IJIRAE::Combined load analysis of rotary cage fixture by FEA and Experimental approach

8/10/2019 IJIRAE::Combined load analysis of rotary cage fixture by FEA and Experimental approach

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International Journal of Innovative Research in Advanced Engineering (IJIRAE) ISSN: 2349-2163

Volume 1 Issue 8 (September 2014) www.ijirae.com

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2014, IJIRAE- All Rights Reserved Page - 386

Combined load analysis of rotary cage fixture by FEA andExperimental approach.1V.S.Jakukore

2L.B.Raut

1PG Student, Mech Dept,

2M.E.Coordinator, Mech Dept,

SVERI Engg College, SVERI Engg College,

Abstract The project idea basically developed from trunnion tables which are one type of fixture having ability to

rotate about its axis and able to fix the component at any angle. There is no requirement of angle plate and sineplates, drilling process is also computer controlled so no guide bush is required, So robust design for extra rigidity,

flexibility and simple to use. In this project task is difficult as design rotary cage fixture for component like cylinder

block, which is heavy of 76 kg. It is not possible to rotate or handle component manually and proceed on them tomake this process accident proof and automated for this purpose we are designing a rotary cage which rotate 360

degree and allow indexing to process on the component. Processes are to be operated on the component are drillingtapping and air blow washing ,Since drilling dont need clamping here components self weight will enough to carry

drilling force and tapping force coming through power tools. Therefore, rotary cage type fixture is critical importance.

Due to these factors, the Rotary cage type fixture has been the topic of research for different aspect such assimulation, bending stress analysis and experimental validation done.

Keywords Combined load analysis, rotating fixture

I.INTRODUCTIONIn this research component engine block go inside the cage along with fixture trolley and going to be fixed inside the

cage by using 3-2-1 principle and cage start rotate by using chain drive and stop at 0, 90,180,270,360 degree rotation by

using proxy sensors and dogs, the stress analysis of cage is carried out for drilling force is also calculated and combined

with cylinder block weight and use for strain stress analysis by using FEA and Experimental approach. Figure showoperational lay out for understanding the concept

.Fig: 1 Operation layout

II.DESIGN REQUIREMENTS:

Design requirements are as follows.a) A load transmit the symmetrically to fixture.

b) A fixture is strong enough to sustain the load of engine block and drilling force.

c) Fixture is designed for long life.

d) A material of fixture AISI304 is use to carry heavy load and corrosion resistant.e) Typically the design process by which such fixtures are created has major four phases such as fixture planning,

fixture layout, fixture element design, fixture body design.

f)

The drilling feed force is obtained from standard formulae available on Sandvick website which is the leading toolmanufacturer company in India.

Fig. 2 Coro drill

Total load on cage = Cylinder block load+ Drilling feed force= 940 + 570=1510 N


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2014, IJIRAE- All Rights Reserved Page -387

III.FEMANALYSIS

The solid model as constructed from the drawing was used as to construct the finite elements models for the rotary

cage fixture assembly. The main advantage of building a model of the complete rotary cage fixture assembly lies in the

accurate weight distribution and representation that the model provides, each of these factors could influence the stressresult obtained during the rotation. The model of the rotary cage fixture is shown in above Figure note the different

colours used on model surface to represent stress distribution.

Fig. 3 Von mises strain distribution of fixture for 00 cage position for

drilling

Fig. 4 : Von mises stress distributi on of fixture for 00 cage position for

drilling

Fig. 5 Von mises strain distribution of fixture for 900cage position for

drilling

Fig. 6 Von mises stress distribution of fixture for 900cage position for

drilling

Fig. 7Von mises strain distribution of fixture for 180 0 cage position fordrilling

Fig. 8Von mises stress distribution of fixture for 180 0 cage position fordrilling


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Fig. 9 Von mises strain distribution of fixture for 2700 cage position for

drilling

Fig. 10 Von mises strain distribut ion of fixture for 2700 cage position for

drilling

Fig. 11 Von mises strain distribution of fixture for 360

0

cage position fordrilling

Fig. 12 : Von mises stress distribution of fixture for 3600 cage position

for drilling

TABLEI FEMRESULTSCOMBINEDLOADOFCYLINDERBLOCKANDDRILLING

Name of

Component

Angles

(FEA RESULTS FOR DRILLING)

Angle 00 90

0 180

0 270

0 0

0

Strain and

Stress

Strain

Stress

(Mpa)

Strain

Stress

(Mpa)

Strain

Stress

(Mpa)

Strain

Stress

(Mpa)

Strain

Stress

(Mpa)

Stress in track

rod at centre 12.01 2.53 1.76 0.54 0.19 0.046 9.45 1.73 12.01 2.53

Rotary cagejoining plate 0.085 0.014 27.68 5.27 31.5 5.93 19.5 3.88 0.085 0.014

Stress in ring 1

6.69 1.37 1.61 0.321 1.01 0.19 6.57 1.01 6.69 1.37


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IV.EXPERIMENTALSETUPANDREADINGSThe drilling feed force is calculated for 12 mm drilling tool of Coro drill of sandvik by using standard formulae

available on sandvik website the calculated force is 570N added force on cylinder block is 285N because the

experimental model is scaled by 50% following figure shows experimental strain readings for different cage positions

Fig13: Strain measurement for track rod 00position Fig14: Strain measurement for track rod 90

0position

TABLEIII EXPERIMENTALREADINGS

V.RESULTANDDISSCUSSION

A. Combination load of engine block and drilling feed force

The stress values obtained from finite element models for the positions where the stain gauges were applied werecompared to the stress values obtained from the strain gauge readings considering Combination load of engine block anddrilling feed force. The comparison is done for 0, 90,180,270,360 degree cage rotation. A stress plot for each rotation of

the von mises stress in complete cage can be seen in chapter no. 4. For the stress value comparison the track rod, rotary

cage joining plate and cage ring shown in following figures. The deviation between the stress value at the maximumstress value is approximately 3% for track rod, for rotary cage joining plate and cage ring 11% and for cage ring 13%

there slight deviation in stress plot between two data sets. The data therefore indicate the method of accuraterepresentation of actual stress obtained during 0, 90, 270, 360 degree cage rotation.

I.A.1 Stresses in track rod for drill ing

It is observe that when cylinder block and trolley come in the cage and drilling feed force is applied stress is

maximum but when cage move to 90 degree position stress is going to be reduce and at 180 degree stress is negligible,

when cage come to its original position a stress generated increase

Name of

Component

Angle

(Experimental Readings for Drilling)

Angle 00 90

0 180

0 270

0 360

0

Strain and Stress Strain

Stress(Mpa)

Strain Stress(Mpa)

Strain Stress(Mpa)

Strain Stress(Mpa)

Strain Stress(Mpa)

Stress in trackrod

14 2.8 2 0.4 Out ofrang

Out ofrange

9 1.8 14 2.8

Rotary cagejoining plate Out of

rangeOut ofrange

32 6.4 27 5.2 21 4.2 Out ofrange

Out ofrange

Stress in ring 1

13 2.6 3 0.6 2 0.4 9 1.8 13 2.6


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0

0.5

1

1.5

2

2.5

3

0 90 180 270 360

Stress(MPa)

Cage Rotation in Degree

FEA

Strain gauge

values

Fig.15 Stress comparision for back strain gauge on track rod and FEA for Drilling

I.A.2 Stresses on rotary cage joining plate for drilling

Initially on zero degree position cage joining plate stress generated is negligible as shown in figure 6.5. The reasionis the load is acting vertically downword direction but at 90 degree position stress is increase because drilling feed force,

at 180, 270 degree position stress is slightly decreses. Hear it shoulde be noted that there are two cage joining plate butwe are measure stress on only one plate on which strain gauge is mounted.

0

1

2

3

4

5

6

7

0 90 180 270 360

Stress(MPa)


FEA

Strain gauge

values

Fig. 16 Stress comparision for strain gauge on cage joining plate and FEA for drilling

I.A.3 Stresses in cage ring for drilling

The cage ring is the strongest part of the fixture initially cylinder block come inside the cage then drilling force is

applied on the cylinder block the net effect on the cage ring is shown in figure

0

1

2

3

0 90 180 270 360

Stress

(MPa)


FEA

Strain gauge

values


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Fig17. Stress comparision for strain gauge on cage ring and FEA for drilling

VI.CONCLUSIONS

The various conclusions obtained during this work are listed below.1. In this work the material used for cage is stainless steel(AISI 304) ,yield strength 210 Mega Pascal and factor of safety

3 so maximum allowable stress is 70 Mega Pascal which is far greater than stress observed by FEM analysis and

experimentation by cage rotation So the given fixture is safe for drilling operation.

2. After manufacturing of rotary cage fixture, observed that it is possible to operate cage fixture successfully and scaling

of model used for experimentation.3. The study further established that the rotational operation of rotary cage or similar structure can be accurately

simulated by menace of structural analysis.4. The stress data obtained from FEA result are very close to the experimental readings of strain and stress.

REFERENCES[1] H.P.Luo,B. Zhang, Z.X. Zhou A rotary flexural bearing for micro manufacturing, CIRP Annals

Manufacturing Technology, 57 (2008) ,179182.[2] Gerald R.Molitor, Holland; Richard G.Bidigare, Hamilton, Cylinder bore finishing bore apparatus , United

States patent [19] Patent Number4, 907,372.[3] N. P. Maniar, D. P. Vakharia Design & Development of Rotary Fixture for CNC International Journal of

Engineering Science Invention ISSN (Online): 2319 6734, ISSN (Print): 2319 6726.

[4] Sandeep Soni & Ravindra Mane Design and Modeling of Fixture for Cylinder. Liner Honing Operation,

Global Journal of Researches in Engineering Mechanic & Mechanics Volume 13 Issue 7 Year 2013[5] Nirav P. Maniar1, D. P.Vakharia, A. B. Andhare, Chetan M. Patel Design of 28 Operations, 4 Axis 3600

Indexing Milling Fixture for CNC, International Journal of Recent Trends in Engineering, Vol. 1, No. 5, May

2009.

[6] V B BHANDARI, Design of Machine Elements, TATA Mc-Graw-Hill Publications, second edition, (2007)89-127,145-150.

[7] Erik K. Henriksen , Jig and Fixture Design Manual , INDUSTRIAL PRESS INC. NewYork, 1902. 244-258.

[8] Panagiotis Kyratsis, Thrust force prediction of twist drill tools using a 3D CAD system applicationprogramming interface,Int. J. Machining and Machinability of Materials, Vol. 10, Nos. 1/2, 2011.

[9] Shailesh S.Pachbhai1, Laukik P.Raut, A Review on Design of Fixtures, International Journal of EngineeringResearch and General Science Volume 2, Issue 2, Feb-Mar 2014.

IJIRAE::Combined load analysis of rotary cage fixture by FEA and Experimental approach

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