CHAPTER 1 INTRODUCTION As modern day industries needs continuous improvement of performance of machining of metals , non metal and all

type of materials. For that , better type of work holders also to be required. Work holders mostly used by industries are 1) mechanical type work holders ,2) magnetic type work holders and 3) vacuum work holders. By mechanical type work holders we can hold high strength and low brittle materials only. But it cant hold high strength and high brittle materials like ceramic material. If we hold ceramic material with mechanical type work holder , it may damage the material .Setup and positioning time is more if we use mechanical type work holders. It is difficult hold works like thin plates or sheets. So machining using mechanical type work holders has some disadvantages. Some of the above problems can be overcome with help of magnetic work holders. Setup and position time can be reduced using magnetic work holder. Thin plates or sheets can be hold using these holders. But it cant hold non-ferrous materials. Using vacuum work holders, we can able to overcome all above problems. It can reduce setup and positioning time. It can able to hold all types of materials. It can hold flat sheet metal for grinding, polishing or welding, a vacuum chuck performs equally well with

thicker metal plates, narrow metal channels or aluminum extrusions that incorporate flat surfaces. A vacuum work holding system can be expanded to accommodate very large work pieces. For example, vacuum chucks have been used successfully for gantry type welding machines with table surfaces as large as 12 feet by 40 feet. Like a magnetic chuck, a vacuum chuck operates simply by flipping a control valve . Unlike a magnetic chuck , however ,a vacuum chuck is suitable for holding non ferrous material . In

contrast to mechanical clamps or a jig that concentrate pressure in small areas, a vacuum chucks applies uniform holding pressure simultaneously to the work pieces entire abutting surface. This prevents deflection of the part during machining. Due to the above advantages on many occasions the mechanist or shop is free from facing with the problem of holding work pieces that are thin, flat, or made from non ferrous and non metallic materials.

CHAPTER 2 LITERATURE SURVEY Manufacturing solutions are frequently the prizes for machine shop operators bold enough to resist the inertia of conventional wisdom. In the metalworking sphere, this inertia includes the premise that secure and reliable work holding is possible only by mechanical means. Considering the critical importance of accurate fixture, its no surprise that vacuum systems may be viewed with some uncertainty by mechanist accustomed to convention work holding devices In the past, acceptance of vacuum chucks has been limited by persistence of traditional practices, as well as by some common misconceptions. Despite evidence to the contrary, for example, the belief that persist that vacuum chucks arent sturdy enough to withstand heavy machining operations. Another prevalent assumption is that vacuum chucks are only suitable for small work pieces. Reinforcing this view, many of the vacuum chucks in use today do serve small application. Machinists may also question whether a vacuum work holding system can be used with common coolant fluid. An additional factor is the ever-present concern about setup time. Addressing this concern was important to aerospace manufacturer smiths industries accession systems (Whippany, new

Jersey). Founded in 1947 as Airborne Accessories, the company specializes today in manufacturing actuation and motion-control systems for commercial and military aircraft, as well as for other

type of military equipment. Many of the devices that smiths manufacture are flight critical components. The firms current customer base split roughly 50/50 between commercial and defense industries With earning last year of more than $52 million, smiths currently has 280 employees, including 39 in its machine shop When their shop receive an order in 1997 for thousands of parts incorporating aluminum plate components,

manufacturing engineer Russ Harter and his supervisor Phil DeMauro needed to find a reliable and efficient work holding system to support their machining strategy . Due to the high cost of the aluminum castings that are used to create the majority of precision parts, Smiths work shop performs only a small amount of unattended machining. dimensional Because most of the parts, receiving this companys product special order is three plate

involving

components presented an entirely different type of work holding challenge As an alternative to setting up and machining each part separately , Mr.Harter wanted to machine several of the 0.160 inch

thick plates from single, larger of aluminum alloy .Because of the very tight hole tolerances required for these parts , deflection of the work

piece needed

to be minimal , and even the slightest positional

shifting was unacceptable . Although a vacuum seemed to be a logical solution , Mr. Harter had no previous experience using devices . one of this

To contact a shop with practical experience, Mr.Harter posted a massage on modern machine shop web site. He soon

received a massage from machine shop in the Midwest that was successfully using vacuum chuck system manufactured by Magna lock , U.S.A. (Rockford, Illiois),affirm that also manufactures magnetic chucks and related control . After investigating other vacuum chuck products , Mr.Harter decided that system was well suited for his applications.

How and Where It Works Because a tight air seal is essential to the holding power of a vacuum chuck , application of these devices is limited to work piece that incorporate flat , non porous surfaces. Although one application is to hold flat sheet metal for grinding , polishing or

welding , a vacuum chuck performs equally well with thicker metal

plates, narrow metal

channels or aluminum extrusion that

incorporate flat surfaces . A vacuum work holding system can be expanded to accommodate very large work pieces . For example , vacuum chucks have been used successfully for gantry type welding machines with table surfaces as large as 12 feet by 40 feet. Like a magnetic chuck, a vacuum chuck operates simply by flipping a control valve . Unlike a magnetic chuck , however ,a vacuum chuck is suitable for holding non ferrous material . In contrast to

mechanical clamps or jigs that concentrate pressure in small areas, a vacuum chucks applies uniform holding pressure simultaneously to the work pieces entire abutting surface . This prevents deflection of the part during machining. Vacuum can be created by using vacuum pumps & venturi vacuum generator. But for our project we using venturi vacuum generator due to following advantages.

In general the following are the advantages of using venturi vacuum generators: Fast cycling : Since there are no moving parts and the time to establish vacuum is low, venturis are ideally suited for fast cyclic applications such as pick & place labeling, etc.

Temperatures : Venturis can operate over a wide range of temperatures , especially at high temperature applications.

Corrosive environments : since venturis can be made out of a wide range of materials and there are no moving parts they are suited for corrosive environments

Noise levels : The only noise generated by venturis is due to air flow and can be minimized by using silencers

Contamination: Venturis, especially the single stage venturis , are quite incentive to contamination. Even if particles are introduced into the device , they can be cleaned with relative ease.

Ease of mounting: Since venturis are quite compact, they can be mounted very close to the work station . This makes them very attractive for integrating them as a part of the end-of- arm tooling . As this minimizes the length of vacuum line , the size can be smaller than if they were mounted at a distance.

Maintenance: Since there are no moving parts associated with venturis , they are practically maintenance free.

Lower Cost: Due to their simplicity , the venturis are low cost

components

When Is A Venturi Undesirable? One of the basic requirements of a venturi vacuum generator is compressed air. If compressed air is not available, an electric vacuum pump is the only alternative. If constant vacuum flow is required, venture may not be the most efficient device compared to vacuum pumps . Also, if the application requires a large vacuum flow at high vacuum, a vacuum pump may be more energy efficient then a venture.

CHAPTER 3 PROBLEM DEFINITION 3.1 Importance of the Project Normally job holding with mechanical fixtures takes more set up and positioning time .Also it is difficult to hold less thickness plates, fragile materials with mechanical fixtures. If we use magnetic

fixtures, it impossible hold non ferrous materials. So we needs workholding devices to hold fragile materials, non ferrous materials and less thickness plates for better accuracy machining .We also requires work holding device which can save setup and positioning time while fixing the job.

CHAPTER 4 OBJECTIVES AND METHODOLOGY 4.1 THE SPECIFIC AIM OF THE PROJECT (OBJECTIVE)

Design and of fragile and

develop other

workholding

device

for

holding

engineering

materials with less time and

more accuracy.

4.2 METHODOLOGY Factors to be considered for machining to find out force

which is maximum while milling operation. Design calculation for the factors considered to get

maximum cutting force and vacuum force. Design of venture block, vacuum table and other

accessories to hold the work piece efficiently while machining. Manufacturing and assembly of vacuum table, venturi block

and other accessories . 10

Testing

and

validate the manufactured vacuum work holder by

fixing it in milling machine.

CHAPTER 5

FACTORS TO BE CONSIDER FOR MACHINING

5.1 FORCES IN MILLING

i.

TANGENTIAL (CUTTING) FORCES

This acts in a direction tangential to the fixed workpiece and represents the resistance to the rotation of the tool

ii.

LONGITUDINAL (THRUST-FEED) FORCES

Longitudinal force acts in the direction parallel to the axis of the work and represents the resistance to the longitudinal feed of the work piece

iii.

RADIAL (PASSIVE) FORCES

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Radial forces acts in a radial direction from the center line of the work piece

5.2 MACHINING PARAMETERS

There are three important parameters in milling operation Cutting speed Depth of cut Feed rate

i.

CUTTING SPEED:-

Cutting speed refers to the relative surface speed between tool and work

ii.

DEPTH OF CUT :-

The depth of cut relates to the depth the tool cutting edges engages the work piece

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iii.

FEED RATE :-

The feed rate is the axial advance of the work along the work for each revolution of the tool

Figure 5.2 Based on above graphs (i.e. cutting forces versus force is maximum among

cutting parameters), cutting all forces while machining.

So cutting force is consider as a main factor for further calculations. Based on cutting force, vacuum force should be calculated.

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CHAPTER 6 DESIGN CALCULATION FOR THE FACTORS CONSIDERED 6.1 Cutting Force Specific cutting energy: A indication independent of of the cutting unit parameter of the as giving process the an ,

efficiency speed,

defined

energy

consumed per

volume o f

removed metal

The rate of energy consumed during machining Pm is

Pm=FC*V

Energy consumed per unit volume of metal removed, specific cutting energy ps is Ps = If AC =1 , then PS =FC Where Pm = Power consumed FC = Cutting force V = Cutting speed ZW = Metal removal rate
Pm F = c Zw AC

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Ac = Undeformed chip cross section area

Material Aluminum alloy Cast irons Copper alloys High-temperature alloys Magnesium alloys Nickel alloys Refractory alloys Stainless steels Steels Titanium alloys

Specific energy 0.4 to 1.1 1.6 to 5.5 1.4 to 3.3 3.3 0.4 4.9 3.8 3.0 2.7 3.0 to to to to to to to 8.5 0.6 6.8 9.6 5.2 9.3 4.1

W-s/mm3

Ps = Specific cutting energy Table 6.1 Approximate Energy Requirements in Cutting Operation

15

Based has

on

above Specific

tabular cutting

column energy

refractory value of

alloys 9.6 W-

maximum

s/mm3. So max cutting force is 9.6 N For machining, vacuum force of work holder should be more then cutting force VACUUM FORCE= VACUUM PRESSURE X AREA OF CONTACT OF VACUUM WITH JOB

VACUUM PRESSURE CAN BE CREATED WITH FOLLOWING WAYS:

1) VACUUM PUMP 2) VENTURI VACUUM PUMP

VENTURI VACUUM PUMP SELECTED FOR VACUUM BASED ON PREVIOUSLY GIVEN REASONS

TABLE

& COMPRESSED AIR

AVAILABLE WITH US

16

6.2 Vacuum Pressure Required VACUUM FORCE =VACUUM PRESSURE *AREA =VACUUM PRESSURE * AREA BASED ON JOB

Take minimum area as 30*30=900 mm2 =0.0009 m2

Cutting force as per data =9.6 N =10 N

10 N = vacuum pressure * 0.0009 m2

17

Vacuum pressure =11111.1 N/m2 = 83.3 mm of Hg =80 mm of Hg

Factor of safety taken as 5

Required vacuum pressure = 400 mm of Hg

CHAPTER 7 DESIGN OF VENTURI BLOCK AND VACUUM TABLE 7.1 Venturi Block Design :(using Bernoullis theorem )

AVAILABLE DATA:

Discharge Q=30 CFM =.0149m3/s Pressure P1 =80 psi =551428.6 N/m2 Pressure P1 =-400mm of hg =-53328.9N/m2 Diameter D1= 9mm =.009m

Calculation:

18

V1 =

4Q

D1

= 234 .8 m/s

p1 V1 p V p + + gz1 = 2 + 2 + gz 2 + 12 2 2

p12 = 0

gz 1 = gz 2

V2= 1124.5 m/s

V2 =

4Q

D2

D2=.004 m

Q=

D 1 2 D 1

D2 4

2( p1 p 2 )

VACUUM FORCE =VACUUM PRESSURE *AREA

=400 mm of hg *

AREA BASED ON JOB

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7.2 Design Of Vacuum table VACUUM TABLE HEIGHT= 300 mm VACUUM TABLE WIDTH = 300 mm VACUUM TABLE DEPTH = 70 mm HOLE DIAMETER = 10 mm GAP BETWEEN TWO HOLES (Pitch) = 15mm GAP BETWEEN HOLES & EDGES(x axis) = 25 mm GAP BETWEEN HOLES & EDGES(y axis) = 22.5 mm NO. OF HOLES = 288 WALL THICKNESS = 16mm TOP & BOTTOM PLATE THIK = 10 mm

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Figure 7.1 Vacuum table rough diagram

Table 7.1 Selection Of Hole Diameter And Number Of Holes Piece S.N Hole dimentions . dia X Y 1 2 3 4 5 6 7 30 30 30 30 30 30 30 30 30 30 30 30 30 30 10 10 5 5 4 4 2.5 Gap 5 2.5 5 2.5 2.5 2 2.5 No. of holes Xh Yh 2.0 2.4 3.0 4.0 4.6 5.0 6.0 2.0 2.4 3.0 4.0 4.6 5.0 6.0 Total Total Total no. of Radius Area area(mm Forc area(m2) 2 holes ) e (N) 0.00031 4.0 5.0 78.5 314.0 4 15.9 0.00045 5.8 5.0 78.5 452.2 2 22.9 0.00017 9.0 2.5 19.6 176.6 7 8.9 0.00031 16.0 2.5 19.6 314.0 4 15.9 0.00026 21.3 2.0 12.6 267.6 8 13.6 0.00031 25.0 2.0 12.6 314.0 4 15.9 0.00017 36.0 1.3 4.9 176.6 7 8.9

21

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30

30 30 30 30 30 40 40 40 40 40 40 40 40 40 40 40 40

2.5 2 2 2 1.5 10 10 5 5 4 4 2.5 2.5 2 2 2 1.5

2 2 1.5 1 1 5 2.5 5 2.5 2.5 2 2.5 2 2 1.5 1 1

6.7 7.5 8.6

6.7 7.5 8.6

44.4 56.3 73.5

1.3 1.0 1.0 1.0 0.8 5.0 5.0 2.5 2.5 2.0 2.0 1.3 1.3 1.0 1.0 1.0 0.8

4.9 3.1 3.1 3.1 1.8 78.5 78.5 19.6 19.6 12.6 12.6 4.9 4.9 3.1 3.1 3.1 1.8

218.1 176.6 230.7 314.0 254.3 418.7 602.9 235.5 418.7 356.7 418.7 235.5 290.7 235.5 307.6 418.7 339.1

10.0 10.0 100.0 12.0 12.0 144.0 2.0 2.4 3.0 4.0 4.6 5.0 6.0 6.7 7.5 8.6 2.7 3.2 4.0 5.3 6.2 6.7 8.0 8.9 10.0 11.4 5.3 7.7 12.0 21.3 28.4 33.3 48.0 59.3 75.0 98.0

10.0 13.3 133.3 12.0 16.0 192.0

0.00021 8 0.00017 7 0.00023 1 0.00031 4 0.00025 4 0.00041 9 0.00060 3 0.00023 6 0.00041 9 0.00035 7 0.00041 9 0.00023 6 0.00029 1 0.00023 6 0.00030 8 0.00041 9 0.00033 9

11.0 8.9 11.7 15.9 12.9 21.2 30.5 11.9 21.2 18.1 21.2 11.9 14.7 11.9 15.6 21.2 17.2

From above tabular column, based on forces 10 mm hole diameter and 5 mm gap between the holes selected. Number of holes in 300 mm x 300 mm area is 288. Force generated in 300 mm x 300 mm area with 10 mm dia hole and 5 mm gap is 1145.4 N

22

CHAPTER 8 MATERIALS REQUIRED Table 8.1 Materials And Their Cost For Vacuum Work Holder Unit

EQUIPMENT REQUIRED FOR VACUUM TABLE UNIT ITEM SI.NO MATERIA DESCRIPTIO MAKE/SUPPLIER . L N VACUUM 1 SELF MS TABLE VENTURI 2 VACUUM SELF MS GENERATOR RECIEVER 3 SELF MS TANK 1/2" BALL 4 AUDCO INDIA LTD MS VALVE ABDULKADAR & NYLON 5 1/2" HOSE SONS INFORCED 6 7 8 9 10 11 1/2" CLAMP 1/2" NIPPLE 1/2" STRAINER 1/2" REGULATOR VACUUM PRESSURE GAUGE 1/2" NRV NA NA VITA VITA MS MS MS NA NA VITA MS UNI UNIT QT TATAL T PRICE Y COST NO 4100 NO 850 1 1 1 3 2 4 10 1 1 2 1 4100 850 1650 2664 73 56 145 1420 880 1100 1430

NO 1650 NOS 888 MTR 36.5 NOS 14

NOS 14.5 NO 1420 NO NO 880 550

NO 1430

GRAND TOTAL 14368

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Table 8.2

Fabricated Materials And Their Cost For Vacuum Work Holder Unit

FABRICATION ITEM LIST ITEM WELDIN MATERIA MACHINE SI.NO. DESCRIPTIO G & GAS QTY L COST COST N CUTTING VACUUM 1 1500 600 2000 1 TABLE VENTURI 2 200 0 500 1 BLOCK 3 4 NOZZLE CONDENSATE TANK 50 650 0 750 100 250 TOTAL 1 1

TATAL COST 4100.00 700.00 150.00 1650.00 6600.00

24

CHAPTER 9 INDIVIUAL MODEL DIAGRAM Figure 9.1 Vacuum Table Top Cover

25

Figure 9.2 Vacuum Table Bottom Piece

26

CHAPTER 10 ASSEMBLED DIAGRAM

Figure 10.1 Vacuum Table

27

Figure 10.2 Venturiblock And Nozzle

28

CHAPTER 11

PRODUCTION DIAGRAM Figure 11.1 Vacuum Table Top Cover

29

Figure 11.2 Vacuum Table Bottom Piece

30

Figure 11.3 Venturi Nozzle

31

Figure 11.4 Venturi Block

32

CHAPTER 12

RESULT AND DISCUSSION Manufactured vacuum work holder fixed on the milling machine table. All accessories connected to the work holder. Pressure of input air to the vacuum generator set at 80 psi with help of air regulator. Vacuum generator produces vacuum pressure from input air pressure. This vacuum pressure stored in vacuum receiver. Vacuum pressure generated in the receiver tank checked set at 400 mm of Hg by adjusting vacuum pressure if required. Initially vacuum valves of vacuum work holder kept closed. Placed the job on the vacuum table and position it correctly. Then open the vacuum valves. Job size is 250 x 200 x10 mm. Balance area is covered with rubber sheet. Start the machine for machining the job by keeping cutting speed at 500 rpm, feed rate at 250 mm/min and depth of cut is 1mm per pass. Job thickness required is 7mm. Machining completed successfully and final plate size is 250mm x 200mm x 7mm.

33

CHAPTER 13 CONCLUTION Trial carried out with vacuum work holder by fixing it on milling machine table and came to following conclusions. Job holding and positioning time become very less. (i.e. 3 to 5 sec) By using vacuum work holder we clamp the 10mm plate very easily. But it is difficult hold this plate with mechanical fixture. Surface of plate (10 mm thickness) fully

machined up to 3mm thickness depth without disturbing the initial set up of plate. But it is not possible with mechanical fixture. Ceramic material job held with vacuum holder

as a trial and found ceramic piece held perfectly. It is not possible with magnetic fixture and ceramic piece may got damage if we held it with mechanical fixture.

34

CHAPTER 14

RECOMMENDATIONS OF FUTURE WORK

Auto vacuum pressure controller unit to control pressure if pressure drops Computerized fluid dynamics analysis to increase performance of vacuum work holder Refine the vacuum table for more applications

35

CHAPTER 15 REFERENCES Prof. Dr.Omer Anlagan, Mechanics of metal cutting, 2005 Haci Saglam, Suleyman Yaldiz *, Faruk Unsacar, The effect of tool geometry and cutting speed on main cutting force and tool tip temperature S_eref Aykut a, Eyup Bagci b,*, Aykut Kentli c, Osman Yazcoglu a Experimental observation of tool wear, cutting forces and chip morphology in face milling of cobalt based super-alloy with physical vapour deposition coated and uncoated tool

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