Jazan Univerity
College of Engineering
Mechanical Engineering Department
Fixtures Design Using Computer for
Cylindrical Workpieces in Drilling
Operations
By
Team Members:
Ahmed Mohammd Ali Hammadi
Hassan Jobran Al-Malki
Jaber Hadi Alassiri
Majed Ali Almalki
Saud Hassan Qurby
Supervisor (s):
Dr. Mahmoud Mohamed Atta Mahmoud
A Senior Project Final Report submitted in partial fulfillment
of the requirement for the degree of BACHELOR OF Science (B.Sc.),
in
Mechanical Engineering
(Rajab 1435)
(May 2014)
College of Engineering
Jazan University
Fixtures Design Using Computer for
Cylindrical Workpieces in Drilling
Operations
APPROVAL RECOMMENDED:
Examination Committee
Dr. Helmy M. O. Abulila
Dr. Gaber El-Awadi
Dr. Mahmoud Mohamed Atta
PROJECT SUPERVISOR (s): Dr. Mahmoud Mohamed Atta
DEPARTMENT HEAD:
Dr. Ali Al Shahrany.
COURSE INSTRUCTOR:
APPROVED:
Dr. Mohamed Nour Al Maghrabi
ABSTRACT
The product quality, manufacturing time, cost and interchangeability
of products are occupied the manufacturing systems planners. Work holding
devices are the tooling elements that have a large effect in all of these
problems. Fixture is a special holding device use to help in controlling these
problems. The lack of fixture flexibility decrease the flexibility of the whole
manufacturing system to face rapid change in products design and high
competitive between products. Modular fixture is the preferred flexible
fixture systems to solve these problems in job or small batch lot size
systems.
Fixture design is a highly complicated procedure and time consuming.
Computer systems and software can be used in creation, or analysis of the
modular fixture design. The use of computer will help in the reducing the
lead time, obtaining most alternatives in a shorter time, saving and using
experiences of others.
Through the present project an excel sheet is prepared for designing
fixtures (selection the suitable modular fixture elements) for drilling holes in
cylindrical workpieces parallel to the its axis. At the end, an assembly sheet
(contains the used modular fixture elements, its position and orientation and
the location of the workpiece with respect to these elements) is prepared.
AutoCAD is used to produce a data base of the 3D model of the modular
fixture elements and make the final assembly of the designed fixture. The
resulting errors in the workpiece, due to the accuracy of the modular fixture
elements, are obtained.
iii
DEDICATION
To our Parents, who, through their financial and moral support were
the source of inspiration and the mainstay in our attaining an education, we
dedicate this project.
iv
ACKNOWLEDGEMENT
This project was written under the direction and supervision of Dr.
Mahmoud Mohamed Atta Mahmoud we would like to express our sincere
appreciation to him for the interest and assistance given to us.
v
TABLE OF CONTENTS
PAGE
ABSTRACT………………………………………………………………..
iii
EDICATION………………………………………………………………….…
iv
ACKNOWLEDGEMENT………………………………………………….…….. v
TABLE OF CONTENTS …………………………………………..……..…
vi
LIST OF FIGURES
viii
NOMENCLATURE
xi
CHAPTER
1. INTRODUCTION
1
1-1 The rule of fixture
1
1.2 The flexible fixture
3
1-3 Problem statement
4
1-4 Problem justification and outcomes
5
2. JIGS AND FIXTURES
6
2-1 Purpose and advantages of jigs and fixture
8
2-2 Fixture design principles
8
2-2-1 Basic requirements of fixtures
9
2-2-2 Locating principles
9
2-2-3 Clamping principles
12
2-3 Modular fixture system
13
3. FIXTUER DESIGN FOR CYLINDRICAL WORKPIECE IN
DRILLING HOLES PARALLEL TO ITS AXIS
17
3-1 Workpiece configurations, locating and clamping surfaces
17
3-2 Fixture design algorithm
20
3-2-1 Locating points and elements
21
3-2-2 Clamping point and elements
26
vi
3-2-3 Assembly sheet
26
3-3 Fixture errors
27
4. RESULTS AND DISCUSSION
29
4-1 Fixture design for blind holes with top clamp
29
4-2 Fixture design for through holes with top clamp
32
4-3 Fixture design for counter boring holes with top clamp
35
4-4 Fixture design for countersinking holes with top clamp
38
4-5 Fixture design for blind holes with side clamp
41
4-6 Fixture design for counter boring holes
with side clamp
1.5”
43
5. FEASIBIILITY STUDIES AND MARKET NEEDS
48
6. CONCLUSIONS, RECIMMENDATIONS AND FUTURE WORK
50
6-1 Conclusions
50
6-2 Recommendations and future work
51
7. APPENDIXES
52
A:
Project team with assigned responsibilities,
52
B:
Faculty advisers and industry sponsors
52
C: Project budget and expenses to date
52
D: Drawing package (if applicable)
52
E: Manufacturing procedures, test procedures and test reports
52
F: Technical reports or evaluations
52
G: Toolroom Starter Sets of CarrLane manufacturing company
53
REFERENCES
58
vii
LIST OF FIGURES
FIGURE No
(Fig. 1.1)
DESCRIPTION
PAGE
The rule of fixture design in manufacturing
system.
2
(Fig. 1.2)
The current flexible fixture methodologies.
4
(Fig. 2.1)
Configuration and construction of a jig.
7
(Fig. 2-2)
Configuration and construction of a fixture.
7
(Fig. 2-3)
The six degrees of freedom of the rigid body.
10
(Fig. 2-4)
The 3-2-1 locating principle to restrict the
workpiece that a three mutually perpendicular
surfaces
11
(Fig. 2-5)
The locating system for cylindrical parts.
12
(Fig. 2-6)
The locating system for internal holes parts.
12
(Fig. 2-7)
Side clamp.
13
(Fig. 2-8)
Top clamp.
14
(Fig. 2-9)
Types of modular fixture systems.
15
(Fig. 2-10)
The hole base system functional sets elements.
16
(Fig. 3-1)
The flowchart for the design procedures for
fixture.
18
(Fig. 3-2)
An example of workpiece configuration
19
(Fig. 3-3)
An example of workpiece configuration in
the machining orientation.
20
(Fig. 3-4)
The flowchart for the design algorithm.
22,23
(Fig. 3-5)
The inputs in the excel sheet.
24
(Fig.3-6)
The used locating elements.
24
(Fig. 3-7)
The excel equation for selection the primary and
secondary location.
24
(Fig. 3-8)
The workpiece with the locators.
25
(Fig. 3-9)
The used clamping elements.
26
viii
(Fig. 3-10)
The effect of the support accuracy and the
distance between the supports on the tilting
angles of the workpiece.
27
The position error due to accuracy of the side
locators.
28
(Fig. 4-1)
The required product for blind holes.
30
(Fig. 4-2)
The required workpiece with its orientation
and in its place, blind holes.
30
A part of excel sheet for blind holes making,
top clamp.
31
The assembly sheet for the blind holes fixtures,
top clamp.
31
The assembly of the blind holes fixture with the
workpiece in place, top clamp.
32
The required product for through holes.
33
The required workpiece with its orientation
and in its place, through holes.
33
A part of Excel sheet for through holes making,
top clamp.
34
(Fig. 3-11)
(Fig. 4-3)
(Fig. 4-4)
(Fig. 4-5)
. (Fig. 4-6)
(Fig. 4-7)
(Fig. 4-8)
(Fig. 4-9)
The assembly sheet for the through holes fixtures,
top clamp.
34
(Fig. 4-10)
The assembly of the through holes fixture with
the workpiece in place, top clamp.
35
(Fig4-11)
The required product for counter boring holes.
36
(Fig 4-12)
The required workpiece with its orientation and
in its place, counter boring holes.
36
A part of Excel sheet for counter boring holes
making, top clamp.
37
The assembly sheet for the counter boring holes
fixtures, top clamp.
37
The assembly of the counter boring holes fixture
with the workpiece in place, top clamp.
38
The required product for countersinking holes.
39
(Fig 4-13)
(Fig. 4-14)
(Fig. 4-15)
(Fig. 4-16)
ix
(Fig. 4-17)
(Fig. 4-18)
(Fig 4-19)
(Fig 4-20)
(Fig. 4-21)
(Fig. 4-22)
(Fig. 4-23)
(Fig. 4-24)
(Fig4-25)
(Fig 4-26)
The required workpiece with its orientation and
in its place, countersinking holes.
39
A part of Excel sheet for countersinking holes
making, top clamp.
40
The assembly sheet for the countersinking holes
fixtures, top clamp.
40
The assembly of the countersinking holes fixture
with the workpiece in place, top clamp.
41
A part of Excel sheet for blind holes making,
with side clamp.
42
The assembly sheet for the blind holes fixtures,
with side clamp.
42
The assembly of the blind holes fixture with the
workpiece in place, side clamp.
43
A part of Excel sheet for counter boring holes
making, side clamp.
44
The assembly sheet for the counter boring holes
fixtures, side clamp.
45
The assembly of the counter boring holes fixture
with the workpiece in place, side clamp.
45
(Fig 4-27)
The views of the fixture of the assembly fig 4-20 46
(Fig. 4-28)
The views of the fixture of the assembly fig 4-26 47
(Fig. 5-1)
The economical comparison between different
methodologies of fixture.
x
49
NOMENCLATURE
Symbols
Description
UNITS
d
Diameter of the primary locating surface
mm
h1
Min. height required for primary locating surface
mm
h2
Min. height of clamping surface
mm
α
Tilting angle of workpiece in the X direction
Deg.
β
Tilting angle of workpiece in the Y direction
Deg
x
Position error of the workpiece
mm
c
Tolerance of the modular fixture elements
mm
θ
Central angle between the primary and secondary locators. Deg
θnew
The expected central angle due to the side locators
tolerances
xi
Deg
CHAPTER 1
INTRODUCTION
CHAPTER 1
INTRODUCTION
The most common problem facing any company is to produce its
products with the highest quality, in the shortest time and with the
minimum cost. The ways to achieve these goals are, in some manner,
conflicted (the high quality with the shortest time and minimum cost),
while other ways are coincide (the shortest time with the minimum cost).
The use of suitable holding device can achieve all these goals together to
a certain high degree. Nowadays, Another problem facing the
manufacturing companies are the interchangeability of the products. This
interchangeability are affected by the manufacturing procedures, and
holding devices used in producing these parts.
1-1
THE RULE OF FIXTURE
Workpiece holding devices are critical components in the
manufacturing system because of its effect in the part accuracy, product
cost and lead time (its effect in loading and unloading time and total
machining time). These holding devices can be classified into two
branches;
a) General purpose holding devices; such as chuck (3 jaws or 4 jaws),
vise, face plate, .. etc. It can be used to hold workpieces but with
larger time to achieve higher accuracy which may increase the cost.
b) Special holding devices; jig and fixture. It can be produced to hold
a certain workpiece lot size or a group of workpieces lot sizes. That
holding devices increase the initial cost but decrease the loading
and unloading time, the current cost, and increase the quality.
1
Fixtures are special workholding devices that designed to hold,
locate and support workpieces against the tool (cutting tool, assembly
tools, or inspection tools) during manufacturing operations (machining,
assembly or inspection).
The rule of the fixture in the manufacturing systems is shown in
fig.1.1 [1]. The fixture design begin with the product geometry and
process planning of the product and ended with the fixture assembly in
the production system.
Fig. 1.1 The rule of fixture design in manufacturing system.
With the use of modern machine tools the machining time is
reduced to a high degree because of the reduce of human effect and the
use of heavier feed and depth of cut. This gives the time for loading and
unloading of the machining parts and the rigidity, to withstand the high
feeding forces, a large amount of considerations in the manufacturing
system. Fixture is used to improve the performance of the manufacturing
system in these fields, reduce the loading and unloading time and increase
the rigidity of the holding devices. The design of the fixture will be
discussed in chapter 2.
2
Fixturing methodologies are usually determined by the size of the
lots. In the mass production manufacturing system, the number of parts
can face the fixture costs and the leading time in design and
manufacturing the indicated fixture. But; in the job or in batch
manufacturing systems the product cost and the lead time to the
production cycle are increased significantly with the design and
manufacturing the fixture to a certain product manufacturing cycle.
1-2
THE FLEXIBLE FIXTURE
The rapid change of in the products design, the shorting of the lead
time and competitive between the different products and the achieving
high accuracy are problems facing the manufacturing system. These
problems required a degree of flexibility in the manufacturing system to
be solved. The flexibilities of the manufacturing systems are faced with
the lake of flexibility in the design and manufacturing of the indicated
fixtures. Without using flexible fixture the overall FMS could not be
realized real flexibility. Fig. 1.2 summarize the current flexible fixture
methodologies, their flexibility source and sub categories.
Modular fixture, which use the assembly of standard components
to achieve the fixture, can be used as a flexible fixture system to face the
small lot size because these components are disassembled and
reassembled to produce much more fixture configurations [1].
The computer is used to increase the speed of selection and
drawing assembly of the mechanical components. This can be used in the
field of fixture design to reduce the lead time used in the design and
manufacturing of the required fixtures.
3
Fig. 1.2 The current flexible fixture methodologies.
1-3
PROBLEM STATEMENT
The previous introduction shows that the problem may be a treated
as how to use the computer to design a flexible system for manufacturing
fixture used to hold a small lot size of products with a small lead time.
Modular fixture are preferred because of its generality and it
consists of a standard elements that are used to accomplish a certain
fixture then disassemblies and reassembled in other fixture and so on.
This increase the flexibility of the system and reduce the tooling cost for
job and small size lots in batch lot manufacturing systems.
The use of computer is to minimize the lead time in design of the
fixture. The lead time in selection the modular fixture components
required for a certain fixture and preparing the assembly sheet of this
fixture. Also; reduce the time which is consumed in preparing the
drawing sheets for this fixture.
4
1-4
PROBLEM JUSTIFICATION AND OUTCOMES
As a result this project uses modular fixture as a flexible fixture
methodology to overcome the problem of small lot size and fixture cost.
The kits of the modular fixture are collected from the catalog of modular
fixture produced by Carr Lane Company, USA. These 3D geometrical
models of these kits, modular fixture elements, are prepared with
AutoCAD software (Note the 2d of these kits are available in the website
of the company).
By using the Excel 2007 the selection of the modular fixture
elements are made, and their position in the base plate and their
orientation are calculated. At the end assembly sheet of the selected
elements, position and orientation are made.
At the end the 3D geometrical model of this assembly sheet of
modular element, which
are prepared through the project, with the
workpiece can be viewed with AutoCAD (version 2004 at later versions).
.
5
CHAPTER 2
JIGS AND FIXTURES
CHAPTER 2
JIGS AND FIXTURES
Jigs and fixtures are devices used to facilitate production work,
making interchangeable pieces of work possible at a savings in cost of
production. They are used to locate and hold the work that is to be
machined. These devices are provided with attachments for guiding,
setting, and supporting the tools in such a manner that all the workpieces
produced with them, jig or fixture, will be exactly alike in every way. So,
The employment of unskilled labor is possible when they can be used in
production work. And the repetitive layout and setup (which are timeconsuming activities and require consider-able skill) are eliminated. Also,
the use of these devices can result in such a degree of accuracy that
workpieces can be assembled with a minimum amount of fitting [3].
Jig is a work holding device that holds, supports and locates the
workpiece and guides the cutting tool for a specific operation. Figure 2-1
shows a configuration and construction of a certain jig. The word jig is
used in the drilling or boring operations and it should have a guiding for
the tool. The jigs consist of clamping element(s), locators, drilling plate
and drilling bush(s) for guiding the drill during the drilling operations.
The elements are assemblies together with different assembling
operations (welding joints, bolted joints, .. etc). jigs are identified with
their basic construction; open jig (such as; plate jig, sandwich jigs, .. etc),
closed jigs (such as; channel jigs and leaf jigs, … etc) [4].
Fixtures have wider scope of application than jigs. Fixture is
primarily a holding device. A fixture, fig 2-2, holds the workpiece firmly
in place for the machining operation, but it does not form a guide for the
tool. They are designed for processes where the tools cannot be guided
6
easily. Within; the fixture there is an element position the way tool, cutter
as an example, with respect to the workpiece called tool setting and it
should be bolted to the machine table. Fixtures are identified with the
machine tool where they are used; milling fixture , turning fixture .. etc.
[2].
Drilling bush
Drilling plate
Clamping
locators
Base and foots
Fig 2-1 Configuration and construction of a jig [5].
Fig 2-2 Configuration and construction of a fixture.
It is sometimes difficult to differentiate between a jig and a fixture,
since their basic functions can overlap in the more complicated designs.
The best means of differentiating between the two devices is to apply the
basic definitions, as follows:
7
1. The jig is a guide device while the fixture is a holding device.
2. The jig has foot to be placed on the machine table while the fixture
may be secured and located to the machine table with a bolts and
tenons respectively.
3. The jigs contain a drilling plate and bushes to guide the tool while
the fixture may contain setting block to position the tool.
2-1 PURPOSE AND ADVANTAGES OF JIGS AND FIXTURES
For the above section the following purpose and advantages of jigs
and fixtures can be noted [6]:
a) It reduces marking, measuring and setting of workpiece times and
maintains the accuracy of performance.
b) Reducing loading time for workpiece and tool adjusting time.
c) Help in achieving consistent quality and high interchangeability.
d) Reduces production cycle time so increases production.
e) More than one tool can be used at the same time.
f) Operating conditions (speed, feed rate and depth of cut) can be
increased due to rigidity of clamping of workpiece by jigs and
fixtures.
g) Comfort the operators since the setting of workpiece can be
eliminated.
h) low skilled operators can be employed which can saves the cost of
manpower.
2-2
FIXTURE DESIGN PRINCIPLES
From the definition of the fixture should contain three main groups
of elements; location elements, clamping elements and supporting
elements. The role and examples of these elements will be discussed later
8
through this chapter. First; the requirements of the fixtures are discussed.
At the end of the chapter the used flexible fixture system, modular fixture
will be discussed.
2-2-1 Basic Requirements of Fixtures
1. Ensuring positional accuracy of workpiece, to achieve the higher
product accuracy.
2. Ensuring operation convenience and safety, the operator can
achieve the required work with min. effort, at min. time and with a
high degree of accuracy.
3. Ensuring productivity in the production system, higher production
rate than the conventional work without fixture.
4. Ensuring low production cost, according to the number of products
required.
2-2-2 Locating Principles
The most important task of fixture design is to locate the workpiece
with an acceptable accuracy. The role of locating system is to ensure a
relative position between the workpiece and machining tools. The
locating process places a set of workpiece faces, called locating datum
surfaces, in contact with fixture locators. If the workpiece surfaces are
separated from contact with the locators, the location is failed. Once the
positions and orientations of locating surfaces are determined other
features or surfaces of the workpiece are determined with respect to the
machine table and the machining tools.
For any rigid body (workpiece), there are six degrees of freedom
describing the position and orientation of this body. Figure 2-3 shows this
6 degrees of freedom, three linear movements in X, Y and Z directions
9
and three rotational movements about X, Y and Z Axes. The aim of the
fixture designer in this stage is to restrict all or part of these 6 degrees of
freedom, so that the position or orientation of the workpiece can be
uniquely determined.
Fig 2-3 The six degrees of freedom of the rigid body.
Based on kinematics principles, six independent point are required
to achieve these restriction. Figure 2-4 shows how to restrict the
workpiece that has a three mutually perpendicular surfaces. This principle
is called 3-2-1 locating principle. This means that the 1 st surface, called
primary locating surface, is restricted against 3 points, the 2 nd surface,
called the secondary locating surface, is restricted with 2 points, while the
3rd surface, called the third locating surface, is restricted with only one
point. The first 3 points restrict the motion along Z direction, rotation
about X and Y axes. The second 2 points restrict the motion along Y
direction, rotation about Z axis. While the last point restrict the motion
along X direction.
01
The role of locating system is to ensure a relative position between the
workpiece and machining tools.
Fig 2-4 The 3-2-1 locating principle to restrict the workpiece that a three
mutually perpendicular surfaces
Figure 2-5 (a) shows the application of the 3-2-1 locating principle
for the cylindrical workpiece. Figure 2-5 (b) shows the use of v-block in
the location of the cylindrical parts, the v-block restricted 5 degrees of
freedom (motions along X and Z directions, rotation about X and Z axis),
the stopper restricted the motion along y direction, while the 6th degrees
of freedom is not taken into considerations because of the symmetry
about Y axis. If the workpiece has internal holes, these holes can be used
as primary and secondary locating surfaces, fig2-6. The primary locating
surface is one internal hole, has cylindrical shape which restricted 5
degrees of freedom, the secondary locator is the farthest hole from the
primary locating hole and its shape is diamond restricted the 6th degree of
freedom. Figure 2-6 (a) shows the workpiece with the locators, while
Figure 2-6 (b) shows the shape of the locators.
00
Stopper
v-block
a) The 3-2-1 locating principle
for cylindrical parts.
b) Using the V block to achieve this
principle for cylindrical parts.
Fig 2-5 The locating system for cylindrical parts.
b) Locators shape
a) Workpiece with locators
Fig 2-6 The locating system for internal holes parts.
2-2-3 Clamping principles
The clamping system purpose is to securely hold the position of
workpiece against locators though the machining process. The basic
requirements of the clamping system to keep the workpiece in the
locating position with minimum deformation are;
1) The clamping should keep the workpiece in contact with locators,
so the location is ensured.
2) The clamping force is enough to resist the machining forces and
not great to cause a deformation in the workpiece.
01
3) The clamping operation should be simple, time saving safe and
easy. Also, no impact load on the workpiece, machine tool and
cutting tools.
4) The clamping device should be suitable for the production type
and batch size.
In order to reduce the deformation the clamping direction should
be directed toward the major locating surface with a large contact areas.
Properly selecting of the clamping direction can lead to smaller clamping
force required. When it is coincide with the gravity or the cutting force it
may be smaller. The clamping position can be determined such that it is
not damage the location and the workpiece deformation is minimum. For
example the clamping forces should be inside the locating points not
outside it.
Figure 2-7 shows a side clamp where the clamping position is
taken at a height lower than the height of the opposite locator. Figure 2-8
shows a top clamp where the clamping position is taken above a
supporting element
Fig. 2-7 Side clamp
2-3
MODULAR FIXTURE SYSTEM
Flexible fixturing has become an important component of flexible
manufacturing systems (FMS) and computer-integrated manufacturing
systems (CIMS). There are several different categories of flexible fixtures
01
(shown in the previous chapter), but modular fixtures are most widely
used in industry for job and batch production [7]. Modular fixturing can
be defined as a system for building several combinations of
standard components that can serve a wide variety of workpieces.
These fixture elements can be assembled and reused in order to
generate different constructions of jigs and fixtures [8]. The flexibility of
the modular fixtures is derived from the large number of fixture
configurations from different combinations of the fixture element.
Fig. 2-8 Top clamp
Commercially available modular fixturing systems can be
classified into two types: T-slot and hole-based systems. Slot-based
modular fixtures have parallel and perpendicular T-slots on the base
plates (Fig. 2-8 a). The use of modular fixtures enhances fixture
flexibility and reduces the time and cost of fixture development, which is
especially beneficial to small-volume production and new product
prototyping.
Hole-based modular fixtures have accurately positioned holes on
the base plates (Fig. 2-8 b). The CarrLane manufacturing company, USA,
hole based modular fixture system, appendix (g) shows the toolroom sets
of it, will be used through this project. The hole base system consists
functional set of elements, fig. 2-9. These sets are base plates set,
supports set, locators set, clamps set and fasten components set.
01
a) T- slot based modular
b) Hole based modular fixture
fixture system
system
Fig. 2-9 Types of modular fixture systems
Fixture design, fabrication, and testing consume a major portion of
production development time. In a manufacturing system, it is desirable
that fixtures be flexible so that the leading time of the products can be
reduced. The use of computer in the selection and in drawing the fixture
elements assembly will reduce this lead time and provide the system with
the past experience from the designers. Excel program can be
programmed to select the most suitable fixture elements and make the
assembly sheet for these elements. Also, AutoCAD [9] can be used to
assemblies these elements and make the required drawing views with the
pre-prepared 3D models of the fixture elements. At the end the predicted
values error can be calculated according to the tolerance of the used
elements.
01
Fig.2-10 The hole base system functional sets elements.
06
CHAPTER 3
FIXTUER DESIGN FOR CYLINDRICAL
WORKPIECE IN DRILLING HOLES
PARALLEL TO ITS AXIS
CHAPTER 3
FIXTUER DESIGN FOR CYLINDRICAL
WORKPIECE IN DRILLING HOLES PARALLEL
TO ITS AXIS
The fixture design tasks begin with the gathering data about the
workpiece (dimensions and geometry), and process plan of the product
(the jobs done in each set up and the machine used to perform that job).
According to the previous information the locating and clamping surface
are obtained, then the locating and clamping point are selected. Then, the
different functional elements are selected and the configuration of the
fixture can be finished. The verification of the fixture be prepared
(determine the resulting errors and the clamping forces and chuck if it
was with the accuracy limits of the workpiece). At the end the assembly
sheet and drawing can be done. Figure 3-1 shows the flowchart of these
procedures.
3-1
WORKPIECE
CONFIGURATIONS,
LOCATING
AND
CLAMPING SURFACES
Though this project, fixture for cylindrical workpiece that required
to drilled with holes parallel to its axis will be designed. Figure 3-2 shows
an example for this workpiece. This type of workpieces are symmetry
about its axis, which means that it is required to restricted five degrees of
freedom only to locate the workpiece completely.
These restrictions are distributed into two surfaces; primary
locating surface has three restrictions and secondary locating surface
71
which has two restriction. The 3 locating restrictions on the primary
location surface restrict the motion in the z direction (direction of the
drill), and rotation about X and Y axes. The two other locating on the
secondary locating system restrict the motion in the direction of X and Y
directions. The rotation about the Z axis, the direction parallel to the drill
axis, is not necessary to restricted because of symmetry about it.
Fig. 3-1 The flowchart for the design procedures for fixture.
The first step in the fixture design is the defined the locating and
clamping surface of the workpiece. This step is made through four stages,
which are;
1- Oriented the workpiece machined surface to the direction of the
tool. The axis of the drill in the drilling machine tool is vertical.
So, the workpiece should be oriented in a vertical position permit
the drill to produce the hole.
71
S1
S3
S2
Drill Axis
Workpiece Axis
Fig. 3-2 An example of workpiece configuration.
2- Defined the primary locating surface. This surface can be taken as
the bottom surface of the working entity (part of the workpiece)
that contains the holes required to machined. In the workpiece
shown in fig 3-2 the surface is S1 because the job is blind hole. If
the hole is through hole the two surface S1 or S2 can be used but
S1 is preferred to minimize the locating element.
3- Defined the secondary locating surface. This surface can be taken
as the side surface of the working entity that contains the holes
required to machined. In the workpiece shown in fig 3-2 the
surface is S3.
4- Defined the clamping surface. With the noting the above three
stages and the clamping action can be either side or top clamp the
defining of the clamping surface either one of the two following
routines;
a) Top clamp; the top clamp is parallel to the direction of the
drill, that means that it will be against the primary locating
surface. So; if the primary locating surface is S1, fig. 3-2, the
clamping surface is S2. While, if the primary locating surface
71
is S2 the clamping surface is S1. To minimize the height of
clamp which leads to minimize the deformation and resulting
error.
b) Side clamp; the side clamp is perpendicular to the direction of
the drill, that means that it will be against the secondary
locating surface. So; the clamping surface is S3.
The previous four stages are done by the user at the end the
geometrical model of the workpiece is made with AutoCAD and the
workpiece is put in the required orientation with the center of the primary
locating surface at the origin of the drawing work space, fig. 3-3.
Fig. 3-3 An example of workpiece configuration in the machining
orientation.
3-2
FIXTURE DESIGN ALGORITHM
After the user determine the primary and the secondary locating
surfaces and the clamping surface, the data collected about the workpiece
is entered to the excel sheet. Figure 3-3 shows the flowchart for the
design algorithm. The input data for the excel sheet are;
1- Diameter of the primary locating surface (d).
2- The minimum height required for the primary locating surface
(h1). This can be one of the following 3 cases;
02
a) The height is zero for the S1 locating surface and blind hole,
fig. 3-2 and fig. 3-3.
b) The conical height of the drill for the S1 locating surface and
through hole.
c) The height of small diameter portion of the workpiece for S2
locating surface.
3- The type of clamp (side clamp or top clamp).
4- Min. height of clamping surface (h2), for top clamp only. For
example, the difference between the two surfaces S1 and S2, in
the three cases illustrate in input 2.
5- The position of the first locator in the primary locating surface,
case (b and c) in input 2 or the first locator in the secondary
locating surface, case (a) in input 2. Note; this input is entered at
the end of execution according to the calculated spread of the
element position.
There are 3 sets of elements in the Carrlane company catalog the
mini size set will be used through this project. Figure 3-5 shows the
inputs in the excel sheet.
3-2-1 Locating Points and Elements
The flowchart shows that, If the height h1 is zero, the three
locating points is on the base plate itself, no bottom location and the side
locators are cylinder support. Else if h1 not equals zero, the two shoulder
support locators are used as bottom and side locators with a riser for
elevating it, if necessary, while the third locator is a rest with a support
riser, fig. 3-6 [10].
The equation for selection of 1st and 2nd locators is shown in
fig. 4-7 where A7 is the height h1 and CL-MF-xxxx are the catalog
elements, appendix (g).
07
Start
Input data:
1. Workpiece diameter (d).
2. Min. height of primary locating surface (h1).
3. Type of clamp.
4. Min. height of clamping surface, for top clamp (h2).
No
Yes
If h1 = 0
Use 3 locating points in hang
the primary locating surface.
st
Use the base plate as the
primary locating surface.
nd
Select 1 & 2 locators as bottom
& side locator (CL-MF25-32XX)
st
nd
Select 1 & 2 locators as
side locator (CL-MF25-3103)
Selection a riser to accommodate the height of
the primary locating system (CL-MF25-1461).
Determine the position (the most suitable no. of cells) of
nd
st
2 locator with respect to the 1 locator, as near as
possible to make central angle 120˚, according to d.
Determine the position of the workpiece
with respect to these two locators.
rd
Obtained the 3 locating point in the primary
locating surface (the point bisect the
complemented angle to the central angle).
No
If h1 = 0
Yes
Determine the Orientation of the two
locators.
rd
Select the 3 locator as a rest pad (CL-MF25-48XX)
and support riser (CL-MF25-33XX) according to the
st
height of the 1 locator.
rd
Determine the position and orientation of 3
st
locator elements with respect to the 1 locator,
the min. and max. distances of the locators.
A
Fig. 3-4 The flowchart for the design algorithm.(cont.)
00
A
side
top
Type of
clamp
Select adjustable low nose edge clamp
(CL-00-SAC) as side clamp.
Select tapped nose high riser clamp (CLMF25-2001) as top clamp.
Determine position of the side clamp (the
most suitable no. of cells).
Determine the position of the clamping point.
Determine the position of the different
component of the clamping (to be assemblies
in AutoCAD).
Determine orientation of the side clamp to
direct it toward the center of workpiece.
Select elements to left the clamp up if the height of the
clamp base larger than the max clamp height of the
clamping element (CL-MF25-2301 or CL-MF252351).
Select elements to lower the clamp point down if
the height of the clamp nose lower than the min
clamp height of the clamping element (CL-MF252502 and CL-MF25-26xx).
Enter the position of the 1st
locator in the base plate.
Obtain the assembly sheet of the fixture.
Assembly the fixture with AutoCAD
End
Fig. 3-4 Cont. The flowchart for the design algorithm
02
Figure 3-5 The inputs in the excel sheet.
Shoulder Support
Cylinders
Figure 3-6 The used locating elements.
=IF(A7=0;"CL-MF25-3103";IF(A7<25.4;"CL-MF253202";IF(A7<31.75;"CL-MF25-3203";IF(A7<38.1;"CL-MF253204";IF(A7<50.8;"CL-MF25-3205";IF(A7<63.5;"CL-MF253206";IF(A7<76.2;"CL-MF25-3205";IF(A7<114.3;"CL-MF253206";"HIGHER"))))))))
Figure 3-7 The excel equation for selection the primary and secondary
location.
02
The location of the 3 locating points in the primary locating surface
are determined according to both the diameter of the primary locating
surface and the diameter of the locating (1ʺ). For balancing the bottom
points should be 120˚ spaced. The problem is to get a two holes in the
base plate the make the central angle for the two locating points as near as
possible to 120˚, fig. 3-8. The distance between the 2 locators (BC) is
determine according to eq. 3-1. The excel is search about two holes to be
as near as possible to the value BC. After that the actual central angle is
obtained. After that the complement angle to the central angle is
calculated and the third supporting point is determine to get the location
of the 3rd support element (X) according to the diameter of the rest pad.
Fig. 3-8 The workpiece with the locators.
Eq. 3-1
Where;
d
the diameter of workpiece
After getting the position X the excel sheet search for a hole to bolt
the extension support at it. Then the orientation of the support riser is
calculated so that the rest pad positioned under the 3 rd locating point
directly. The selection of the shoulder support cylinders are determine
according to the height h1, it should be larger than it. The sum of heights
02
of rest
pad and extension support is the same as shoulder support
cylinders or the sum of its height with the riser block is used.
3-2-2 Clamping point and Elements
The clamping point and element is determined according to the
choice of the user, top or side clamp, fig. 3-9.
For the top clamp the same point for the 3rd supporting point is
raised up to the clamping surface and taken as the top clamping point.
The clamping element is divided to 4 sub-elements and the relative
position of each is calculated.
For the side clamp, the 3rd point is moved to the edge of the
cylinder and move up to be in the level below the upper edge of the side
locator. The side riser clamp is raising up to compensate the height if the
rest pad. After that the side clamp is oriented toward the center of the
workpiece.
Serrated Edge Clamps
Figure 3-9 The used clamping elements.
3-2-3 Assembly Sheet
After calculating the locating and clamping points, selecting the
suitable fixture elements, and calculating its position and orientation. The
user entered the position of the 1st locator, in the base plate of the fixture,
according to the selection of the base plate and the spreading of the
fixture elements. The excel sheet collect all these data in the separate
02
sheet, for assembly purpose. The sheet contains all the selected elements,
their position and orientation.
3-3
FIXTURE ERRORS
The resulting errors in the fixture assembly are of two types; the
first one is the tilting of the workpiece with respect to the x and y
direction, according to fig. 3-3. These value of error depends on the
accuracy of the rest height and the distance between the supports,
fig. 3-10. The tilting angle can be calculated with eq. 3-2 and eq. 3-3.
Fig. 3-10 The effect of the support accuracy and the distance between the
supports on the tilting angles of the workpiece.
Eq. 3-2
Eq. 3-3
Where;
c
the tolerance of the supporting elements lengths.
l1, l2 the distance between locators.
01
The second type of error is the position error of the workpiece,
fig. 3-11. The error x is calculated according to eq. 3-4 and eq. 3-5.
Eq. 3-4
Where;
θnew is the new central angle as an effect of the error, eq.3-5.
Eq.3-5
Fig. 3-11 The position error due to accuracy of the side locators.
01
CHAPTER 4
RESULTS AND DISCUSSION
CHAPTER 4
RESULTS AND DISCUSSION
As mentioned in the previous chapter the workpieces are of
cylindrical shape and the machining operations is drilling to holes, which
are parallel to the workpiece axis. Through this chapter the results
obtained from the excel sheet for different examples of workpieces will
be shown and discussed.
4-1 FIXTUER DESIGN FOR BLIND HOLES WITH TOP CLAMP
The required product is shown in fig. 4-1. The required job is to
machine two blind holes in the flange of the workpiece. Figure 4-2 shows
the workpiece in the machining orientation with a node in the place of the
required holes and the workpiece is scaled to inches. As shown in fig. 41, the inputs for the excel sheet are; d is equal 76 mm., h1 equals zero and
h2 equals 12 mm. fig. 4-3. Also, the other two inputs are; top clamp and
the 1st locator is assembled in the cell (9,1). The output assembly sheet
for this workpiece is shown in fig.4-4. Figure 4-5 shows the assembly of
the fixture with a workpiece in place. The fixture consists of two side
locators, and one top clamp. The clamping nose is down loaded with two
elements (contact bolt and extension).
The resulting errors are;
1- The max tilting of the base plate is 1.93x10-3˚.
2- the position error is 0.02366 mm. (graphically).
92
Fig. 4-1 The required product for blind holes.
Fig. 4-2 The required workpiece with its orientation and in its place, blind
holes.
03
Fig. 4-3 A part of Excel sheet for blind holes making, top clamp.
Fig. 4-4 The assembly sheet for the blind holes fixtures, top clamp.
03
Fig. 4-5 The assembly of the blind holes fixture with the workpiece in
place, top clamp.
4-2 FIXTUER DESIGN FOR THROUGH HOLES WITH TOP
CLAMP
The required product is shown in fig. 4-6. The required job is to
machine two through holes in the flange of the workpiece. Figure 4-7
shows the workpiece in the machining orientation with a node in the
place of the required holes and the workpiece is scaled to inches. As
shown in fig. 4-6, the inputs for the excel sheet are; d is equal 76 mm., h1
equals 10 mm. and h2 equals 12 mm. fig. 4-8. Also, the other two inputs
are; top clamp and the 1st locator is assembled in the cell (8,1). The output
assembly sheet for this workpiece is shown in fig.4-9. Figure 4-10 shows
the assembly of the fixture with a workpiece in place. The fixture consists
of two shoulder support cylinder (bottom and side locators), and one top
clamp. The clamping nose is down loaded with two elements (contact
bolt and extension).
The resulting errors are;
1- The max tilting of the workpiece is 0.026˚, which composed of
the tilting for the plate 1.93x10-3˚ and the tilting due to the
supports (tan-1(0.03048/ 72.173) = 0.024˚).
2- The position error is 0.02366 mm. (graphically).
09
Fig. 4-6 The required product for through holes.
Fig. 4-7 The required workpiece with its orientation and in its place,
through holes.
00
Fig. 4-8 A part of Excel sheet for through holes making, top calmp.
Fig. 4-9 The assembly sheet for the through holes fixtures, top clamp.
03
Fig. 4-10 The assembly of the through holes fixture with the workpiece in
place, top clamp.
4-3 FIXTUER DESIGN FOR COUNTER BORING HOLES WITH
TOP CLAMP
The required product is shown in fig. 4-11. The required job is to
machine two counter boring holes in the flange of the workpiece. Figure
4-12 shows the workpiece in the machining orientation with a node in the
place of the required holes and the workpiece is scaled to inches. As
shown in fig. 4-11, the inputs for the excel sheet are; d is equal 76 mm.,
h1 equals 50 mm. and h2 equals 12 mm. fig. 4-13. Also, the other two
inputs are; top clamp and the 1st locator is assembled in the cell (9,1). The
output assembly sheet for this workpiece is shown in fig.4-14. Figure 415 shows the assembly of the fixture with a workpiece in place. The
fixture consists of two shoulder support cylinder (bottom and side
locators), and one top clamp. The clamping nose is down loaded with two
elements (contact bolt and extension).
The resulting errors are;
03
1- The max tilting of the workpiece is 0.026˚, which composed of
the tilting for the plate 1.93x10-3˚ and the tilting due to the
supports (tan-1(0.03048/ 72.173) = 0.024˚).
2- The position error is 0.02366 mm. (graphically).
4-11 The required product for counter boring holes.
Fig. 4-12 The required workpiece with its orientation and in its place,
counter boring holes.
03
Fig. 4-13 A part of Excel sheet for counter boring holes making, top
clamp.
Fig. 4-14 The assembly sheet for the counter boring holes fixtures, top
clamp.
03
Fig. 4-15 The assembly of the counter boring holes fixture with the
workpiece in place, top clamp.
4-4 FIXTUER DESIGN FOR COUNTERSINKING HOLES WITH
TOP CLAMP
The required product is shown in fig. 4-16. The required job is to
machine two countersinking holes in the flange of the workpiece. Figure
4-17 shows the workpiece in the machining orientation with a node in the
place of the required holes and the workpiece is scaled to the inches in
dimensions. As shown in fig. 4-16, the inputs for the excel sheet are; d is
equal 76 mm., h1 equals 75.4 mm. and h2 equals 49.4 mm. fig. 4-18.
Also, the other two inputs are; top clamp and the 1 st locator is assembled
in the cell (10,2). The output assembly sheet for this workpiece is shown
in fig.4-19. Figure 4-20 shows the assembly of the fixture with a
workpiece in place. The fixture consists of two shoulder support cylinder
(bottom and side locators) raised up with riser block, and one top clamp.
The clamping is raised up with two spacer blocks .
03
The resulting errors are;
1- The max tilting of the workpiece is 0.034˚, which composed of
the tilting for the plate 1.93x10-3˚ and the tilting due to the
supports (tan-1(0.04064/ 72.173) = 0.032˚).
2- The position error is 0.02366 mm. (graphically).
4-16 The required product for countersinking holes.
Fig. 4-17 The required workpiece with its orientation and in its place,
countersinking holes.
02
Fig. 4-18 A part of Excel sheet for countersinking holes making, top
clamp.
Fig. 4-19 The assembly sheet for the countersinking holes fixtures, top
clamp.
33
Fig. 4-20 The assembly of the countersinking holes fixture with the
workpiece in place, top clamp.
4-5 FIXTUER DESIGN FOR BLIND HOLES WITH SIDE CLAMP
The required product is shown in fig. 4-1. The required job is to
machine two blind holes in the flange of the workpiece. Figure 4-2 shows
the workpiece in the machining orientation with a node in the place of the
required holes and the workpiece is scaled to the inches. As shown in fig.
4-1, the inputs for the excel sheet are; d is equal 76 mm., h1 equals zero
and h2 equals 12 mm. fig. 4-21. Also, the other two inputs are; side clamp
and the 1st locator is assembled in the cell (7,1). The output assembly
sheet for this workpiece is shown in fig.4-22. Figure 4-23 shows the
assembly of the fixture with a workpiece in place. The fixture consists of
two side locators, and one side clamp. The clamping action is oriented
toward the workpiece center.
The resulting errors are;
1- The max tilting of the base plate is 1.93x10-3˚.
2- The position error is 0.02366 mm. (graphically).
33
Fig. 4-21 A part of Excel sheet for blind holes making, with side clamp.
Fig. 4-22 The assembly sheet for the blind holes fixtures, with side
clamp.
39
Fig. 4-23 The assembly of the blind holes fixture with the workpiece in
place, side clamp.
4-6 FIXTUER DESIGN FOR COUNTER BORING HOLES WITH
SIDE CLAMP
The required product is shown in fig. 4-11. The required job is to
machine two counter boring holes in the flange of the workpiece. Figure
4-12 shows the workpiece in the machining orientation with a node in the
place of the required holes and the workpiece is scaled to the inches in
dimensions. As shown in fig. 4-11, the inputs for the excel sheet are; d is
equal 76 mm., h1 equals 50 mm. and h2 equals 12 mm. fig. 4-24. Also,
the other two inputs are; side clamp and the 1st locator is assembled in the
cell (8,1). The output assembly sheet for this workpiece is shown in
fig.4-25. Figure 4-26 shows the assembly of the fixture with a workpiece
in place. The fixture consists of two shoulder support cylinder (bottom
and side locators), and one side clamp.
The resulting errors are;
30
1- The max tilting of the workpiece is 0.026˚, which composed of
the tilting for the plate 1.93x10-3˚ and the tilting due to the
supports (tan-1(0.03048/ 72.173) = 0.024˚)
2- The position error is 0.02366 mm. (graphically).
Fig. 4-24 A part of Excel sheet for counter boring holes making, side
clamp.
33
Fig. 4-25 The assembly sheet for the counter boring holes fixtures, side
clamp.
Fig. 4-26 The assembly of the counter boring holes fixture with the
workpiece in place, side clamp.
Also, the view of the fixture assembly can be obtained from the
AutoCAD software, which can be easy understood with the assembly
sheet. Figures 4-27 shows the front and plan for the fixture assembly of
fig. 4-20, while 4-28 shows the views of the fixture assembly of fig. 4-26.
33
Front
Plan
Fig. 4-27 The views of the fixture of the assembly fig 4-20
33
Front
Plan
Fig. 4-28 The views of the fixture of the assembly fig 4-26.
33
CHAPTER 5
FEASIBIILITY STUDIES AND MARKET
NEEDS
CHAPTER 5
FEASIBIILITY STUDIES AND MARKET NEEDS
As mentioned in the previous chapters the fixture is used to increase
the quality and interchangeability of the product and to reduce the leading
time and cost. Traditional fixture is not flexible, take much more time to
design and manufacturing and downgrade the flexibility of the
manufacturing system.
Modular fixture system is one of the flexibility system that can
increase the flexibility of the manufacturing system and reduce the
manufacturing cost. The flexibility of the modular fixturing system come
from that it's standard elements are constructed for a certain job then it
disassembled and reconstructed again and again for many times.
The studies proved that the modular fixture systems are the most
economical fixturing systems in the small lots batch manufacturing and job
shop manufacturing system. The studies, also, proved that for smaller lot
size the lower fixturing cost the modular fixture is.
Also, the computer is used in the design to reduce the lead time in the
designing processes and make the design task easier and improve the
communication and the quality.
So, using computer software to design modular fixtures is a task
increase the flexibility of the manufacturing system. This help in facing the
rapid change in the products design, the trend toward reduce the lots sizes in
batch manufacturing system, and job shop or prototype manufacturing
system. Also, it reduce the manufacturing cost and reduce the price of the
product and increase the competition of the company.
48
The cost of the one mini size fixture set of modular fixture for
CrrLane manufacturing co. is $20439 (about 76745 SR). Okolischan, R.,
[11] made an economical study to compare modular fixture with permanent
and hydraulic permanent fixtures without taken the workpiece material cost,
because it is cost in all of the 3 methods, eq. 5-1.
Eq. 5-1
The results of this study, fig. 5-1, are;
1- For the lot size is 100 pieces the modular fixture is the best choice
(its cost is half of that of permanent fixture and less than the one
third of the hydraulic fixtures).
2- For the lot size is 2500 pieces the hydraulic fixture is the best
choice (its cost is the min. cost of the 3 fixture methods).
Which shown that for small lot size the modular fixture is the most
economical choice.
Fig 5-1 The economical comparison between different methodologies of
fixture.
This mean that the project is feasible and have a consider marketing
needs.
49
CHAPTER 6
CONCLUSIONS RECIMMENDATIONS AND FUTURE WORK
CHAPTER 6
CONCLUSIONS, RECIMMENDATIONS AND FUTURE
WORK
6-1 CONCLUSIONS
Through the present project an excel sheet is prepared for designing
fixtures, selection the suitable modular fixture elements, of CarrLane
manufacturing company USA. These fixtures are used to drilling holes in
cylindrical workpieces parallel to its axis. The excel sheet, also, determine
the position and orientation of the modular elements with respect to
workpiece in the suitable base plate, which is selected also by the sheet. At
the end, an assembly sheet is prepared, by the program. The assembly sheet
contains the used modular fixture elements, its position and orientation and
the location of the workpiece with respect to these elements.
The AutoCAD used to produce a data base of the 3D model of the
modular fixture elements, of the CarrLane manufacturing company. This
data base is used to make the assembly of the designed fixture with or
without the workpiece in place.
The maximum resulting errors of the workpiece, due to the accuracy
of the fixture elements are predicted. These error depending on the accuracy
of the modular fixture elements (0.01016 mm. for most of the modular
fixture elements)
and the number of elements used to construct the
functional element (locators and supports elements).
From the previous chapters the following conclusions could be
extracted;
50
1- The excel sheet can be used instead of the human to make the
selection of the modular fixture elements and calculate it's position
and orientation.
2- This excel sheet make the designer easier and faster.
3- Using pre-prepared data base make the assembly of the designed
fixtures easy and faster.
4- The using of AutoCAD improve and make the output of the
designed fixture easier and readable.
5- The resulting error of the products as a result of using the
designed fixtures can be minimize with the using of minimum
number of fixture element.
6-2 RECOMMENDATIONS AND FUTUER WORK
The results show that the using of computer saves the money and
effort of the company and the designer, the recommendation is to follow the
working in this field and added the following items to the present work in
the future;
1- Extend the designing effort to another workpieces configuration to
the present work.
2- Extend the present work to another machining operations.
3- Increase the data base elements to include the all elements of the
company catalog.
4- Make an integration between the excel sheet and AutoCAD.
51
CHAPTER 7
APPENDICES
CHAPTER 7
APPENDICES
A: Project Team with Assigned responsibilities
1. Ahmed Mohammd Ali Hammadi
2. Hassan Jobran Al-Malki
3. Jaber Hadi Alassiri
4. Majed Ali Almalki
5. Saud Hassan Qurby
B: Faculty Advisers and Industry sponsors
C: Project Budget and Expenses to date
D: Drawing package (if applicable)
E: Manufacturing procedures, Test procedures and Test reports
F: Technical reports or evaluations
52
G: Tool room Starter Sets of CarrLane manufacturing company.
53
54
55
56
57
REFERENCES
REFERENCES
[1] Rong; Y Kevin, Zhu; Y. Stephens, " Computer-Aided Fixture
Design"; Marcel Dekker, Inc., USA, 1999.
[2] Rong; Y. N., Huang; S. H., and Hou; Z. K., "Advanced Computeraided Fixture Design", Elsevier Inc., USA, 2005.
[3] Miller; R. , Miller; M. R., " Audel™ Automated Machines and Tool
making All New 5th Edition", Wiley Publishing, Inc., USA, 2004.
[4] Carr Lane Manufacturing Co. Staff, "Jig and Fixture Handbook", Carr
Lane Manufacturing Co., USA, 1992.
[5] Black; J. T., Kohser; R. A., "DeGarmo's Material and Processes in
Manufacturing", 3rd Edition, John Wiley & Sons Inc, USA, 2008.
[6]
WWW.ignou.ac.in/upload/jig.pdf,
International Open University.
ignou
is
Indira
Gandhi
[7] Segal; L., Romanescu; C. and Gojinetchi; N., " Application of
Modular Fixturing For FMS", Buletinul Institutului Politehnic DIN
IASI, University of Iasi, Romania, 2001
[8] Farhan; U. H., " An Integrated Computer-Aided Modular Fixture
Design System for Machining Semi-Circular Parts", Master thesis
submitted to the Faculty of Computing, Health and Science, Edith
Cowan University, Australia, April 2013.
[9] Yarwood; A., " An Introduction to AutoCAD 2004: 2D and 3D
Design", Newnes An imprint of Elsevier, Great Britain, 2004.
[10] Carr Lane Manufacturing Co., "Carr Lane Catalog USA".
[11] Okolischan, R., "The 5 Steps of Fixture Design", Carr Lane
manufacturing Co.
85
CAPSTONE DESIGN PROJECT
PROJECT SUBMISSION
CAPSTONE DESIGN MANUAL
CAPSTONE DESIGN PROJECT
Project Submission
and
ABET Criterion 3 a-k Assessment Report
Project Title:
DATE:
Fixtures Design Using Computer for Cylindrical Workpieces
in Drilling Operations
16 / 7
/ 1435
PROJECT ADVISOR:
Jaber Hadi Alassiri
Team Leader:
Team Members:
Dr. Mahmoud Mohamed Atta Mahmoud
Ahmed Mohammd Ali Hammadi
Hassan Jobran Al-Malki
Majed Ali Almalki
Saud Hassan Qurby
Design Project Information
Percentage of project Content- Engineering Science %
Percentage of project Content- Engineering Design %
Other content % All fields must be added to 100%
Please indicate if this is your initial project declaration
or final project form
30%
70%
__________________
□
√
Project Initial Start Version
Final Project Submission
Version
Do you plan to use this project as your capstone design project? _____________________________
□ Projects in Engineering Design
□ Independent studies in Engineering
□ Engineering Special Topics
Mechanism for Design Credit
Fill in how you fulfill the ABET Engineering Criteria Program Educational
Outcomes listed below
Please list here all subjects (math, science, engineering) that have
An ability to apply knowledge of mathematics, been applied in your project.
Outcome (a),
science, and engineering fundamentals.
Example: let’s consider CAFD (computer aided fixture design (machining
operation, fixturing system, tolerance, engineering drawing)
Outcome (b).
In this part, if the project included experimental work for
validation and/or verification purposes, please indicate that.
An ability to design and conduct experiments,
and to critically analyze and interpret data.
Prepared by Dr. REfaat Khater
2
CAPSTONE DESIGN MANUAL
Outcome (c).
All projects should include a design component. By design we
mean both physical and non physical systems.
An ability to design a system, component or
process to meet desired needs within realistic Designing modular fixtures for drilling operations. The modular elements
constraints such as economic, Environmental, are collected from CarrLane manufacturing company catalog. The
assembly sheets and the 3d geometrical model of the fixture are prepared.
Social, political, ethical, health and safety,
manufacturability, and sustainability
This outcome is achieved automatically by the fact that all projects
An ability to function in multi-disciplinary composed of at least 3 students. However, if the project involved
students from other departments, that would be a plus that is worth
teams.
to be highlighted.
Outcome (d).
An ability to identify, formulate and solve
engineering problems.
In order to meet this specific outcome, it would help if you have a
Problem Statement section in your project report. If not, then
briefly highlight how the “students” were able identify, formulate
and solve the project’s problem.
Outcome (f).
Here professional and ethical responsibility depends on the project
context.
Outcome (e).
An understanding of professional and ethical
responsibility.
Outcome (g).
Good report and good presentation will fulfill this outcome
An ability for effective oral and written
communication.
This outcome is usually fulfilled by highlighting the economic
The broad education necessary to understand feasibility of the project, and emphasizing that the project
the impact of engineering solutions in a global would not harm the environment and does not negatively affect
economics, environmental and societal context human subjects.
This project help in reducing the lead time, human effort for
.
machining operation in a certain company. Also, the project
increase the accuracy and interchangeability of the product and
increase the competitive of the company.
Outcome (h).
Outcome (i).
A recognition of the need for, and an ability to
engage in life-long learning.
Outcome (j).
A knowledge of contemporary issues.
This outcome is fulfilled by suggesting a plan for future studies
and what else could be done based on the outcome of the current
project.
Extensive literature review by the “students” for the current state of
the art will fulfill this outcome.
List all technologies included in the project (hardware and
An ability to use the techniques, skills, and software)
modern engineering tools necessary for Excel program and AutoCAD software.
engineering practice.
Outcome (k).
Prepared by Dr. REfaat Khater
3
CAPSTONE DESIGN MANUAL
By signing below certify that this work is your own and fulfills the criteria
described above
Student Team Signatures
Ahmed Mohammd Ali Hammadi
Hassan Jobran Al-Malki
Jaber Hadi Alassiri
Majed Ali Almalki
Saud Hassan Qurby
Project Advisor Signature Dr. Mahmoud Mohamed Atta Mahmoud
Date
College Coordinator of Capstone Projects
_________________________
Approved By
_________________________
Prepared by Dr. REfaat Khater
4
‫الملخص العربى‬
‫تصميم المثبتات باستخدام الحاسب االلى‬
‫للمشغوالت االسطوانية فى عمليات الثقب‬
‫المشكلة المشتركة بين المؤسسات الصناعية هى انتاج منتجات عالية الجودة فى وقت قصير‬
‫و تكلفة منخفضة والتبادلية بين المنتجات‪ .‬مثبتات المشغوالت هى الجزء الحرج فى نظم االنتاج حيث‬
‫انها تؤثر فى دقة وتكلفة المنتج و الوقت المتقدم لعملية التشغيل‪.‬‬
‫مرونة نظم التصنيع (لمواجهة التغير المستمر فى تصميم المنتجات و تقليل الوقت المتقدم و‬
‫التنافسية بين المنتجات) يتواجه بعدم مرونة تصميم و تصنيع نظم التثبيت‪ .‬المثبتات المعيارية هى‬
‫احد اهم المثبتات المرنة بسبب عموميتها‪.‬‬
‫تصميم المثبتات معقد جداً و مستهلك كبير للوقت‪ .‬استخدام الحاسب اآللى يساعد على تسهيل‬
‫عملية التصميم و التحليل للمثبتات المعيارية فهو يساعد على تقليل الوقت المتقدم و حساب البدائل‬
‫المختلفة فى وقت قصير و توفير استخدام مهارات االخرين‪.‬‬
‫خالل المشروع الحالى يستخدم الكمبيوتر لتصميم و اختيار اجزاء المثبت من بين االجزاء‬
‫المعيارية (الممثلة فى اجزاء نظم الثبيت المعيارية ) للمشغوالت االسطوانية فى عمليات الثقب لثقوب‬
‫موازية لمحور المشغول‪ .‬فى النهاية يتم اعداد ورقة تجميع االجزاء المستخدمة فى المثبت‪.‬‬
‫يستخدم الحاسب فى اعداد قاعدة بيانات للنماذج ثالثية االبعاد ألجزاء المثبتات المعيارية و‬
‫اعداد النماذج الهندسية النهائية لألجزاء المجمعة‪.‬‬
‫كلية الهندسة‬
‫قسم الهندسة الميكانيكية‬
‫استخدام احلاسب االىل فى تصميم املثبتات‬
‫للمشغوالت االسطوانية فى عمليات الثقب‬
‫طالب فريق العمل‪:‬‬
‫احمد محمد على حمدى‬
‫حسن جبران المالكى‬
‫جابر هادى العسيرى‬
‫ماجد على المالكى‬
‫سعود حسن قربى‬
‫مشرف المشروع‪:‬‬
‫د‪ /‬محمود محمد عطا محمود‬
‫تقرير مشروع التخرج مقدم للحصول على درجة البكالوريوس‬
‫فى الهندسة الميكانيكية‬
‫(رجب‬
‫(مايو‬
‫‪)5341‬‬
‫‪)4153‬‬