so manufacturing

processes supported by use of jigs and fixtures maintain a consistent quality.

(d) Due to low variability in dimension assembly operation becomes easy, low

rejection due to les defective production is observed.

(e) It reduces the production cycle time so increases production capacity.

Simultaneously working by more than one tool on the same workpiece is

possible.

(f) The operating conditions like speed, feed rate and depth of cut can be set to

higher values due to rigidity of clamping of workpiece by jigs and fixtures.

(g) Operators working becomes comfortable as his efforts in setting the

workpiece can be eliminated.

(h) Semi-skilled operators can be assigned the work so it saves the cost of

manpower also.

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(i) There is no need to examine the quality of produce provided that quality of

employed jigs and fixtures is ensured.

3.10 IMPORTANT CONSIDERATIONS WHILE DESIGNING JIGS AND

FIXTURES

Designing of jigs and fixtures depends upon so many factors. These factors are

analysed to get design inputs for jigs and fixtures. The list of such factors is

mentioned below :

(a) Study of workpiece and finished component size and geometry.

(b) Type and capacity of the machine, its extent of automation.

(c) Provision of locating devices in the machine.

(d) Available clamping arrangements in the machine.

(e) Available indexing devices, their accuracy.

(f) Evaluation of variability in the performance results of the machine.

(g) Rigidity and of the machine tool under consideration.

(h) Study of ejecting devices, safety devices, etc.

(i) Required level of the accuracy in the work and quality to be produced.

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3.11 MEANING OF LOCATION

It is very important to understand the meaning of location before

understanding about the jigs and fixtures. The location refers to the

establishment of a desired relationship between the workpiece and the jigs or

fixture correctness of location directly influences the accuracy of the finished

product. The jigs and fixtures are desired so that all undesirable movements of

the workpiece can be restricted. Determination of the locating points and

clamping of the workpiece serve to restrict movements of the component in any

direction, while setting it in a particular pre-decided position relative to the jig.

Before deciding the locating points it is advisable to find out the all possible

degrees of freedom of the workpiece. Then some of the degrees of freedom or

all of them are restrained by making suitable arrangements. These arrangements

are called locators.

3.12 PRINCIPLES OF LOCATIONS

The principle of location is being discussed here with the help of a most

popular example which is available in any of the book covering jigs and

fixtures. It is important that one should understand the problem first.

Any rectangular body many have three axis along x-axis, y-axis and z-axis. It

can more along any of these axes or any of its movement can be released to

these three axes. At the same time the body can also rotate about these axes too.

So total degree of freedom of the body along which it can move is six. For

processing the body it is required to restrain all the degree of freedom (DOF) by

arranging suitable locating points and then clamping it in a fixed and required

position. The basic principle used to locate the points is desirable below.

Six Points Location of a Rectangular Block

Considering the six degree of freedom of a rectangular block .It is made to rest

on several points on the jig body. Provide a rest to workpiece on three points on

the bottom x-y surface. This will stop the movement along z-axis, rotation with

respect to x-axis and y-axis. Supporting it on the three points is considered as

25

better support then one point or two points. Rest the workpiece on two points of

side surface (x-z), this will fix the movement of workpiece along y-axis and

rotation with respect to z-axis. Provide a support at one point of the adjacent

surface (y-z) that will fix other remaining free movements. This principle of

location of fixing points on the workpiece is also named as 3-2-1 principle of

fixture design as number of points selected at different faces of the workpiece

are 3, 2 and 1 respectively.

Body to be restrained (each of the axis can be divided into two halves positive

and negative)

FIGURE 3.8 : AVAILABLE DEGREE OF FREEDOM OF

RECTANGULAR BLOCK

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3.13 LOCATION OF A CYLINDER ON A VEE BLOCK

The analysis of the principle of location of a cylinder on a Vee block is

indicated in Figure 3.9. All the degrees of freedom of the cylindrical object are

restrained. It is only fixed to move along axis AB. It can rotate about the axis

AB. These free movements are also indicated in the figure. If the operation to be

done on the cylindrical object requires restriction of the above mentioned free

movements also than some more locating provisions must also be incorporated

in addition to use of the Vee block.

FIGURE 3.9 : LOCATING A CYLINDER ON A VEE BLOCK

3.14 DIFFERENT METHODS USED FOR LOCATION

There are different methods used for location of a work. The locating

arrangement should be decided after studying the type of work, type of

operation, degree of accuracy required. Volume of mass production to be done

also mattes a lot. Different locating methods are described below.

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3.14.1 FLAT LOCATOR

Flat locators are used for location of flat machined surfaces of the

component. Three different examples which can be served as a general principle

of location are described here for flat locators. These examples are illustrated in

Figure 3.10.

FIGURE 3.10: METHOD OF LOCATING USING FLAT LOCATORS

A flat surface locator can be used as shown in first figure. In this case an

undercut is provided at the bottom where two perpendicular surfaces intersect

each other. This is made for swarf clearance. The middle figure shows flat

headed button type locator. There is no need to made undercut for swarf

clearance. The button can be adjusted to decide very fine location of the

workpiece. There can be a vertical button support as shown in third figure,

which is a better arrangement due to its capacity to bear end load and there is a

provision for swarf clearance automatically.

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3.14.2 CYLINDRICAL LOCATORS

A cylindrical locator is shown in Figure 3.11. It is used for locating

components having drilled holes. The cylindrical component to be located is

gripped by a cylindrical locator fitted to the jigs body and inserted in the drilled

hole of the component. The face of the jigs body around the locator is undercut

to provide space for swarf clearance.

FIGURE 3.11 : CYLINDRICAL LOCATOR

3.14.3 CONICAL LOCATOR

A conical locator is illustrated in Figure 3.12 . This is used for locating

the workpieces having cylindrical hole in the workpiece. The workpiece is

found located by supporting it over the conical locator inserted into the drilled

hole of the workpiece. A conical locator is considered as superior as it has a

capacity to accommodate a slight variation in the hole diameter of the

component without affecting the accuracy of location. Degree of freedom along

z-axis can also be restrained by putting a template over the workpiece with the

help of screws.

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FIGURE 3.12 : CONICAL LOCATOR

3.14.3 JACK PIN LOCATOR

Jack pin locator is used for supporting rough workpieces from the button

as shown in Figure 3.13. Height of the jack pin is adjustable to accommodate

the workpieces having variation in their surface texture. So this is a suitable

method to accommodate the components which are rough and un-machined.

FIGURE 3.13: JACK PIN LOCATOR

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3.14.4 DRILL BUSH LOCATOR

The drill bush locator is illustrated in Figure 3.14. It is used for holding

and locating the cylindrical workpieces. The bush has conical opening for

locating purpose and it is sometimes screwed on the jigs body for the

adjustment of height of the work.

FIGURE 3.14 : DRILL BUSH LOCATOR

3.14.5 VEE LOCATORS

This is quick and effective method of locating the workpiece with desired

level of accuracy. This is used for locating the circular and semi-circular type of

workpieces as shown in Figure 3.15. The main part of locating device is Vee

shaped block which is normally fixed to the jig. This locator can be of two types

fixed Vee locator and adjustable Vee locator. The fixed type locator is normally

fixed on the jig and adjustable locator can be moved axially to provide proper

grip of Vee band to the workpiece.

FIGURE 3.15: FIXED V LOCATOR

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3.15 CLAMPING

To restrain the workpiece completely a clamping device is required in

addition to locating device and jigs and fixtures. A clamping device holds the

workpiece securely in a jig or fixture against the forces applied over it during on

operation. Clamping device should be incorporated into the fixture, proper

clamp in a fixture directly influence the accuracy and quality of the work done

and production cycle time. Basic requirement of a good clamping device are

listed below :

(a) It should rigidly hold the workpiece.

(b) The workpiece being clamped should not be damaged due to application of

clamping pressure by the clamping unit.

(c) The clamping pressure should be enough to over come the operating

pressure applied on the workpiece as both pressure act on the workpiece in

opposite directions.

(d) Clamping device should be capable to be unaffected by the vibrations

generated during an operation.

(e) It should also be user friendly, like its clamping and releasing should be easy

and less time consuming. Its maintenance should also be easy.

(f) Clamping pressure should be directed towards the support surfaces or

support points to prevent undesired lifting of workpiece from its supports.

(g) Clamping faces should be hardened by proper treatments to minimize their

wearing out.

(h) To handle the workpieces made of fragile material the faces of clamping

unit should be equipped with fibre pads to avoid any damage to workpiece.

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3.15.1 DIFFERENT TYPES OF CLAMPS

Different variety of clamps used with jigs and fixtures are classified into

different categories are discussed here.

3.15.2 STRAP CLAMP

This is also called edge clamp. This type clamping is done with the help

of a lever pressure acting as a strap on the workpiece. Different types of strap

clamps are discussed below.

Heel Clamp

The simple form of a heel clamp is shown in Figure 3.16. Rotation of the

clamp in clockwise direction is prevented and it is allowed in anticlockwise

direction. For releasing the workpiece the clamping nut is unscrewed. The free

movement in anticlockwise direction takes place before un-securing the nut to

release the workpiece.

FIGURE 3.16 : HEEL CLAMP

Bridge Clamp

The bridge clamp is illustrated in Figure3.17. It applies more clamping

pressure as compared to heel clamp. The clamping pressure experienced by the

workpiece depends on the distances x and y marked in the Figure 3.17 . To

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release the workpiece the nut named as clamping nut is unscrewed. The spring

lifts the lever to release the workpiece.

FIGURE 3.17 : BRIDGE CLAMP

Edge Clamp or Side Clamp

A side clamp is also known as edge clamp. In this case the surface to be

machined is always clamped above the clamping device. This clamping device

is recommended for fixed length workpiece. The clamping device is illustrated

in Figure. Releasing and clamping of the workpiece can be accomplished by

unscrewing and screwing of the clamping nut respectively

FIGURE 3.18 : EDGE CLAMP OR SIDE CLAMP

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Screw Clamp

The screw clamp is illustrated in Figure 3.19. It is also known as clamp

screw. This clamping apply pressure directly on the side faces of the workpiece.

There is a floating pad at their end to serve the following purposes :

(a) It prevents displacement of workpiece and slip.

(b) It prevents denting of clamping area of workpiece.

(c) The available cushion prevents deflection of screw.

In addition to the above there are some disadvantages associated with this

method. The clamping pressure largely depends on the workpiece, it varies from

one workpiece to other. It is more time consuming and more efforts are

required.

FIGURE 3.19 : SCREW CLAMP

Latch Clamp

Latch clamps are used to clamp the work piece, the clamping system is

normally locked with the help of a latch provided. To unload the work piece the

tail end of the latch is pushed that causes the leaf to swung open, so releasing

the work piece. Here time consumed in loading and unloading is very less as no

screw is tightened but clamping pressure is not so high as in other clamping

devices. Life of this type of clamping device is small.

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Power Driven Clamping

Light duty clamps are used manually because small power is required to

operate these clamps. Hand clamping leads to application of variable pressure,

operators fatigue and more time consumed. The power driven clamping over

comes the above mentioned problems of hand clamping. Power clamps are

operated on the base of hydraulic or pneumatic power. Power clamps are high

pressure clamping, these are quick acting, easily controllable, reliable and less

time consuming.

3.16 JIGS

Jigs along with fixtures are specifically designated machine parts, which

can be manufactured by any of the following methods : (a) Machining, (b)

Forging, (c) Casting and (d) Complicated.

Jigs are fabricated in different pieces and joined together by welding.

Normally jigs are made of hardened steel, which are wear resistant, corrosion

resistant, and thermally in sensitive. Their dimensional accuracy directly

influences the accuracy of performance of the operations where these are used.

3.16.1 DIFFERENT TYPES OF JIGS

Different types of jigs used are described below :

3.16.2 DRILLING JIGS

Drilling jigs are used for large number of operations. Different types of

drilling jigs are described below.

3.16.3 TEMPLATE JIG

This is a simple plate of metal or wood which carries correct locations of

holes to be made in the workpiece. Size of template jig should be same as that

of the workpiece. It is overlapped with the workpiece and drilling is done

quickly. Use of this jig avoids the marking operation completely.

3.16.4 PLATE TYPE JIG

If the work is to be done on very large scale, an improvement can be

made to template jig that is plate type jig. This uses a plate having drill pushes

36

and suitable means to hold and locate the works that it can be clamped to the

plate and holds drilled directly through the bushes in correct positions.

3.16.5 OPEN TYPE JIG

In this jig the top is kept open and workpiece is placed on the base of the

jig and the drill plate. Carrying the drill bushes is placed on the top to guide the

tool. After the operation is over, the drill plate is removed and workpiece is

replaced.

FIGURE 3.20 : OPEN TYPE JIG

37

3.16.6 SWINGING LEAF TYPE JIG

This type of jig carries a leaf or plate, arranged at the top or on one side,

which is capable of swinging about a fulcrum. It is normally the drill plate itself

which is pivoted about a point at its one end. A swinging leaf type jig is shown

in Figure 4.15. The work is loaded and unloaded with the help of swinging bolt.

FIGURE 3.21 : SWINGING TYPE JIG

3.16.7 BOX TYPE JIG

Its construction is like a box and it is used for the components having

irregular shape and to be operated at different places. This type of jig provides

rigid support, so machining on the various places of workpiece becomes

comfortable.

3.16.8 SOLID TYPE JIG

This is also used for drilling holes in articles of simple shapes and

relatively smaller sizes. This is made of standard section of rolled steel.

3.16.9 POT TYPE JIG

This jig is used for drilling holes in hallow cylindrical components having

smaller size. Here the body of the jig is like a pot that is used to accommodate

the workpiece comfortably. Location on the inside surface of the component is

38

provided by the clamp projecting from the bush plate located over the top of the

workpieces.

3.16.10 INDEX JIGS

This type of jig is equipped with the facility of indexing, which creates

positional division of the workpiece suitably. This jig is used for quick drilling

of equidistant holes on the circular surface of the workpiece. By means of

indexing device a hole is drilled then the workpiece is moved (indexed) to next

position under the drill bush for drilling automatically.

3.16.11 MULTI-STATION JIGS

These jigs are designed for multi-spindle machine where many operations

can be performed simultaneously. Each spindle of the machine carries a

different tool to perform a different operation. Tools and spindles are arranged

in the sequence in which operations are to be performed.

3.16.12 UNIVERSAL JIG

As indicated by the name universal jigs are meant to do large number of

operations. These may have replaceable elements on them. Selection and

mounting of an element depends on the type of operation to be performed.

39

3.17 FIXTURES

Fixtures are designed specifically for an operation and so these are named

on the base of the operation to be carried out with their help. Fixtures are used

to hold the workpiece properly to carryout the operations. Different types of

fixtures are listed below.

(a) Turning fixtures

(b) Milling fixtures

(c) Fixture for grinding

(d) Fixture for broaching

(e) Fixture for boring/drilling

(f) Tapping fixture

(g) Fixture for welding

(h) Assembling fixture

40

CHAPTER 4

PROJECT DESCRIPTION

4.1 DESIGNING OF FIXTURE

A Fixture is a tool,which is used to examined manufactured parts for

industry seldom will any manufactured parts be made,moved ,assembled or

inspected without the use of fixture.

Fixture might hold the raw material going into a stamping press,load

them into the press,hold them during assembly to other parts and hold them

during inspection.A fixture is differ fro other tools in that they are designed to

hold a specific part during a specific operation.

4.2 CLASSIFICATION OF MACHINING FIXTURE

SURFACE MACHINING

ROTORY MOTION STRAIGHT LINE MOTION

SINGLE POINT CUTTER

LATHE FIXTURE PLANNING,SHAPING &

SLOTTING FIXTURE

MULTI-POINT CUTTER

MILLING FIXTURE FOR

CIRCULAR FEED

FIXTURES FOR CIRCULAR

GRINDING

MILLING FIXTIRE FOR STRAIGHT

LINE FEED

BROACHING FIXTURE

SURFACE FIXTURE

SAWING FIXTURE

HOLE MACHINING

SINGLE POINT CUTTER MULTI POINT CUTTER

BORING JIGS DRILL,TAPPING,REAMING JIGS

HONING AND LAPPING JIGS

TABLE 4.1 : CLASSIFICATION OF MACHINING FIXTURE

41

4.3 CLASSIFICATION OF MANNUAL FIXTURES

PURPOSE TYPE

PREPARATORY OPERATIONS LAYOUT FIXTURES

METALLURGICAL OPERATIONS HEAT-TREATMENT &

ANNEALINGS FIXTURE

JOINING OPERATIONS WELDING,SOLDERING,BRAZING,

RIVETING FIXTURES

WIRE-SWITCHING, CRIMPING &

ASSEMBLY FIXTURES

QUALITY CONTROL INSPECTION FIXTURE

MEASURING FIXTURE

PRESSURE TESTING FIXTURE

TABLE 4.2 : CLASSIFICATION OF MANNUAL FIXTURES

4.4 COMPONENTS OF GANG RIVETING FIXTURE

Bottom plate

Bottom pad plate

Bottom punch holder plate

Bottom stripper plate

Top stripper plate

Top punch holder plate

Top pad plate

Top plate

Shank

Centre bunk

Top punch

Bottom punch

42

Cap screw

Bottom insert

Top insert

Guide bush

Guide pillar

Dowel pin

SOC.Head bolt

Spring

Sleeve

4.4.1 BOTTOM PLATE

The bottom plate is the base for the gang riveting fixture; it helps to

hold the machining surface and the punch holder. The bottom plate is the lower

working member of the die set. Its shape corresponds with that of the top plate

except that it is provided with clamping flanges. The flanges have provision for

fastening the die holder to the bolster plate of the press. Usually the bottom

plate is made thicker than the top plate. This is to compensate for the weakening

effect of slug and blank holes. The bottom plate surface which should be in the

following dimensions

B.P = 525*420*8 thick in mm

The material which is used in the manufacture of this plate is

MILD STEEL.

4.4.2 BOTTOM PAD PLATES

The bottom pad plates which are used to support the bottom plate.

In this plate which consists of several components that spring, cap screw and the

tool die are placed over this plates.

B.P.P (OD)= 300*20 thick in mm

The material is used here is mild steel

43

4.4.3 BOTTOM PUNCH HOLDER

The bottom punch holder which consist of punch, machining

surface placed over this plate

B.P.H (OD)= 300*30 thick in mm

The material is used in this component are Oil Hardened Non-

shrinking Steel (OHNS)

4.4.4 BOTTOM STRIPPER PLATE

This plate, which is consist of the fixed plate position to hold the clutch plates and assembly plates.

B.S.P (OD) = 300*30 thick in mm

The material used in this is MILD STEEL

4.4.5 TOP PLATES

Likewise the bottom plates which are similar to the top plate the work holding devices are fixed along the requirements, the components and dimensions are similar to the bottom plates

FIGURE 4.1: EXAMPLE OF TOP & BOTTOM PLATES

44

4.4.6 GUIDE BUSHES

Guide bushes are precision ground bushes which are press fitted

into accurately bored holes in the top plate. The guide bush which is required to

reduce the vibration and the mis alignment caused due to the surface finish and

during the machining process.

G.B I (OD*ID*Lg) =64 *40*115

G.B II (OD*ID*Lg) = 62*38*115

The materials used in this are OHNS

FIGURE 4.2: GUIDE BUSHES

4.4.7 GUIDE PILLAR

Guide pillars are precision ground pins which are press fitted into accurately bored holes in the bottom plate. Guide pillars are assembled into corresponding guide bushes to align punch and die components with a high degree of accuracy. The commonly used type of pillars Small diameter guide pillars which are usually hardened and centre less ground. Large diameter pillar which are ground between centres after hardening or case hardening. Removable guide pillars can be easily removed from the die set for resharpening the cutting elements. They are employed for large dies and for dies having more than two pillars.

45

G.P I(OD * Lg) = 50*210 in mm

G.P II(OD * Lg) = 50* 240 in mm

The materials used in this are OHNS

FIGURE 4.3: GUIDING PILLARS

4.4.8 SHANK

The shank is the end of a drill bit grasped by the chuck of a drill.

The cutting edges of the drill bit contact the workpiece, and are connected via

the shaft with the shank, which fits into the chuck. In many cases a general-

purpose arrangement is used, such as a bit with cylindrical shaft and shank in a

three-jaw chuck which grips a cylindrical shank tightly. Different shank and

chuck combination can deliver improved performance, such as allowing higher

torque, greater centering accuracy, or moving the bit, but not the chuck, with a

hammer action.

SHANK (OD * Lg) = 83*76 in mm

The materials used in this are MILD STEEL

46

FIGURE 4.4 : SHANK

4.4.9 SOCKET HEAD BOLT

Are high-strength tension fasteners designed for clamping

assemblies and are commonly used in tool and die fixturing applications. Socket

Screws, also known as Allen head screws, are available in several head styles

and materials. Used in many applications, Socket Screws are reliable and

durable.

SOC.Head Bolt = M6*25Lg = 3 Nos

SOC.Head Bolt = M10*25Lg =12 Nos

SOC.HEAD BOLT = M10*80Lg = 1 No

The material used in this are STD materials

FIGURE 4.5: SOCKET HEAD BOLT

47

4.4.10. DOWEL PIN

A dowel is a solid cylindrical rod, usually made of wood, plastic,

or metal. In its original manufactured form, a dowel is called a dowel rod.

Dowel rods are often cut into short lengths called dowel pins. Dowels are

employed in numerous, diverse applications including as axles in

toys, detents(e.g., in gymnastics grips), structural reinforcements in cabinet

making, and supports for tiered wedding cakes. Other uses include:

As furniture shelf supports

As moveable game pieces (i.e., pegs)

As supports for hanging items such as clothing, key rings, tools, toilet

roll dispensers and picture frames

To precisely align two objects in a dowel joint: a hole is bored in both

objects and the dowel pin is inserted into the aligned holes

As a core to wrap cable or textiles around

DOWEL PIN (OD * Lg) = 10*110

The material used in these are STD materials.

FIGURE 4.6:DOWEL PINS

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4.4.11 SLEEVE

Sleeves may be placed and hydraulic operated clamps mounted on the

upper end of each of the bucks for holding the cuffs of the sleeves during a

pressing operation. Each clamp includes a head or block having a vertical

clamping surface, a pneumatic cylinder mounted within the block having its

piston rod extending generally perpendicularly outwardly through the surface,

and a T-clamp connected to the rod for movement toward and away from the

surface upon actuation of the cylinder. A pneumatic control circuit controls

operation of the cylinders. A hold down device located between the bucks

applies tension to the sleeves of a rivet during a pressing operation .

FIGURE 4.7: SLEEVES

49

4.4.12 INSERT OF TOOL ( TOP & BOTTOM )

A Insert tool is generally refers to any cutting or punching

tool where the cutting edge consists of a separate piece of material,

either brazed, welded or clamped on to a separate body.

TOP INSERT (OD * LG) = 19*13 in mm = 24 Nos

BOTTOM INSERT (OD * LG) = 16*17 in mm = 24 Nos

FIGURE 4.8: TOOL INSERTERS

4.4.13 PUNCH( TOP & BOTTOM )

A punch press is a type of machine press used to cut holes in

material. It can be small and manually operated and hold one simple die set, or

be very large, CNC operated, with a multi-station turret and hold a much larger

and complex die set. The tool is placed slightly above the bottom bed plate by

providing two parallel blocks accurately ground to the same size. This is a

necessary action since many tools, scrap (cut pieces which are a waste) is

50

discharged through the bottom element of the tool, not necessarily in the centre

of the tool. the scrap or the blank ( the required portion ) come out from the die

at different places . These have to be taken out horizontally from between the

parallels placed. Otherwise they get accumulated inside the tool itself and cause

severe damage to the tool.

TOP PUNCH (OD* Lg) =16*71 = 24 Nos

BOTTOM PUNCH (OD* Lg) = 16*65 =24 Nos

FIGURE 4.9: FIXED PUNCH

4.4.14 SPRINGS

Damping is an influence within or upon an oscillatory system that

has the effect of reducing, restricting or preventing its oscillations. In physical

systems, damping is produced by processes that dissipate the energy stored in

the oscillation. Examples include Viscous drag in mechanical

systems, resistance in electronic, and absorption and scattering of light in optical

oscillators. Damping not based on energy loss can be important in other

oscillating systems such as those that occur in biological systems.

The damping of a system can be described as being one of the following:

Overdamped: The system returns (exponentially decays) to equilibrium

without oscillating.

51

Critically damped: The system returns to equilibrium as quickly as possible

without oscillating.

Underdamped: The system oscillates (at reduced frequency compared to

the undamped case) with the amplitude gradually decreasing to zero.

Undamped The system oscillates at its natural resonant frequency (o).

For linear Damping

The force may be related to the velocity by

This force may be used as an approximation to the friction caused

by drag and may be realized, for instance, using a dashpot. (This device

uses the viscous drag of a fluid, such as oil, to provide a resistance that is

related linearly to velocity.) Even when friction is related to , if the

velocity is restricted to a small range, then this non-linear effect may be

small. In such a situation, a linearizied friction coefficient may be

determined which produces little error.

When including a restoring force (such as due to a spring) that is

proportional to the displacement and in the opposite direction, and by

setting the sum of these two forces equal to the mass of the object times

its acceleration creates a second-order differential equation whose terms

can be rearranged into the following form:

where 0 is the undamped angular frequency of the oscillator and is a

constant called the damping ratio. This equation is valid for many

different oscillating systems, but with different formulas for the damping

ratio and the undamped angular frequency.

52

The value of the damping ratio determines the behaviour of the system

such that = 1 corresponds to being critically damped with larger values

being overdamped and smaller values being underdamped. If = 0, the

system is undamped.

SPRING(OD*TH*Lg) = 30*4*55 = 24Nos

FIGURE 4.10 : SPRING ASSEMBLY

4.5 MACHINES INVOLVE TO FABRICATE JIG AND FIXTURE

CONVENTIONAL MILLING MACHINE

LATHE MACHINE

DRILLING MACHINE

BANDSAW MACHINE

CNC MILLING MACHINE (3-AXIS)

CNC MILLING MACHINE (5-AXIS)

53

4.6 TOOLING DETAILS

Tooling details are the overall construction characteristics and special

features incorporated into the jig or fixture. Permanent work holders are

designed and built to last longer than temporary workholders. So, permanent

jigs and fixtures usually contain more-elaborate parts and features than

temporary workholders.There are several other differences between permanent

and temporary workholders in this area. These include the type and complexity

of the individual tooling elements, the extent of secondary machining and

finishing operations on the tool, the tool-design process, and the amount of

detail in the workholder drawings. Since the elements for modular workholders

are usually part of a complete set, or system, only rarely will additional custom

components need to be made.Permanent workholders contain different

commercial tooling components based on expected tool usage. Permanent jigs

intended for a high-volume drilling operation, for example, often use a

renewable bushing and liner bushing together. A throwaway jig for a smaller

production run often uses a simple press-fit bushing.The secondary operations

normally associated with tooling include hardening, grinding, and similar

operations to finish the workholder. Usually, permanent workholders are

hardened and ground to assure their accuracy over a long production run. Since

they are intended only for short production runs, throwaway jigs and fixtures do

not require these operations. Another secondary operation frequently performed

on permanent tools, but not temporary tools, is applying a protective finish,

such as black oxide, chrome plating, or enamel paint.In designing a permanent

workholder, the designer often makes detailed engineering drawings to show

the toolroom exactly what must be done to build the workholder. With

temporary workholders, the design drawings are often sent to the toolroom as

simple freehand sketches.

54

Permanent tools are normally designed for long-term use. This being the

case, the drawings and engineering data for the permanent jig or fixture then

become a permanent record. With modular workholders, the designer may

either construct drawings or specify building the workholder directly around the

part. Here only a parts list and photographs or video tape are kept as a

permanent record.

Certain workholding applications require special fixture characteristics.

For example, a particularly corrosive environment may require stainless steel

components and clamps to deliver a satisfactory life cycle. In other cases,

variable workpiece dimensions, as in a casting, necessitate clamping devices

which can compensate for these variations. Appearance of a finished part might

require the use of nylon, plastic, or rubber contact points to protect the part.

Similarly, the selection of tooling details can enhance the productivity of

some permanent tools. For example, utilizing small hydraulic clamps may allow

loading many parts on a workholder due to the compactness of the design. This

would enhance productivity by reducing load/unload time as a percentage of

total cycle time. Duplicate fixtures are sometimes justified for machining

centers because they allow loading of parts on one pallet during the machining

cycle on the other pallet.

4.7 TOOLING OPERATION

The performance of any workholder is critical to the complete usefulness

of the tool. If the workholder cannot perform the functions desired in the

manner intended, it is completely useless, regardless of the cost or the extent of

the detail. As the performance of a permanent, modular, or general-purpose

workholder is considered, several factors about the machine tools must be

known. These factors include the type, size, and number of machine tools

55

needed for the intended operations.Work holders are sometimes designed to

serve multiple functions. For example, it is possible to have a work holder that

acts both as a drill jig and a milling fixture. These tools are called combination

tools or multiple-function work holders.Despite the work holder design or the

size of the production run, every jig or fixture must meet certain criteria to be

useful. These criteria include accuracy, durability, and safety. Accuracy, with

regard to jigs and fixtures, is the ability of a work holder to produce the desired

result, within the required limits and specifications, part after part, throughout

the production run.

To perform to this minimum level of accuracy, the work holder must also

be durable. So, the jig or fixture must be designed and built to maintain the

required accuracy throughout the expected part production. If part production is

continuous, year after year, the jig or fixture must be more durable than is

necessary for only one production run. The final consideration, safety, is

actually the most important. No matter how good the design or construction, or

how well it produces the desired accuracy, if the work holder is not safe, it is

useless. Safety is a primary concern in the design of any workholder.Safety, as

well as speed and reliability of part loading, can often be improved by the use of

power clamping, either pneumatic or hydraulic. Once set, power clamps will

repeatedly clamp with the identical force. This is not always true with manual

clamps, which depend on operator diligence for the proper application of

clamping force. In addition, power-clamping systems can have interlocks to the

machine control which will shut the machine down if the system loses power

a clear safety advantage for both operator and machine tool.

4.8 APPLICATIONS FOR JIGS AND FIXTURES

Typically, the jigs and fixtures found in a machine shop are for

machining operations. Other operations, however, such as assembly, inspection,

56

testing, and layout, are also areas where workholding devices are well suited.

Figure 1-7 shows a list of the more-common classifications and applications of

jigs and fixtures used for manufacturing. There are many distinct variations

within each general classification, and many workholders are actually

combinations of two or more of the classifications shown.

4.8.1 EXTERNAL-MACHINING APPLICATIONS:

Flat-Surface Machining

Milling fixtures

Surface-grinding fixtures

Planing fixtures

Shaping fixtures

Cylindrical-Surface Machining

Lathe fixtures

Cylindrical-grinding fixtures

Irregular-Surface Machining

Band-sawing fixtures

External-broaching fixtures

4.8.2 INTERNAL-MACHINING APPLICATIONS:

Cylindrical- and Irregular-Hole Machining

Drill jigs

Boring jigs

Electrical-discharge-machining fixtures

Punching fixtures

Internal-broaching fixtures

57

4.8.3 NON-MACHINING APPLICATIONS:

Assembly

Welding fixtures

Mechanical-assembly fixtures

(Riveting, stapling, stitching, pinning, etc.)

Soldering fixtures

Inspection

Mechanical-inspection fixtures

Optical-inspection fixtures

Electronic-inspection fixtures

Finishing

Painting fixtures

Plating fixtures

Polishing fixtures

Lapping fixtures

Honing fixtures

Miscellaneous

Layout templates

Testing fixtures

Heat-treating fixtures

58

4.9 DESIGNING RESULT

The designing of the tool are given below

FIGURE 4.11 GANG RIVETING FIXTURE

BOTTOM DIE TOP DIE

59

`

FIGURE 4.12 VARIOUS PARTS

SHANK CENTRE BUNK

BOTTOM

PUNCH

TOP

PUNCH

BOTTOM

INSERT

TOP

INSERT

GUIDE PILLAR-I

GUIDE PILLAR - II

GUIDE BUSH-I

GUIDE BUSH -II

SLEEVE

60

FIGURE 4.13 BOTTOM PUNCH HOLDER

FIGURE 4.14 BOTTOM STRIPPER PLATE

61

FIGURE 4.15 BOTTOM PLATE

FIGURE 4.16 TOP PLATE

62

FIGURE 4.17 TOP STRIPPER PLATE

FIGURE 4.18 TOP PUNCH HOLDER

63

CHAPTER 5

RESULT AND DISCUSSION

5.1RESULT

The designed components which tend to eradicate the man power,

cycle time and the easy flow of the process. The designing of the gang riveting

tool which has little complex and involved more precision to develop the design

and implement in the organisation. The designing of the tool which are

discussed below.

5.2 COMPONENTS LIST

S.NO PART NAME NO.OF

PARTS

MATERIAL

1 BOTTOM PLATE 1 MS

2 BOTTOM PAD PLATE 1 MS

3 BOTTOM PUNCH HOLDER 1 OHNS

4 BOTTOM STRIPPER PLATE 1 MS

5 TOP STRIPPER PLATE 1 MS

6 TOP PUNCH HOLDER 1 OHNS

7 TOP PAD PLATES 1 MS

8 TOP PLATE 1 MS

9 SHANK 1 MS

10 CENTRE BUNK 1 OHNS

11 TOP PUNCH 24 D2

12 BOTTOM PUNCH 24 D2

13 CAP SCREW 24 STD

14 BOTTOM INSERT 24 OHNS

15 TOP INSERT 24 OHNS

64

16 GUIDE BUSH - I 1 OHNS

17 GUIDE BUSH II 1 OHNS

18 GUIDE PILLAR I 1 OHNS

19 GUIDE PILLAR- II 1 OHNS

20 DOWEL PIN 4 STD

21 SOC.HEAD BOLT

M10* 55Lg

24 STD

22 SOC.HEAD BOLT

M6 *25 Lg

6 STD

23 SPRING 24 STD

24 SOC.HEAD BOLT

M10*80Lg

1 STD

25 SLEEVE 24 MS

TABLE 6.1 LIST OF COMPONENTS

5.3 DISCUSSION

The gang riveting fixture which consist of the following measures

Dimensions of Facing plate

Inner PCD = 192 mm

Outer PCD = 247.5 mm

Thickness = 3.5 mm

Rivet hole Diameter = 11.3 mm

Rivet diameter = 4.8515 mm

Rivet height = 5.6722 mm

Rivet head diameter = 9.15\9.65 mm

ANGLE

Angle between riveting hole = 18

65

Locating pins

PCD = 219.5mm

Flaring diameter = Rivet dia * 1.25 mm

= 4.8515*1.25 = 6.064375 mm

Load capacity = p=F/A ,

F= normal force, A= surface of contact

It can withstand with a maximum load of 2000kPa to maintain the flaring

diameter without any damage to the plate.

5.4TOOLING:

Provide two non-plated thru tooling holes, dia 0.125 +0.003/-0.003 as far

apart as practical.

Tooling hole to tooling pin tolerance +0.000/-0.003.

A 0.050 annular area around tooling holes must be clear of components

and test pads.

66

5.4 MERITS & DEMERITES OVER RIVETING MACHINE

5.4.1MERITS

It reduces the operation fatigue.

It increases the cycle time.

Quality of the component increased.

Increased productivity.

More secure for workers than the riveting machine.

5.4.2DEMERITS

It consumes time to set the rivets .

Proper maintance and survilance should be maintained.

Mis-alignment of tool cause damages to the plate.

67

CHAPTER - 6

CONCLUSION

6.1 CONCLUSION

The objective of the project is to design the gang riveting fixture, to

reduce the operation which consumes repetitive action to the assembly of the

driven clutch plate. From the state of scratch path is being designed with the

help of AutoCAD. The work is carried out with the basis of step by step

calculation at each level to the complete designing of gang riveting fixture.The

approach of the project could be a part of the work towards the improvement of

production in your organisation.

The maximum load that can be applied for the tool is 2000Kpa.

6.1 RECOMMENDATION

With the introducing of this tool that tends to increase the production

level increase with the high tolerance and accuracy. This will be more precision

in accuracy and the inspection .

68

6.3 REFERENCE

MECHANICAL DESIGN ,2ND EDITION BY PETER R.N CHILDS

B.Sc(Hons)

MECHANICAL ASSEMBLIES BY DANIEL E. WHITNEY..

AUTOCAD2010-APROBLEM SLOVING APPROACH.

Design of final riveting tool by the organisation..

69