ISSN Vol.03,Issue.10, November-2015, Pages:

Size: px

Start display at page:

Download "ISSN Vol.03,Issue.10, November-2015, Pages:"

Erick Adams
5 years ago
Views:

WWW.IJITECH.ORG ISSN 2321-8665 Vol.03,Issue.10, November-2015, Pages:1838-1844 Modelling and Analysis of Drill JIG NIRAV NEWAR 1, K. S.

1 ISSN Vol.03,Issue.10, November-2015, Pages: Modelling and Analysis of Drill JIG NIRAV NEWAR 1, K. S. CHAITNAYA 2, PHANI SHANKAR 3 1 PG Scholar, Dept of Mechanical, Aurora's Scientific Technological & Research Academy, Hyderabad, India, niravnewar7@gmail.com. 2 Assistant Professor, Dept of Mechanical, Aurora's Scientific Technological & Research Academy, Hyderabad, India. 3 Associate Professor, Dept of Mechanical, Aurora's Scientific Technological & Research Academy, Hyderabad, India. Abstract: This project deals with modeling and analysis of a DRILL JIG. The modeling was done in advanced modeling software CATIAV5R20 and analysis was done by using the predominant analysis software ANSYS Firstly, this modeling involves in modeling of individual parts of this DRILL JIG assembly and by using part module of the CATIAV5R20. In the Assembly module the individual components will be assembled by using bottom up approach which is a technique where the components will be imported and assembled. Secondly, Mechanism will be shown in the DMU Kinematics module, after converting the normal constraints into mechanical constrains. Finally, the modal and static structural analysis was done at different loading conditions on the DRILL JIG by using ANSYS By this analysis the strength of the DRILL JIG will be achieved. Keywords: DRILL JIG assembly, CATIAV5R20, ANSYS. I. INTRODUCTION Tool design is concerned with design and development of machines and special tooling, methods and techniques required by today s high speed mass manufacture at high efficiency and productivity. Its main objective is to produce component at a competitive price, maintaining quality and increased production. All this calls for selection of best tool materials for adequate tool life, providing simple and easy to operate tools for high efficiency, design of tools to be fool proof with no possibility of wrong operation, quality consciousness at all levels. The employment of jigs and fixtures is an important aspect of workshop engineering for the production of articles in large quantities with a high degree of accuracy and interchangeability at a competitive cost. The purpose of jigs and fixtures is to maintain low manufacturing costs and to increase industrial efficiency. Thus the jigs and fixtures are mainly used to reduce costs and ensure interchangeability which allows for rapid assembly. Its purpose is also to speed up machining times by eliminating time of handling and setting of the component parts. Further jigs and fixtures are taking the place of the skilled man in the production factory and making it possible to employ unskilled or semi- skilled operators. The primary objective of the use of jigs and fixtures is to facilitate the holding and supporting of the component by using fixtures, position it properly and guide the cutters so that every component will be uniform. It is also employed to accommodate several components at one setting and thus taking advantage of multiple machining. It is particularly very suitable where correct positioning of various holes at various exact places is important and which otherwise would consume lot of time in marking etc. A. 1JIGS Jig is a work holding device that holds, supports and locates the work-piece and also guides the cutting tool for a specific operation. Jigs are, usually fitted with hardened steel bushings for guiding drills or other cutting tools. Holes are bored in the structure, so that when tools are fed through them and into the component, holes are made in the component in the correct positions as required by the component drawing. It is usually necessary for the work to be held in the jig by clamping. Jig is usually not fixed to the machine table by clamping. However, for drilling holes above 6mm diameter, it is usually necessary to fasten the jig securely to the table. Jigs are used for mass drilling, reaming and tapping. B. Fixtures Fixture is a work holding device that holds, supports and locates the work piece but does not guide the cutting tool for a specific operation. The cutting tools are set in position by machine adjustment or by trial and error method. Setting gauges or setting blocks and feeler gauges are often provided to enable the initial setting of work to the cutter to be quickly and easily accomplished before machining. The fixture is generally bolted or fixed securely to the machine table in such a position that the work is in the correct relationship to the cutter. Fixtures are used for mass milling, turning and grinding operations. II. LITERATURE SURVEY According to NBV Lakshmi Kumari, G.Prsasnna Kumar, from the paper "Design and Analysis of Indexing Type of Drill Jig" In the context of the advanced technology engineers and scientists have visualized and conceptualized many designs and success of their designs and concepts is the 2015 IJIT. All rights reserved.

2 materialization of their designs. In short it can be said that production and manufacturing units consummate the design process. Thus the industry which gives shape to a theoretical design is a very potential and influential element in the technological development. The main objective of using jigs and fixtures in an industry is to achieve the Interchangeable Part Concept, and these are mainly used where production of goods is on large scale. The basic elements in the design of indexing type of drill jig is the component model, location, orientation and clamping. The scope of this paper is to design an indexing type of drill jig for a component having angular holes at 25 deg such the design is validated and verified. The present paper entitled Design and Analysis of Indexing type of Drill Jig is the work done for the design and analysis of Jig. Jigs are mainly used for mass production and for interchangeable parts concept, for a long period in the manufacturing of Jigs. Modeling is done using Solid works Software and Analysis by using ANSYS. According to Abdullah Jasim Mohammed, Dr. Mohammed Tariq, from the paper "Design and Analysis of Drill Jig for a Shaft using ANSYS" In order to compete with the evergrowing competent market, it is indispensable for an industrialist to aim for higher production coupled with the enhanced quality with an objective of reduction in the cost of potential. This necessitates to automation and usage of Tooling aids such as Jigs and Fixtures which involve comparatively much lower initial investments and higher productivity. The main factor of automation and utility at modernization of the tool design adopts tooling aids, such as Jigs and Fixtures. As sequel to this observation and aiming at higher productivity, it is proposed to study the performance parameters of modeling and assembly of drill Jigs using the software package PRO E and the analysis is done by using Ansys. Jigs and Fixtures are defined as devices used in the designing and manufacturing of the various parts of machines and intended to make interchangeable work, at reduced cost as compared with the cost of producing each machine detail individually. Pro E modeling provides capabilities to help the design engineer to perform conceptual and detailed deigns. It is a feature and constrained based solid modeler that allows users to create and edit complex solid models interactively. Ansys is a powerful tool for analyzing. Thus with the help of Pro E and Ansys the present model of drill jig is designed and analyzed. According to Fazlina Binti Mansor, from the paper "designing and evaluating of jig for holding cylindrical parts for mass production for drilling operation" The project study is about a designing and evaluating of jig for holding cylindrical parts for mass production of drilling operation. Three designs were draw and compared in terms of material and also the strength of the jigs to select the best design. This report begins with an introduction of jigs which is definition and important component in jigs and advantages of the jigs. Drilling jig is used whenever it is necessary to drill hole to exact location. The objective of this study is to design and analyze the drilling jig which can hold 30 work piece of small cylindrical parts. Designs were evaluate in terms of force applied to the jig. Three new jig were designed using Solid Works software. The design was analyze using FEA tools which are Algor software. Pugh Concept Selection also NIRAV NEWAR, K. S. CHAITNAYA, PHANI SHANKAR applied in selection the best design. Material AISI 1040, AISI 1018 and Iron, Fe selected to make analysis and as the result, material AISI 1040 were chosen for the jig. Design also evaluate by using two difference force value which is 400 N and 1000 N to choose the strongest design. The results for force 400 N showed that design 3 have lowest maximum von mises value with N/mm2 compared to design 1 with N/mm2 and design 2 with N/mm2. Design 3 were selected to be the final design and AISI 1040 selected as the jig material because it strongest compared to AISI 1018 and Iron, Fe. III. INTRODUCTION TO ANSYS The purpose of a finite element analysis is to model the behavior of a structure under a system of loads. In order to do so, all influencing factors must be considered and determined whether their effects are considerable or negligible on the final result. Much software is used for this purpose. ANSYS, Pro-E, Unigraphics, NISA, MSC, NASTRAN etc. The ANSYS program is self-contained general purpose finite element program developed and maintained by Swanson Analysis Systems Inc. The program contains many routines, all interrelated and all for main purpose of achieving a solution to an engineering problem by Finite Element Method. ANSYS provides a complete solution to design problems. It consists of powerful design capabilities like full parametric solid modeling, design optimization and auto meshing, which gives engineers full control over their analysis. The following are the special features of ANSYS software: It includes bilinear elements. Heat flow analysis, fluid flow and element flow analysis can be done. Graphic package and extensive preprocessing and post processing. The following shows the brief description of steps followed in each phase: TABLE I: Various Stages of ANSYS A. Meshing Manual Meshing: In manual meshing the elements are smaller at joint. This is known as mesh refinement, and it enables the stress to be captured at the geometric discontinuity. Manual meshing is long and tedious process for

3 models with any degree of geometric complication, but with useful tool emerging in pre-processes, the task is becoming easier. Meshing Controls: The default meshing controls that the program uses may produce a mesh that is adequate for the model we are analyzing. In this case, we need not specify any meshing controls. However if we do use meshing controls we must set them before meshing the solid model. Meshing controls allow us to establish the element shape, midside node placement and element size to be used in meshing the solid model, this step is one of the most important of the entire analysis for the decisions we make at this stage in the model development will profoundly affect the accuracy and economy of the analysis. B. Smart Sizing of Element Smart element sizing (Smart sizing) is a meshing feature that creates initial element sizes for free meshing operations. Smart sizing gives the mesher a better chance of creating reasonably shaped elements during automatic mesh generation. C. Free and Mapped Mesh A free mesh is one that has no restrictions in terms of element shapes, and no specific pattern applied to it. Compared to a free mesh, a mapped mesh is restricted in terms of the element shape it contains and the pattern of the mesh. A mapped mesh contains only quadrilateral (area) or only hexahedron (volume) elements. If this type of mesh is desired, the user must build the geometry as series of fairly regular volumes and/or areas that can accept a mapped mesh. D. Pre-Processor The pre-processor stage in ANSYS package involves the following: Specify the title, which is the name of the problem. Set the type of the analysis to be used, i.e., structural, thermal, fluid, or electro-magnetic, etc, Create the model: The model is drawn in 1D,2D, or 3D space in the appropriate units (m, mm, in, etc). The model may be created in pre-processor, or it can be imported from another CAD drafting package through a neutral file format9 like IGES, STEP, ACIS, Para solid, DFX, ETC., ). The same units should be applied in all directions, otherwise results will be difficult to interpret, or in extreme cases the result will not show up mistakes made during loading and restraining of the model. Define the element type, this may be 1D, 2D or 3D, and specify the analysis type being carried out. Apply mesh: Mesh generation is the process of dividing the analysis continuum in to number of discrete parts or finite elements. The finer the mesh, the better the result, but the longer the analysis time therefore, the compromise between accuracy and solution speed is usually made. Assign the properties: Material properties (Young s Modulus, Poisson s ratio, density, and if applicable coefficient of expansion, friction, thermal conductivity, damping effect, specific heat, etc.,) have to be defined. Modelling and Analysis of Drill JIG Solution: Apply the loads. Some type of load is actually applied to the analysis model. The loading may be in the form of a point load, pressure or a displacement in a stress analysis, a temperature or heat flux in a thermal analysis and a fluid pressure or velocity in a fluid analysis. The loads may be applied to a point, an edge, a surface or even to a complete body. Applying the boundary conditions: After applying load to the model in order to stop it accelerating infinitely through the computer virtually either at least one boundary condition must be applied. FE solver can be logically divided in to three main parts, the pre-solver, the mathematical-engine and the post-solver. The pre-solver reads the model created by the pre-processor and formulates the mathematical representation of the model and calls the mathematical-engine, which calculates the results. The result returned to the solver and the post-solver is used to calculate the strains, stresses, etc., for each node within the component or continuum. E. Post-Processor In this module, the results of the analysis are read and interpreted. All post-processor include the calculation of stress and strain in all of the X, Y, or Z directions, or indeed in the direction at an angle to the coordinate axes. The principle stress and strain may also be plotted. F. Structural Analysis Structural analysis is probably the most commonapplication of the FEM. The term structural implies not only civil engineering structures such as bridges and buildings, but also naval, aeronautical, and mechanical components such as pistons, machine parts and tools. The primary unknowns (nodal degree of freedom) calculated in a structural analysis are displacements other qualities, such as strains, stresses and reaction forces are derived from the nodal displacements. G. Modal Analysis Definition: We use Modal Analysis to determine the vibration characteristics (Natural frequencies and mode shapes) of a structure of a machine component while it is being designed. It also can be a starting point for another, more detailed, Dynamic Analysis, such as a transient dynamic, a harmonic response analysis, or a spectrum analysis. Uses for Modal Analysis: The Natural frequencies and mode shapes are important parameters in the design of a structure for Dynamic loading conditions. They are also required if you want to do a spectrum analysis or a mode superposition harmonic or transient analysis. We can do modal analysis on a pre stressed structure, such as a spinning turbine blade. Another useful feature is modal cyclic symmetry, which allows you to review the mode shapes of a cyclically symmetry structure by modeling just a sector of it. Modal Analysis in the ANSYS family of products is a linear analysis. Any nonlinearity, such as plasticity and contact (gap) elements, are ignored even if they are defined. You can choose from several mode extraction methods: subspace, Block Lanczos, Power Dynamics, reduced, unsymmetrical,

NIRAV NEWAR, K. S. CHAITNAYA, PHANI SHANKAR and damped. The damped method allows you to include damping in the structure. Details about mode extraction methods are covered later in this section. IV.

time-varying loads as shown in Figs.1 to 23.

4 NIRAV NEWAR, K. S. CHAITNAYA, PHANI SHANKAR and damped. The damped method allows you to include damping in the structure. Details about mode extraction methods are covered later in this section. IV. STRUCTURAL STATIC ANALYSIS Definition: A static analysis calculates the effects of steady loading conditions on a structure, while ignoring inertia and damping effects, such as those caused by time-varying loads as shown in Figs.1 to 23. A static analysis can, however, include steady inertia loads (such as gravity and rotational velocity), and time-varying loads that can be approximated as static equivalent loads (such as the static equivalent wind and seismic loads commonly defined in many building codes). A. Project Schematic Fig.4. Total Deformation 2. Fig.1. Project Schematic. B. Modals Fig.5. Total Deformation3. Fig.2. Mesh. Fig.6. Total Deformation 4. Fig.3. Total Deformation. Fig.7. Total Deformation 5.

Equivalent Stress. At 2000 Force Static: Fig.10. Force. Fig.14.

5 Modelling and Analysis of Drill JIG Fig.8. Total Deformation 6. Fig.12. Total Deformation. At 4000 Force Static: Fig.9. Fixed Support. Fig.13. Equivalent Stress. At 2000 Force Static: Fig.10. Force. Fig.14.Total Deformation. At 6000 Force Static: Fig.11. Equivalent Stress. Fig.15. Force.

6 NIRAV NEWAR, K. S. CHAITNAYA, PHANI SHANKAR Fig.16. Equivalent Stress. Fig.20. Total Deformation. At Force Static: Fig.17. Total Deformation. At force 8000 Static: Fig.21. Force. Fig.18. Force. Fig.22. Equivalent Stress. Fig.19. Equivalent Stress. Fig.23.Total Deformation.

V. RESULTS TABLE II: Modelling and Analysis of Drill JIG [4] "ANSYS Acquires SpaceClaim Corporation, A Leading Provider Of 3-D Modeling Software" [5] Wikipedia. Fig.24. Fig.25. VI.

7 V. RESULTS TABLE II: Modelling and Analysis of Drill JIG [4] "ANSYS Acquires SpaceClaim Corporation, A Leading Provider Of 3-D Modeling Software" [5] Wikipedia. Fig.24. Fig.25. VI. CONCLUSION Strength calculation was done by using predominant software ANSYS and natural frequencies were achieved for the modal with the help of modal analysis. From the results achieved at loads 2000N till 10000N it has given lower stress values and deformation for the modal according to the different load applications. By this it can be stated that at peak loads the modal which was created for the application will with stand for higher loads and the material was structural steel. VI. REFERENCES [1] Henriksen Erik Karl s - Jig and Fixture Design Manual. [2] Venkatesh, Izman - Precision Engineering. [3] Day, Martin (September October 2003 Gehry Dassault and IBM too. AEC Magazine. Retrieved

Stress analysis of Camshaft by using ANSYS Software

Stress analysis of Camshaft by using ANSYS Software Samta Jain, Mr. Vikas Bansal Rajasthan Technical University, kota (Rajasathan), India Abstract This paper presents the modeling and static structural