FIXTURE DESIGN AND DEVELOPMENT FOR ALIGNMENT & WELDING TO PIPES

Batch no. VII

NAME OF THE STUDENTS

Pradeep Behera, Regn no. – 112082038 Pralay Shankar Mohanty Regn no. – 112082039 Sibani Shankar Mishra Regn no. – 112082050

Guided By

Prof K S Sundar SOME/SASTRA University

Index –of First Review

About the project

To whom and how this fixturet will be helpful

Drawings

Cost effectiveness

Advantages

Project Fabrication plan

# As per our shop visit we have found that the pipes are welding by utilizing so many time in alignment & welding with more man power & effort .So we have planned to prepare a fixture which can be help full for reducing the man effort as well as man power with time ..

# This savings will be a good impact for company & to reduce fatigue for labor & time

requirement of alignment

1-allignment is the main & basic need for joining of two materials .

2-The pipes which are being to joint with each other by butt welding are machined for edge preparation .After edge preparation the both pipes kept in aligned position in such a manner that the three axis should be match with each other.

3-The joining of two pipes is more essential for boiler industry .The seamless steel pipes which has the crucial role for boiler parts such as header ,steam lines , elbow joint ,bend joint etc are procured /prepared from small length for transportation & machine facility point of view ,some times formed bend pipes also .These are required to form long pipes by joining with one another .

After alignment of pipes

End prepared pipesAfter welding

*To reduce the cycle time.

*To reduce additional man power.

*To reduce manufacturing cost.

*To increase productivity.

*To reduce effort of man power

*To avoid fatigue

*To improve quality of the product.

*To create safe working environment.

*To reduce human effort.

OBJECTIVES OF THE FIXTURE

DESCRIPTION OF THE FIXTURE

The main parts of the fixture are-1. Rollers 2. Shaft3. Bearing & Housing4. lead screw & half nut5. Column6. Base Plate7. Hand Wheel8. Adjustable v blocks 9.Stand Wheels

FIXTURE FOR ALIGNING & WELDING THE END PREPARED PIPES

COST BENEFITS

Old Method

1.Man power:1 welder and 2 Helper,1 fitter,1 crane operator

2.Alignment time for one joint : 1 hour

3.Cost for 1 no joint: Rs.150x1x5(man hr) =Rs.750

4- total 10 joint is possible in three shift

5- Yearly joint cost : 10 x 300 x 750 = 22,50,000 INR

New Method

1.Man power:1 welder and fitter,1 crane operator

2.Alignment time for one joint : 15min (15/60 Hrs)

3.Cost for 1 no joint: Rs.150x1x (15/60*3)(man hr) =Rs.112.5

4- total 10 joint is possible in three shift

5- Yearly joint cost : 10 x 300 x 112.5 = 3,37,500 INR

Total savings per annum : 19,12,500 INR

SIDE VIEW OF ALIGNMENT FIXTURE

30

75

75

18

200150

FRONT VIEW OF FIXTURE

130

1800

1900

2500

90

30250

30

30

210

210 13

0

175

290

20

100HAND

WHEEL

BALL WHEEL

FREQUENTLY USED SEAMLESS STEEL PIPES

PIPE OD X THICK

370 X 35360 X 30560 X 70270 X 50550 X 65560 X 60320 X 90660 X 80711.2X45660.4X75457.2X95457 X 80457 X 60406.4X55368 X 60324 X 50219.2X32720 X 65

SPECIFICATION

SA213TP304HSA335P91SA335P22SA335P12SA335P11SA312TP316SA335P92SA335P5SA335P9SA192SA312TP321SA335P92SA335P23

Adjustable v blocks

•The adjustable v blocks are used to support & keep the circular section such as pipes to a required height .

•This is also used to align the pipes in vertical axis

WEIGHT OF THE USED PIPES

* Since the weight of pipe (660x80 ) is maximum ie. 2.333 ton ,the design will be made by considering this weight

* The fixture has to be withstand the load of 2500 kg vertical load along with its own weight .

* The 03 layer of plate has to be a capacity to bear the static load & dynamic load by avoiding from any bending moment .

*The two adjustable V- block has to be with stand the above load . ie 1.25 ton on each block

DESCRIPTION OD THK ID LENGTH VOLUME DENSITY WT IN KG

370 X 35 370 35 300 2000 73679.9 8 589.44

360 X 30 360 30 300 2000 62211.6 8 497.69

560 X 70 560 70 420 2000 215541.2 8 1724.33

270 X 50 270 50 170 2000 69124 8 552.99

550 X 65 550 65 420 2000 198103.1 8 1584.82

560 X 60 560 60 440 2000 188520 8 1508.16

320 X 90 320 90 140 2000 130078.8 8 1040.63

660 X 80660 80 500 2000 291577.6 8 2332.62

711.2X45711.2 45 621.2 2000 188388.036 8 1507.10

660.4X75 660.4 75 510.4 2000 275899.02 8 2207.19

457.2X95457.2 95 267.2 2000 216226.156 8 1729.81

457 X 80 457 80 297 2000 189525.44 8 1516.20

457 X 60 457 60 337 2000 149684.88 8 1197.48

406.4X55406.4 55 296.4 2000 121450.868 8 971.61

368 X 60 368 60 248 2000 116128.32 8 929.03

324 X 50 324 50 224 2000 86090.8 8 688.73

219.2X32219.2 32 155.2 2000 37643.6736 8 301.15

720 X 65 720 65 590 2000 267541.3 8 2140.33

WT=VOLUME X DENSITY =3.142/4 X(D1^2- D2^2) X L

PLATE MATLS : PLAIN CARBON STEELAISI-SAE1020 UPPER PLATE SIZE : 1800X1000X42 MM WT1 =volume x density =1.8x1x42x7.86 =594.2 kg

MIDLE PLATE SIZE :1900X1600X42 WT2 =volume x density =1.8x1.6x42x7.86=951 kg

LOWER PLATE SIZE :2500X1650X50WT3 =volume x density =2.5x1.65x50x7.86= 1621 KG

LEAD SCREW : 800 X50X3 pitch SQUARE THREADWT=13 KGLEAD SCREW NUT :40 ( 02 NOS)WT= 0 . 50 KG

SHAFT : 50X1700 X4 NOSWT=10.79 X4 = 43.16 KG

PINION: 110X50X4 WT=1.5 KG appx

RACK :1300X50X4 WT=20 KG appx

HANDLE (OD x length):25X100WT=0.39X4=1.56 KG

HANDLE STUB : 65X50WT=0.43 KG

BEARING (CYLINDERICAL ROLLER TYPE)UPPER PLATE : (4 NOS)BEARING SIZE: SKF NU2211 (d=55,D=100,B=25,,static force=4650 kgf, dynamic force=5400 ,N=8000 rpm ) -----PSGDB-pg4.21SHAFT : 55x1054 .Wt=19.66 kg

MIDDLE PLATE : (4 NOS)BEARING SIZE: SKF NU2212 (d=60,D=110,B=28,,static force=6200 kgf, dynamic force=7100 ,N=6000 rpm ) -----PSGDB-pg4.21SHAFT :60x1660Wt=36.84 kg

STRAP /SCREW SUPPORT PLATE : 120X100X60 ( 04 NOS) Wt=.12x.1x60x7.86x4=22.64 kg :100X100X40 (8 NOS)Wt=.1x.1x40x7.86x8STAND LEG (OD X LENGTH): 100X700 (04 NOS) ( total wt=43.16x4=172.64 kgBALL WHEEL : 04 NOS

DESIGN OF V-BLOCKAngle of v-block=90 degreeWeight of v blockWt of V-plates=2(volume x density)=2(4.96m^3 x 7.86)=78kgWt of lower plate=530 x 70 x .210 x 7.86=61.24kgWt of base plate=300 x 20 x.250 x7.86=13.75kgWt of screw area=3.142/4 x(80)^2 x 350=13.5kgWt of collar =350 x(75^2-45^2)=31.1kg

Wt of nut=0.5kgWt of handle=.39kg x 4=1.56kgSupporting strap=(.5 x 75 x120 x 10 x 7.86)x 4 =2.4kgTotal wt of one V-blocks=78+61.24+13.75+13.5+31.1+.5+1.56+2.4=202.05kg ie.203kgV-BLOCK WT=203kgMETAL : Mild Steel PlateScrew nut : Chromium

Wt of two v-blocks=203 x2=406kgPipe wt=2500kgLoad on first surface plate=2500+406=2906kg

V BLOCK DESIGNThe adjustable V block has to carry a load of 2.5 ton of pipes metalMax height to be lift (vertical) =175 mmW=2.5 ton=2500x10=25000N since 1 kgf=10 N appx H1=175 mm,(asume Screw matls comp strength=100 mpa,tensile strength=200 mpa,Nut is phosphorus bronze having elastic limit=100 mpa in tension ,& 90 mpa compn),80mpa shearIe. σet= σec=200N/MM^2,FOS=2)Since screw is under compression ,W= ∏/4dc^2xσec/FOS25500= ∏/4dc^2x200/2 So dc =18 mm Standard dia=30 mm {Pg-626 book} (as per avl it has take as 80 mm)

Torque required to rotate the screw in nut D=(d0+dc)/2=(36+30)/2=33 mmTan alpha =p / ∏ d=6/(∏x33)=0.579

Asume µ =Tan θ =.014Torque =pxd/2 =w [tan α+tan θi)/(1-tan α x tan θ)] x d/2=25500[.0579+.14/(1-.0579x.14)]x33/2=83946 NmmTensile stress due to axial load=σc=W/A=w/ (∏/4 d^2)=25500/(3.142 / 4x30^2)=36N/mm^2Stress due to torque ==16T/ ∏ dc^3=16x83946/(3.142x30^3)=15.8 N/mm^2

Nominal dia(d1)

Maj dia bolt(d)

Majdianut(D)

Min dia(dc)

Pitch(p) Depth of thread bolt

Depth of thread nut

Core area(Ac)

36 36 36.5 30 6 3 3.25 707

Max principal stress due to tensile & compressiveσc max=1/2 [σc+ √ {σc^2+ (4τ^2)]=.5[36+ √ (36^2+4x15.8^2)=42 N/mm^2Since design vale ie 100mpa is much higher than this value design is safe Max =1/2 [σc+ √ (4τ^2)=.5x √(36^2+4x15.8^2)]=24 N/mm^2Since this value is less than asume value (100 mpa) design safe

Design of nutHeight of nut=nxp=no of threadxpitchT=thickness of screw =p/2=6/2=3 mmAsume load is UDL & Bearing preassure =Pb=18 N/mm^2 Pb =w/{ ∏/4(d1^2-d2^2)}xn18=25500/[3.142/4(36^2-30^2)xnNo of thread (n)=5 Take n=10 nos Height of nut =h=nx6=10x6=60 mmShear stress on screw =w/(∏ndt)=25500/(∏x10x30x3)=9 N/mm^2Shear stress on nut= w/(∏nd1t)=25500/ (∏x10x36x3)=8 N/mm^2Since develop stress is less than asume stress ,design is safe Collar designConsidering crushing of collarOd of nut W= ∏/4(D^2-d^2) σt σt= σt asume / Fos 25500= ∏/4(D1^2-36^2) 100/2

D1=50 mm Od of nut=50 mmW= ∏/4(D2^2-d^2) σc

25500=3.142[D^2- 50^2}x90/2D=60 mm ie outer dia of collar

Thickness of nut collarW= ∏d1t1 τ25500=3.142x50xt1x80/2T1=8 mmThickness of nut collar=8mm

Plate designDue to impact load low -carbon steel with case hardening is preferredFirst plate size=(1800 x 1000 x 42)mm^3Area=1800 x 1 =1.8 m^2Force=mass x acceleration due to gravity = 2906 x9.81 =28507.86 ie.28508N=28058KNStress=force/area=28508/1.8=15837.7 ie.15838N/m^2

For rolling action:Shaft designThe shaft is subjected to bending moment only

M/I= σb/yM=bending momentI=moment of inertia

σb=bending stressy=distanceSince total 28.5KN ie.29KN on both shaft Load on shaft=28.5KN + plate wt=28.5+(594.2 x9.81)=34.337 ie.34.4KNLoad on each bearing=34.4/4=8.584 ie.8.6KNWt of four bearings=4 x (3.142(R^2-r^2)x thk=4x3.8kg=15.2kg

First plate designAssuming concentrating load(ie. Creating maximum stress),

t1=k √ [(a x b x f)/(σt(a^2+b^2)] a=length of plate b=breadth of plate k=coefficient=3.45 P=loadσt =design stress =697N/mm^2 (for C45 steel)So t1=3.45[(1800x1000x28508)/(697x(1800^2+1000^2)]^(1/2)=14.4mm1stPlate thickness assumed as =20mm

First shaft row designLoad on each shaft=34.4/2=17.2kNLength=1800+(30x2)+(20x2)=1900mmConsidering shaft as an simple supported beam with UDL on it,M=WL^2/8 =17.28x1000x1.9^2/8=7761Nm^2=791kgfmMax bending moment= (3.141/32)xsigmabxd^3=7761 =>(3.141/32)x.114d^3=7761 =>d=90mm (DDB-PG 7.20 ,R20 SERIES)

Bearing designForce fall on bearing=34.4kn+shaft force=34.4 KN+(2x97.06x9.81)=36.3 KNShaft wt=( OD90 & L 1900) =97.06KGThere will be 04 no's of bearing are required at this stageForce fall on each bearing =36300/4=9076 N=9076/9.81=925 KGFFrom data book the standard size of bearing is =SKF6318 qty-=04 nos[d=90,D=190,B=43,r=4,static force=9800KGF,Dynamic force =11200 KGF]Second plate designWeight falling on 2nd plate =34.4kn+shaftwt above the plate+4 bearing wt=34400/9.81+(2x97.06)+(4x7.42)=3731 kgForce falling on 2nd plate=3731x9.81=36596N=36.6KNSo 2nd plate has to be a capacity to withstand 36.6KN ForcePlate size =1800x1600Thickness of plate (t2)=k3√[abf/{σt(a^2+b^2)}] k3=3.45 pg253

3.45 √[1800x1600x36600/{697(1800^2+1600^2)}]=17.7 ie 25 mm (std size )T2=thick of 2nd plate=25 mmSecond plate shaft designThere will be 02 nos of shaftLoad on each shaft=(36.6KN+plate force) /2={36600+(680x9.81)}/2=21632N

Required shaft length=1700 mmM=WL^2/8=21700x1.7^2/8=7840 NM^2Since max bending moment (M)=∏/32xσbxd^3 σb=920kgf, DDB-7.24

SO d2=96 MM ie. 100 mmBearing sizeFrom DDB PG-4.14,BEARING size-SKF100BC03{d=100,D=215,B=47,r=4,static capacity=13200kgf,dynamic capacity=13700kgf }Bottom plate /3rd plate designLoad falls on this plate =(21.7KNX2)+(shaft wtx2)+bearing wt=(21700x2)+(2x105x9.81)+(4x10.5x9.81)=45.9 KN ie.46 KN forcePlate size=2500X1680Thickness of plate (t3)=K3 √ [(a x b x f)/(σt(a^2+b^2)]

=3.45 √ [(2500x1680x4600)/[697(2500^2+1680^2]=25mmThickness of 3rd plate (t3)=30mm Wt of matls upto this plate =46kn/9.81 +3rd plate wt=4690+972=5.7ton Lead screw design to provide to & fro motion to 1st plate W=∏/4xdc^2xσt28500= ∏/4xdc^2x100 since σt=100N/MM^2

.dc=20 mmStandard size of scre thread=25 mm Pg-626 D bookNominal dia(d1)

Maj dia bolt(d)

Majdianut(D)

Min dia(dc)

Pitch(p) Depth of thread bolt

Depth of thread nut

Core area(Ac)

28 28 28.5 25 3 1.5 1.75 491

Length of the stud =600 mmOther end there is a supporting rod of 18 mm dia which has to fit with bush in the supporting strap having length =600 mm2nd plate Rack & pinion designLength of rack=1500 mmModule =3Press angle=20degreeNo of teeth in pinion=12Centre distance =ZM/2+H=51.8 mmPitch dia=d=zm=36Addendum for pinion=M(1+X)=4.8Addendum forrack=3Bearing size=SKF6309 (with housing) [d=45,D=100,B=25,stat force=3000.Dyn=4150)Qty=2 nosShaft=45 mm having length 1500mmRotating wheel designWheel dia=170 mm, having 04 support with hub Hub dia for 1st plate=90 id & 110 od Hub dia for 2nd plate= 100 id & 120 odStand & bottom wheel designThere are 04 nos of ball wheel rqd having 360 deg movement in their own axis .The capacity of the ball wheel =5.7 ton/4 =56 KNF/4 =14 KN