senior year project report

1

Acknowledgements

It gives us a great pleasure to present this project report as a part of final year

degree course in Production engineering.

We would like to express our profound gratitude and appreciation towards Prof.

C.N. Datye, Prof. (Miss) S.S. Mane for their constant guidance and help during the

entire course of the project.

We also wish to acknowledge the encouragement and suggestions provided by

Prof. S.S. Kuber, Prof. R.A.Waikar, Prof. P.K.Kale, on a timely basis during the course

of completion.

We would like to express our hearty and sincere gratitude towards Mr. Shripad

Khire (Manager-Process Planning, ThyssenKrupp Industries India) and Mr. Nitin

Gawhane (HR, ThyssenKrupp Industries India), for spending their valuable time with

us in helping us to complete this project.

We are also indebted to our HOD - Prof. Rajesh Dhake, and all other staff

members of Production department who have helped us directly / indirectly throughout

our endeavour.

Nilesh Sakhare

Neha Sahni

Pritam Solanki

2

Contents

Sr. No. Title Page no.

1. Company profile 5

2. Abstract 9

3. Problem Statement 9

4. Literature survey - Know-how of fixture and its related terminologies

4.1 Concept of locating 10

4.2 Principle of location 10

4.3 Common locating devices used 13

4.4 Clamping 13

4.5 Common clamping devices used 13

4.6 Base plate with grid pattern of holes 14

4.7 Modular fixtures 14

4.8 Standard fixture parts 14

5. Equipments involved

5.1 Specifications of the equipments 15

5.2 Objective/Need of fixture design 19

6. Design approach

6.1 An overview of the job (i.e. column) 20

6.2 Study of the job 22

6.3 Study of degrees of freedom of the job 27

6.4 Initial fixture design proposed 29

6.5 Importance of using base plate 31

6.6 Final fixture design accepted (Assembly drawing & Part drawings 33

7. Justification for the design

7.1 Calculations for face milling process involved 47

7.2 Calculations for drilling process involved 49

7.3 Calculations of allowable force/load that can be taken by elements 50

7.4 Calculated results for factor of safety

7.4.1 Assumptions made 53

7.4.2 Distribution of action of forces 53

7.4.3 Tabulated values of F.O.S for various elements 54

8. Cost analysis

8.1 Process sheet for base plate 1 (includes cost of machining) 64

8.2 Process sheet for base plate 2 (includes cost of machining) 68

8.3 Process sheet for tenon (includes cost of machining) 70

8.4 Process sheet for locating pin (includes cost of machining) 71

8.5 Cost of raw material 72

8.6 Process sheet for machining the columns (includes cost of machining) 73

9. Conclusion 74

10. Testing 75

11. Scope for improvement 75

10. References 76

3

List of figures

Fig. 1 - Company products 7

Fig. 2 - Degrees of freedom of an object in space 11

Fig. 3 - Six-point location system 12

Fig. 4a - Plano-miller machine 15

Fig. 4b - Skoda machine 16

Fig. 4c - HMT machine 17

Fig. 5 - Problem of bottlenecking of boiler drums - as seen on Plano-miller machine 19

Fig. 6a - Sugar Centrifugal machine 20

Fig. 6b - Columns of Sugar Centrifugal Machine 21

Fig. 7 - Left-hand and right-hand column 22

Fig. 8 - Various views of LH column 23

Fig. 9 - Various views of RH column 24

Fig. 10 - Dimensional drawing of the column 25

Fig. 11 - Analysis of degrees of freedom of the column 28

Fig. 12a - Sketch of initial fixture design 29

Fig. 12b - Sketch of initial fixture design 30

Fig. 13a - Use of base plate - as seen in 1st set-up 31

Fig. 13b - Use of base plate - as seen in 2nd

set-up 32

Fig. 14a - Assembly drawing for set-up 1 33

Fig. 14b - Part drawing for set-up 1

- Base plate 34

- Clamp and clamp rest 35

- Support block, screwjack and round plate 36

- Fabricated support block 37

- Bracket : Plates 1, 2 & 3 38

- Tenon 39

4

Fig. 15a - Assembly drawing for set-up 2 40

Fig. 15b - Part drawing for set-up 2

- Base plate 41

- Clamp and clamp rest 42

- Support block, screwjack and round plate 43

- Fabricated support block 44

- Locating pin 45

Fig. 16 - Assembly drawing of T-shaped fixture for lifting the column 46

Fig. 17 - Nomogram for calculation of power requirement 48 48

Fig. 18a - Pictorial sequence of machining of base plate 1 66

Fig. 18b - Pictorial sequence of machining of base plate 1 67

5

1. Company profile

6

A brief insight....

- Established in 1957, ThyssenKrupp Industries India Pvt. Ltd. (TKII) is a business unit of

ThyssenKrupp Foerdertechnik, a Group Company of ThyssenKrupp Technologies of the world

renowned ThyssenKrupp AG, Germany.

- Today, ThyssenKrupp is one of the world's largest industrial conglomerate with three main

lines of business activity: Steel, Capital Goods and Services, in all of which it occupies

leadership positions.

- Over the last five decades, TKII has grown to become one of the most trusted names in the

fields of Sugar Plant & Machinery, Open Cast Mining & Bulk Material Handing Systems,

Cement Plant & Machinery and Steam & Power Generation Plants.

7

Fig. 1 - Company products

Bulk material handling

system (conveyor)

Conveyor dryer

Stacker Five roller mill

8

Fig. 1 - Company products

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Bucket wheel excavator

Power plant Oil / Gas fired boiler

Batch centrifugal

9

2. Abstract

The main aim of the project is to shift the machining centre of the side arms (columns) of the

sugarcane machinery manufactured by Thyssenkrupp Industries India Ltd. Previously, these columns

used to be manufactured on Skoda machine, which otherwise could have been used to handle much

larger workpieces. The set-up time required to machine the columns simultaneously on Skoda is too

high. Presently, this scheduled procedure of production causes the problem of bottlenecking on Plano-

miller machine. Moreover, the Skoda machine costs around Rs. 2000/hr for actual machining of the

columns, as compared to Rs. 1200/hr that can be possibly incurred on the proposed HMT machine.

Hence, the shifting pattern for the given workpieceto be followed is :

The suggested solution of the officials is the shifting of machining of columns to smaller

machining centres like HMT so that bigger machines like Skoda and Plano-miller could be ultimately

used for larger jobs . Also, since HMT machine has two pallets, while one column is being machined

(say left-handed), offline setting of the other column (say right handed) can be done. This reduces the

overall setting time by a significant amount.

The working outline includes designing of two different fixture set-ups for the desired

machining operations to be done, as per the given geometry of the job.

3. Problem statement

Design of fixture for machining (with reference to the columns of Sugar Centrifugal

Machines in ThyssenKrupp Industries India)

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Plano-miller Skoda HMT

10

4. Know-how of fixture and its related terminologies

Fixture [4][5] is a special purpose tool which is used to facilitate production (machining,

assembling and inspection operations) when workpieces are to be produced on a mass scale. Some of

the manifold uses of designing and setting-up fixtures include :

1. To increase the production.

2. To provide for interchangeability.

3. To enable heavy and complex-shaped parts to be machined by being rigidly held to a machine.

4. Their use improves the safety at work, thereby lowering the rate of accidents.

Hence,

“ A fixture is a work holding device which only holds and positions the work, but does not in itself

guide, locate or position the cutting tool. “ The setting of the tool is done by machine adjustment. A

fixture is bolted or clamped to the machine table.

4.1 Concept of locating....

The question of properly locating, supporting and clamping the work is important since the

overall accuracy is dependent primarily on the accuracy with which the w/p is consistently located

within the fixture. There must be no movement of the work during machining. Locating refers to the

establishment of a proper relationship between the workpiece and the fixture so that as many

degrees of freedom (out of 12) should get restricted as possible.

4.2 Principle of location....

In a state of freedom, any workpiece (assuming it has true and flat faces) may move in either of

the two opposed directions along three mutually perpendicular axes XX, YY and ZZ axes. These six

movements are called “movements of translation”. Also, the w/p can rotate in either of two opposed

directions around each axis, clockwise and anticlockwise. These six movements are called “rotational

movements”. The sum of these two types of movements gives the twelve degrees of freedom of a w/p in

space. To confine the workpiece accurately and positively in another fixed body (fixture), the

movement of the workpiece in any of the twelve degrees of freedom must be restricted.

11

Usually, six locating pins, three in the base of the fixed body, two in a vertical plane and one in

another vertical plane, the three planes being perpendicular to one another, restrict nine degrees of

freedom. In case three more pins are used for the remaining three degrees of freedom, then that would

make loading and unloading of w/p into the fixture impossible. Hence, the remaining three degrees of

freedom may be arrested by means of a clamping device. This method of locating a w/p is popularly

called “3-2-1” principle or “six point location” principle. [5]

Fig. 2 - Degrees of freedom of an object in space

12

Fig. 3 - Six-point location system

13

4.3 Common locating devices used....

Pins are stops which are inserted in the body of fixture, against which the workpiece is pushed

to establish the desired relationship between the workpiece and the fixture. Pins of various designs and

made of hardened steel are the most common locating devices used. Depending upon the relation

between the workpiece and pin, the pins may be classified as [5]:

1. Locating pins

a. Conical locating pins

b. Cylindrical locating pins

2. Support pins

a. Adjustable type

b. Fixed type

3. Jack pins

Other locating devices include V-type locator, diamond pin locator, bushes, etc.

4.4Clamping....

If the workpiece cannot be restrained by the locating elements, it becomes necessary to clamp

the w/p in the fixture body. The purpose of clamping is to exert a pressure to press a w/p against the

locating surfaces and hold it there in opposition to the cutting forces i.e.to secure a reliable (positive)

contact of the work with locating elements and prevent the work in the fixture from displacement

and vibration in machining[5].The most common example of a clamp is the bench vise, where the

movable jaw of the vise exerts force on the w/p thereby holding it in the correct position of location in

the fixed jaw of the vise.

4.5Common clamping devices used....

Some of the common clamping devices used in practice [5] are :

1. Clamping screws

2. Hook bolt clamp

3. Lever type clamps

a. Bridge clamps

b. Heel clamps

c. Swinging strap (latch) clamps

d. Hinged clamps

4. Quick acting clamps

a. C-clamps

14

b. Quick acting nut

c. Cam-operated clamp

** No clamping devices are used if a very heavy stable job is to be machined, whose weight is very

great compared to the forces developed in the cutting process, if these forces are in a direction that

cannot disturb the setting of the job.

** Clamping devices are also unnecessary if the job is deprived of all of its degrees of freedom when it

is loaded into a fixture.

4.6Base plate with grid pattern of holes....

A base plate (square or rectangular) with a grid pattern of holes [5] is especially suitable as a

work-holding device for N/C and CNC machine tools. The holes are usually on 25mm centres. Every

other hole is tapped to hold down studs or screws. The remaining holes are jig-bored to 0.005mm

accuracy, and these holes hold dowel pins. The dowel pins act as locators and the studs and screws are

used for clamping the w/p on the plate. The grid plate, in turn, is bolted directly on the machine table.

This system can be used for an infinite varieties of w/p.

The bottom-left hole is taken as the zero reference point. With this, the grid pattern and hence

the w/p will be placed in the first quadrant. All the dimensions measured from the reference point will

be positive in magnitude. The N/C machine tool is set-up by bringing the machine spindle directly over

the reference hole with the help of a dial indicator mounted on the spindle. The w/p is then located and

held on the grid plate in reference to the set-up point.

** One major drawback of grid plate is that the chips get accumulated in the holes. However, this can

be avoided by keeping all the unused holes plugged.

4.7Modular fixtures....

These fixtures are commonly used on N/C and CNC machining centres [5]. The fixtures

comprise of modular components based on the grid principle (A module is an interchangeable “plug in”

item that may be combined with other interchangeable items to form a complete unit i.e. a modular

fixture is built up on the building block principle). The w/p locators are located approximately on the

grid pattern and then the w/p is precision-machined under tape control. Dowel pins are not used.

4.8 Standard fixture parts....

The basic purpose of standardization [5] of any manufactured items is to ensure

interchangeability (which is the basis of mass production) and facilitate the manufacture of parts. It also

facilitates maintenance and repair. When designing and manufacturing fixtures, maximum use should

be made of standard, readily purchasable (or available in store) component parts. This will reduce the

cost of design and manufacturing considerably.

The standardized component parts for fixtures include : Washers, various types of screws, studs

and nuts, T-bolt and T-nut, toggles, cam and wedge etc.

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15

5.Equipments involved

5.1 Specifications of the equipments….

Skoda : X6000, Y3500, Z1600+400

Spindle – 200 (ISO - 60)

Plano-miller : X6000, Y2000, Z2000

Spindle ISO 50

On table : Max. wt. = 35000kg

HMT (Twin Pallet) : Pallet 1000*1000

X1750, Y1300, Z1000

ATC 60 tools

Spindle ISO 5

Fig. 4a - Plano-miller machine

16

Fig. 4b – Skoda machine

17

Fig. 4c – HMT machine

18

Bottlenecking

19

Fig. 5 – Problem of bottlenecking of boiler drums --- as seen on Plano-miller machine

5.2 Objectives….

- To avoid bottlenecking of Plano-miller machine (as shown in Fig. 5)

- To eliminate the necessity of using a costlier work-center (Skoda machine), by designing a suitable

fixture which can be accommodated on the proposed HMT machine .

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20

6.Design approach

6.1An overview of the job involved....

Fig. 6a – Sugar Centrifugal Machine

21

Fig. 6b - Columns of Sugar Centrifugal Machine

Finished

left-

hand

column

Fabricat

ed left-

hand

column

22

6.2 Study of the job....

The given component is not a regular shaped workpiece. It is an eccentric component. Also,

when we look at the specifications of HMT machine, it is quite obvious that both the columns can’t be

machined simultaneously. The geometry of the column (i.e. the need to machine faces which are

perpendicular and/or parallel to each other) and the limitations of the machine space utilisation call for

designing two different set-ups of fixture to hold the column while machining.

Fig. 7 – Left-hand and right-hand columns

Left-hand

column

Right-hand

column

23

Fig. 8 – Various views of LH column

24

Fig. 9 – Various views of RH column

25

Fig. 10 – Dimensional drawing of the column

26

As per the functional requirement, six faces of the LH column and three faces of the RH

column are to be machined. Since these faces are parallel and/or perpendicular to each other, they are to

be machined in two different orientations. Each of the face requires milling and drilling operations. The

requirements are as shown below :

Face number Operation required

*1 Milling Tapping three M20 holes

2 Milling

Drilling two Ø27 holes, two Ø50.2 holes

Tapping two M24 holes

3 Milling Drilling two M20 holes

4 Milling Tapping two M20 holes

*5 Milling Tapping two M20 holes

*6 Milling Drilling four M10 holes

*Additional holes to be drilled and tapped - ½” BSP hole & 1½” BSP hole

* indicates those operations are to be performed on LH column only. The rest are to be

performed on both

“Thus, LH column requires total 6 milling operations, 21 drilled holes and 11 tapped holes

RH column requires total 3 milling operations, 10 drilling holes and 4 tapped holes “

27

6.3 Study of degrees of freedom of the column....

As mentioned in the previous title, the given component requires two different fixture set-ups for

holding. So the basic approach to design started with the analysis of degrees of freedom [5] of the

column in both the orientations possible.

1st set-up :

Element for restricting degree Degree of freedom restricted

of freedom

Base plate YY↓

Screwjack XX CL/ACL , ZZ → , YY ←

Clamp YY ↑ , XX ↕ , YY CL/ACL (also

restricted due to the weight of the

column) , ZZ CL/ACL

L-shaped support ZZ ←

2nd

set-up :

Element for restricting degree Degree of freedom restricted

of freedom

Base plate YY ↓

Screwjack XX CL/ACL , ZZ →

Locating pin YY ↓ , YY CL/ACL , ZZ ↔ , XX ↕

Clamp YY ↑, YY CL/ACL , ZZ CL/ACL

**(where ↕ indicates linear movement, and CL/ACL indicate rotational movements in both the

directions as applicable to the respective axes)

28

Fig. 11 – Analysis of degrees of freedom of the column[2]

29

6.4 Initial fixture design proposed (not to scale)....

Fig. 12a - Sketch of initial design proposed

30

Fig. 12b - Sketch of initial design proposed

31

6.5 Importance of using base plate....

While designing a fixture, the pre-requisite condition that is to be considered is that “both the

columns should be machined together”. This is to maintain the centre distance and height of the

columns from the point of view of positioning the central shaft of the sugarcane machinery set-up.

However, because of the geometry of the column and limitations of the specifications of the machine,

two different fixture set-ups have to be designed. In order to comply with the condition put forth, base

plates of known dimensions are being used. Every time before any process is started on the required

face, respective dimensions (height and centre distance) will be measured with respect to the known

dimensions of the base plate. Also, the dimensions will be measured post process in succession. Then,

as per the tolerances set, the dimensions are checked and kept within the limits in every pass.

One more use of the base plate is for quick-setting of the column in the second set-up. The base

plates for both the set-ups are being provided with holes for tenons and allen screws. Tenons and allen

screws serve the purpose of locating (fixing) the base plate with respect to the modular fixture. In case

of second set-up, additional holes (for locating pins and allen screws) are being drilled to quickly

set/position the column.

Fig. 13a –Necessity of base plate – as seen in set-up 1

32

Fig. 13b – Necessity of base plate – as seen in 2nd

set-up

33

6.6 Final fixture design accepted....

Fig. 14a – Assembly drawing for set-up 1

34

Fig. 14b – Part drawing of set-up 1 : Base plate

35

Fig. 14b – Part drawing of set-up 1 : Clamp and clamp rest

36

Fig. 14b – Part drawing of set-up 1 : Support block,screwjack and round plate

37

Fig. 14b – Part drawing of set-up 1 : Fabricated support block

38

Fig. 14b – Part drawing of set-up 1 : Bracket – Plates 1, 2 and 3

39

Fig. 14b – Part drawing of set-up 1 : Tenon

40

Fig. 15a – Assembly drawing for set-up 2

41

Fig. 15b – Part drawing of set-up 2 : Base plate

42

Fig. 15b – Part drawing of set-up 2 : Clamp and clamp rest

43

Fig. 15b – Part drawing of set-up 2 : Support block, screwjack and round plate

44

Fig. 15b – Part drawing of set-up 2 : Fabricated support block

45

Fig. 15b – Part drawing of set-up 2 : Locating pin

46

Fig. 16 – Assembly drawing of T-shaped fixture for lifting the column

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47

7. Justification for the design

7.1 Calculations for face milling process involved....

Cutting forces generated

Component

Part

Power

required

(kW)

Px

(kgf)

Py

(kgf)

*Pz

(kgf)

Part no. 2

(rough mill)

21.6 403.92 257.04 734.4

Part no. 2

(finish mill)

16.9 316.03 201.11 574.6

Part no. 3 17.6 329.12 209.44 598.4

Part no. 3 12 224.4 142.8 408

Part no. 4 19.5 364.65 232.05 663

Part no. 4 14.3 267.41 170.19 486.2

Part no. 1 8.5 158.95 101.15 289

Part no. 1 6.05 113.135 71.995 205.7

Part no. 5 9.35 157.08 111.265 317.9

Part no. 5 8.4 157.08 99.46 285.6

1. Actual power required (considering correction factors) [7]

N’ = N*K1*K2*K3

where N = Power obtained from nomogram,

K1 = Correction factor for material,

K2 = Correction factor for feed and cutter location w.r.t workpiece

width

K3 = Correction factor for negative geometry

48

2. Tangential force Pz = (6120*N’)/v kgf

3. Axial force Px = 0.55*Pzkgf

4. Radial force Py = 0.35*Pzkgf

Sample calculation :

Consider rough milling of bottom plate part 2.

Power obtained from nomogram(for cutter dia. = 160mm, v = 180m/min, feed = 400mm/min., d =

2mm, width of workpiece = 250mm) is 18kW (approx.)

For the given face, K1 = 1, K2 = 1, K3 = 1.2

Therefore, actual power required (N)= 18*1*1*1.2 = 21.6 kW

Pz = (6120*21.6)/180 = 734.4 kgf

Px = 0.55*734.4 = 403.92 kgf

Py = 0.35*734.4 = 257.04 kgf

Fig. 17 – Nomogram for calculation of power requirement

49

7.2 Calculations for drilling process involved....

Cutting forces generated

Drill size Power

Required (kW)

Px

(kgf)

Pz

(kgf)

U drill Ø27 1.1745 65.772 55.355

U drill Ø22 1.329 74.443 64.096

U drill Ø35 0.5709 31.9725 15.577

U drill Ø49 0.79931 44.761 15.5772

Drill Ø17.5 0.1 67.3105 57.533

Chamfer Ø20 0.32625 36.54 31.154

Chamfer Ø22 0.3586 40.194 31.1545

Drill Ø12.5 0.5709 31.9725 31.1545

Drill Ø19 0.6198 34.713 31.1545

Drill Ø35 1.14187 63.945 62.309

Drill Ø50 1.61325 91.35 62.309

1. Machine power in kW for U drill [10] (kW)

P = (Vc*f*D*Kc)/(1000*60*4*ƞ)

where f = feed rate in mm/rev.

Kc= specific cutting force in N/mm2

D = diameter in mm

Vc = cutting speed in m/min.

ƞ = machine output (0.7 to 0.85)

50

2. Feed force Ff=Px = 0.7*(D/2)*f*Kc (N)

3. Tangential force Pz = ((P*1000*60)/((2∏n)*(D/2))*1000 (kgf)

** The cutting forces generated during reaming operation are almost negligible. Hence they are

not being considered for the calculation purpose.


For drilling a hole of dia. 27mm on part no. 2, the cutting parameters are Vc= 120 m/min. , f = 60/1500

= 0.04 mm/rev. , D = 27mm, Kc= 1740

N/mm2, ƞ = 0.8 (say). Then,

P = (120*0.04*27*1740) / (1000*60*4*0.8) = 1.1745 kW

Px = 0.7*(27/2)*0.04*1740 = 657.72 N = 65.772 kgf

Pz = ((1.1745*1000*60) / ( 2∏* 1500)*(27/2))*1000 = 553.85 N = 55.385 kgf

7.3 Calculations of allowable force / load that can be taken by various elements….

Values of allowable stresses [1] (for varying load)that are involved in the design are :

For M.S. Tension : 3.5 kgf/mm2 , Shear = 2.2 kgf/mm

2 , Compression = 10.5 kgf/mm

2 , Bending =

3.5 kgf/mm2 , Bearing pressure = 2.9kgf/mm

2

For EN .8 Shear = 3.7 kgf/mm2

For EN .24 Shear = 8.7 kgf/mm2

1. Clamp

Effective area = (70-28)*30 = 1260mm2

Allowable tensile force = 1260*3.5 = 4410 kgf

Allowable shear force = 1260*2.2 = 2772 kgf

µ = 0.1 to 0.15 for a pair of M.S.

Hence, allowable frictional force = 0.15*2772 = 415.8 kgf

2. Stud (M24*375L)

Pitch = 2mm Core dia. = 24-2 = 22mm

51

Area of stud = (3.14/4)*222 = 380.1327mm

2

Allowable shear force = 2.2*380.1327 = 836.29 kgf

3. Bolt (M24*75L)

Pitch = 2mm Core dia. = 24-2 = 22mm

Area of stud = (3.14/4)*222 = 380.1327mm

2


4. Allen screw (M20*50L)

Area = (3.14/4)*17.52 = 240.5281 mm

2

Allowable tensile force = 3.5*240.5281 = 841.848 kgf


5. Allen screw (M10*20L)

Area = (3.14/4)*8.52 = 56.745mm

2

Allowable compressive force = 10.5*56.745 = 595.8225kgf

6. Lock nut M24

Area = (3.14/4)*242 = 452.3893mm

2

7. Lock nut M30

Area = (3.14/4)*302 = 706.8583 kgf


8. Support block

Area = (3.14/4)*(602-40

2) = 1570.796 mm

2

Allowable compressive force = 3.5*1570.796 = 5497.786 kgf

52

9. Round plate

Effective area = (3.14/4)*(602-11

2) = 2732.4002 kgf


10. Locating pin

Area = (3.14/4)*302 = 706.858 mm

2


11. Tenon

Area = (3.14/4)*(162-6

2) = 172.7875 mm

2


12. Bracket for support

Plate 1 : Area = 16*75=1200mm2

Allowable shear force = 2.2*1200 = 2640 kgf

Plate 2 : Area = 16*(75-(10-1.5)) = 1064 mm2

Allowable bending force = 3.5*1064 = 3724 kgf

Plate 3 : Area = 16*87.7 = 1403.2 mm2

Allowable bending force = 3.5*1403.2 = 4911.2 kgf

Weld : Throat thickness = 16cos26.5 = 14.32 mm

Area = 14.32*87.7 = 1254.864 mm2


13. Screw jack

Height of lock nut = 0.8*30 = 24 mm

Pitch = 3.5 mm

Hence, no. of threads in engagement = 24/3.5 = 6.857 i.e. 7

53

a.Bearing area = (3.14/4)*[(30/cos14.5)2 – (26.5/cos14.5)

2] = 165.7002 mm

2

Allowable bearing force = 2.9*165.7002*7 = 3363.714 kgf

b. Shear area for screw = 3.14*dc*t*n = 3.14*26.5*(3.5/2)*7 = 1019.8395 mm2

Shear area for nut = 3.14*do*t*n = 3.14*30*(3.5/2)*7 = 1154.5353 mm2


7.4 Calculated results of Factor of safety….

7.4.1 Assumptions :

1. The allowable forces are being calculated for varying load condition

2. The cumulative forces acting on the set-up are not being distributed for calculation purpose. The

entire force is being assumed to act on all the individual elements

3. The weight of the column was not distributed while making the calculations.

4. The entire screwjack type arrangement only acts as a support to accommodate the geometry of the

job, and majorly to take care of the vibrations produced during machining. Still, for calculation

purpose, it is considered to be a load bearing element to evaluate its strength

**Points 2 and 3 justify why the factor of safety obtained in the calculations is pretty high.

7.4.2 Distribution of action of forces on various elements….

1. Due to milling, three forces Px,Pyand Pzact on the column. Tangential component Pzprovides the

necessary torque for rotation. This component may tend to lift the column about an axis that is parallel

to the axis of the cutter. This lifting is prevented by the clamps, such that, in the first set-up, two clamps

are in tension and the remaining two are in compression, alternately. In the second set-up, one is in

tension and the other is in compression, alternately.

2. Px acts as a shearing force. Hence, this shearing is resisted by bolts, allenscrews,tenons, locating pins,

and frictional component of clamp.

3. Py tends to rotate the column about an axis perpendicular to the axis of the cutter. This rotation is

resisted by bolts, allen screws, tenons, and locating pins.

4. The screwjack type arrangement resists Pz component of milling and drilling operations involved.

5. During drilling, Px component will provide the shearing force. This will be resisted by bolts, allen

screws, tenons, and locating pins .

54

7.4.3 The tabulated values of the factor of safety of various elements used

Part 3

Operation Operation

Rough Milling Drilling

Px

(kgf)

Py (kgf) Pz (kgf) Px (kgf) Py

(kgf)

Pz (kgf)

329.12 209.44 598.4 67.3105 - 51.533

Weight of job 400 kgf

Wt. of base plate 318.396 kgf

Fixture elements Factor of safety

1. Clamp 1.26 - 7.36 6.177 - -

2. Bolt 2.54 3.99 - 12.42 - -

3. Clamp rest 3.02 4.75 - 14.78 - -

4. Lock nut M24 3.02 4.75 - 14.78 - -

5. Stud 2.54 3.99 - 12.42 - -

6. Bracket

Plate 1 - - 3.146 - - 9.033

Plate 2 - - 4.057 - - 10

Plate 3 - - 5.35 - - 13.2

Weld section - - 3.01 - - 7.5

7. Round plate - - 6.02 - - 13.31

8. Screwjack - - 2.25 - - 4.97

55

3.37 7.44

9. Support block - - 5.506 - - 12.17

10. Allen screw

(M20 * 50 L)

- - 1.686 - - 3.73

11. Allen screw

(M20 * 50 L)

1.45 1.736 - 2.265 - -

12. Allen screw

(M10 * 20 L)

- - 1.193 - - 2.64

13. Tenon 1.435 1.62 - 1.91 - -

14. Lock nut M30 4.72 7.42 - 23.103 - -

----------------------------------------------------------------------------------------------------------------------

Part 2

Operation Operation


Px (kgf) Py (kgf) Pz (kgf) Px (kgf)

Py

(kgf) Pz (kgf)

403.92 257.04 734.4 74.433 - 64.096


Wt. of base plate 318.396 kgf


1. Clamp 1.029 - 6.004 5.586 - -

56

2. Bolt 2.07 3.25 - 11.23 - -

3. Clamp rest 2.46 3.87 - 13.37 - -

4. Lock nut M24 2.46 3.87 - 13.27 - -

5. Stud 2.07 3.25 - 11.23 - -

6. Bracket

Plate 1 - - 2.7 - - 8.66

Plate 2 - - 3.53 - - 9.7

Plate 3 - - 4.66 - - 12.8

Weld section - - 2.62 - - 7.2

7. Round plate - - 5.3 - - 12.9

8. Screwjack - - 1.97

2.965 - -

4.83

7.25

9. Support block - - 4.846 - - 11.8

10. Allen screw

(M20 * 50 L) - - 1.48 - - 3.627

11. Allen screw

(M20 * 50 L) 1.316 2.96 - 2.23 - -

12. Allen screw

(M10 * 20 L) - - 1.05 - - 2.567

13. Tenon 1.339 1.54 - 1.896 - -

14. Lock nut M30 3.849 6.04 - 20.8 - -

57

Part 4

Operation Operation


Px (kgf) Py (kgf) Pz (kgf) Px (kgf) Py

(kgf)

Pz (kgf)

364.65 232.05 663 67.3105 - 51.533


Wt. of base plate 172.7kgf


1. Clamp 1.14 - 6.65 6.177 - -

2. Bolt 2.29 3.60 - 12.42 - -

3. Clamp rest 2.729 4.288 - 14.78 - -

4. Lock nut M24 2.72 4.28 - 14.78 - -

5. Stud 2.29 3.60 - 12.42 - -

6. Bracket

Plate 1 - - 2.92 - - 9.03

Plate 2 - - 3.79 - - 10

Plate 3 - - 4.99 - - 13.2

Weld section - - 2.81 - - 7.44

7. Round plate - - 5.655 - - 13.3


3.16

- - 4.96

7.449

58

9. Support block - - 5.17 - - 12.17

10. Allen screw

(M20 * 50 L)

- - 1.583 - - 3.728

11. Allen screw

(M20 * 50 L)

1.384 1.674 - 2.264 - -

12. Allen screw

(M10 * 20 L)

- - 1.12 - - 2.639

13. Tenon 1.6037 1.867 - 2.348 - -

14. Lock nut M30 4.264 6.70 - 23.1 - -

15. Locating pin 3.42 4.137 - 5.596 - -

16. Allen screw

(M24*375L)

1.784 2.078 - 2.741 - -

----------------------------------------------------------------------------------------------------------------------

Part 1

Operation Operation



(kgf)

Pz (kgf)

158.95 101.15 289 67.3105 - 51.533




59

1. Clamp 2.61 - 15.25 6.177 - -

2. Bolt 5.26 8.26 - 12.42 - -

3. Clamp rest 6.26 9.83 - 14.78 - -

4. Lock nut M24 6.26 9.8 - 14.78 - -

5. Stud 5.26 8.26 - 12.42 - -

6. Bracket

Plate 1 - - 4.983 - - 9.032

Plate 2 - - 6.12 - - 10.03

Plate 3 - - 8.071 - - 13.2

Weld section - - 4.54 - - 7.447

7. Round plate - - 8.72 - - 13.31


4.882

- - 4.968

7.449

9. Support block - - 7.979 - - 12.17

10. Allen screw

(M20 * 50 L)

- - 2.44 - - 3.728

11. Allen screw

(M20 * 50 L)

1.893 2.117 - 2.264 - -

12. Allen screw

(M10 * 20 L)

- - 1.729 - - 2.639

13. Tenon 2.054 2.23 - 2.348 - -

14. Lock nut M30 9.78 15.37 - 23.1 - -

60

15. Locating pin 4.67 5.218 - 5.596 - -

16. Allen acrew

(M24*375L)

2.286 2.482 - 2.613 - -

----------------------------------------------------------------------------------------------------------------------

Part 5

Operation Operation



(kgf)

Pz (kgf)

174.85 111.27 317.9 91.35 - 62.309




1. Clamp 2.37 - 13.87 4.55 - -

2. Bolt 4.78 7.51 - 9.15 - -

3. Clamp rest 5.69 8.94 - 10.89 - -

4. Lock nut M24 5.69 8.9 - 10.8 - -

5. Stud 4.78 7.51 - 9.15 - -

6. Bracket

Plate 1 - - 4.72 - - 8.71

Plate 2 - - 5.842 - - 9.75

61

Plate 3 - - 7.70 - - 12.86

Weld section - - 4.334 - - 7.237

7. Round plate - - 8.373 - - 13.00


4.685

- - 4.853

7.275

9. Support block - - 7.658 - - 11.89

10. Allen screw

(M20 * 50 L)

- - 2.345 - - 3.64

11. Allen screw

(M20 * 50 L)

1.841 2.069 - 2.153 - -

12. Allen screw

(M10 * 20 L)

- - 1.659 - - 2.577

13. Tenon 2.010 2.197 - 2.263 - -

14. Lock nut M30 8.89 13.9 - 17.02 - -

15. Locating pin 4.54 5.115 - 5.323 - -

16. Allen acrew

(M24*375L)

2.237 2.445 - 2.518 - -

----------------------------------------------------------------------------------------------------------------------

Part 6

Operation Operation


62


(kgf)

Pz (kgf)

19.55 43.01 78.2 34.51 - 38.46




1. Clamp 21.2 - 56.3 12.04 - -

2. Bolt 42.7 19.44 - 24.2 - -

3. Clamp rest 50.9 23.1 - 28.8 - -

4. Lock nut M24 50.9 23.1 - 28.8 - -

5. Stud 42.7 19.44 - 24.233 - -

6. Bracket

Plate 1 - - 8.277 - - 9.45

Plate 2 - - 9.36 - - 10.4

Plate 3 - - 12.35 - - 13.72

Weld section - - 6.948 - - 7.719

7. Round plate - - 12.57 - - 13.7


7.034

- - 5.117

7.67

9. Support block - - 11.49 - - 12.53

10. Allen screw

(M20 * 50 L)

- - 3.52 - - 3.84

63

11. Allen screw

(M20 * 50 L)

2.522 2.388 - 2.435 - -

12. Allen screw

(M10 * 20 L)

- - 2.49 - - 2.717

13. Tenon 2.538 2.441 - 2.4756 - -

14. Lock nut M30 39.77 36.1 - 45.06 - -

15. Locating pin 6.233 5.90 - 6.019 - -

16. Allen acrew

(M24*375L)

2.824 2.716 - 2.754 - -


Factor of safety = Maximum allowable force / Working force

1. Clamp

F.O.S.xm = 415.8/329.12 = 1.26

F.O.S.xd = 415.8/67.3105 = 6.177

F.O.S.zm = 4410/598.4 = 7.36

2.Bolt

F.O.S.xm= 836.29/329.12 = 2.54

F.O.S.ym = 836.29/209.44 = 3.99

F.O.S.xd = 836.29/67.3105 = 12.42

----------------------------------------------------------------------------------------------------------------------

64

8. Cost Analysis

8.1 Process sheet for base plate 1

Sr. No.

Operation sequence Cutting parameters [3] [6] [7] Machining time

(minutes)

1. Face mill surface F by 2mm

(n=1) v=100, sz=0.30, d=2, z=16, Ø=160,

L=1311.44 t = 1.37 *2

Repeat this for surface E

2. Face mill surface C by 2mm

(n=1) v=100, sz=0.30, d=2, z=16, Ø=160,

L=607.44 t = 0.636 *2

Repeat this for surface D

3. Face mill surface A by 2mm

(n=4) v=100, sz=0.30, d=2, z=16, Ø=160,

L=1354.8442 t = 1.289 *8

Repeat this three more times

Face mill surface B in a similar manner

4. Drill Ø21 holes

(n=8) v=33, f=0.30, Ø=21, L=68.49 t = 0.45 *8

Drill 8 holes in all

Ream Ø22 holes

(n=8) v=20, f=0.6, Ø=22, L=69.18 t = 0.39 *8

Ream 8 holes in all

5. Bore to Ø32*35mm

(n=8)

v=31, f=0.25, d=2.5, L=35, Ø=22 v=31, f=0.25, d=2.3, L=35, Ø=27

v=33, f=0.125, d=0.2, L=35, Ø=31.6

t = 0.32 *8 t = 0.38 *8 t = 0.84 *8

Bore 8 holes in all

6. Drill Ø16 holes

(n=4) v=30, f=0.25, Ø=15, L=65.04 t = 0.408 *4

Ream Ø16 holes

(n=4) v=20, f=0.3, Ø=16, L=54 t = 0.45 *4

Drill and ream 4 holes in all

7. Tap M24 holes

65

Drill Ø21 holes v=33, f=0.30, Ø=21, L=68.49 t = 0.45 *4

Tap M24*3 holes v=12, f=0.4, Ø=24, L=54 t = 0.84 *4

Drill and tap 4 holes in all

8. Finish mill all surfaces

Surfaces E and F

(n=2) v=135, sz =0.4, d=1, Ø=160, z=16,

L=1306.69 t = 0.76 *2

Surfaces C and D

(n=2) v=135, sz =0.4, d=1, Ø=160, z=16,

L=606.69 t = 0.35 *2

Surfaces A and B

(n=4) v=135, sz =0.4, d=1, Ø=160, z=16,

L=1352.16 t = 0.78 *8

9. Chamfering t = 1 (say)

Total machining time (exclusive of allowances and setting time) T = 51.416

Total machining time (assuming 12% allowance + setting time=30 minutes) T = 87.5859

Where v = cutting speed in m/min,

d = depth of cut in mm,

sz = feed in mm/tooth,

f = feed in mm/rev. ,

Ø = dia. of cutter for milling or drilling / diameter of previous hole for boring in mm,

z = no. of teeth on milling cutter,

n = no. of passes/cuts per surface

= no. of holes,

L = length of cut

= length of workpiece + approach of the drill (0.2 Ø) + length of the drill point (0.29 Ø)

+ overtravel (0.29 Ø) ----- for drilling

= length of the work + approach length ( 0.5*( Ø-( Ø2-B2)^0.5 ) for milling,

where B=width of workpiece.

66

Fig. 18a – Pictorial sequence of machining of base plate 1

67

Fig. 18b – Pictorial sequence of machining of base plate 1

Cost of machining base plate (C1) = Rs. 1751.178 /- approx.

68

8.2 Process sheet for base plate 2

Sr.

No.

Operation

sequence Cutting parameters [3] [6] [7]

Machining time

(minutes)

1. Face mill surface F

(n=1)

v=110, sz=0.30, d=3.5, z=16, Ø=150,

L=1116.262 t = 0.99 *2

Repeat this for surface E

2. Face mill surface C

(n=1)

v=110, sz=0.30, d=3.5, z=16, Ø=150,

L=409.261 t = 0.365 *2

Repeat this for surface D

3. Face mill surface A

by (n=3)

v=110, sz=0.30, d=2, z=16, Ø=150,

L=1145.308 t = 1.022 *6

Repeat this two more times

Face mill surface B in a similar manner

4. Drill Ø21 holes

(n=8) v=33, f=0.30, Ø=21, L=67.49 t = 0.44 *8

Drill 8 holes in all

Ream Ø22 holes

(n=8) v=20, f=0.6, Ø=22, L=68.18 t = 0.39 *8

Ream 8 holes in all

5. Bore to Ø32*35mm

(n=8)

v=31, f=0.25, d=2.5, L=35, Ø=22 v=31, f=0.25, d=2.3, L=35, Ø=27

v=33, f=0.125, d=0.2, L=35, Ø=31.6

t = 0.32 *8 t = 0.38 *8 t = 0.84 *8

Bore 8 holes in all

6. Drill Ø16 holes

(n=4) v=30, f=0.25, Ø=15, L=63.35 t = 0.398 *4

Ream Ø16 holes

(n=4) v=20, f=0.3, Ø=16, L=53 t = 0.44 *4

Drill and ream 4 holes in all

69

7. Drill Ø30 hole

(n=2) v=35, f=0.30, Ø=25, L=70.25 t = 0.525 *2

Bore to Ø30*53mm v=31, f=0.25, d=2.25, Ø=25, L=53

v=33, f=0.125, d=0.25, Ø=29.5, L=53 t = 0.537 *2

t = 1.1907 *2

8. Drill Ø25 holes

(n=2) v=35, f=0.35, Ø=25, L=70.25 t = 0.45 *2

Ream Ø26 holes

(n=2) v=20, f=0.65, Ø=26, L=70.94 t = 0.445 *2

Bore to Ø38*30mm

v=32, f=0.236, d=3, L=30, Ø=26 v=31, f=0.25, d=2.5, L=30, Ø=32

v=34, f=0.125, d=0.3, L=30, Ø=37

t = 0.32 *2 t = 0.389 *2

t = 0.8205 *2

9. Tap M24 holes

Drill Ø21 holes v=33, f=0.30, Ø=21, L=67.49 t = 0.44 *2

Tap M24*3 holes v=12, f=0.4, Ø=24, L=53 t = 0.83 *2

Drill and tap 4 holes in all

10. Finish mill all surfaces

Surfaces E and F

(n=2)

v=135, sz=0.4, d=1.5, Ø=150, z=16,

L=1107.837 t = 0.60 *2

Surfaces C and D

(n=2)

v=135, sz=0.4, d=1.5, Ø=150, z=16,

L=404.837 t = 0.2208 *2

Surfaces A and B

(n=4)

v=135, sz=0.4, d=1.5, Ø=150, z=16,

L=1142.308 t = 0.623 *6

9. Chamfering t = 1 (say)


Total machining time (assuming 12% allowance + setting time=30 minutes) T = 85.35936

Cost of machining base plate 2(C2)=Rs. 1707.1872 /- approx.

70

8.3 Process sheet for tenon

Sr. No.

Operation sequence

Cutting parameters [3] [6] [7] Machining time

(minutes)

1. Face off 3mm

Rough facing v=20, f=0.25, d=2, Ø=25, L=12.5 t = 0.196

Finish facing v=25, f=0.15, d=1, Ø=25, L=12.5 t = 0.261

2. Rough turn to Ø23*35 mm

v=35, f=0.30, d=1, Ø=25, L=12.5 t = 0.261


v=35, f=0.25, d=2.5, Ø=23, L=17 t = 0.1403

4. Make a groove of

Ø14*2 mm v=15, f=0.15, d=2, Ø=18, L=2 t = 0.0542

5. Finish turn to Ø16*15 mm

v=40, f=0.15, d=1, Ø=18, L=15 t = 0.1413

6. Drill and tap M6*20 mm hole

Drilling v=18, f=0.10,Ø=5, L=23.45 t = 0.2046

Tapping v=15, f=0.10,Ø=6, L=20 t = 0.251

7. Part off at 35 mm v=15, f=0.10, d=8, Ø=23, L=2 t = 0.096 *3

8. Finish turn to

Ø22*18 mm from the other side

v=45, f=0.15, d=0.5, Ø=23, L=18 t = 0.192

9. Face off 3 mm

Rough facing v=20, f=0.25, d=2, Ø=22, L=11 t = 0.152

Finish facing v=25, f=0.15, d=1, Ø=22, L=11 t = 0.202

10. Chamfer 2*45°, 3*15° t = 2 (say)


Total machining time (assuming 12% allowance & setting time=15 mins.) T = 19.864

Cost of machining 8 tenons (C4) = Rs. 3178.24/-

71

8.4 Process sheet for locating pin

Sr. No.

Operation sequence

Cutting parameters [3] [6] [7] Machining time

(minutes)

1. Face off 3mm

Rough facing v=20, f=0.25, d=2, Ø=55, L=27.5 t = 0.9503

Finish facing v=25, f=0.15, d=1, Ø=55, L=27.5 t = 1.267

2. Rough turn to Ø51.2*68 mm

v=40, f=0.30, d=1.9, Ø=55, L=68 t = 0.979


v=30, f=0.30, d=2.6, Ø=51.2, L=28 v=30, f=0.30, d=2.5, Ø=46, L=28 v=30, f=0.30, d=2.5, Ø=41, L=28 v=30, f=0.30, d=2.5, Ø=36, L=28

t = 0.5004 t = 0.445

t = 0.4007 t = 0.3518

4. Finish turn to Ø30*28 mm

v=45, f=0.15, d=0.5, Ø=31, L=28 t = 0.4039

5. Chamfer 2*15° t = 1 (say)

6. Part off at 68 mm v=20, f=0.15, d=10, Ø=51.2, L=2 v=20, f=0.15, d=10, Ø=31.2, L=2 v=20, f=0.15, d=10, Ø=11.2, L=2

t = 0.107 t = 0.0653 t = 0.0234

7. Finish turn to

Ø50.2*40 mm from the other side

v=50, f=0.15, d=0.5, Ø=51.2, L=40 t = 0.857

8. Face off 3 mm

Rough facing v=20, f=0.25, d=2, Ø=50.2, L=25.1 t = 0.791

Finish facing v=25, f=0.15, d=1, Ø=50.2, L=25.1 t = 1.055

9. Chamfer 5*20° t = 1 (say)


Total machining time (assuming 12% allowance & setting time=15 mins.) T = 26.4204

Cost of machining 2 locating pins (C5) = Rs. 1056.816/-

72

8.5 Cost of raw material

Total weight of set-up 1

= [ Volume of (base plate + support block + screwjack + round plate + bracket + clamp + clamp rest +

allen screws + stud + nut with washer + bolt + lock nuts) * Density of mild steel ]

+ (Volume of tenons * Density of EN 8)

= (48175.542 * 10-6 * 7850) + (33.8412 * 10-6 * 7845)

= 378.4434 kg

Total weight of set-up 2

= [ Volume of (base plate + support block + screwjack + round plate + bracket + clamp + clamp rest +

allen screws + stud + nut with washer + bolt + lock nuts) * Density of mild steel ]

+ (Volume of tenons * Density of EN 8) + (Volume of locating pins * Density of EN 24)

= (28236.83308 * 10-6 * 7850) + (33.8412 * 10-6 * 7845) + (184.8827 * 10-6 * 7872)

= 223.1442 kg

Total weight of T-shaped fixture

= Volume of (flange + t-shaped structure + rib) * Density of mild steel

= (468.769 + 1499.52 + 250) * 10-6 *7850

= 17.4135 kg

Hence, total weight of fixture = 619.001132 kg

Unit cost of raw material = Rs. 45/kg

Therefore, total cost of raw material (C5) = 45 * 619.001132 = Rs. 27855.05094 /-

*Total cost of fixture (excluding the machining cost of screwjack and t-fixture )

= C1 +C2 + C3 + C4 + C5 = 35548.47214 /- approx.

73

8.6 Process sheet for machining of columns

Cost of machining both the columns= Rs. 11784 /-

--------------------------------------------------------------------------------------------------------------------------------

74

9. Conclusion

Cost of machining the columns previously on Skoda machine = Rs. 45000/- approx..

Cost of machining the columns now on HMT machine = Rs. 11784/- approx.

Thus, the proposed design gives a cost benefit by a very large margin. This is because of the

changeover of the machining centre of the columns, and also due to a substantial reduction in the setting

time involved.

BEFORE AFTER

Total time required to machine

the columns previously on

Skoda machine

Total time required to machine

the columns on the proposed

HMT machine

% reduction in total machining

time

22.5 hours 9.82 hours 56.35%

----------------------------------------------------------------------------------------------------------------------

75

10. Testing

The proposed HMT centre (where the columns are to be machined) is currently overloaded with

other work schedules. Hence, unless the estimated targets are achieved, the given fixture design cannot

be tested there, and ultimately finalised. As such, the new production set up for the columns is on hold,

and they are being still machined on Skoda.

11. Scope for improvement

As far as the given project is concerned, we tried to reduce the set up time and cost by

proposing a new fixture design. And this design promises to give substantial savings. But, as such,

because of time constraints, there doesn’t seem anymore scope for improvement.

However, other than the project work, we do want to suggest some other changes that could

hopefully give fruitful benefits to the company in the long run. Firstly, the raw materials in the yard in

front of Hall no. 2 are not kept in an organized manner. Had we been associated with the company for

some more time, we could have thought over a new layout for storage which could have had different

predefined areas for storing different materials. Secondly, there is a need for a proper shed to cover

these materials. Aesthetically, that’s not a good sign. So that’s probably a grave point to contemplate on

its solution.

------------------------------------------------------------------------------------------------------------

76

12. References

1. CMTI Bangalore, Tata McGraw Hill Education Pvt. Ltd., 32nd

reprint

2. Donald Eary& Gerald Johnson, Process Engineering for Manufacturing

3. HajaraChowdhury, Elements of Workshop Technology, Media Promoters & Publishers Pvt. Ltd.,

Vol. 2 : Machine Tools, Twelfth Edition

4. Design Data, PSG College of Technology, DPV Printers

5. M.H.A. Kempster, An Introduction to Jig & Tool Design, ELBS, Third Edition

6. P. C. Sharma, A Textbook of Production Engineering, S. Chand & Company Ltd., Eleventh

Edition

7. Production Technology HMT Bangalore, Tata McGraw Hill Education Private Limited, 32nd

Reprint

8. R.S. Khurmi, J.K. Gupta, A Textbook of Machine Design, S. Chand & Company Ltd., Eurasia

Publishing House (Pvt.) Ltd., Fourteenth Edition

9. V.B. Bhandari, Design of machine Elements, McGraw Hill Education India Pvt. Ltd., Third

Edition

10. Catalogue of Komet group

Web links :

1.www.onesteel.com/images/db_images/productspecs/OSMB%20Technical%20Book%20Aug04.pdf

2. www.engineersedge.com/drill_sizes.htm

3. www.engineershandbook.com/Tables/drill2.htm

4. www.substech.com/dokuwiki/doku.php?id=alloy_steel_sae_4340

5. www.roymech.co.uk/Useful_Tables/Matter/Strength_st.htm

6. www.westyorksteel.com/EN24.html

7. www.steelo.com/AISI_1040.htm

senior year project report

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