DESIGN OF HYDRAULIC FIXTURE FOR MACHINING ON AL-NISSAN 180M DIFFERENTIAL CARRIER MODEL

DESIGN OF HYDRAULIC FIXTURE FOR MACHINING ON AL-NISSAN 180M DIFFERENTIAL CARRIER MODEL Prof D.B. Shelke 1, Sujay Deshmukh 2, Sumeet Chakravarty 3, Ankit Prakash 4, Pranav Pise 5 1 head Of The Deparment, Padmabhooshan Vasantdada Patil Institute Of Technology, Bavdhan, Pune, Maharashtra, 411038, India 2 department Of Mechanical Engineering, Padmabhooshan Vasantdada Patil Institute Of Technology, Bavdhan, Pune, 3 department Of Mechanical Engineering, Padmabhooshan Vasantdada Patil Institute Of Technology, Bavdhan, Pune, 4 department Of Mechanical Engineering, Padmabhooshan Vasantdada Patil Institute Of Technology, Bavdhan, Pune, 5 department Of Mechanical Engineering, Padmabhooshan Vasantdada Patil Institute Of Technology, Bavdhan, Pune, Abstract-- In machining operation it is necessary to clamp the component on the fixture and avoid unwanted vibrations while machining on the component in order to achieve precision while performing various machining operations like Cover Face Milling, Bearing Cap Face Mounting Milling, Drilling, and Tapping. To perform these operations more accurately on the AL-Nissan 180M Advantek Series Differential Carrier on a Vertical Machining Center (VMC) to achieve accuracy, reduce clamping time and apparently economic saving. The Hydraulic Swing Type clamps are designed according to the requirement of clamping force. The design is evaluated in FEA software ANSYS by performing Modal, Harmonic Response and Static Structural analysis. Index Terms AL-Nissan 180M Advantek Series Differential Carrier, ANSYS, Modal analysis, Harmonic Response analysis, Static Structural analysis, VMC. I. INTRODUCTION Machining Fixture is a precision device used for constraining the movement/vibration of work piece while performing machining operations. In order to achieve better precision and reduce the clamping time as well as to eliminate manual loading efforts, Hydraulic Machining Fixtures are used vastly in industries. This work focuses on Hydraulic Machining Fixtures. The fixture comprise of Hydraulic Swing Clamps, it is important to locate the swing clamp in a way that the clamps will not interfere with the machining operations that are to be performed by VMC on the work piece. The main function of this hydraulic fixture is to apply clamping force on the work piece so that it can resist the external unwanted forces generated while machining operations. Proper fixture design is crucial to product precision, accuracy and surface finish of the work piece. In this work, design of Hydraulic Fixture for differential carrier to perform machining operations in VMC is done. VMC operations are much cheaper than HMC so it is convenient to perform few operations on VMC also. For this currently a mechanical fixture is being used. Our job is to change the mechanical fixture with hydraulic in order to save time without compromising with the quality of machining. The cast component is loaded in fixture where it is located against casting lugs and clamped on cover face rib with pull down clamps and machined on cover face like- Milling of cover face, Milling of Bearing cap mounting face, bearing cap mounting drilling, tapping, cover face hole drilling. In new setup the mechanical pull down clamps are replaced with hydraulic swing clamps with change in mounting location of clamps. II. MODAL ANALYSIS Modal analysis is the study of dynamic properties of structure under vibration excitation. Modal analysis considers mass and stiffness of the structure to find various periods at which it will resonate. Modal analysis calculates the natural frequency of system alone. We get the result in form of mode shapes. A mode is a shape with a corresponding natural frequency at which the structure will absorb all the available energy supplied by an excitation. IJIRT 144480 INTERNATIONAL JOURNAL OF INNOVATIVE RESEARCH IN TECHNOLOGY 285

III. HARMONIC RESPONSE Harmonic response analysis is a technique used to determine the steady state response of a linear structure to loads that vary sinusoidally with time. The idea is to calculate the structure s response at several frequencies and obtain a graph of some response quantity versus frequency. Peak responses are then identified on the graph and stresses reviewed at those peak frequencies. IV. STATIC STRUCTURAL A static structural analysis determines the displacements, stresses, strains, and forces in structures or components caused by loads that do not induce significant inertia and damping effects. Steady loading and response conditions are assumed that is, the loads and the structure's response are assumed to vary slowly with respect to time. A static structural load can be performed using the ANSYS, Samcef, or ABAQUS solver. The types of loading that can be applied in a static analysis include: Externally applied forces and pressures, Steady-state inertial forces (such as gravity or rotational velocity), Imposed (nonzero) displacements, Temperatures (for thermal strain). V. LITERATURE REVIEW A number of analytical, experimental and research along with various patented studies have been conducted related to the use of Machining Fixtures. They are used for clamping various work pieces depending upon their geometries. Hans-Christian Möhring, Petra Wiederkehr (2016),worked on Intelligent Fixtures for High Performance Machining, 7 th HPC 2016 CIRP Conference on High Performance Cutting,Science Direct,the journal paper deals with the study in which the influence of the clamping setup and of the work piece characteristics at various steps of machining process is analyzed. Experimental and theoretical results regarding the dynamic process behavior reveal the relevance of these influence with respect to machining performance and work piece quality. April 2017 IJIRT Volume 3 Issue 11 ISSN: 2349-6002 Chetankumar M. Patel, Dr.G.D.Acharya, ScienceDirect, Procedia Technology 14(2014)405-412, 2 nd International Conference on Innovations in Automation and Mechatronic Engineering ICIAME 2014, Design and manufacturing of 8 cylinder hydraulic fixture for boring yoke on VMC- 1050, various area related to design of fixture are already been very well described by various renowned authors, but there is a need to couple and apply all these research work to an industrial application. This paper integrates all these aspects and the evolutionary functional approach of design fixture in proved from the fact that a real industrial component is considered for fixture designing. In addition of designed fixture being hydraulic type, it is also collet type and has expanding customized collet as its main fixturing element. This fixture shows great time saving in production. Shailesh S Pachbhai, Laukik P Raut, DESIGN AND DEVELOPMENT OF HYDRAULIC FIXTURE FOR MACHINING HYDRAULIC LIFT HOUSING, International Journal of Mechanical Engineering and Robotics Research, Vol. 3,No. 3, ISSN 2278-0149. Hydraulic lift housing is engine part of an agricultural tractor which plays an important role in application of lifting trolley of tractor and machining of hydraulic lift housing is an important task. Loading and unloading of work piece in manual clamping is time consuming process, so reducing machining time, set up time etc. is a main aim of process. The job having cylindrical shape, this is a challenging task for design engineer, hence hydraulic fixture design is incorporated in manufacturing industry. Sandeep Soni and Ravindra Mane, Global Journal of Researches in engineering, Online ISSN : 2249-4596,Print ISSN : 0975-5861, Design and Modeling of Fixture for VII. PROPOSED SOLUTION By replacing the mechanical pull down type clamps by hydraulic Cylinder Liner Honing operation, this paper uses newer and swing type clamp the process becomes more fast. As hydraulic innovative design of present day manufacturing industries for pressure is applied on the casting lugs of work piece for holding locating, positioning, clamping, for uniform clamping the work piece is more stable during machining operations. More hydraulic clamping are used. Fixture design is one of the number of jobs can be performed in a day as lot of loadingunloading time is saved during whole process. By important factors that play a vital role in providing manufacturing processes with more productivity and have brought many benefits like reduced rejection. IJIRT 144480 INTERNATIONAL JOURNAL OF INNOVATIVE RESEARCH IN TECHNOLOGY 286 VI. PROBLEM IDENTIFICATION Designing a hydraulic fixture for performing machining operations in VMC. Currently mechanical pull down type clamps are being used on the fixture for which clamping needs to be performed manually. As the clamps are pull down type there occurs a minute play between the work piece and the clamps which results in unwanted vibrations. As mechanically the operator needs to load the work piece by hands and check for any misalignment the work becomes time consuming.

performing machining operation on a VMC, it saves machining cost of INR 45 per component. VIII. DESIGN OF FIXTURE LOCATION AND CLAMPING CONSIDERATIONS In machining, work holding is a key aspect; fixtures are the elements responsible to satisfy this goal. Centering, locating, orienting, clamping and supporting are considered the functional requirements of fixture. The raw material is the cast differential carrier on which facing, drilling and taping needs to be performed. The hydraulic swing clamp for constraining the work piece is selected from Hydraulic Clamping System Catalogue by AMF. The double acting cylinder swing clamp is selected by considering clamping force and area available to clamping on casting lugs. From the catalogue the swing clamp with base flange mounting, precision design is selected. The two clamps are placed on each side of the work piece. Both the clamps are connected by single pipe line. Enough care is taken so that clamps must not loosen up by vibrations caused by the tool while machining. The clamping stroke is 13 mm and the total stroke of piston is 29.5 mm. The cylinder considered for the clamping is barrel from steel, hardened and burnished. Piston rod hardened and chrome plated. Piston rod has internal thread and clamping arm positioning. The swing motion is executed via three ball guides, thereby increasing positioning accuracy, repeat accuracy and service life. IX. FIXTURE DESIGN require extra space for mounting. The materials used for various components of the fixture are as follows: Top Plate and Base Plate: Mild Steel (M.S) Resting Points: EN7 X. CALCULATIONS VMC CALCULATIONS MAZAK (V) HP= 25 RPM =1200 FEED RATE (Vf) = 0.017 m.sec -1 Radial Depth of cut (Ae) = 0.002m Axial Depth of cut (Ap) = 0.02m Diameter of cutter (Dc) = 0.025m RPM= SFM/(Dc*C) Proportionality Constant (C) = 0.2618 SFM= 0.0109 m.sec -1 CUTTING FORCE (CF) Cutting force constant (Cf) = 26406 CF= (HP*Cf)/SFM = (25*26406)/25.76 CF= 25.627 KN CLAMPING FORCE (F) Coefficient of Friction (K) = 0.62 F = CF/K = 25.627/0.62 F = 41.33 KN F= 41.33 KN CUTTING SPEED (Vc) EXISTING FIXTURE NEW FIXTURE The CAD model of fixture is made in Solidworks. The new model has additional blocks as the cylinders of hydraulic clamp POWER REQUIRED (KW) Vc = (Dc*π*N)/1000 = (25*π*1200)/1000 Vc = 0.09425 m.sec -1 POWER REQUIRED (P) P= (Ae*Ap*Vc*CF)/(6*10^4*η) = (2*20*0.09425*25.627*10 3 )/(6*10^4*0.8) P = 2.016 KW FEED PER TOOTH (Fz) Number of teeth (Z)=12 Fz = Vf/(Z*N) = 0.017/(12*1200) Fz = 0.00000118 m.z -1 IJIRT 144480 INTERNATIONAL JOURNAL OF INNOVATIVE RESEARCH IN TECHNOLOGY 287

MATERIAL REMOVAL RATE (Q) Q= (Ae* Ap * Vf)/1000 =(0.002*0.020*0.017)/1000 Q= 0.00000000068 m 3.sec -1 ANSYS ANALYSIS RESULTS MODAL ANALYSIS First Mode shape acquired at 1480 Hz (Working Frequency 200 Hz) Equivalent Stress (von Mises) = 0.0862 MPa STATIC STRUCTURAL Total deformation = 11.63 mm HARMONIC RESPONSE ANALYSIS Frequency = 1500 Hz Sweeping Phase Angle = 0 degree Total Deformation = 0.0000413 mm Equivalent Stress (von Mises) = 0.0571 MPa Total Deformation = 0.0001212 mm IJIRT 144480 INTERNATIONAL JOURNAL OF INNOVATIVE RESEARCH IN TECHNOLOGY 288

STATIC STRUCTURAL ANALYSIS OF SWING CLAMP April 2017 IJIRT Volume 3 Issue 11 ISSN: 2349-6002 REFERENCES [1] Hans-Christian Möhring, Petra Wiederkehr (2016), Intelligent Fixtures for High Performance Machining, 7 th HPC 2016 CIRP Conference on High Performance Cutting,Science Direct, Procedia CIRP 46 (2016) 383-390 Total Deformation = 1.23 mm [2] Chetankumar M. Patel, Dr. G. D. Acharya, ScienceDirect, Procedia Technology 14(2014)405-412, 2 nd International Conference on Innovations in Automation and Mechatronic Engineering ICIAME 2014, Design and manufacturing of 8 cylinder hydraulic fixture for boring yoke on VMC- 1050 [3] Sandeep Soni and Ravindra Mane, Global Journal of Researches in engineering, Online ISSN: 2249-4596, Print ISSN : 0975-5861, Design and Modeling of Fixture for Cylinder Liner Honing operation [4] Shailesh S Pachbhai, Laukik P Raut, DESIGN AND DEVELOPMENT OF HYDRAULIC FIXTURE FOR MACHINING HYDRAULIC LIFT HOUSING, International Journal of Mechanical Engineering and Robotics Research, Vol. 3,No. 3, ISSN 2278-0149. Equivalent stress (von Mises) = 315.33 MPa ACKNOWLEDGMENT Every orientation work has an imprint of many people and it becomes duty of author to express deep gratitude for the same. We take this opportunity to express our deep sense of gratitude towards our esteemed guide Prof. D. B. Shelke for guiding us throughout this project. We thank Mr. Rhidhesh Bhadoria, industrial guide, DANA SPICER INDIA PVT. LTD. For giving us this opportunity to work on this project and also providing facilities for successful completion of this project. With all respect we would like to thank all the people, who have helped us directly or indirectly. [5] P. Subramanyam, V. Nageshwara Reddy, Design of Fixture for Cylinder Block Machining, International Journal of Scientific Engineering and Technology Research, ISSN 2319-8885, Vol.2, Issue 18. [6] S. R. Majumdar, Oil hydraulic systems Principles and Maintenance, McGraw Hill Education (INDIA) Private Limited. IJIRT 144480 INTERNATIONAL JOURNAL OF INNOVATIVE RESEARCH IN TECHNOLOGY 289