Design and analysis of a turning fixture for oil tank …...fixture as special plates designed to...

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@IJRTER-2016, All Rights Reserved 39 Design and analysis of a turning fixture for oil tank cover MGB Sunil Kumar K 1 , Srinivasa Chari V 2 , Lakshiminarayana T H 3 ,Kumarswamy j 4 1 Asst prof, Mechanical Engineering Department, RLJIT, Doddaballapur Karnataka 2 Asst prof, Mechanical Engineering Department, Atria IT, Bangalore Karnataka 3 Asst prof, Mechanical Engineering Department, RLJIT Doddaballapur Karnataka 4 Asst prof, Mechanical Engineering Department, RLJIT Doddaballapur Karnataka AbstractThe Main Gear Box (MGB), which is placed just under the main rotor on the helicopter, is the mechanical part of the helicopter that transmits the engine’s power towards Main Rotor Head and Tail Rotor Head and generates the power for the different accessories (electric and hydraulic). Its role is to reduce the engine’s speed and increase t he torque to the Main Rotor Head. The Shaft transmits the power from the Main Gear Box to the sleeves and the blades. The Main gear box is composed of several satellites and planetary gears aiming to reduce the speed of the shaft from engine output and transmit adequate power to the main and the tail rotors. A fixture is a device for holding the work piece in a definite position during machining operations. But it does not control position of the tool or instrument which is being used. The name fixture is derived from the fact that fixture is always clamped to machine table. Tuning fixture is used for facing, boring and turning operations. The fixture mainly consists of locating and clamping the devices as the axis of work piece must accurately coincide with the spindle axis. Most of the turning fixture as special plates designed to facilitate quick loading, locating of work piece in mass location. In this project we designed analysis of few concepts for improved productivity of a turning fixture for oil tank cover MGB in helicopter manufacturing. KeywordsDesign, MGB (Main Gear Box), Concept, Turning fixture, Oil Tank and Analysis I. INTRODUCTION 1.1 MODELING Scientific modelling is a scientific activity. The aim of which is to make a particular part or feature of the world easier to understand, define, quantify, visualize, or simulate. It requires selecting and identifying relevant aspect of a situation in the real world and then using different aims, such as conceptual model to better understand, operational models to operationalize, mathematical model to quantify, and graphical model to visualize the subject. Modelling is an essential and inseparable part of scientific activity, and many scientific discipline have their own ideas about specific type of modelling. There is also an increasing attention to scientific modelling in fields such as philosophy of science, systems theory, and knowledge visualization. There is growing collection methods, techniques and meta-theory about all kinds and specialized scientific modelling. 1.2 The Process of Generating a Model Modelling refers to the process of generating a model as a conceptual representation of some phenomenon. Typically a model will refer only to some aspects of the phenomenon in question, and two models of the same phenomenon may be essentially different, that is to say that the difference or differences between them is more than just a simple renaming of components. Such differences may be due to differing requirements of the model’s end users, or to conceptual or aesthetic differences among the modellers and to contingent decisions made during the modelling process. Aesthetic considerations that may influence the structure of a model might be the modeller’s preference for a reduced ontology, preference’s regarding probabilistic model v/s continuous time, e tc. For this reason, users of a model need to understand the model’s original purpose and the assumptions made that and pertinent to its validity.

Transcript of Design and analysis of a turning fixture for oil tank …...fixture as special plates designed to...

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Design and analysis of a turning fixture for oil tank cover MGB

Sunil Kumar K 1, Srinivasa Chari V 2, Lakshiminarayana T H 3,Kumarswamy j 4 1 Asst prof, Mechanical Engineering Department, RLJIT, Doddaballapur Karnataka

2 Asst prof, Mechanical Engineering Department, Atria IT, Bangalore Karnataka 3 Asst prof, Mechanical Engineering Department, RLJIT Doddaballapur Karnataka 4 Asst prof, Mechanical Engineering Department, RLJIT Doddaballapur Karnataka

Abstract—The Main Gear Box (MGB), which is placed just under the main rotor on the helicopter, is the mechanical part of the helicopter that transmits the engine’s power towards Main Rotor Head

and Tail Rotor Head and generates the power for the different accessories (electric and hydraulic). Its

role is to reduce the engine’s speed and increase the torque to the Main Rotor Head. The Shaft transmits

the power from the Main Gear Box to the sleeves and the blades. The Main gear box is composed of

several satellites and planetary gears aiming to reduce the speed of the shaft from engine output and

transmit adequate power to the main and the tail rotors.

A fixture is a device for holding the work piece in a definite position during machining

operations. But it does not control position of the tool or instrument which is being used. The name

fixture is derived from the fact that fixture is always clamped to machine table. Tuning fixture is used

for facing, boring and turning operations. The fixture mainly consists of locating and clamping the

devices as the axis of work piece must accurately coincide with the spindle axis. Most of the turning

fixture as special plates designed to facilitate quick loading, locating of work piece in mass location.

In this project we designed analysis of few concepts for improved productivity of a turning

fixture for oil tank cover MGB in helicopter manufacturing.

Keywords—Design, MGB (Main Gear Box), Concept, Turning fixture, Oil Tank and Analysis

I. INTRODUCTION

1.1 MODELING

Scientific modelling is a scientific activity. The aim of which is to make a particular part or

feature of the world easier to understand, define, quantify, visualize, or simulate. It requires selecting

and identifying relevant aspect of a situation in the real world and then using different aims, such as

conceptual model to better understand, operational models to operationalize, mathematical model to

quantify, and graphical model to visualize the subject. Modelling is an essential and inseparable part

of scientific activity, and many scientific discipline have their own ideas about specific type of

modelling. There is also an increasing attention to scientific modelling in fields such as philosophy of

science, systems theory, and knowledge visualization. There is growing collection methods, techniques

and meta-theory about all kinds and specialized scientific modelling.

1.2 The Process of Generating a Model

Modelling refers to the process of generating a model as a conceptual representation of some

phenomenon. Typically a model will refer only to some aspects of the phenomenon in question, and two models of the same phenomenon may be essentially different, that is to say that the difference or

differences between them is more than just a simple renaming of components. Such differences may

be due to differing requirements of the model’s end users, or to conceptual or aesthetic differences

among the modellers and to contingent decisions made during the modelling process.

Aesthetic considerations that may influence the structure of a model might be the modeller’s

preference for a reduced ontology, preference’s regarding probabilistic model v/s continuous time, etc.

For this reason, users of a model need to understand the model’s original purpose and the assumptions

made that and pertinent to its validity.

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Building a model requires abstraction. Assumptions are used in modelling in order to specify

the domain of application of the model. For example, the special theory of relativity assumes an inertial

frame of reference. This assumption was contextualized and future explained by the general theory of

relativity. A model makes accurate predictions when its assumptions are valid.

And does not make accurate predictions when its assumptions do not hold. Such assumptions are often

the point with which older theories are succeeded by new ones (the general theory of relativity works

in non-inertial reference frames as well).

1.3 The Process of Evaluating a Model

A model is evaluated first and foremost by its consistency to empirical data; any model inconsistent

with reproducible observations must be modified or rejected. One way to modify the model is by

restricting the domain over which it is credited with having high validity. A case in point is Newtonian

physics, which is highly useful except for the very small, the very massive phenomena of the universe.

However, a fit to empirical data alone is not sufficient for a model to be accepted as valid. Other factors

important in evaluating a model include.

1. Ability to explain past observations

2. Ability to predict future observations

3. Cost of use, especially in combination with order models

4. Refutability, enabling of the degree of confidence in the model

5. Simplicity, or even aesthetic appeal

II. METHODOLOGY

2.1 Tooling Developmental Approach

A detail study is carried out about the component/part before start of design work. The oil tank

is a casting part and needs to be machined through a number of process and stages for a final product.

This is done through sequential Instruction sheets provided for manufacturing.

2.2 NX Overview

NX the product development solution from Siemens PLM software, delivers the advanced

performance and leading edge technologies you need to master complexity and compete globally.

Supporting every aspect of product development, NX delivers tightly integrated, unified solutions for

design, simulation and manufacturing that are unmatched in power and flexibility. NX solutions

redefine productivity and efficiency, helping you to deliver more innovative products faster and at

lower cost. More than integrated CAD/CAM/CAE, NX also provides collaboration, data management, process automation and decision support tools that help you upgrade your development processes to

gain and keep a competitive advantage.

2.3 CAD/CAM TECHNOLOGY:

CAD/CAM technology was initiated in the aerospace industry but is now widely spreading in

all industries. It can be defined most simple as the use of computers to translate a products specific

requirement into the final physical product. It plays a key role in areas such as design, analysis,

production planning, detailing, documentation, NC part programming, tooling fabrication, assembly,

jig and fixture design, quality control and testing. Whenever any deviation is noted, a programmable

controller takes automatic corrective action to compensate for the deviation.

2.4 Design Steps Followed:- The steps followed are as follows and the relevant drawings are enclosed at the end of the report.

2.4.1 CAD MODEL

CAD modelling is a method of designing the object to be manufactured as per requirements.

CAD model is a 2-D or 3-D model of the object in the form of a drawing. Since the CAD model is the

duplicate model of the object to be produced in the particular operation, it can also be called as the

copy model. CAD model gives the shape and size of the model which specifies the exact dimensions

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of the component to be produced. It also specifies the material to be used and the operation to be carried

out on the component.

DESIGN PROCESS FLOW CHART:

2.4.2 Milling fixture:-

Fig 2.4.2:- Turning operation by using Milling fixture

III. MODELING AND ANALYSIS

MODELING

MATERIAL USED

3.1 Aluminium Alloys: 1. The alloys in which aluminium (Al) is the predominant metal.

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2. The typical alloying elements are copper, magnesium, manganese, silicon and zinc.

3. There are two principal classifications, namely casting alloys and wrought alloys, both of which

are further subdivided into the categories heat-treatable and non-heat-treatable.

4. Aluminium alloys are widely used in engineering structures and components where light weight

or corrosion resistance is required.

5. Aluminium alloy compositions are registered with The Aluminium Association. Many

organizations publish more specific standards for the manufacture of aluminium alloy, including

the Society of Automotive Engineers standards organization, specifically its aerospace standards

subgroups, and ASTM International.

3.2 Properties of Aluminium

a) Strong, Malleable.

b) Has a low density.

c) Is resistant to corrosion.

d) Is a good conductor of heat and electricity.

e) Can be polished to give a highly reflective surface.

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3.3 2D-design

Fig 3.3 2D Model of turning fixture

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3.4 3D Models

Fig 3.4(a):- 3D view of turning fixture

Fig 3.4(b):- 3D view of turning fixture

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Fig 3.4(c):- 3D view of turning fixture

Fig 3.4(d):- 3D view of turning fixture

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IV. ANALYSIS

4.1 FEM METHOD

4.1.1 Introduction

The finite element method (FEM) is a numerical technique for solving problems which are

described by partial differential equation formulated as functional minimization a domain of interest

is represented as an assembly of finite elements. Approximating functions in finite element are

determined in terms of nodal values of a physical field which is sought. A continuous physical problem

is transformed in to a discredited finite element problem with unknown nodal values. For linear

problem, a system of linear algebraic equation should be solved. Various inside finite elements can be

recovered using nodal values.

Two features of FEM are worth to be mentioned

a. Piece-wise approximation of physical fields on finite elements provide good precision even with

simple approximating functions.

b. Locality of approximation leads to sparse equation system for a discredited problem. This helps

to solve problems with very large number of nodal unknown.

4.1.2 How The FEM Works?

To summarize in general terms how the finite element works we list main steps of the finite element

solution procedure below

STEP 1: Discretization of the structure

The first step in FEM is to divide the structure or solution region into subdivisions or elements.

Hence the structure is to be modeled with suitable finite elements. The number type, size and

arrangement of the elements are to be decided.

STEP 2: Selection of a proper interpolation model

Since the displacement solution of a complex structure under any specified load condition

cannot be predicted exactly. We assume some suitable solution within an element to approximate the

unknown solution. The assumed solution must be simple from computational standpoint. In general

the solution or the interpolation model is taken in the form of polynomial.

STEP 3: Derivation of element stiffness matrices and load vectors

From the assumed interpolation model, the stiffness matrix and the load vectors of element are

too derived by using either equilibrium conditions or suitable vibrational principle.

STEP 4: Assemblage of element equation to obtain the overall equilibrium equations

Since the structural is composed of several finite elements the individual element stiffness matrices and load vectors are to be assembled in a suitable manner and the overall equilibrium equation

have to be formulated as [k] * ϕ = P

Where [k] = Global stiffness matrix

Φ = Global nodal displacement

P = Global load vector

STEP 5: Solution for unknown nodal displacements

The overall equilibrium equations have to be modified to account for the boundary condition of

the problem. After the incorporation of the boundary conditions

STEP 6: Computational of element strain and stresses

From the unknown nodal displacement the element strains and stresses can be computed by

necessary equations of solid in structural mechanics.

In fact, Finite element modelling is a powerful computer tool for determining stresses and

deflections in a given structure which is too complex for classic analysis.

Material properties such as Young’s modulus (E) and poisssion`s ratio (µ) are entered along

with boundary conditions such as displacements (u), applied loads (P), etc

The FEM method has these characteristics:

1. Solving arrays of large matrix equations.

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2. Fundamentally simple concepts involving basic stiffness and deflection equations.

3. The first step is the construction of a structural model that breaks a structure into simple shapes or

elements located space by a common coordinate grid system.

4. The coordinate points, nodes, are locations in the model where output data are provided.

5. Essentially, FEM geometrically divides a structure into small elements with easily defined stress

and deflection characteristics.

The method appears complex because a model of an air frame structure can have thousands of elements

or members, each with its own set of equation. Because of the very large number of equations and

corresponding data involved, the finite element method is only possible when performed by computer.

With FEM, modeling is critical because it establishes the structural locations where stresses are

evaluated, thus:

1. If a component is modeled inadequately, the resulting computer analysis could be quite misleading

in its predictions in areas of maximum stress, deflection etc.

2. Modeling inadequacies include the incorrect placement of elements and attempting to define

structure with an insufficient number of elements.

3. Such errors can be avoided by anticipating areas of maximum strain, but doing so requires

engineering experience.

4. In most cases, the computer capacity, time required and cost of analysis increases with the number

of elements used in the model.

5. The efficiency can be increased by concentrating elements in the interested areas of high stress

while minimizing the number of elements in low stress areas.

It is not uncommon to develop FEM for prototype design for which experimental data can be

obtained. Strain gauging is probably the most common method of obtaining experimental data in

structural tests.

Once FEM results and experimental data have been correlated, design modifications can be

made, and these subsequent changes are often tested through FEM before being implemented

prototype.

FEM is useful in design work, such as structural repair or modifications, where a structural

beef-up or change in contemplated. A FEM baseline model can be made for existing structure for

which stress and deflection data are known. A comparison is made between FEM results. Proposed

design modifications can then the new FEM results will have the same accuracy and requires the same calibration as the baseline case.

4.1.3 Steps in ANSYS

The analysis procedure in ANSYS is divided into three major parts

a) Pre-processing

b) Processing

c) Post-processing

Pre-processing Here the entire model of the structure is created and the material properties, loads and the

constraints are specified. Input to FEM is provided here.

Geometry: The geometric model is a description of the form of the object to be modeled and some

properties that are directly related to the object.

Adding Material Property: Mesh definition is followed with associating the appropriate material

properties, that covers relevant properties like young's modulus, density, Poisson’s ratio, thickness,

cross sectional area etc.

Meshing: It is one of the basic activities that help in converting the constructed geometry into nodes

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and elements. It involves discretization of the geometric domain into valid zones for analysis. Thus

meshing produces a discretized domain that becomes the starting point for the assignment and

computations of different analysis quantities. Meshing essentially converts the geometric definition in

the problems space into a representation for a numerical solution in the solution space.

Processing

This involves computation of results such as displacements, stresses and strain in the case of

static analysis. Once the data describing the FEM model has been assembled and submitted the

software will process it to produce the necessary information required by the user.

Output data are:

a. Component displacements

b. Element data recovery

c. Grid point data

Post-processing This involves interpretation of results generated during the processing stage, Such as deformed

shape of the structure, graphical representation of stresses, strains and displacements, the animation

can also be obtained during the process.

Applications of FEM:-

1. Aerospace engineering: stress analysis of aircraft component, wings, turbines, missiles of space

craft component etc.

2. Automobile engineering: stress analysis of crankshaft, cylinder, bearings, brakes, piston body etc.

3. Bio engineering and biochemical: stress analysis in bone, heap replacement, teeth replacement

etc.

4. Civil engineering: stress analysis of dam, retainer wall, soil mechanics etc.

5. Electrical and electronics engineering: thermal analysis of IC board, magnetic analysis.

6. Mechanical engineering: 1D, 2D, 3D stress analysis of gear box, pressure vessel, vibration

harmonic analysis etc.

7. Structural engineering: stress analysis of frames, trusses, electrical poles, towers etc.

4.2 Introduction to ANSYS

ANSYS, Inc. is an engineering simulation software developer that is headquartered south of

Pittsburgh in the South pointe business park in Cecil Township, Pennsylvania, and United States.

ANSYS was listed on the NASDAQ stock exchange in 1996. In late 2011, ANSYS received the highest possible score on its smart select Composite Ratings according to Investor’s Business Daily.

The organization reinvests 16 percent of its revenue each year into research to continually refine the

software.

4.2.1 Products Overview

ANSYS offers engineering simulation solution sets engineering simulation that a design

process requires. Companies in a wide variety of industries use ANSYS software. The tools put a

virtual product through a rigorous testing procedure (such as crashing a car into a brick wall, or

running for several years on a tarmac road) before it becomes a physical object.

Automotive

1. Toyota Prius HEV aerodynamics optimization for fuel faster simulation results.

2. Red Bull Racing aerodynamics optimization for faster speed.

Aerospace

1. Parker Aerospace high-performance computing for faster simulation results.

2. Astrobotic Technology and Carnegie Mellon University spacecraft structural analysis for strength

and stiffness.

3. Terrafugiaroadable aircraft for proof-of-concept testing.

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Energy

1. Columbia power wave energy device shape optimization to reduce maintenance costs and

breakdowns.

2. Indre Electric permanent magnet wind turbine generator optimization for reliable operation.

Electronics

1. University of Arizona antenna performance optimization.

2. Fujitsu Semiconductor Limited integrated circuit (IC) design optimization.

Consumer Products

1. Dyson bladeless fan airflow performance optimization.

2. Racing System drag reduction.

Products

Simulation Technology: Structural Mechanics, Multiphysics, Fluid Dynamics, Explicit Dynamics,

Electromagnetic, Hydrodynamics.

Work Flow Technology: ANSYS Workbench Platform, High performance Computing, Geometry

Interfaces, Simulation Process and Management.

4.3 STRUCTURAL ANALYSIS

Definition Structural analysis is probably the most common application of the finite element method. The

term structural implies not only the civil engineering structure such as bridges and buildings, but also

naval, aeronautical and mechanical structures such as ship hulls, aircraft bodies and machine housings,

as well as mechanical components such as machine parts and tools.

4.3.1 Types of analysis

The seven types of structural analysis available in the ANSYS family of products are explained

below. The primary unknowns (nodal degrees of freedom) calculated in the structural analysis are

displacement. Other quantities such as stresses, strain and reaction forces are then derived from the

nodal displacements. Structural analyses are available in the ansys metaphysics, ANSYS Mechanical,

ANSYS structural and ANSYS Professional program only. You can perform the following types of

structural analysis.

1. Static Analysis: Used to determine displacements, stresses etc., under static loading conditions of

both linear and nonlinear static analysis. Nonlinearities can include plasticity, stress stiffening,

large deflections, large strain, hyper elasticity, contact surface and creep.

2. Modal Analysis: Used to calculate the natural frequencies and mode shapes of a structure and different mode extraction is also available.

3. Harmonic Analysis: Used to determine the response of a structure of harmonically time varying

loads. All nonlinearities mentioned under static analysis are allowed.

4. Transient Dynamic Analysis: Used to determine the response of a structure to arbitrarily time

varying loads. All nonlinearities mentioned under static analysis are allowed.

5. Spectrum Analysis: It is an extension of modal analysis, used to calculate stresses and strains due

to response spectrum or a probability spectrum distribution input.

6. Buckling Analysis: This is used to calculate buckling loads and determine the buckling mode

shapes. Both linear and nonlinear buckling analyses are possible.

7. Dynamic analysis: This type of structural analysis is only available in the ANSYS LS-DYNA

program. ANSYS LS-DYNA provides an interface to the LS-DYNA explicit finite element

program.

Structural analysis is the determination of the effects of loads on physical structure and their

components. Structure subject to this type of analysis include all that must withstand loads, such as

bridges buildings, vehicles, machinery, furniture, attire, soil strata, prostheses and biological tissue.

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Structural analysis incorporates the fields of deformations, internal forces, stresses, support reactions,

accelerations and stability. The result of the analysis are used to verify a structures fitness for use, often

savings physical tests. Structural analysis is thus a key part of the engineering design of structures.

4.3.2 Structure and Loads A structure refers to a body or system of connected parts used to support a load. Important

example related to Civil Engineering includes buildings, bridges, towers, and in other branches of

engineering, ship and aircraft frames, tanks pressure vessels, mechanical systems, one most serve a

specified function for public use, the engineer must account for its safety, aesthetics, and serviceability,

while taking into consideration economic and environmental constraints. Other branches of

engineering work on a wide variety of non-building structures.

4.4 ANALYTICAL METHOD

Calculation:

Given:

Load: P = 100N

Inner diameter: Di = 166mm

Outer diameter: Do = 230mm

Young’s modulus = 71Gpa

Length = 270mm

Formulae:

Area = π (Di2)/4 = π (166)2/4 = 21642.4317mm2

Normal stress = P/A = 100/21642.4317 = 0.00462055N/mm2

Deformation = PL/AE = 100*270/21642.431*71000 = 0.0000175mm

4.5 FEA Approach for Fixture

The Fig 4.5 shows FEA Model of turning fixture

Fig 4.5:- Turning Fixture

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4.6 FEM MODEL OF FIXTURE

The Fig 4.6 shows the meshing of the fixture model using triangular elements. By default

ANSYS chooses triangular elements depending on the contours of fixture. Since there are stepped and

many variation in the contours, tri elements were selected. If any other elements are chosen, the

meshing element orientation will fail. The total number of elements used are 58934.

Fig 4.6 :-Meshed Model of Fixture

4.7 Fixed Support

Fig 7.11:-Fixed support

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4.8 Force Applied

Fig 7.12: Force Applied

V. ESTIMATION AND COSTING

5.1 Definition of Estimation:

Estimation can be as an art of finding the cost, which is likely to be incurred on the

manufactured. Thus, it is the calculation of a probable cost of an article before the manufacturing

starts. It also includes predetermination of the quantity and quality of material, labor required, etc.

5.2 Functions of Estimation:

1. Determine material cost.

2. Determine labor cost.

3. Cost of material to be procured.

4. Determine cost of tools and equipment's.

5. Overhead charges including selling, packaging and transport.

6. Selling price after adding due profit.

5.3 Aims of Estimation:

1. To help the factory owner in deciding the manufacturing.

2. To decide about the amount of overheads, this helps in comparing and checking the actual

overhead of the factory.

3. To decide about the wage rate of the workers. “Time Study".

4. It helps to decide whether a particular item should be procured from market or to

manufacture.

5.4 Advantages of Estimation:

1. To help the owners in deciding the selling price.

2. To help in filling up of tenders.

3. To decide about the amount of overheads this helps in comparing and checking the actual

overhead of the factory.

4. To decide about the wage rate of the workers.

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5. It helps to decide whether a particular item should be procured from market or to manufacture.

5.5 Procedure of Estimation of Tool Cost:

PRIME COST = Raw material cost + Machining cost + standard item cost +

heat treatment + Mould base cost.

TOTAL COST = Prime cost + Risk factors + Over heads + Design charges + Inspection + Profit.

Table 5.:- Cost Estimation sheet

VI.RESULT AND DISCUSSION In order to validate the result obtained from ANSYS, we need a solution which is based on the

theoretical concepts. The following table shows the results obtained from analytical calculations.

Table 6.1 Analytical method

STRESS (ϭ)

DEFORMATION (ẟ)

0.00462055N/mm2

0.0000175mm

Sl.

No.

Factor

of A

Cost

in Rs

1 13086

2 4795

3 Inspection & Process cost 650

A 18531

89.00

B 0.10 1853

C 0.02 371

D 0.2 3706

24461 24,500/-

Dia H

1 MANDREL AL.ALLOY 240 280 12668.54 1 2.85 36.105 358 12926

12926

Det.

No. Matl Size Qty

Cost

each

Total

cost

in Rs

2 BOLT STD M12*50 8 20 160

160

SL.

NO.

No of

details

Total

hrs Rate/hr

Total

Cost

(in Rs)

1 Cutting off 1 1 100 100

2 Turning (CONVENTIONAL) 1 10 217 2170

5 Milling (CONVENTIONAL) 1 7 323 2261

11 Bench 1 4 66 264

4795

SL.

NO. Opeation/Process involved

Total

hrs Rate/hr

Total

Cost

(in Rs)

1 1 200 200

2 30 15 450

650

Basic Cost

Material cost

Machining/ Labour Cost

Other Cost

Risk Factor Cost (Allowances)

Packing & Transportation Cost

Profit

Cost Estimation sheetProject: ALH Tool No: ALH-SK-H-1286

Issue: H0 Dwg: 201C 636H 6700 201 Description: TURNING FIXTURE (OIL TANK COVER)

Sub Total

DESCRIPTION

TOTAL COST (A+B+C+D)

MATERIAL COST

Material Cost for Round shape

Det.

No. Details as per BOM Material

Size in mm Total

Cost

Volume

in cm3

Qty

in nos.

Density

in g/cm3

Mass

in kg

Rate

/ kg

Total material cost

Commercial items

MACHINING/ LABOUR COST

Opeation involved

Details as per BOM

Total Cost

Total Cost

Inspection & Process cost

Inspection Cost/Report

Finishing / Anodizing

Total Cost

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International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 02, Issue 12; December - 2016 [ISSN: 2455-1457]

@IJRTER-2016, All Rights Reserved 54

In ANSYS once the solver is processing stage solves the problem, solution will be displayed. These

solutions are the part of post-processing stage. The following are the results obtained from ANSYS

6.1 NORMAL STRESS Fig 6.1 shows the stress distributed on the fixture it can be observed that red color indicates

that maximum stress concentrated around the cut outs. Green colour indicates the nominal stress.

Fig 6.1:- Normal Stress

6.2 Deformation When the fixture is subjected to the static loads, it undergoes deformation. Fig 6.2 shows the

deformation of the fixture. The Red color shows maximum deformation i.e 9.0998e-7. The

deformation is maximum in this region because the component is placed there.

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International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 02, Issue 12; December - 2016 [ISSN: 2455-1457]

@IJRTER-2016, All Rights Reserved 55

Fig 6.2:-Deformation of Fixture

6.3 Comparison

Table 6.3 shows the maximum stress and deformation obtained from the analytical calculation and

FEA analysis.

Table 6.3 Comparison of Results

VII. CONCLUSION

Turning fixtures have been designed to accommodate all the modular coils with a

minimum of unique parts. Common fixture used for multiple stations. Footprint is reasonably small,

minimizing area used. Enclosures would grow for a larger turning fixture. “Ring” permanently

mounted to coil minimizes handling risks by reducing the number of times that the coil is manipulated.

Loads and stresses are easily manageable. Design approach leans to low tech, low tolerance

philosophy, which will keep costs down. Precision machining is minimized. Low-cost materials

specified. The present project work highlights the method of designing and analysis of turning fixture

for the manufacture of MGB oil tank.

Page 18: Design and analysis of a turning fixture for oil tank …...fixture as special plates designed to facilitate quick loading, locating of work piece in mass location. In this project

International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 02, Issue 12; December - 2016 [ISSN: 2455-1457]

@IJRTER-2016, All Rights Reserved 56

REFERENCES

1. Kline WA, DeVor RE, Lindberg JR(1982) The Prediction of cutting forces in end milling with application to cornering

cuts. Int J Mach Tool Des Res 22(1):7-22

2. Koeingsberger F, Sabberwal AJP(1982) An investigation into the cutting forces pulsations during milling operations.

Int J Mach Tool DesRes 1:15-33

3. TIEN-Ching Wu: Automatic turning head light Structure:Patent no. US6309089 B1, 30 oct 2001

4. Michael J.Barnes and Speak; Adjustable headlight, headlight adjusting and direction sensing control system and

method of adjusting head lights ; patent no; US5868488 A, 9 feb 1999.

5. Chian-yin Tseng; Direction adjustable device for an automobile with a steering linkage: Patent no. US6767119 B2, 27

jul 2004.

6. Chion-Dong Lin; steering wheel controlled car light piloting system, Patent no. US5416465 A; 16 may 1995.

7. Design concept of a turning fixture for oil tank cover mgb International Journal of Recent Trends in Engineering &

Research (IJRTER)Volume 02, Issue 11; November - 2016 [ISSN: 2455-1457]

8. Michael J.Barnes and Speak; Adjustable headlight, headlight adjusting and direction sensing control system and

method of adjusting head lights ; patent no; US5868488 A, 9 feb 1999.