Faculty of Mechanical Engineering

SMR 4712 TOOLING FOR PRODUCTION

GROUP ASSIGNMENT: FIXTURE 2011/2012-SEM 1

LECTURER PM ZAINAL ABBIDIN

SECTION 02

NO. 1. 2.

GROUP MEMBERS EDWIN LEONG FUH ZHENG JAZIZ AMIRUDDIN B. JAMALUDDIN

MATRIX NO AM080173 BM083002

TABLE OF CONTENTS

CHAPTER 1 INTRODUCTION 1.1 Project Title

TITLE

PAGE 1 1 2 2

1.2 Introduction to Tool Design 1.3 Tool Design Objectives

TOOL DESIGN 2.1 Tool Design Process 2.1.1 Definisg Requirements 2.1.2 Gathering and Analyzing Information 2.1.3 Developing Several Options 2.1.4 Choosing the Best Options 2.1.5 Implementing the Design 2.2 Guidelines for Economical Design

3 3 4 4 5 6 6 6

JIG AND FIXTURE 3.1 Introduction 3.2 Elements of Jigs and Fixtures 3.3 Advantages of Jigs and Fixtures 3.4 Fixture

7 7 7 8 9

MACHINING 4.1 Introduction 4.2 Milling 4.2.1 Horizontal Milling Machine 4.2.2 Vertical Milling Machine

10 10 10 11 12

SUPPORT AND LOCATOR 5.1 Type of Support 5.1.1 Adjustable Support 5.1.2 Solid Support 5.2 Type of Locator 5.2.1 Pin-Type Locator 5.2.2 Diamond or Relieved Locator

14 14 14 15 15 15 17

MODULAR FIXTURING AND CLAMP 6.1 Modular Fixture 6.2 Tooling Plate and Blocks 6.2.1 Grid Address System 6.3 Clamp 6.3.1 Toogle Clamps

18 18 19 19 20 20

OPERATION 7.1 Operation Description 7.2 Tool 7.3 Production Plan 7.4 Part Drawing 7.5 Fixture 1 7.6 Fixture 2

21 21 22 22 24 26 36

CONCLUSION

47

Appendices

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CHAPTER 1

INTRODUCTION

1.1

Project Title

Design a modular fixture(s) to machine the six faces indicated by the arrows.

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1.2 Introduction to Tool Design

Tool design is the process of designing and developing the tools, methods, and techniques necessary to improve manufacturing productivityandefficiency. It plays an important role in manufacturing industry by providing the right machine and special tooling needed for todays fast paced and high-volume production.

Moreover, it does this at the lowest cost as possible but still maintains its top level of quality. Tool design is an engineering art because it involves a process of creative and also technical problem solving skills due to the fact that almost every product needs different kind of tool and process to be manufactured.

Tool design is also an integral part of the product-planning process, interacting with product design, manufacturing, and marketing to ensure that the product produced will satisfy customers requirements.

1.3 Tool Design Objectives

The main objective of tool design is to lower manufacturing costs while maintaining top quality and increase the rate of production.

The following objectives need to be satisfied:

i. Provide simple, easy-to-operate tools for maximum efficiency. ii. Reduce manufacturing expenses by producing parts at the lowest possible cost. iii. Design tools that consistently produce parts of high quality. iv. Increase the rate of production with existing machine tools. v. Design the tool to make it foolproof and to prevent improper use. vi. Select the materials that will give adequate tool life. vii. Provide protection in the design of the tools for maximum safety for operators

CHAPTER 2

TOOL DESIGN

2.1 Tool-Design Process

The core of tool design is actually a problem solving process and can be divided into five steps as shown below.

Defining Requirements

Gathering and Analyzing Information

Developing Several Options

Choosing the Best Options

Implementing the Design

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2.1.1 Defining Requirements

The design problem to be solved and the specification needed must be stated clearly in this step. Therequirements should be stated as broad as possible but to the extent that specifically enough to define the scope of the design project. A new type of tooling might be required for first-time production of a new product, or to improve the production of an existing part. Tooling can be designed either for only one part or the whole product.

2.1.2 Gathering and Analyzing Information

The data will be collected and assembled for further evaluation. When collecting the information, ensure that the part documents and records such as part print, process sheets, and machine specifications are current or the latest. The most important part of this step is notetaking because it allows the tool designer to keep a record of important data for future references. By doing so, the loss of brilliant ideas or thoughts will be prevented

Four aspects to be taken into considerations: i. Workpiece Consideration The most important factor. Create the largest impact on the work-holders final design. Considerations include: ii. Part size and shape. Required accuracy. Part material properties. Locating and clamping surfaces. Number of pieces.

Manufacturing Operations Consideration Considerations include: Type of operations required. Number of operation performed. Sequence of operations. Inspection requirements.

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iii. Time restrictions.

Equipment Consideration Controls the type of equipment needed for machining, assembly, and inspection operations. Determines whether the work-holder is designed for single or multiple parts. Typically, equipment criteria include factors such as: Types and sizes of machine tools. Inspection equipment. Scheduling. Cutting tools. General plant facilities.

iv.

Personnel Consideration Deal with the end user or operator. The first and most important consideration in this phase is safety. Therefore, all tools must be designed with complete safety to protect to operator. Operator fatigue, efficiency, economy of motion, and operation speed should be considered too. Designer must understand well the general aspects of design safety and all appropriate government and company safety rules and codes.

2.1.3

Developing Several Options

Imagination and creativity is crucial in this step since a workpiece can be located and clamped in different ways therefore a brainstorming session should be conducted to devise a strategy for developing a successful tool design.

Several good tooling alternatives should be brainstormed. Besides, more options should be added during this phase to ensure that they are feasible.

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2.1.4 Choosing the Best Options

This step is a cost or benefit analysis of different tooling options such as tooling durability, operator comfort and safety, and etc.

2.1.5

Implementing the Design

This phase consists of turning the chose design approach into reality. Final details will be decided, detailed drawings will be made, and the tooling will be built and tested.

2.2 Guidelines for Economical Design

i. ii. iii. iv. v. vi. vii.

Simplify tooling operations. Use standard tooling components. Use prefinished materials. Eliminate unneeded finishing operations. Keep tolerances as liberal as possible. Keep the function and operation of a work-holder as simple as possible. Reduce the design complexity and thus reduce the misunderstandings between the designer and machine operator.

CHAPTER 3

JIG AND FIXTURE

3.1 Introduction

Jigs and fixtures are production-workholding devices used to manufacture duplicate parts accurately. The correct relationship and alignment between the cutter, or other tool, and the workpiece must be maintained. In order to do so, a jig or fixture is designed and built to support, hold, and locate every part to ensure that each is drilled according to its specifications. Both terms are frequently used incorrectly in shops. A jig is a guiding device and a fixture a holding device.

Jigs and fixtures are used to locate and hold the work that is to be machined. These devices are provided with attachments for guiding, setting, and supporting the tools in such a way that all the workpieces produced in a given jig or fixture will be exactly identical in every way. The employment of unskilled labor is possible when jigs and fixtures can be used in production work. A jig or fixture can be designed for a particular job. The form to be used depends on the requirement and shape of the workpiece to be machined.

3.2 Elements of Jigs and Fixtures

Basically, all the jigs and fixtures were made of:i. Clamping Elements To hold the workpiece securely in the located position during operations. ii. Locating Elements To position the workpiece accurately with respect to the tool guiding or setting elements.

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iii. Tool Guiding and Setting Elements To aid the setting or guiding of the tools in the correct position with respect to the workpiece

3.3 Advantages of Jigs and Fixtures

i.

Cost Reduction Reduction in scrap, higher production rate, easy assembly and savings in labor costs result in substantial reduction in the cost of workpieces produced with jigs and fixtures. All of these combines and decrease the expenditure on the quality controls of the machine parts.

ii.

Productivity The use of jigs and fixtures eliminate individual marking, positioning, and frequent checking. This can reduce operation time and increase productivity. Two or more workpieces can be machined simultaneously. Besides, jigs and fixtures enable complex parts to be machined by being held rigidly to the machine.

iii.

Interchangeability Jigs and fixtures facilitate uniform quality in manufacturing. There is no need of selective assembly. Any parts of the machine fit properly in assembly and all similar components are interchangeable. Marking out and setting before machining can be eliminated.

iv.

Skill Reduction Jigs and fixtures simplify locating and clamping of the workpieces. Tool guiding elements ensure correct positioning of the tools with respect to the workpieces, the make the use of lower skilled labor possible.

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3.4 Fixture

Fixture is a production tool that locates, holds, and supports the work securely so that the required machining can be performed effectively. What makes a fixture unique is that each one is built to fit a particular part or shape. Set blocks and feeler or thickness gauges are used with fixtures to reference the cutter to the workpiece. A fixture anchors the workpiece firmly in place for the machining operation, but it does not form a guide for the tool.

A fixture supposed to be securely fastened to the table of the machine where the work is being done. Fixtures design vary significantly from its purpose and cost such as simple, expensive and also complicated devices. Moreover, fixtures also make metalworking operations performed on special equipment to be much more simple.

Fixtures are usually classified by the type of machine on which they are used. It can also be identified by a sub classification. As an example, a fixture which is designed to be used on a milling machine will be called a milling fixture.

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CHAPTER 4

MACHINING

4.1 Introduction

Machining processes are often necessary in order to impart the desired dimensional accuracy geometric features, and surface finish characteristics to components, especially those with complex shapes that cannot be produced economically or with other shaping techniques. On the other hand, these processes generally takes time, waste some material in the form of chips, and may have adverse effects on surfaces produced. Material is very expensive for high volume production. However, machining has very low set-up cost compared to forming, molding and casting processes.

4.2 Milling

Milling is the process of cutting away material by feeding a workpiece past a rotating multiple tooth cutter. The cutting action of the many teeth around the milling cutter provides a fast method of machining. There are several type of machined surface like angular, flat, or curved and many other shape combinations. A milling machine is a machine tool used to machine solid materials. Milling machines are often classed in two basic forms, horizontal and vertical, which refers to the orientation of the main spindle. Both types range in size from small, bench-mounted devices to room-sized machines

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4.2.1 Horizontal Milling Machine

A horizontal mill has the same sort of xy table, but the cutters are mounted on a horizontal arbor across the table. Many horizontal mills also feature a built-in rotary table that allows milling at various angles; this feature is called a universal table. Horizontal milling machine normally used when a lot of material has to be removed by the cutters or there is less of need for accuracy for the shape material.

Picture of Horizontal Milling Machine

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4.2.2 Vertical Milling Machine

This milling machine produce machined surfaces by progressively removing material from a work piece uses a rotating milling cutter. In the vertical mill the spindle axis is vertically oriented. Milling cutters are held in the spindle and rotate on its axis. The spindle can generally be extended (or the table can be raised/lowered, giving the same effect), allowing plunge cuts and drilling. There are two subcategories of vertical mills: the bed mill and the turret mill. This milling machine can also act like a drill press because the spindle is perpendicular to the table and be adjust to the workpiece.

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Diffrence between horizontal and vertical milling

Other Types of Milling

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CHAPTER 5

SUPPORT AND LOCATER

5.1 Types of support

5.1.1 Adjustable Support

Adjustable Support is used when the surface is rough or uneven. Normally used with one or more solid locator to allow any adjustment needed to level the work.

Screw rest button

Gripper Swivel Contact Bolts

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5.1.2 Solid Support

Solid support is the simplest type of support to use on tool base. This type of support can be machined or installed into the tool base. It is used when a machined surface acts as a locating point.

Rest Button

5.2 Types of Locator

5.2.1 Pin-type

Pin-type locator is a precision locating pins with a tapered tip for easy part loading, and a shoulder to resist downward forces. Diamond pins are relieved, to locate only in 1 axis. Round Pins are also useful as side locators.

Pin Type Locator

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Positioning of the locator

A series of locating pins can take the place of a locating plug. The pins are positioned at three points, 120 degrees apart, around the internal diameter of the hole. This arrangement is usually much more economical than making a custom plug.

Foolproofing.

Foolproofing is a method to ensure that the part will fit or match into the tool only in its correct position. The simplest way to foolproof a workholder is to position one or two pins in a location that ensures correct orientation.

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5.2.2 Diamond or Relieved Locator

Another style of pin is the diamond or relieved pin, which is usually used along with ther round pin to reduce the time it takes to load and unload the tool. It is easier to locate a part on one round pin and one diamond pin than to locate it on two round pins.

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CHAPTER 6

MODULAR FIXTURE AND CLAMP

6.1 Modular Fixture

Modular fixture is a permanent fixture, except for a few key differences. First, modular fixtures can be assembled entirely from reusable off-the-shelf components, without machining. Next, many modular components are adjustable and universal. Finally, specially designed tooling plates and blocks, with a standard grid pattern, are the foundation of a good modular system.

By using modular fixture, a workholder can be economically built even for a one-part run. Jobs that do not repeat on a regular basis are well suited to modular fixturing; modular fixturing permits rapid setup of short-notice production runs.

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6.2 Tooling Plate and Blocks

Tooling plates and blocks are the main structural elements of any modular-fixturing system. The type, style, and number of plates and blocks available determine the variety of fixtures that can be built, and also the number of machine tools that can be used.

Tooling plates and blocks

6.1.1 Grid Address System

The grid pattern of multipurpose holes on every tooling plate and tooling block face is labelled with letters in one direction and numbers in the perpendicular direction. Toolingblock faces are numbered (counter-clockwise) with Roman numerals. This allows recording the mounting-hole location of each component (e.g., A2, B3, D7, etc.) as part of permanent documentation. Multipurpose holes are spaced within .0008 inches of true position on all

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tooling plates and blocks. The mini system is even more accurate, with all holes spaced within .0004 inches. 6.3 Clamp

The function of a clamp is to hold a part against the locators during the machining cycle. To be effective and efficient, clamps must be planned into the tool design. Clamp should always contact the work at its most rigid point. This prevents the clamping force from bending or damaging the part. In modular clamps, toggle clamps are widely used.

6.3.1 Toggle Clamps

A toggle clamp is a quick-acting mechanical linkage where two of the elements make up a toggle action. Actuating the clamp first moves it into position, then applies clamping force by compressing or stretching the linkage elements after contacting the workpiece, then positively locks it by moving the toggle actions center pivot past the centreline of the other two pivots, against a stop.

Horizontal-Handle Hold-Down Clamps .... Vertical-Handle Hold-Down Clamps

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CHAPTER 7

OPERATION

7.1 Operation Description

A vibrator arm which is shown in chapter 1 is already machined to the desired shape. The process that we will carry on is the finishing process using a CNC milling machine of the six surfaces that is indicated. In order to maintain the accuracy of the product, two milling modular fixtures have been design to carry out the finishing milling processes. Standard parts were chosen from the Carrlane catalog and a few parts were customized to suit the processes. Both fixtures are design to hold the part and to restrict the movement of the part so that it could be mill to get it required specification. The following operation will be performed using the designed fixtures.

Milling Operation 1 using Fixture 1 i. ii. iii. Milling of surface 1.56 x 1.62 Milling of surface 3.37 x 1.94 Milling of surface 4.93 x 1.94;

Milling Operation 2 using Fixture 2 i. ii. iii. Milling of surface 1.62 x 1,50 Milling of surface 1.447 x 1.50 Milling of surface 2.24 x 1.25

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Fixture 1 locates the part by using a round pin and a diamond pin. This reduces the time it takes to load and unload the tool Also, the diamond pin work as a relieved locator. Relieved locators reduce the area of contact between the vibrator arm and the locator. By locating the work piece by using two internal holes, eleven direction of movement have been restricted. Finally, the last direction is restricted by a strap clamp.

Fixture 2 locates the part by using a round pin and a few supports. By locating the work piece using an internal hole, nine direction of movement have been restricted. Another two solid support that is place horizontally relative to the work piece further restrict two direction of movement. Finally a toggle clamp is use to restrict the last direction.

7.2 Tool

The milling cutting tool is selected from ITS catalog. We choose one of the finishing end mills cutters with the following specification:

Code No Cutter Diameter No of Flute Total Length Flute Length

S314DU 20 mm 4 110 mm 45 mm

7.3 Production Plan

Below shows a production plan for the operations

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PRODUCTION PLAN PART NO PART NAME QUANTITY 2735 7500 Vibrator Arm DRW NO PROCESS PLANNAR REV DATE 2735 Edwin A 21-Nov-11 OPR NO DESCRIPTION DEPT. 1 Mill Face 1.56' x 1.62' Mill Face 3.37' x 1.94' Mill Face 4.93' x 1.94' Mill Face 1.62' x 1.50' Mill Face 1.447' x 1.50' Mill Face 2.24' x 1.25' ITS Finishing End Mill #7 Finishing #7 Finishing #7 Finishing #7 Finishing #7 Finishing #7 Finishing 20 mm

ORDER NO PAGE 1 OF 1 MACH TOOL Horiz. Mill TSU-03 Horiz. Mill TSU-03 Horiz. Mill TSU-03 Horiz. Mill TSU-03 Horiz. Mill TSU-03 Horiz. Mill TSU-03 Modular Fixture #002 Modular Fixture #002 Modular Fixture #002 Modular Fixture #001 Modular Fixture #001 Modular Fixture #001 SPECIAL TOOL NO

ITS Finishing End Mill

20 mm

ITS Finishing End Mill

20 mm

ITS Finishing End Mill

20 mm

ITS Finishing End Mill

20 mm

1 OPR NO

ITS Finishing End Mill TOOL DESCRIPTION

20 mm SIZE

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7.4 PART DRAWING

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7.5 FIXTURE 1

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7.6 FIXTURE 2

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CHAPTER 8

CONCLUSION

As a future engineer majoring in manufacturing, we should be able to design a simple and yet effective tool that simplified the work of operator. A tool that is functioning well will lower the cost while maintaining the quality of the product. Other than that, it should be able to increase the production rate.

Other than that, certain basic knowledge such as machine tool and cutter for different operation should be familiarize so that we are prepare to put these knowledge into practice during out future career,

Last but not the least; we succeed in designing two modular fixtures that could function properly. We apply all the basic principles that we learn into this project. This helps us to understand more and would be a good experience in designing jig and fixture if we are to become a tool engineer in our future career

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Appendices.

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Standard Parts Used in Fixture 1 No 1 2 3 4 5 6 7 8 9 10 Part Name Rectangular Tooling Plate 0.625 Round Locating Pin 0.5 Diamond Locating Pin Socket Head Cap Screw Clamp Rest Screw Clamping Studs Jam Nut Clamping Spring Flat Washer Spherical Nut & Washer Part Number CL-MF25-0151 CL-624-RLT CL-4990-DLT CL-1/2-13X1.50-SHCS CL-6-CRS CL-1/2-13X4.5-STUD-S CL-8-JN CL-9-SPG CL-2-FW CL-3-SNW Quantity 1 1 1 2 1 1 2 1 1 1 SET

1. Rectangular Tooling Plate : CL-MF25-0151

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2. 0.625 Round Locating Pin: CL-624-RLT 3. 0.5 Diamond Locating Pin: CL-4990-DLT

4. Socket Head Cap Screw: CL-1/2-13x1.50-SHCS

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5. Clamp Rest Screw: CL-6-CRS

6. Clamping Studs: CL-1/2-13x4.5-STUD-S

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7. Jam Nut: CL-8-JN

8. Clamp Spring: CL-9-SPG

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9. Flat Washer: CL-2-FW

10. Spherical Nut & Washer: CL-3-SNW

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Standard Parts Used in Fixture 2 No 1 2 3 4 5 6 7 8 9 10 11 12 Part Name Rectangular Tooling Plate 0.625 Round Locating Pin Rest Button Socket Head Cap Screw 1.38 Socket Head Cap Screw 1.12 Socket Head Cap Screw 0.62 Halfway Extension Support Locating Bush Toogle Clamp Adapter Toogle Clamp Jam Nut Hex Head Spindles Part number CL-MF25-0151 CL-624-RLT CL-12-RB CL-5/16-18x1.38-SHCS CL-5/16-18x1.12-SHCS CL-1/4-20x.62-SHCS CL-MF25-3605 CL-MF25-4300 CL-MF25-5401 CL-450-VTC-S CL-3-FJN-S CL-516212-SA-S Quantity 1 1 4 2 1 4 1 2 1 1 2 1

1. Rectangular Tooling Plate: CL-MF25-0151

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2. 0.625 Round Locating Pin: CL-624-RLT

3. Rest Button: CL-12-RB

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4. Socket Head Cap Screw 1.38: CL-5/16-18x1.38-SHCS 5. Socket Head Cap Screw 1.12: CL-5/16-18x1.12-SHCS 6. Socket Head Cap Screw 0.62: CL-1/4-20x.62-SHCS

7. Halfway Extension Supports: CL-MF25-3605

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8. Locating Bush: CL-MF25-4300

9. Toogle Clamp Adapter: CL-MF25-5401

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10. Toogle Clamp: CL-450-VTC-S

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11. Jam Nut: CL-3-FJN-S

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12. Hex Head Spindles: CL-516212-SA-S

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Milling Cutter: Dc = 20 mm