![www.tjprc.org SCOPUS Indexed Journal editor@tjprc.org
FINITE ELEMENT ANALYSIS OF CENTER PIN AND
BRACKET OF JIG – FIXTURE ASSEMBLY
RAJWARDHAN KULTHE1
, VIRAJ MEKHE2
, MIHIR MORE3
SANGRAM NANDAWADEKAR4
& VIKAS DEULGAONKAR5
1,2,3,4
Department of Mechanical Engineering, Marathwada Mitra Mandal’s,
College of Engineering, Pune, Maharashtra, India
5
Dean & Associate Professor, Department of Mechanical Engineering,
Marathwada Mitra Mandal’s, College of Engineering, Pune, Maharashtra, India
ABSTRACT
The manufacturing industry caters the range of products to satisfy the ever changing market needs.
To overcome the increasing production demands, the industry implies various techniques. We need a technique for
increasing the production of drilling two holes on a Railway Pinion, improve the quality of product and reduce the
operation time. This project aims to design the Jig and Fixture for the same. The 3-dimensional Computer Aided Model
of the components is made using CATIA V5-R21 software. To study the behavior of component, simulation is carried out.
Preprocessing of the CAD model is carried in Hypermesh software. Boundary conditions are applied using physical
situations of the components. Finite element analysis of the components is done, and the results obtained are compared
with the theoretical analysis and also with the available literature. The stresses and deformations are found within desired
limits. Using FE analysis, the parts are manufactured and assembled.
KEYWORDS: Design, Drill Jig, Manufacturing, Stress, Deformation & Static Analysis
Received: May 10, 2019; Accepted: May 30, 2019; Published: Jul 06, 2019; Paper Id.: IJMPERDAUG201964
INTRODUCTION
For any manufacturing unit, productivity is of great concern to maintain the profitability and sustainability
of the unit. Various factors govern productivity of the manufacturing unit, which includes but not limited to skilled
man-power, quality of products, availability of machinery and raw material i.e. inventory, human factor, working
environment and many more. However, with the availability of modern machinery, the heart of production unit has
become the design of Jig and Fixtures. These are the sole components, which keep on changing the available
machinery as per product dimensions and shape. One such case is considered in present the work. The objective is
to minimize the cycle time and simplify the drilling operation for Radial drilling machine. This is done using
classical/theoretical approach. Present literature reveals the use of CAD/CAE and experimentation techniques to
validate the classical design.
Design and Analysis of indexing jig for drilling operation discussed by NBV Lakshmi Kumari and G.
Prasanna Kumar [II] mainly focuses on designing aindexing Jig and analysis backed up by manual calculations.
Finite element analysis and experimental simulation of Chassis Mounted Platform for off-road wheeled combat
and transport utility vehicles are discussed by Deulgaonkar V. R [III] while dealing with designing of the mounting
OriginalArticle
International Journal of Mechanical and Production
Engineering Research and Development (IJMPERD)
ISSN(P): 2249-6890; ISSN(E): 2249-8001
Vol. 9, Issue 4, Aug 2019, 643-648
© TJPRC Pvt. Ltd.](https://image.slidesharecdn.com/finiteelementanalysisofcenterpinandbracketofjig-fixtureassemblyijmperd2019-190906112156/85/Finite-element-analysis-of-center-pin-and-bracket-of-jig-fixture-assembly-ijmperd-2019-1-320.jpg)
Finite element analysis of center pin and bracket of jig fixture assembly ijmperd 2019
- 1. www.tjprc.org SCOPUS Indexed Journal [email protected] FINITE ELEMENT ANALYSIS OF CENTER PIN AND BRACKET OF JIG – FIXTURE ASSEMBLY RAJWARDHAN KULTHE1 , VIRAJ MEKHE2 , MIHIR MORE3 SANGRAM NANDAWADEKAR4 & VIKAS DEULGAONKAR5 1,2,3,4 Department of Mechanical Engineering, Marathwada Mitra Mandal’s, College of Engineering, Pune, Maharashtra, India 5 Dean & Associate Professor, Department of Mechanical Engineering, Marathwada Mitra Mandal’s, College of Engineering, Pune, Maharashtra, India ABSTRACT The manufacturing industry caters the range of products to satisfy the ever changing market needs. To overcome the increasing production demands, the industry implies various techniques. We need a technique for increasing the production of drilling two holes on a Railway Pinion, improve the quality of product and reduce the operation time. This project aims to design the Jig and Fixture for the same. The 3-dimensional Computer Aided Model of the components is made using CATIA V5-R21 software. To study the behavior of component, simulation is carried out. Preprocessing of the CAD model is carried in Hypermesh software. Boundary conditions are applied using physical situations of the components. Finite element analysis of the components is done, and the results obtained are compared with the theoretical analysis and also with the available literature. The stresses and deformations are found within desired limits. Using FE analysis, the parts are manufactured and assembled. KEYWORDS: Design, Drill Jig, Manufacturing, Stress, Deformation & Static Analysis Received: May 10, 2019; Accepted: May 30, 2019; Published: Jul 06, 2019; Paper Id.: IJMPERDAUG201964 INTRODUCTION For any manufacturing unit, productivity is of great concern to maintain the profitability and sustainability of the unit. Various factors govern productivity of the manufacturing unit, which includes but not limited to skilled man-power, quality of products, availability of machinery and raw material i.e. inventory, human factor, working environment and many more. However, with the availability of modern machinery, the heart of production unit has become the design of Jig and Fixtures. These are the sole components, which keep on changing the available machinery as per product dimensions and shape. One such case is considered in present the work. The objective is to minimize the cycle time and simplify the drilling operation for Radial drilling machine. This is done using classical/theoretical approach. Present literature reveals the use of CAD/CAE and experimentation techniques to validate the classical design. Design and Analysis of indexing jig for drilling operation discussed by NBV Lakshmi Kumari and G. Prasanna Kumar [II] mainly focuses on designing aindexing Jig and analysis backed up by manual calculations. Finite element analysis and experimental simulation of Chassis Mounted Platform for off-road wheeled combat and transport utility vehicles are discussed by Deulgaonkar V. R [III] while dealing with designing of the mounting OriginalArticle International Journal of Mechanical and Production Engineering Research and Development (IJMPERD) ISSN(P): 2249-6890; ISSN(E): 2249-8001 Vol. 9, Issue 4, Aug 2019, 643-648 © TJPRC Pvt. Ltd.
- 2. 644 Rajwardhan Kulthe, Viraj Mekhe, Mihir More, Sangram Nandawadekar & Vikas Deulgaonkar Impact Factor (JCC): 7.6197 SCOPUS Indexed Journal NAAS Rating: 3.11 platform along with its analysis for stress and deflection present in the said component. WORK-PIECE DESCRIPTION The work-piece considered under the project is the Pinion used in Indian Railways’ transmission system, which is press fitted in the tapered hole. After due time, the pinion needs to be taken out for timely maintenance. The Gun drills are used to pass pressurized fluid in the tapered section. This function allows the pinion to be easily removed from the system. Figure 1: Pinion Work-Piece Figure 2: Cross-Sectional View of Pinion The main motive of the project is to design, analyze and manufacture a ‘Jig and Fixture’ for drilling two holes on the circumference for proper flow of lubricant in the gear. CAD MODELING In present work, considering the length to diameter ratios for circular components and length to respective dimension ratio for non-circular components, solid modeling technique is used. To avoid complexity during finite element analysis, the computer aided model is prepared using extrude, pocket, pad, hole and chamfer commands. For Computer aided design of the components, use of CATIA V5-R21 is done. The computer aided models are shown in figure. Figure 3: Bracket Figure 4: Center Pin All the components designed for the Jig-Fixture assembly is done, keeping in mind the space constraints. Numerous permutations of dimensions were carried out and finalized on the basis of force analysis, cost and dimensional constraints. Figure 5: Final Design
- 3. Finite Element Analysis of Center Pin and Bracket of Jig – Fixture Assembly 645 www.tjprc.org SCOPUS Indexed Journal [email protected] FINITE ELEMENT ANALYSIS Material Selection Jig and fixtures are made from a variety of the materials. After studying properties, availability and cost of materials, we have come to the conclusion that MS is the most suitable material for jig and fixture. MS is selected because, it shows good resilience against deformation, and also it is more economical and easily available when compared to other materials like Cast Iron and Carbon Steel. MS can be easily hardened with methods like carburizing, case hardening, Shot peening etc. Properties of MS are given below in the table. Table 1: Mechanical Properties of Mild Steel Sr. No Property Value 1. Ultimate Tensile strength 440 MPa 2. Yield strength 370 MPa 3. Modulus of Elasticity 210 GPa 4. Density 7860 kg/m3 5. Poisson’s Ratio 0.290 6. Hardness 131 BHN Meshing And Mesh Quality Check Very first step in Analysis is meshing, which means discretization. The component is divided into finite number of small elements. This helps in converting the problem with infinite DOF’s into finite DOF’s. With the use of Hypermesh 13.0, meshing operation is done on Bracket and Center Pin. Dimensions of the model i.e. length(515mm), breadth(250mm) and height(200mm) are compatible, also the stresses are induced in all the 3 dimensions. Hence, 3-Dimensional solid meshing is done and parabolic tetra elements are used. Firstly, 2-Dimensional meshing is performed on the surface and then they are converted into 3-Dimensional tetra elements. Primary mesh size is assumed as the smallest dimension of the object, and iterations were conducted with changing primary mesh size. Mesh size is selected with the help of Convergence criteria. The values of stresses, displacement and time taken for solving with different mesh sizes has been tabulated, and the optimum mesh size of 2 mm is selected having less deviation in stress & deformation values than other mesh size’s results, along with optimum solving time. Table 2: Mesh Size and Quality Criteria Comparison Mesh Size (mm) Number of Elements Number of Nodes Warpage Aspect Ratio Skewness Jacobian 0.4 1532201 1943310 0.010 1.57 11 0.982 1 308742 386459 0.012 1.83 14 0.953 2 63121 77899 0.037 2.08 17 0.925 3 23583 28665 0.504 4.95 24 0.848 4 11849 14183 1.425 7.82 31 0.652
- 4. 646 Rajwardhan Kulthe, Viraj Mekhe, Mihir More, Sangram Nandawadekar & Vikas Deulgaonkar Impact Factor (JCC): 7.6197 SCOPUS Indexed Journal NAAS Rating: 3.11 Figure 6: Meshed Center Pin Figure 7: Meshed Bracket Boundary Conditions Application of loads on intended portions and fixing the bolted and fabricated areas is known as applying ‘Boundary Conditions’. This is the most important step after meshing, because the results depend on the value and position of loads and constraints. Forces are evenly distributed over the nodes in the area, where the force is acting in reality. For Center pin, we have constrained the threaded portion and applied the hand force of 150N on the handle, a vertically downward force of 74.4 N which is the self-weight reaction force of pinion on the front taper portion. For bracket, the bolting positions are constrained, and a force of 3kN which is the maximum load bearing capacity of thread is applied on rest buttons. Hand force = 75N on each end. Weight of Pinion = 180N Vertical reaction Force of Pinion = 74.4N Horizontal force acting on Bracket = 3kN Figure 8: Boundary Conditions on Center Pin Figure 9: Boundary Conditions on Bracket FEA Analysis The model is solved in Optistruct solver of Hypermesh 13.0 using applied boundary conditions. After solving the problem, next step is known as post processing. In post processing, the results are shown in user understandable format i.e. Stress induced at the object is shown in the form of color bands, which shows how uniformly the stress is distributed and at which point, the magnitude of stress or deformation is maximum that shows where the possible failure can occur.
- 5. Finite Element Analysis of Center Pin and Bracket of Jig – Fixture Assembly 647 www.tjprc.org SCOPUS Indexed Journal [email protected] Figure 10: Deformation in Bracket Figure 11: Stresses in Bracket Figure 12: Displacement In Center Pin Figure 13: Stresses In Center Pin Table 3: Resultant Stresses Induced in the Various Components of Jig and Fixture Components Induced Stress (N/mm2 ) Permissible Stress (N/mm2 ) Center pin 39 370 Fouling pin 32 370 Locating pin 23 370 Bracket 28 370 Jig plate 21 370 RESULTS AND CONCLUSIONS The results achieved from CAE analysis are compared with the calculated results for validation purpose. CAE results are little bit deviated from the actual results, due to various parameters as shown below in the table. Table 4: Comparison of CAE and Calculated Values Sr. No. Component Stress (N/mm2 ) Deflection (mm) CAE Permissible CAE Permissible 1 Bracket 27.58 370 0.016 2 2 Center Pin 39.09 370 0.030 2 After analyzing the critical components in our model, we came to know that the values of stresses induced are less than the yield strength of the material, and also the values of deformation are in the range of few microns, which indicates that it will not affect the accuracy in the Drilling operation and can fulfill the purpose of precisely drilling the holes in the pinion. Simulation of impact of load and its consequences are observed using the Hypermesh 13.0. The obtained results were well within the limits according to safety and failure aspects. Therefore, it can be said that the design is safe and fool proof.
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