1.

INTRODUCTION TO PROJECT
1.1 PROBLEM DEFINATION
Our project is to design a new clamping fixture for ball O/D weld overlay
machine. The current clamping fixture is causing defect in the final product after hard
facing which is undesirable current clamping procedure is leading to distortion in the
work piece which leads to change in original dimension of job. Because the specimen to
be weld overlaid is expensive so mounting is critical aspect to be taken care of the project
is to create a new fixture that can avoid the Oblonging of ball due to existing clamping
fixture.
1.2 OBJECTIVE OF PROJECT
The goal of our project is to design and analyses new fixture replacing the
existing fixture which is not capable of keeping the dimensions of ball unchanged. This
goal includes being able to repeatedly weld the ball specimen without causing them
undergo cold cracking due to internal stresses developed during welding process the
scope of the project is limited to one weld overlay O/D machine as the requirement for
weldoverlaid ball is not as frequent as other valve bodies.

Objectives

Basis of measurement

1. Axial alignment

distance from perfect alignment

2.Distortion tests

Repeated testing

3.Does not damage material

Cost

of

new

specimen

&time

for

replacement.
4.Inexpensive

Cost of machine and purchase material.

Table 1: Objective

DCOER, Department of Mechanical Engineering

1.3 INTRODUCTION ABOUT COMPANY

1.3.1 COMPANY PROFILE

Virgo engineers is one of the worlds fastest growing groups in the flow control industry
with manufacturing locations in our countries across three continents more than nine
hundred employees globally virgo has emerged as leading manufacturer of ball valves
and automation systems serving diverse markets in over sixty countries worldwide
.Virgos rapid growth in global markets in sixty countries worldwide Virgos rapid
growth in global markets is testimony to the companies

steadfast commitment to

customer first policy combined with an unflinching adherence to high ethical standards.
Since starting operations in 1986 Virgo has focused on manufacture and sales of
automated and manually operated turn valves over the years Virgo has acquired several
prestigious international certifications and approvals from major oil and engineering
enginee
companies, becoming one of the leaders in the ball valve industry. Virgo valves and
automation systems are now being used in about 1500 projects in more than sixty
countries. Virgo continually strives to achieve the highest quality standard for its
products
oducts to meet the demand of global customers and has acquired a number of
prestigious international product and quality certification.

DCOER, Department of Mechanical Engineering

PRODUCT RANGE:
Virgo offers ball valves from 1/2 to 60 size and in pressure classes ANSI 150 to 2500
The product lines includes following valves:

Trunnion mounted ball valves

Floating ball valves

Metal seated ball valves

Welded ball valves

Top entry valves

There is wide choice of standard materials such as duplex, super duplex, inconel, Monel,
etc. as per applications need

1.3.2 AUTOMATION:Virgo also offers single point responsibility for the complete valve automation system.
Testing of the complete automation package can be done at specified differential
pressures and operating conditions as per customers requirement.
Some of the valve automated packages offered by the virgo are as follows

Remote operated valve

Emergency shutdown valves

Valves with gas over oil actuators

Line break systems

Fire proof actuator system

Motor operated systems

Hydraulically operated system

Electro hydraulic actuated systems

Valves with partial digital stroking

DCOER, Department of Mechanical Engineering

After initiating operations for more than twenty years the company has
successfully launched several new brands and products for a variety of applications
and industries. Today Virgo engineers offer its products under following brands.
1.3.3 BRANDS:

Virgo ball valves

Vintrol

EVS

Tritork

1.3.4 CERTIFICATIONS:
Virgo continually strives to achieve the highest quality standards for its products to
meet the demand of global customers and has acquired number of prestigious
international product and quality certifications as listed below.

ISO 9000

API spec 60

CE (quality system-pressure equipment directive)

GOST certifications

OHSAS 18001:1999(operational health and safety)

EXIDA-SIL (safety integrity certifications)

DCOER, Department of Mechanical Engineering

1.4 INTRODUCTION TO VALVE

A valve is a device that regulates the flow of substances (gases, fluidized solids,
slurries, or liquids) by opening, closing, or partially obstructing various passageways.
Valves are technically pipe fittings, but usually are discussed separately. Valves are used
in a variety of applications including industrial, military, commercial, residential,
transportation. Plumbing valves are the most obvious in everyday life, but many more are
used. Some valves are driven by pressure only which are mainly used for safety purposes
in steam engines and domestic heating or cooking appliances. Others are used in a
controlled way, like in Otto cycle engines driven by a camshaft, where they play a major
role in engine cycle control.

Fig 1.4.1: Top Entry Ball Valve

DCOER, Department of Mechanical Engineering

APPLICATIONS OF VALVE:

Oil and Gas Product Pipelines and Transmissions

Compressor Stations and Measuring Skids

Onshore and Offshore Platforms

Dehydration, Dryer, Gas Separation Systems

1.5 INTRODUCTION TO WELDING

1.5.1 WELDING:
Welding is recognized all over the world today as a remarkably versatile means of metal
fabrication welding in combination with allied process like thermal cutting, brazing
,braze welding and metal spraying has provided ample freedom to modern designer to
develop metallic products in which optimum mechanical properties, lightness and
aesthetics are harmoniously blended.
1.5.2 WELDING CLASSIFICATION:

Fig 1.5.2.1: Classification Of Welding

DCOER, Department of Mechanical Engineering

1.5.3. METAL INERT GAS WELDING:

MIG welding is an abbreviation for metal-inert-gas welding. It is also known as
GMAW,which stands for gas metal arc welding in this process, coalescence is achieved
by an electric arc formed between the work piece and a continuous consumable solid wire
electrode which is fed through a gun at controlled speeds. Inert gas usually argon or
argon mixture flows through the gun and forms a blanket over the weld puddle to protect
it from atmospheric contamination.

FIG 1.5.3.1: MIG (For Metal Inert Gas) Welding.

DCOER, Department of Mechanical Engineering

The welding can be semi-automatic or fully mechanized. In the semi-automated version,

the welder concerns himself only with gun-to-work distances, gun manipulation, and
welding speed, wire feed rates electrical settings ,and gas flow are preset .when the
equipment is completely mechanized all of these variables and welding and functions are
performed automatically without need for a welder. The power source is a rectifier or
motor generator giving DC reverse polarity is generally used (electrode positive) as it
gives better melting, deeper penetration and better cleaning action. Four distinct
techniques are possible in MIG welding depends on electrode size, shielding gas, arc
voltage and weld current.

Spray mode:-this technique uses heavy wires, large current and preferably argonoxygen mixture. This gives high heat input, high deposition rate and deep
penetration it is preferred for heavy gauge welding.

Globular mode:-when current is low, metal transfer in large globules. This result
is poor arc stability, shallow penetration and excessive spatter hence this
technique is used

Short circuiting mode: this technique is the most practical at currents below
200amps and with fine wires (0.8-1.2m diameter).it permits welding thinner
sections with ease and is extremely practical for welding in all positions.

Pulsed transfer: it is controlled method of spray transfer welding requiring more

sophisticated power source whereas the 3 types of transfers described previously
can be obtained with standard power sources and wire feed units. This made of
transfers can be used on mild and alloy steels, stainless steel and is particularly
useful with aluminum and alloys and light medium plates.

MIG is a versatile process and is generally replacing manual metal arc and TIG welding
most metals can be easily welded including aluminum, carbon steels, low. However for
carbon steels and low alloy steels, MAG or co2 welding is often preferred because it
avoids the use of expensive argon gas.

DCOER, Department of Mechanical Engineering

1.5.4. HARDFACING:
The types of wear to which metallic components may be subjected in service are
1. Frictional wear or metal to metal wear
2. Abrasive wear:

scratching abrasion

grinding abrasion

gauging abrasion

3. Wear due to repeated impact.

4. Corrosive wear.
5. High temperature wear.
To meet such types of wear simply in various combinations, correct choice of hard
facing deposit is necessary.

Fig 1.5.4.1: Hard-faced ball

Hard facing has the following advantages:

A highly wear-resistant or corrosion resistant deposit can be placed exactly at the

areas where wear occurs in service

A wide range of alloys can be used to deposit with ease.

Expensive alloys can be used sparingly and economically

DCOER, Department of Mechanical Engineering

Since most hard facing alloys are brittle, the load is carried by tough base metal.

Alloys can be easily applied in situ and under site conditions.

1.5.5 DEFECT IN BALL VALVE:

Distortion:
A hard-faced component is subjected to distortion. The cause of distortion is explained
in fig .the blank (i.e. original component) is 30 cm long and cold while the weld-metal is
deposited in the molten state across the whole length if the weld deposit was free and not
bonded to the base metal it would shrink by 6.5 mm on cooling to room temperature. But
since it is bonded to the blank, it pulls the blank inside and distorts its a result of
distortion, flat jobs become curved cylindrical jobs contract across the diameter and rings
may become dished or concave. Thicker the weld deposit and greater the length of the
deposit more severe is the distortion one must therefore use minimum amount of weld
deposit. A thin blank distorts more than a thick blank. When distortion is prevented by
the large mass of blank or by clamping or tacking ,the weld deposit is subjected to severe
strain during cooling, with the result that it develops cracks.in such cases preheating of
the blank helps to reduce the tendency to distortion as weak as to weld-metal cracking. A
hard-faced job has internal stresses due to unequal heating during hard facing the deposit
is in a state of stress because it has not able to contract completely and the blank
underneath is under compression components meant for critical service are therefore
stress relieved before use. Examples are aero valve and steam valves.

DCOER, Department of Mechanical Engineering

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Fig1.5.5.1: Distortion In Welding

1.5.5. DISTORTION - PREVENTION BY DESIGN

1. Elimination of welding
2. Weld placement
3. Reducing the volume of weld metal
4. Reducing the number of runs
5. Use of balanced welding
6. Modification in fixture design

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1.6 INTRODUCTION TO FIXTURE

1.6.1 BASIC CONCEPT OF FIXTURE
The fixture is a special tool for holding a work piece in proper position during
manufacturing operation. For supporting and clamping the work piece, device is
provided. Frequent checking, positioning, individual marking and non-uniform quality in
manufacturing process are eliminated by fixture. This increase productivity and reduce
operation time. Fixture is widely used in the industry practical production because of
feature and advantages.
To locate and immobilize work piece for machining, inspection, assembly and other
operations fixtures are used. A fixture consists of a set of locators and clamps. Locators
are used to determine the position and orientation of a work piece, whereas clamps exert
clamping forces so that the work piece is pressed firmly against locators. Clamping has to
be appropriately planned at the stage of machining fixture design. The design of a fixture
is a highly complex and intuitive process, which require knowledge. Fixture design plays
an important role at the setup planning phase. Proper fixture design is crucial for
developing product quality in different termsof accuracy, surface finish and precision of
the machined parts In existing design the fixture set up is done manually, so the aim of
this project is to replace with hydraulic fixture to save time for loading and unloading of
component. Hydraulic fixture provides the manufacturer for flexibility in holding forces
and to optimize design for machine operation as well as process function ability.

1.6.2 TYPES OF FIXTURES

Facing Fixture:Milling machines are extensively used for facing seating and mating flat surfaces. Milling
is often the first operation on the work piece. The work piece is positioned by three
adjustable spherical ended pads A. These pads are adjusted to suit the variation in the
size of work piece and lock in the position by check nuts. Two self-adjusting supports
A are pushed upward by light spring. These springs are used to make sure that the

DCOER, Department of Mechanical Engineering

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support A is positively in contact with the work piece. Clamping screw is used to lock
support B. On tightening the edge clamp, the work piece is pushed against the fixed
jaw. This jaw is keyed in the fixture body to provide solid support to work piece against
the heavy thrust developed in the operation.
Face Plate Fixture: It can be used conveniently for machining of simple and small components. Addition of
locators and clamps on face plate help in quick location and clamping of work piece.
Face plate fixture is useful for facing number of work pieces simultaneously on the lathe.
Turning Fixture: These are generally special face plates. Their swing should be lesser than the swing of the
machine. These are used for quick location and clamping.
Back Plate for Turning Fixture: It consists of work piece locating and clamping elements. These fixtures are generally
used for facing turning and boring operation. The work piece should be located correctly
with respect to rotating Machine spindle for all these operations.
1.6.3 ADVANTAGES OF FIXTURE

It eliminates marking out, measuring, and other setting methods before machining.
It enables production of identical parts which are interchangeable. This facilitates the
assembly operations.

The speed, feed and depth of cut for machining can be increase due to high clamping
rigidity of fixture.

It reduces the operators labor and consequent fatigue as the handling operations are
minimized.

It requires semi-skilled operator to perform the operations as the setting operations of

the tool and the work are mechanized. This saves the labor cost.

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 It reduces the expenditure on the quality control of the finished products.

It reduces the overall cost of the machining by fully or partly automatizing the
processes.

1.6.4. PURPOSE OF FIXTURE DEVELOPMENT:

In order to maintain the work piece stability during a machining process, an operational
fixture has to satisfy several requirements to fully perform its functions as a work holding
device. The following constraints must be observed while designing a variable fixture:

Deterministic Location:
A work piece is said to be kinematically restrained when it cannot move without
losing contact with at least one locator. The work piece is constrained by a set of
appropriately placed locators so that it is presentable for the machining
operation. Locating errors due to locators and locating surfaces of the work piece
should be minimized so as to accurately and uniquely position the work piece
within the machine coordinate frame.

Total Constraint:
A work piece should be fully constrained at all times to prevent any movement.
Clamps should provide locking forces to hold the work piece in place once it is
located. A totally restrained part should be able to remain in static equilibrium to
withstand all possible processing forces or disturbance.

Constrained Deflection:
Work piece deformation is unavoidable due to its elastic/plastic nature, and the
external forces impacted by the clamping actuation and machining operations.
Deformation has to be limited to an acceptable magnitude in order to achieve the
tolerance specifications.

1.6.5. PRINCIPLE OF FIXTURE DESIGN

Designing of fixtures depends upon so many factors. These factors are analyzed to get
design inputs for fixtures. The list of such factors is mentioned below:

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a. Study of work piece and finished component size and geometry.

b. Type and capacity of the machine, its extent of automation.
c. Provision of locating devices in the machine.
d. Available clamping arrangements in the machine.
e. Available indexing devices, their accuracy.
1.6.6. EXISTING FIXTURE:
(1) Weld overlaying of ball on outer diameterIt is a significant operation in valve manufacturing. The reason behind weld overlaying is
instead of using expensive material with good properties for ball manufacturing less
expensive material can be used as a substrate and layer of expensive material can be
deposited by welding.
Individual components in the ball welding fixture: Main shaft
Grippers
Hollow shaft
Internal expanding collet
Hollow Rotating tube centers
Tee-nut
(2)Mounting procedure with existing fixture:

-current fixture for weld overlaying of ball consists of one main shaft on which
first of all one hollow shaft and gripper is mounted.

-once these two components have been mounted the job specimen is placed which
is a ball for weld overlaying procedure

-after the job specimen is situated another gripper and hollow shaft is placed from
other end

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-finally the tee-nut which is locking nut is mounted and the assembly is mode
enact by rotating it.

Fig 1.6.6.1: Current Fixture

1.6.7. DEMERITS OF CURRENT FIXTURE:

Distortion of job specimen is observed the shape of the ball becomes oblong
which is not desired at all.

Improper clamping of the ball.

Damaged edgesof ball are also observed due to gripper making dents and destroying the
edged of bore.

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2. LITERATURE REVIEW
Literature survey defines that what data you have collected and studied in order to
implement the project ? for that reason we have to survey different technical papers
present today which would be beneficial with respect to our project for that reason we
finalize following papers for the guidance in our project.
The whole project is divided into four stages i.e. fixture planning, fixture layout, fixture
body design and fixture analysis. Each stage describes fixture design cycle through which
we have gone.

FIXTURE
PLANNING

FIXTURE LAYOUT

FIXTURE DESIGN
(CATIA)
FIXTURE ANALYSIS
(ANSYS)
FIXTURE PLANNING: [1]
A paper by, A.D. Kachare, thoroughly presents fixture plannng stage, Fixture planning
is to conceptualize a basic fixture configuration through analyzing all the available
information regarding the material and geometry of the work piece and operation
required. Resources available like machine bed space, machine height, machine capacity
are determined. Next is to define the position and orientation of valve body within fixture
on which clamping operation is to be done.

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FIXTURE LAYOUT: [7]

A paper by,Shankar.G,S.Balamurugan, thoroughly presents fixture layout stage.
Generation of fixture layout is to represent the fixture concepts in a physical form. As per
the orientation and position of ball during operation, we come at the conclusion to use
cylindrical holding fixture which can hold the component properly about the
circumferential surface of the component. After this we come to know that if the fixture
is manufactured as a single body. Then we have determined the position of nut on the
fixture body for clamping purpose.
FIXTURE DESIGN:[6]
A paper, Arun lele, focuses on fixure design of collet..Fixture design starts with the
material selection. We have selected the EN 45A material for fixture which is spring
steel. The material has high strength and good wear resistance. After this we have
selected mild steel for rotating tube centers for clamping purpose. We have calculated
force acting on component during clamping operation which 5KN and deformation in the
fixture body manually. We did 3D modeling of fixture body in CATIA software
FIXTURE ANALYSIS:[5]
N.M.Kumbhar, G.S.Patil, The study of these two papers helped us to present a method
for finding deformation and stresses using ANSYS software. In analysis part we have
imported 3D model from CATIA into ANSYS software. In next step, we applied
boundary conditions to the model by fixing base plate in all direction. Now the force is
applied in horizontal direction to get stresses and maximum deflection generated on the
shaft on which fixture is mounted.

DCOER, Department of Mechanical Engineering

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3. FIXTURE DESIGN
3.1 MATERIAL SELECTION:
In the structural design it is of importance to be familiar with the knowledge of material
properties and structural behavior in their service life conditions. While selecting suitable
materials, the requirements of the relevant part relating to the functions, stress conditions
and service life have first of all to be considered.
3.1.1 CRITERIA FOR MATERIAL SELECTION:
1. Purpose of application
2. Availability and cost of material
3. Past experience
4. Mechanical and chemical properties
3.1.2 AVAILABLE MATERIALS:
Using material selection criteria we have selected two materials i.e. EN 45A and mild
steel which would exhibit required properties under service life of fixture. These two
steels are known as high carbon and low carbon and are recommended for the
applications where wear resistance, medium strength and good toughness are required. In
this sense it is used mechanical engineering for highly stressed components, for example
in automobile industry, for parts like gears, crankshaft..
Material For Collet:
Collets are made up of following materials
C=0.55-0.68 Mn=0.74-1.26 Si=0.75 -1.04
1. EN 45A
2. DIN 1.2826
3. IS: 3749 ~ 55 Si 7
4. BOHLER SP CS (c=0.6,Si=0.9,Mn=0.4,cr=1.2,v=0.1)

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But we chose EN 45A from suggestions of company and availability of material.

3.1.3 PROPERTIES:

Use of Manganese (Mn):

1. Improves the strength properties of steel.

2. High wear resistance.
3. For 1% of Mn tensile strength of steel increases by about 10kgf/mm^2
4. Favorable for clamping operations.

Use of chromium (Cr):

1. Increase the hardness and strength of steel.

2. Improves resistance to heat and non-scaling properties.
3. Improves corrosion resistance of steel.
4. For 1% of Cr tensile strength of steel increases by 8 to 10kgf/mm^2

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4. CALCULATION
4.1THREAD FORCE CALCULATION:

Thread Force calculation

Thread dimension:
Input the thread size (d) = 120 mm
Input the Thread pitch (p) = 6 mm
Using machinery hand book calculating thread nomenclature
Basic Major diameter of the thread d = Size
Basic pitch diameter d2 = Size (0.649519P) =116.103 mm
d2 = 116.103mm
Basic root or minor diameter d1= Size (1.082532P)
Induced thread force from standard tightening torque
Tt = (2 2.5 3 3.5 4 5) kgf-m

Tt = (19.613 24.517 29.42 34.323 39.227 49.033) J

By using relationship between torque and clamping force.

Tf = K Ff d
Where,
K = Torque co efficient which is taken as 0.2
Ff = clamp load=0.75 proof load
d = Size
Ff = 0.92380
=349.6245
=85.65 KN
Torque (Tt) =0.100.12064.24
=770.86 N-m

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FORCE Turning force developed by tightening nut can be given by following equation

Ff1 =

? ? ? ? ?? ?
(? ? ? ? ?? ?)? (? ? ? ? ? )? (? ? ? ?? ?? )? (? ? ? ?? ?? )

Where; = 30
=K
Len = 150 mm
b = 1.5 d
2=0.165

Ff1 =(?

? ? ? ? ? .? ? ?? ? ? ?
? ? ? .? ? ?? ? ? ? ? )? (? ? .? ? ? ? ? .? ? ? )? (? .? ? ? ? ?? ? ? ? ? ? ? )? (? .? ? ? ? ?? ? ? ? ? .? ? ? ? )

Ff1 = 15 KN

Referring bolts manufacturers catalogue approximately 15% of force created by

The bolts remaining 85% are utilized to overcome the friction.
Axial force developed by bolts 15% of Ff1.
Ff2= 15%Ff1
So we can conclude this force is induced axially by bolts while Fastening.
Deflection in the shaft:
? ? = ? ? /? ?

= 15 1000 1250/ 11309.733 210

= 0.0078 mm

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4.2 COLLET DESIGN:

Fig 4.2.1: Slit length of collet

Depending on shaft diameter selection of slit length thickness:
Shaft dia

10 15 20 25 40 50

60

70

80

90

100 120 150

Slit length 15 30 40 50 60 90 100 110 120 130 135 140 145 150
Table No 2: Slit Length
Selection criteria for wall thickness of slit:
Slit length

Wall thickness

above

up to

15

15

30

1.2

30

40

1.4

40

50

1.6

50

60

1.8

60

80

80

100

2.5

100

120

120

150

3.5

150

..

Table No 3: Wall Thickness

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Collet Expansion Values:

Shaft dia
Collet

above

upto

Above Upto

Above up to

above

upto

above

upto

..

12

12

40

80

120

120

0.5+0.3

40

1+0.5

80

1.5+0.5

2+0.5

3+0.5

expansion
Table No 4: Expansion Values

4.2.1. FORCE CALCULATION:

Fig 4.2.1.1: Force diagram

Clamping force W developed by the collet is determined as follows:
Force Q produced by drive (a pneumatic cylinder or manually) acts upon a collet along it
0-0 suppose the collets are having n number of jaws: each jaw will receive a part of force
Q= & will act as wedge mechanism. Each force Q/n produces reaction force Q/n the
conical surface E-H takes up reaction force R/n is the resultant force triangle ABC.The
part W/n is found from force triangle ABC.
W/n = Q/n tan x
Hence w= Q/tan x

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Since W=W & Q= Q

W = Q /tan x kgf (N)

????

W=?? ? ? ? =8665.511 N

4.2.3 HEAT TREATMENT :

1.Clamping portion to HRc 54
2. Stock portion tempered to blue, red, and yellow respectively from guide phi D to clamping
area.
3. The collet is heat treated by flame near the slit ends gradually and universally by rotating on
a coneith diameter is expanded uniformly to a desired value. The collet is cooled down to room
temperature on fixture

Figure 4.2.3.1 : Heat Treatment Of Collet

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5. 3D MODELLING
3D modeling of entire fixture body is done using CATIA software. For the better
understanding and visualization of each part within fixture body, modeling has been done.
Fixture body mainly consists of parts which are assembled together to form a single unit.
These are collet, fixture grippers, hollow tapered shaft and each part is explained in detail by
its geometry and function.
1.BALL VALVE:
This is the actual job on which operation weld overlaying is to be done. The whole ball is
covered by overlay filler material called Inconel which is superior to base metal.

Figure 5..1 : Ball

2.COLLET:
This part is inserted in the ball before mounting on shaft. After tightening this collet expands
and holds the ball while welding

Figure 5.2 : Collet

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3.ROTATING TUBE CENTRE:This is a hollow shaft which is tapered at one end in such a way that it fits in tapered section
of collet and these are two in number,which is assembled from both sides of collet which
leads to expansion of collet.

Figure 5.3 : Rotating Tube Centre.

4.GRIPPER:
These are the parts which grip the rotating tube centers from internal surface and transmit the
tightening force further to collet.

Figure 5.4: Grippers

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5.TEE-NUT:
Tee nut helps in tightening the whole assembly of rotating tube centers and collet and hollow
shafts used to fill the void space

Figure 5.5: Tee Nut

6.ASSEMBLY OF FIXTURE:

Figure 5.6:Assembly

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6. ANALYSIS OF FIXTURE
In this project, structural analysis of fixture body is carried using ANSYS software to
determine the total maximum deformation and the stresses induced in the fixture during
operation. For meshing purpose tetrahedral elements are chosen because of their usage
in fixture design problems. Solid92 type of element is used which has a quadratic
displacement behavior and is well suited to model irregular meshes. The element is
defined by ten nodes having three degree of freedom at each node.
Serial no:

Number of elements

Number of nodes

9595

43138

Table 5: Number of nodes and elements

6.1 TOTAL MAXIMUM DEFORMATION (mm):
After meshing we applied a force on the component axially in downward direction,
which causes deformation in fixture body. The value of maximum deformation we get is
0.21 mm. figure (5 shows maximum deformation in the fixture body.)

Figure 5.1.1 :Deformation In X Axis Direction

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Figure5.1.2 : Deformation In Y Direction.

Figure 5.1.3 : Deformation In Z Direction

Figure 5.1.4 :Total Deformation

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6.2 MAXIMUM EQUIVALENT STRESS IN HOLE AREA (N/mm2):

Maximum stresses are developed at extreme right side of main shaft where it is fixed

The

below figure, in figure no: (6.2.1) shows the enlarged view of stress development in shaft.
The red color shown in shaft area subjected to maximum stress having value 4.5 N/mm2

Figure 6.2.1: Maximum Equivalent Stress

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7.FABRICATION
PART NAME :COLLET
MATERIAL SIZE :220 mm 200mm
MATERIAL : EN 45A
WEIGHT : 15 Kg
QUANTITY : 1

Sr.no

OPERATION

MACHINE

TIME

Turning

VMC

30 min

Tapering

VMC

35 min

Slot cutting

Gas cutting

40 min

Table No 6 : Fabrication Of Collet

PART NAME :HOLLOW TAPERED SHAFT
MATERIAL SIZE : 210mm210mm
MATERIAL

: Mild steel

QUANTITY

:2

SR.NO.

OPERATION

MACHINE

TIME

Turning

VMC

20 min

Tapering

VMC

20 min

Table No.7:Fabrication Of Tapered Shaft

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8.COST ESTIMATION
8.1 COST OF MATERIAL: Following table shows cost of material
Sr.No

PART NAME

WEIGHT

RATE

PER TOTAL

Kg

COST

Collet

15 Kg

60

900

Tapered Hollow shaft

17 Kg

60

1020

Hollow shaft

4 Kg

60

240

Table No 8 :Cost Estimation

8.2.COST OF MACHINING: Following table represent cost of machining
Sr.No

Machine

Time

Rate/hr

Total

VMC

105 min

360

600/-

Gas cutting

40 min

400

300 /-

Table No 9 :Cost Of Machining

8.3 OTHER COST:

Sr.No

Details

Total cost

Transport

400

Other/Overhead

500

Rs

900
Table No.10 Other Cost

DCOER, Department of Mechanical Engineering

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8.4 TOTAL PROJECT COST:

=Cost of material + Cost of machining + other cost
=2160+900+900
=3960 Rs/TOTAL PROJECT COST=3960 RS/-

DCOER, Department of Mechanical Engineering

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9. ADVANTAGES & DISADVANTAGES

9.1. ADVANTAGES
a) It can be used for rotational systems
b) Easy mounting and compact
c) No supervision needed
d) Denting of edges of ball are avoided
e) Low cost
9.2. DISADVANTAGES
a) Mounting takes care and little time
b) Suitable for mass production

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10. RESULTS
In this project our main goal was to design the fixture in such way that it may not cause
the ball to oblong or distort and denting of ball edges while holding should not occur
which would lead to re work and further increase in overall cost of manufacturing. It was
observed by visual inspection of geometric parameters that distortion of ball is reduced to
great extent by employing the new fixture and edges are more dented due to improper
holding of job specimen
The fixture for clamping operation as per the requirements has been attempted
successfully in order to increase the productivity.
The analysis for maximum deformation and maximum equivalent stress of designed
fixture is carried out by FEA method using ANSYS software is summerized as follows.

Sr.No

Total Deformation
(mm)

0.0002126

Maximum
Equivalent
Stress
(N/mm2)

Yield Srtength
Of Fixture
Materil
(N/mm2)

Factor Of
Safety

6.21

248

15

Figure 10: Result Table

DCOER, Department of Mechanical Engineering

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11. CONCLUSION
It has been great experience while completing our project we came across alt of practical
knowledge as well as experience. We had an opportunity to learn how projects are carried
out. We got opportunity and freedom to apply our ideas to improve the assigned project
and check whether these ideas are fruitful.We paid special attention during each and
every manufacturing process that was carried out in the manufacturing we came to know
how theoretical aspects are implemented in actual practice, we got to learn about different
manufacturing processes, welding, polishing ,gas-cutting, etc.Then the actual cost is
calculated. We are really pleased to see our fixture operating successfully.

DCOER, Department of Mechanical Engineering

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12.REFERENCES
[1]

A.D. Kachare, First Operation Machining Fixture, International Journal of

Engineering and Innovative Technology (IJEIT) ,volume-2, october 2012.

[2]

H.S.Shan, Manufacturing technology, Pearson education, volume-1,2012.

[3]

V.B. Bhandari, Design of machine elements,Tata McGraw,Hill co. August 2005.

[4]

Edward G. Hoffman, Jig and fixture design, fifth edition, 2003.

[5] N.M.Kumbhar, G.S.Patil,Finite Element Modelling and Analysis of Workpiece

Fixture System,volume-2,2012.
[6] Arun lele , Design guidelines for collet,30 May 2013.

[7] Shankar.G,S.Balamurugan, Machining Fixture Layout Optimization, International

Journal of Machine and Construction Engineering, Volume 2 Issue 1 Mar 2015.

[8]

www.scribd.com/Guidelines-for-Collect-Design.

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