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