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Jigless Manufacturing for Parts

The document summarizes a presentation on developing a jigless manufacturing process for aluminum and steel parts. Jigless manufacturing aims to minimize the use of jigs and fixtures in mass production by providing location, clamping, support and resistance to cutting forces. It describes applying this process to drill, chamfer and ream holes in an intake manifold component using a robot, grippers and locators. It includes calculations of cutting forces, clamping forces and selection of a robot, grippers and fixture to hold the part. The next steps are to finalize the jigless cell layout, analyze costs and cycle times, incorporate safety measures and study other applications of this process.

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83 views16 pages

Jigless Manufacturing for Parts

The document summarizes a presentation on developing a jigless manufacturing process for aluminum and steel parts. Jigless manufacturing aims to minimize the use of jigs and fixtures in mass production by providing location, clamping, support and resistance to cutting forces. It describes applying this process to drill, chamfer and ream holes in an intake manifold component using a robot, grippers and locators. It includes calculations of cutting forces, clamping forces and selection of a robot, grippers and fixture to hold the part. The next steps are to finalize the jigless cell layout, analyze costs and cycle times, incorporate safety measures and study other applications of this process.

Uploaded by

akshaytomar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd

Octane’20

Review Presentation
Project Title: Jigless Manufacturing For
Aluminum / Steel Parts
Department: Engineering
Mentor: Mr. SM Sampgaonkar
What is Jigless Manufacturing ?

It is a method which is adopted to minimize the use of Jigs and Fixtures in Mass Production processes.
• This method is used in aircraft assembly systems, welding systems.
Main advantages of Jigless machining are :
1. Reduction in manufacturing cost .
2. Reduction in Changing Time .
3. Flexibility in manufacturing process.
A Jigless system must provide following functionalities :
4. Location
5. Clamping
6. Support
7. Resistance to cutting force
8. Safety
Component

MANIFOLD INTAKE JB581407


Operation to be performed by jig less machining process.
1) Drilling dia. 6.2 (04 nos.)
2) Back chamfering for above 4 holes.
3) Drilling dia. 4.2 with chamfer. (01 no.)
01 & 02 4) Reaming dia. 5

03 & 04
Cutting Force Calculations

• Thrust Force =

Where : K = Material Factor


Z = No. of cutting edges
D = Tool diameter
d (d1)= Diameter to be enlarged
S = 0.5*Feed per revolution (f)
• Torque :
• In Drilling :
• In Reaming And Countersinking :
Cutting parameters Calculations
Material
Diameter Feed per Rotation Removal Thrust
of drill Revolution Speed (in Feed Rate(mm^ Force (in Torque (in Power (in
[Link]. Operation (D) (mm) (mm/rev) RPM) (mm/min) 3/min) Kgf) Nmm) HP)

Drilling
1 (6.2mm) 6.2 0.12 1500 180 5434.326 39.36919 2446.922 0.150475

Drilling
2 (4.2mm) 4.2 0.1 1500 150 2078.163 22.84073 1049.104 0.060275

Chamfering
3 6.2 mm) 6.2 0.1 200 20 603.814 10.87651 2068.015 0.017513

Chamfering
4 (5 mm) 5 0.1 200 20 392.699 10.87651 1993.619 0.01139

Reaming
5 (5mm) 5 0.1 500 150 2945.243 13.05184 65.85546 0.025149
Clamping Methods

Eccentric Cam Clamps


Strap Clamp

Toggle Clamp

Equalisers
Gripper Selection

Zimmer 2 jaw parallel


gripper-GPP5013SC-
00-A
Gripping force 422 kg
IP-64 class
Robot Selection

FANUC M-900 series


Part Holding Fixture
Heel Pin
Strap Clamp
Clamping nut

Brass Clamp
Pad

Central Locator
Gripper

Rough
Locator 1
Rough
Locator 2
Flow Of Process
Calculation of Clamping Forces

Force And
Torque
Applied
Net Reaction
Force
Force Setup
OVERALL MAXIMUM CLAMPING FORCE

Reaction Force (N)

X direction Y direction Z direction

500.25 430.41 230.78

Moment (N mm)

X direction Y direction Z direction

9859.1 2500 16794


GRIPPING FORCE ANALYSIS

Gripping Net Reaction


Point Force on Left
Finger
Overall Maximum Gripping Force

Reaction Force (N)

X direction Y direction Z direction

Left Finger 256.52 436.46 79.814

Right Finger 243.73 258.8 199.21

Moment(N mm)

X direction Y direction Z direction

Left Finger 305.45 1227.7 28258

Right Finger 514.27 4255.8 11119


Targets for Final review

• Developing the Jigless machining cell layout.


• Cost and cycle time analysis.
• Safety measures for this process
• Case study for other similar components

Arm Change Rocker Arm


THANK YOU

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