FABRICATION OF WELDING

FIXTURE FOR EXHAUST

MANIFOLD
TRICHY ENGINEERING COLLEGE
PROJECT GUIDE:

Mr. P.ASHOK KUMAR, ME, Ph.D.,

(HOD MECHANICAL)

PROJECT MEMBERS:

S.MANIVEL (814612114052)
V.MARTIN ANTONY RAJ (814612114053)
R.MOSES ANTHONY RAJ (814612114058)
S.MUTHU (814612114059)
 ABSTRACT

In welding process fixture used to hold the

component is complicated one. Normally chuck
type fixture is used for welding purpose and is an
oldest method.

Fixture is not in proper we obtain poor

weldablity. Because, inadequate fixture design.
So, we can improve weldablity, by using suitable
welding fixture.
 We must use welding fixture to avoid
dislocation, miss alignment, welding defects like
crack, porosity, undercut, fatigue of weld.

To overcome the problem while holding

complicated job we design the suitable fixture for
exhaust manifold welding.

By using the fixture we can increase the

productivity. In this fixture mainly used for mass
production.
 FIXTURES

More of a permanent tool that is used for assembly

purposes.

Typically does not have as much flexibility as a jig.

Most likely used for high volume production.

Made of durable materials such as tool steel, iron,

aluminum alloys, etc.
 WELDING FIXTURES PURPOSE

1.To minimize distortion caused by heat of

welding

2.To permit welding in more convenient

position

3.To increase welding efficiency and

productivity.

4.Minimise fitting up problem.

 MATERIALS USED

1. SA105 carbon steel

2. High speed steel
3. Collet steel
4. Mild steel
5. Cast iron
6. High tensile steel
 TYPES OF FIXTURE

1. Plate fixture
2. Vise jaw fixture
3. Indexing fixture
4. Multi station fixture
5. Duplex fixture
 COMPONENTS OF FIXTURE

Locators:
A locator is usually a fixed component of a fixture.
It is used to establish and maintain the position of a part
in the fixture by constraining the movement of the part.

Clamps:
A clamp is a force actuating mechanism of a
fixture. The forces exerted by the clamps hold a part
securely in the fixture against all other external forces.
Fixture Body:
Fixture body, or tool body, is the major structural
element of a Fixture. It maintains the relationship
between the fixture elements namely, Locator, clamps,
supports, and the machine tool on which the part is to
be processed.

Supports:
A support is a fixed or adjustable element of a
fixture. When severe part displacement is expected
under the action of imposed clamping and processing.
 METHODOLOGY

Study the Process

Data Collection
Fixture Design
Fabrication
Inspection and Proofing
Result & Conclusion
LINE DIAGRAM
 WORKING

This fixture contains five columns as well as

locators. The column supports the total exhaust
manifold.
The strap clamp contains bolt which is used to
tighten the work piece as exhaust manifold. The
base plate contains large drills with threading.
If the exhaust manifold is small, the columns are
place closed to the manifold. We can rotate the
fixture 45 to 120 degree.
PHOTOGRAPHY
 CALCULATIONS
1.Stress in the clamp
By hooks law
= load / area
Area =l*b
Length = 35mm
Breath = 15mm
Area = 525mm
Force = 100.20N
= 100 / 525
Stress () = 0.019 N/mm
2.Strain in the clamp
Strain = stress / youngs modulus
Youngs modulus for steel = 2.1* 105 N/mm2
= 0.019 / 2.1* 105
Strain = 9*10-8
FACTOR OF SAFETY:
FOS = Yield stress / Allowable stress
From PSGDDB Page no. 7.77
FOS = 4
4 = 250 / Allowable stress
Allowable stress = 62.4MPA
CALCULATION FOR LOCATING PIN
Diameter of the pin = 8mm
Length of the pin = 50
Moment of inertia I = / 64 (D4)
= / 64 * (84)

Moment of inertia I = 201 mm4

Bending moment = force * length
= 100 * 50
= 5000 N-mm
Bending stress b = Mb / I * (C)
From PSGDDB page no. 5.98
= 5000 / 201 * 12
Bending stress b = 298.50 N/mm2
 TEST REPORT
Welding without fixture (A)
Welding with fixture (B)
TEST RESULT
 ADVANTAGES

This fixture will increase the weldablity.

It can be used to mass production.
Reduce the worker cost.
It will reduce the holding time.
It can be used to both manual and automatic
welding process.
 APPLICATIONS

It is widely used in automobile industries.

It is also used in multi cylinder engine

vehicles like car, bus etc.

 CONCLUSION

In current growing technologies we need to

rectify the problems while welding the irregular
shaped component.
So, we design this fixture to avoid poor
weldablity and other welding problems. We sure
this fixture will very useful to mass production
with minimized problems.
 REFERENCES

1. Donaldson, Tool design

2. Joshi, P.H., Jigs and fixture, second edition,.

3. Vijayaragavan , Design of Jigs and fixture

4. Design data book - P.S.G.Tech.

5. Machine tool design handbook Central machine tool

Institute, Bangalore.

6. Strength of Materials - R.S.Kurmi

 JOURNALS REFERED

1. A Review on Design of Fixture

International journal of engineering research and general science
volume 2, Feb-mar 2014.

2. Design of welding fixture and positioners

International journal of engineering research and general science
volume 2, Aug-sep 2014.

3. Design of Welding Fixture

INTERNATIONAL JOURNAL OF SCIENTIFIC & TECHNOLOGY
RESEARCH VOLUME 3, ISSUE 6, JUNE 2014
THANK YOU