SPONSORED BY – MAHINDRA SONA LTD. SATPUR, NASHIK-422007

PROJECT PRESENTATION ON –“DESIGN & MANUFACTURING OF DRILL JIG FOR END YOKE USED IN UNIVERSAL JOINT”

SUBMITTED BY , EXAM SEAT NO 1. KHEMNAR PRADEEP B80690814 2. LASALKAR SARVESH B80690816 3. PATIL BHUSHAN B80690818

PROF. M. A. AHIRE (INSTITUTE GUIDE)

Mr. S.V. BHUSAL & Mr. D.J. BHADANE (COMPANY GUIDE)

Dept. of Mech. Engg.- GES’s R. H. Sapat C.O.E., M.S. & R , Nashik-5

Present operation sequence Proposed operation sequence

Broaching Drilling and Tapping

Keyway Milling Broaching

Drilling and TappingKeyway Milling

Broaching re-pass

PROBLEM STATEMENT:-

“Design and development of Drill Jig for elimination of broach repass operation by changing process sequence.”

STEPS IN JIG DESIGN :-

1)PRODUCT ANALYSIS : Product Name - End yoke Product No - 3204533F Product Weight - 1.2 kg Product Material - SAE1141

Composition - C-0.37-0.45% ; Mn-1.35- 1.65%

P- 0.060% ; S-0.08-0.35% Heat Treatment - HND & TEM :-229-269 BHN

2)OPERATION CONSIDERATIONS:-

Operation - Drilling on circular cross section. Hole size - 7.8mm - 8.1mm Drill bit diameter - 7.8 mm Speed - 700 rpm Depth of cut - 10 mm Feed - Manual

Study of old jig & available other jig & fixture.

Machining Time(tm):-

tm= Length of drill travel(L) ,mm

Feed rate(s) * Rpm(n)

tm= l+0.3d tm= 10+0.3(7.8)

s*n 0.15*700

tm= 0.1175 minute.

Ref:- Westerman Table ; Pg. No :- 106

Machining Time(tm) = 7.05 sec.Fig no. 1. Drill bit

L

0.3d

3)MACHINE STUDY:-

Drilling Machine: Available Space For Jig:-

1. Bed Size = 680 mm x 330 mm

Bed consist of two slots at a distance of 255mm from each side of bed. These slots provide clamping arrangement for jig & fixture

2. Distance from tip of tool to base = 175 mm

3. Drill bit length =100 mm

Motor Specifications:-

1. Rating = 1HP / 0.75Kw

2. Rpm = 940 rpm

3. Torque = 7620 N/mm^2

Support Plate

Side butting blocksV-Block

Jig Plate

Support Plate

Main Hole Locater

Base Plate

C-Washer

Drill Bush

Fig no. 2. Assembly of drill jig

CUTTING FORCE IN DRILLING:-

Power (K w) = 1.25*d^2*k1*n*(0.056+1.5s)

10^5

Where, k1= Material factor ; Ref - (P.T hmt; pg. no- 141)

s = Feed rate, mm/rev; Ref- (As above)

Drill Thrust(kg f) = 1.16*k1*d*(100*s)^0.85

= 173.49 kg f

Ref - (P.T hmt; pg. no- 141)

P = 0.3141 Kw

Thrust = 1702.02 N

Torque(T):-

T= P*60*1000 = 0.3141*60*1000

2*3.14*n 2*3.14*700

Cutting Speed(V):- Ref :- T.O.M. By Khurmi Gupta

V = 3.14* d* n = 3.14* 7.8* 700

60*1000 60*1000

Ref :- P.T ; By R.K JAIN

Tooling Force(F):-

F= Power = 314.13

Velocity 0.2858

Ref :- T.O.M. By Khurmi Gupta

T= 4.2849 N-m

V= 0.2858 m/sec

F= 1099.13 N

4)LOCATION:-

Fig no. 3. Main hole locater

Fig no. 4. V-Block

5)CLAMPING FORCE CALCULATION:-

= Nf*Tooling Force (F) = 1.5*1099.13

Coeff. of friction of w/p material 0.3

Ref:- Care lane cutting & clamping force (pdf) ; Pg.No- 2

www.reidsupply.com(pdf) ; Pg. No- 7

From Clamping Force range Screw/Bolt size is selected from book is,

Ref:- Jig & Fixture Design; By Edwrd.G. Hoffman

Care lane cutting & clamping force (pdf) ; Pg.No- 2

For Clamping we used, C-Washer & M 16 Nut.

Clamping Force = 5495.65 N

Selected Size = M16

Material Chart

Component No Component Number Component Material

1. Base Plate Mild-Steel

2. Support Plate Mild-Steel

7. Washer Mild-Steel

9. C-washer Mild-Steel

11. Jig plate Mild-Steel

Composition in %

C Si S P Mg

0.2-0.3 0.25 0.05 0.05 0.57

Properties

Density Hardness

(BHN)

Modulus of Elasticity

(Gpa)Breaking Strength Ultimate Tensile Strength

7850 140 190 430 555

RemarksAbove mentioned parts are not subjected to much stresses & wear. Hence Mild-steel is selected for these components. Mild-Steel have following advantages:- Easily available, Cheap cost, Economical, Most widely used.

(Kg/m^3)(N/mm^2)(N/mm^2)

Material Chart

Component No Component Number Component Material

3. Vee-Block SAE 8620

4. Main hole locator SAE 8620

8. Hinge pin SAE 8620

12. Side butting block SAE 8620

Composition in %

C Mn Si Ni Cr Mo

0.17-0.23 0.60-0.95 0.20-0.35 0.35-0.75 0.35-0.65 0.15-0.25

Properties

DensityHardness

(BHN)

Modulus of Elasticity(Gpa) Breaking Strength Ultimate Tensile Strength

7859 220 210 690 821.8

RemarksAbove mentioned parts are subjected to the stresses & friction, hence material have wear resistance property. Thus, SAE8620 materials selected for these components.SAE 8620 have following advantages:- Used for high resistance surface, High hardness . Resist shock load, High strength.

(N/mm^2)(Kg/m^3) (N/mm^2)

Material Chart

Component No Component Number Component Material

5. Drill Bush EN 31

6. Linear Bush EN 31

Composition in %

C Mn Si Cr S P

0.9-1.2 0.3-0.75 0.10-0.35 1-1.6 0.5 0.5

Properties

Density Hardness

(BHN)

Modulus of Elasticity

(Gpa)Breaking Strength Ultimate Tensile Strength

7810 229 210 1102.45 1158

RemarksAbove mentioned parts Drill bush, Linear bush required to be hardened material, for that we have selected EN 31 Material. It has following advantages:- High hardness, Used for high resistance surface, Resist shock load, High strength.

(Kg/m^3) (N/mm^2) (N/mm^2)

COST ESTIMATION

Raw Material Cost = Rs 2273

Operation Cost = Rs 11545

Standard Part Cost = Rs 320

Total Cost of Project :-

= Raw Material Cost + Operation Cost + Std. Part Cost

= 2273 + 11545 + 320

= Rs 14138

Cost Analysis for Broach Re-pass :-

Lot Size Selected (Ls) = 500 Parts Parts per Hour (Ph) = 75 parts/hr Cost per Part (Cp) = 8.50 Rs/part Cost Saving per Hour = 638 Rs/hr Total Saving for A Lot Size (Ts) = 4250 Rs Cost Saving per Day (approximate) = 4785 Rs/day Cost Saving Per Year (approximate) = 14,35,500 Rs/year Operation Cost Saved per Year (actual) = 17000 Rs/year

All Formulas are mentioned in Project ReportRef : Jig & Fixture Design; By Edwrd.G. Hoffman;Pg no. 91,94.

Time Analysis for Broach Re-pass :- Operation Time for Single Batch (Ot) = 7 hr Job Handling Time (Ht) = 0.5 hrs Total Time Saved Per Batch = 10.5 hrs Total Time Saved Per Year = 42 hrs Total Time Saving/Year in Terms of money =18900 Rs/year Total Yearly Benefits = Rs 35900

Payback Period = 4 Months Break –Even Point = 1664 Parts

Ref : Jig & Fixture Design; By Edwrd.G. Hoffman; Pg no. 91,94

Benefits of Project:- Save Electricity, Save Oil, Increased Productivity, Save Machining Cost, Broaching Machine is free for another job.

Result: -“The complete process of broach re-pass is eliminating,

with increasing productivity & rejection make zero.” 

CONCLUSION

Yearly profit earned by company is actually of Rs. 35,900/-

If parts are continuously manufactured for whole year; then profit will be of Rs. 14,35,500/-

The total machining time saved for a batch of 500 parts is around 10.5 Hrs.

Rejection tends to zero & productivity increases.

Customer’s satisfaction by obtaining their required surface finish & dimensions.

1. “Jig and Fixture Design”, By Edwrd G. Hoffman; Delmar Cengage Learning; 5th Edition;

2. “Production Technology”, By HMT; TATA McGraw Hill; 24th Edition2006;

3. “Westermann Tables”, By Hermann Jutz &Eduard scharkus; New Age International(P)Ltd.; 3rd Edition

2008;

4. “Design Data”, By PSG College of Technology; Kalaikathir Achchagam; 2nd Edition 2010;

5. “Material science & Metallurgy”, By O. P. Khanna; Dhanpat Rai Publications; 11th Edition; 2007;

6. “Jigs and fixtures”, By P.H.Joshi; Tata Mc-GrawHill company limited; 6th Edition 2010;

7. “Material Analysis”, By Mahindra & Mahindra Steel Division; Industrial and Engg Journals;

8. “Design of a 5-Axis Fixture System”, By Brian Dorchik, Steven Feroli, Ryan McGlone, Ryan

McLaughlin; Worcester Polytechnic Institute, Worcester, Massachusetts; 2007;

9. “Dedicated Fixture Design for Polishing of Silicon”, By Taufif Bin Zakaria; Report submitted in partial

fulfillment of the requirements for the award of the degree of Bachelor of Mechanical Engineering;

November 2008;

10. “Manufacturing Tooling (Jig Design)” By Nageswara Rao Posinasetti; February 12, 2008;

11. “Introduction of Jig & Fixture” (Pdf).

12. “Care lane cutting & clamping forces” (Pdf).

13. http://www.mahindrasona.com/about.htm

REFERENCES

THANKS