DESIGN AND FABRICATION OF DRILL JIG FOR THE COMPONENT ''AILERON LEVER FRAME 6 UPPER'' FOR ''HAWK MK-132'' AN ADVANCED JET TRAINER

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1 International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 4, April 2017, pp , Article ID: IJMET_08_04_039 Available online at ISSN Print: and ISSN Online: IAEME Publication Scopus Indexed DESIGN AND FABRICATION OF DRILL JIG FOR THE COMPONENT ''AILERON LEVER FRAME 6 UPPER'' FOR ''HAWK MK-132'' AN ADVANCED JET TRAINER Akash Thammannagowda Graduate Apprentice Trainee, B.E.M.L Earth Movers Limited, Mysore, India Venkatesh H DY Manager, Hawk Machine Shop, Aircraft Division, HAL, Bangalore, India Santhosh Kumar T C Assistant Professor, Department of Mechanical Engineering, B G S Institute of Technology, B G Nagara, India ABSTRACT Hindustan Aeronautical Limited is one of the Asia's premier aerospace Company. It is governed under the management of Indian Ministry of Defense. Currently one of the ongoing project by HAL is HAWK MK-132 an Advanced Jet Trainer (AJT), which is produced in india by HAL under the license from British Aerospace. HAWK Trainer Aircraft consist of many assembly and sub-assembly one such assembly is a ''AILERON LEVER FRAME 6 UPPER'' is used to control stability of an Aircraft. The problem that has been found before the designing of the drill jig is that the operator has to make the hole taking reference dimensions each time for making the hole. This is turns to increases the Idle time of machine, Operator fatigue, Reduce Accuracy, production loss which is huge setback for the mass production industry. Our project have developed a new process plan under the guidance of Methods department which helped in solving errors, Reducing Machining time and Wastage of materials which existed in previous process plan by implementation of conventional machining methods. We have designed a new drill jig with the help of Tool Design Department which came in handy for the operator's to carry out the drilling action and to achieve Mechanical accuracy and Interchangeability for the component which was difficult to perform previously. Our project was tested and has been successfully implemented. Key words: HAL, AJT, HAWK Trainer Cite this Article: Akash Thammannagowda, Venkatesh H and Santhosh Kumar T C, Design and Fabrication of Drill JIG for the Component "Aileron Lever Frame 6 Upper" for "Hawk Mk-132" An Advanced Jet Trainer. International Journal of Mechanical Engineering and Technology, 8(4), 2017, pp editor@iaeme.com

2 1. INTRODUCTION Akash Thammannagowda, Venkatesh H and Santhosh Kumar T C 1.1. Problem Due to the criticality of drilling the 8mm hole on the component. To reduce the effort and errors involved while drilling the holes in Aileron lever frame 6 upper component of HAWK MK-132 Aircraft Scope of the Project The above said component is one of the most important component in the wing assembly of the HAWK MK-123 Aircraft. The machining of the above component is a tedious and complicated process. This requires the proper tooling in order to maintain the required standard and since this is one of the critical component up to standard are very critical. The Design and Fabrication of the drill jig for the above component can help this process of manufacturing and also help in maintaining consist and standard in quality of the product and their by providing for interchangeability of the component and also reduces the need of a skilled operator. 2. COMPONENT STUDY 2.1. Bill of Material Table 1 Bill of materials Figure 1 Component study editor@iaeme.com

3 Design and Fabrication of Drill JIG for the Component "Aileron Lever Frame 6 Upper" for "Hawk Mk-132" An Advanced Jet Trainer By the preliminary observation and study of the D - Drawing of component obtained from HAWK machine shop. According to dimension mentioned in the component first we are designed a component. The above component is called as AILERON LEVER FRAME 6 UPPER Used in wing assembly of the HAWK MK-132 Aircraft. For this component it is required to drill two holes of 8mm diameter. In the present manual operation huge errors are appeared as discussed in past. To avoid these problems a drill jig is manufactured Final Assembly of the Tool Figure 2 Isometric view of the tool Figure 3 Front view of tool Figure 4 Top view of tool 3. FABRICATION OF THE TOOL Owing to fact that the entire jigs and fixture was built from either scrap or leftover materials the fabrication process required constant monitoring it is cost effective since it involved only machining process was not tedious because only standard dimensions and mostly conventional machines were used. The design of the drill jig and fixture was simple keep in mind the fabrication process. The tooling department and hawk machine shop, HAL offered tremendous support was of great magnitude during the process of fabrication. The following components that were fabricated: 1. Base Plate 2. V-Blocks 3. Guide Block 4. Locating Shank Bolt and Nut 5. Locking Screw 6. Side Clamping Block 7. Legs 8. Studs 9. Liner Bush and Drill Bush editor@iaeme.com

4 Akash Thammannagowda, Venkatesh H and Santhosh Kumar T C The dimensions of anyone of the components cannot be compromised; hence the tolerance levels had to be maintained very low. Figure 5 Base Plate Figure 6 V-Blocks Figure 7 Thrust Pad Figure 8 Guiding Block Figure 9 Locking Screw Figure 10 Clamping Element Figure 11 Linear Bush Figure 12 Drill Bush Figure 13 Jig Feet editor@iaeme.com

5 Design and Fabrication of Drill JIG for the Component "Aileron Lever Frame 6 Upper" for "Hawk Mk-132" An Advanced Jet Trainer 4. ASSEMBLY AND PROVING 4.1. Assembly Figure 14 Final Assembly The process of putting together a number of manufactured parts to make a complete product, such as a machine is called end assembly. Component or end item comprising of a number of parts or sub assemblies put together to perform a specific function, and capable of disassembly without destruction. Before starting assembly process we sent all cylindrical process called flattening. This process is done by fixing the component on a milling machine. The side clamp which is fabricated was attached to the studs. Then it is placed in position to the height of the component. The fixed v-block is directly butted to the base plate by means of a dowel pin and moveable v-block is hold the component through the guide block by using locking screw and the jig feet s are provided to give the support to the tool on the drill bed of the drilling machine during its operation Proving Figure 15 Assembly Proving Proving process is done so that the jig or fixture which has been designed is done in a proper fashion and it is capable of completing an operation which it was intended to do. In proving we check whether the operation which is being done is effectively carried out editor@iaeme.com

6 Akash Thammannagowda, Venkatesh H and Santhosh Kumar T C Once the fixtures is ready the component to be machined were placed in the fixture and constrained in its positioned. The component fitted perfectly without any further required correction or adjustments. The final finished component was also placed in the position on the fixture and verified. It was observed that the component fit into the fixture perfectly. The position of the side clamp is verified to the requirement and was found to be satisfactory. The fixture, along with the component is placed on the base plate. Clamped to the base plate, and the tool is guided with the help of the drill bush. Figure 16 Finished component 5. DATA ANALYSIS AND RESULT The most important objectives of the fixtures were to reduce the cycle time substantially and to reduce the cost of production. Since the cost of the fixtures is a part of the total production cost, steps have been taken to reduce the same. The cost of production includes the machining time of the component this includes the machining time of the component this includes the machining hours that the component takes. The machining time of the component comprises of two steps: Set-up time Actual machining time. It was so observed that the set-up time is reduced by a considerable extent, thus the main objectives of reducing the overall machining time is achieved. The machining time includes the following: The time taken to true the tool according to requirements. Time taken for machining operation. The time taken for machining operation will remain unaffected. Thus the only way to reduce the overall time is to reduce the time taken the tool according to requirements. Based on the information given to us by the MSD Department, machine operators and supervisors, the truing process for the component time consuming, tedious and prone to errors during inspection. Truing the process which is used to make true, or adjust exactly or accurately. This is done in order to evade eccentricity in setting of the component for a machining. And ensuring the set-up is proper for machining editor@iaeme.com

7 Design and Fabrication of Drill JIG for the Component "Aileron Lever Frame 6 Upper" for "Hawk Mk-132" An Advanced Jet Trainer Thus providing a fixtures would successfully eliminate the above mentioned problems. The main characteristics of the fixtures is that it reduces the time taken for truing, in fact, it removes the need for truing thus eliminating the time, effort and need for truing. From the obtained data it was observed that 33.33% of the total time taken to machine the component is truing time. This massively decreases the rate of production by increases the cycle time. It is also estimated that by using the jigs and fixtures the rate at which the operations are carried out is increased by 33.33%. But the main practical reason is the reduction of efforts and errors due to truing. And thus by using the fixtures the cycle time reduced and hence the rate of production is increased. Based on the information given to us by the MSD department operator, supervisors, the truing process of the component is time consuming, tedious and prone to errors during inspection. The data obtained is as follows: Table 2 Data Analysis SI NO. Setup Time(in mm) Unit Time(in mm) As per the estimates that are made based on the data available it can be concluded that; The truing time for components is eliminated. Loading time is eliminated By using jig and fixtures the operation time of SI NO.1-2 can be reduced by nearly 33.33% ex. about 9 minutes for a single component. The set up time required for the component is reduced by 46.66% (15 min to 7 min). The required from actual machining is reduced by 33.33%(6 min to 2 min) 6. CONCLUSION All the objectives of the project that were defined prior to the design and fabrication of the jig and fixture are achieved. It offers with the following advantages Improved productivity. Interchange ability and quality. Reduction in manufacturing cost. Reduces the requirement of the skilled operators. Owing to the data obtained and the advantages that are observed, the jig and fixture helps the manufacturing of the part and in turn the Project Hawk at HAL, by offering a sound quality product in the wing assembly of the HAWKMK-132. REFERENCES [1] Fundamentals of Tool Design by HOEFMAN [2] Tool Design by DONALDSON ET.AL [3] Introduction to Jig & Tool Design by M.H.A.KEMPSTER editor@iaeme.com

8 Akash Thammannagowda, Venkatesh H and Santhosh Kumar T C [4] Tool Design for Beginner by NANJUNDA SWAMY (H.A.L) [5] Production Tooling Equipment by S.A.J. PARSONS [6] Fundamentals of Tool Design by A S T M E [7] Work Shop Technology Volume 1&2 by HAJRA CHOUDHARY editor@iaeme.com