DESIGN AND ANALYSIS OF DRILL JIG AT

VARIABLE MATERIALS

Abstract

This project chiefly treated modeling of DRILL JIG and also the analysis over that. The
modeling of the element was done by mistreatment the advanced modeling code. The analysis
was done by mistreatment one amongst the foremost necessary numerical strategies is FEA and
also the code used is ANSYS 1.0.

By mistreatment the options of the code DRILL JIG was sculptural. The modelings of the
individual components are worn out the half module and also the assembly of the individual
components was worn out the assembly module by mistreatment bottom up methodology.

In the analysis, the behaviors of the DRILL JIG are shown in half dozen mode shapes by
mistreatment modal analysis. The static structural analysis was done at totally different load
conditions for various materials and results are tabulated and graphs were plot. From that the
most effective material are chosen.
 Chapter 1

1. INTRODUCTION

Tool design cares with design and development of machines and special tooling,
strategies and techniques needed by today’s high speed mass manufacture at high potency and
productivity. Its main objective is to provide element at a competitive value, maintaining quality
and accrued production. All this concerns choice of best tool materials for adequate tool life,
providing straightforward and simple to work tools for prime potency, design of tools to be
proof with no chance of wrong operation, quality consciousness in any respect levels.

The utilization of jigs and fixtures is a vital facet of workshop engineering for the
assembly of articles in giant quantities with a high degree of accuracy and changeability at a
competitive value. The aim of jigs and fixtures is to take care of low producing prices and to
extend industrial potency.

So the jigs and fixtures square measure chiefly wont to scale back prices and guarantee
changeability that permits for fast assembly. Its purpose is additionally to hurry up machining
times by eliminating time of handling and setting of the element components. additional jigs and
fixtures square measure taking the place of the experienced man within the production industrial
plant and creating it potential to use unskilled or semi- experienced operators.

The first objective of the utilization of jigs and fixtures is to facilitate the holding and
supporting of the element by mistreatment fixtures, position it properly and guide the cutters in
order that each element are uniform. it's extensively utilized to accommodate many parts at one
setting and so taking advantage of multiple machining. it's notably terribly appropriate wherever
correct positioning of varied holes at various precise places is very important and that otherwise
would consume ton of your time in marking etc.
1.1JIGS:

Jig may be a work device that holds supports and locates the work-Piece and additionally
guides the cutter for a selected operation. Jigs are, sometimes fitted with hardened steel bushings
for guiding drills or different cutting tools. Holes square measure bored within the structure, in
order that once tools square measure fed through them and into the element, holes square
measure created within the element within the correct positions PRN by the element drawing. it's
sometimes necessary for the work to be control within the jig by clamping. Jig is sometimes not
fastened to the machine table by clamping. However, for drilling holes higher than 6mm
diameter, it's sometimes necessary to lock the jig firmly to the table. Jigs square measure used for
mass drilling, reaming and sound.

1.2 FIXTURES:

Fixture may be a work device that holds supports and locates the piece of work however
doesn't guide the cutter for a selected operation. The cutting tools square measure set in position
by machine adjustment or by trial and error methodology. Setting gauges or setting blocks and
feeler gauges square measure usually provided to alter the initial setting of labor to the cutter to
be quickly and simply accomplished before machining. The fixture is usually fastened or
fastened firmly to the machine table in such a footing that the work is within the correct
relationship to the cutter. Fixtures square measure used for mass edge, turning and grinding
operations.
1.3 DIFFERENCES BETWEEN JIGS AND FIXTURES

JIGS FIXTURE

This Holds, supports and locates the work and This holds supports and locates the work piece
also guides the cutting tool. but does not guide the tool.

Jigs are not clamped to the table of the machine. Fixtures should be clamped to the machine.

Jigs are special tools used in drilling, reaming, Fixtures are special tools used in milling,
boring and tapping operations. planning, shaping machines.

This is lighter in construction. This is heavier in construction.

Gauge blocks may be provided for effective

Gauge blocks are not necessary.
handling.

1.4 PRINCIPLES OF JIGS AND FIXTURES:

Locating Point:

The most necessary demand in jigs or fixture design square measure sensible facilities to
be provided for the work, the article to be machined could simply be inserted and quickly taken
out from the jig in order that no time is wasted in inserting the work piece within the position to
perform operations. The position of labor piece ought to be correct with relevancy tool guiding
within the jig or setting components within the fixture.

Fool Proof:

The design of jigs and fixtures ought to be such it might not allow the work piece or the
tool to be inserted in any position except the right one.
Clamping Device:

It ought to be as straightforward as potential while not sacrificing effectiveness. The

strength of the clamp ought to be such not solely to carry the work piece firmly in situ however
additionally to require the strain of the cutting tools while not springing or giving once planning
the jigs and fixtures. The clamps ought to be convenient, quickly operated and supply less
fatigue to the operator.

Reduction of Idle Time:

The idle time is reduced by loading and unloading arrangements. Design of jigs and
fixtures ought to be such the method of loading, clamping and unloading time of the work piece
takes minimum as so much as attainable.

Weight of the Jigs or Fixtures:

The jigs or fixtures ought to simply be handled, smaller in size and lower in value in
relevancy the number of fabric used for his or her creating. However at identical time, it
shouldn't sacrifice any of the rigidity and stiffness.

Jigs supplied with Feet:

Ordinary drill jigs ought to be continuously supplied with feet or legs on all sides that are
opposite the holes for the bushings. In order that the jig is placed level on the table of the
machine on the edges of the jig wherever no feet are needed if the body is created from a casting,
it's of advantage to own tiny protruding lugs for bearing surfaces once parturition out and
designing. Jig feet are usually solid with the jig frame. Once the jig feet are made up of machine
steel generally within the forged iron jigs, detachable feet are used.

Material used for Jigs and Fixtures:

Jigs and fixtures are product of hardened material to avoid frequent injury and to resist
wear. the fabric used for jigs and fixtures are soft-cast steel, cast iron, die steel, steel, high speed
steel, nickel-chrome steel, bronze, plastic material etc.
1.5 Essential options of Jigs and Fixtures

A jig or fixture should satisfy the subsequent conditions

Reduction of ideal time:

The design of jigs or fixtures ought to be such the method of loading and unloading the
parts takes the minimum attainable time and allows on straightforward location and clamping
ought to be such idle time is reduced to minimum.

Cleanliness:

It’s of nice importance that jigs or fixtures are therefore designed that there's no time is
wasted in giving it to clear the headscarf, burrs, chips etc., that otherwise, it might spoil the
locating faces and also the instrumentality can continuously load sort of a assortment through for
these foreign materials.

Replaceable elements or Standardization:

The locating and supporting surfaces, as so much as attainable ought to be similar that's
not for good mounted. once wiped out, they'll get replaced by new ones. Moreover, they must be
standardized in order that their interchangeable manufacture is feasible.

Provision for Coolant:

The jigs or fixtures should have adequate arrangement for the leading edge of the tool in
order that the tool is cooled.

Hardened Surfaces:

All locating and supporting surfaces, equivalent to faces of locating pins, ought to be
product of hardened materials as so much as conditions allow, in order that they're not quickly
wiped out and their accuracy is preserved for a extended time.
Inserts or Pads:

It is a awfully necessary provision all told jigs and fixtures. Inserts or pads of sentimental
materials like brass, animal skin of fiber must always be riveted to those faces of the clamps
which can are available contact with the finished surfaces of the work pieces in order that these
surfaces don't seem to be spoiled as results of the metal like contact.

Fool-proofing:

Since the utilization of jigs and fixtures permits for the use of unskilled employee, the
look of such instrumentality ought to be such it might not allow the piece of work or the tool be
inserted in any position although the right one. For this, pins or different devices of
straightforward nature are typically incorporated within the instrumentality in such position that
they'll continuously spoil the position of the element or hinder the fitting of cutlery till the unless
the later care in correct position.

Economic soundness:

The instrumentality to be used ought to be economically sound, ie., worth} of its coming
up with and producing ought to be in proportion to the amount and price of the producer.

Easy manipulation:

The jig or fixture ought to be as lightweight in weight as attainable and may be

straightforward to handle and manipulate in order that the working person needn't to subject to
fatigue.

Position of clamps:

The clamps ought to be therefore positioned that clamping happens directly higher than
the points supporting the piece of work therefore on avoid distortion and springing of the work,
that otherwise can lead to an inaccurate work. Moreover, the clamps ought to be sturdy enough
to resist bending below clamping pressure.
Clearance:

Sufficient quantity of clearance ought to be provided round the add order that the
operator’s hand will simply enter the body for putting the piece of work and any variations
within the size of the piece of work is accommodated.

Safety:

The design of jig ought to be such it shouldn't represent any danger to the operator.

1.6 FACTORS TO BE THOUGHT-ABOUT FOR DESIGN OF JIGS FIXTURES

1. Variety of part or work-piece.

2. Capability of the machine.

3. Production needs.

4. Location.

5. Loading and un-loading arrangements.

6. Clamping arrangements.

7. Clearance between jig and part.

8. Ejectors.

9. Base or body construction.

10. Tool guiding and cutter setting.

11. Rigidity and vibration.

12. Safety.

13. Cost.

14. Material list or bill of fabric.

1.7 LOCATING PRINCIPLES

To ensure precision in any machining operations the work-piece should be properly

positioned with relevance the cutter. The locating principle refers to the dimensional and point
relationship between the work-piece and cutter.

The locater may be a device to determine and maintain the position of a neighborhood
during a jig or fixture to make sure the repeatability of a piece holder.

Locating principles area unit in the main classified as follows

 locating from plane surface

1. Solid support

2. Adjustable

3. Equalizing

 locating from circular and cylindrical surfaces

1. Mounted V – locators

2. Adjustable V – locators

 locating from irregular surface

1. Profile location

2. Sight location

1.8 DESIGNS OF LOCATORS

1. Pin and button locater.

2. Diamond pin locater.

3. Nesting or Cavity locater.

 4. Spherical locater.

5. Sight locater.

6. Split locater.

7. Raised contact locater.

8. Fixing locater.

9. Rest pad locater.

1.9 CLAMPING DEVICES

Once the work-piece is found it's necessary to check it against the locating surfaces and
hold it there against the force acting upon it. The tool designer refers to the present action as
clamping and also the mechanism used for this action area unit called clamps.

Various clamping devices area unit as follows

1. Screw clamp

2. C – clamp

3. Strap clamp

4. Swing clamp

5. Pivoted clamp

6. Hinged clamp

7. Wedge clamp

8. Latch clamp

9. Toggle clamp

10. Cam action clamp

11. Equalizer clamp

1.10 COMPONENTS OF A JIG

1. Jig body.

2. Jig feet.

3. Jig bush.

4. Jig plate or bush plate.

5. Locators.

6. Clamping devices.

7. Fool proof system.

1.11TYPES OF JIGS

1. Plate jig.

2. Latch jig.

3. Channel jig.

4. Box jig.

5. Post jig.

6. Angle plate jig.

7. Table jig or flip over jig.

8. Angular post jig.

9. Pot jig.

10. Rack and pinion compartmentalization automatic jig.

11. Gas jig.

CHANNEL JIG:

Plate jig in the main consists of one bushing plate with a provision for locating and
clamping of work. The work profile is found by six location pins and clamped by 2 knurled
screws against the situation pins. Sometimes, it's economical to form the jigs channel formed so
as to change location and clamping.

Figure: Plate Jig

It will then be known as a channel jig. In any drill jig, the work ought to be supported
adequately against bending thanks to the downward thrust of the drill. Moreover, there ought to
be enough clearance below the work for overshoot of the drill when passing through the work.
This will be achieved by providing through the work.
 Figure: Channel Jig

2.1 NORMAL COMPONENTS

JIG BUSH:

The cutlery is found and target-hunting by jig bushes. They’re fitted with bush plate. The many
kinds of bushes are fastened, liner, renewable, slip and screw bushes. The materials ordinarily
used for creating bush could also be direct hardening sort steel cherish nut thirty one, T90, 20
Mn V8. The hardness is sometimes sixty +- two HRC a case hardened depth of zero.5 to 0.8 mm.

EJECTORS:

The ejectors are accustomed take away the work from the shut fitted locators cherish full nest or
ring nest. This can be settled behind the work. Ejectors are accustomed speed up the operation by
reducing the unloading time. So, the assembly rate will increase significantly.

The ejectors of the subsequent sorts are utilized in jigs and fixture.

1. Mechanical sort

2. Spring plunger
PRESSURE PADS:

A pressure pad could also be necessary once the work contains sharp corners or irregular
surfaces. They’re used higher than or below the work piece relying upon size and form of the
work piece. Pressure pads are accustomed absorb shocks. Pressures for the pads are applied by
springs, air or fluid mechanics. Oil - resistant ester pads will stand up to a lot of larger pressure
per area unit with less deflection and so less area is needed than springs.

WASHER:

Washers are used for positive clamping force. The washers ought to have hardness worth
comparatively low compared to pairing surface since they're simply offered and low cost.
They’re used for compensating length in bolt size and to grip the clamping force. the categories
of washers are C washer, Swing C washer, Spherical washer, Plain washer and internal star
washer.

HAND GRIP SCREWS:

They are used for positive clamping. The handle is employed to tighten the half. the
categories of hand grip screws are cylindrical finish, groove end, and floating finish.

QUARTER flip SCREW:

It is additionally known as thumbscrew latch. Quarter flip screws are designed in such
some way that the operator will flip the screws simply even once the threads are coated with
dried oil, dirt and chips. The quarter screw is unbroken perpendicular to verify adjustment.
ADVANTAGES OF JIGS

1. To cut back the price of production.

2. To assure high accuracy of components.

3. To extend production.

4. To avoid wasting labor value.

5. To worth the standard management expense.

3. TYPES AND FUNCTIONS OF JIGS AND FIXTURES

JIGS AND FIXTURE

Jigs and fixtures are production-work holding devices accustomed manufacture duplicate
components accurately. The right relationship and alignment between the cutter, or different tool,
and also the work should be maintained.

To do this, a jig or fixture is intended and designed to carry, support, and find each half to
make sure that everything is trained or machined at intervals the desired limits.

Jigs and fixtures are therefore closely connected that the terms are generally confused or
used interchangeably. The distinction is within the approach the tool is target-hunting to the

Work piece. A jig may be a special device that holds, supports, or is placed on an area to
be machined. it's a production tool created so it not solely locates and holds the

Work piece however additionally guides the cutlery because the operation is performed.
Jigs are sometimes fitted with hardened steel bushings for guiding drills or different cutting
tools.
 As a rule, little jigs aren't mounted to the drill press table. If, however, holes higher
than .25 in. in diameter are to be trained, it's sometimes necessary to lock the jig to the table
firmly. A fixture may be a production tool that locates, holds, and supports the work firmly that
the needed machining operations will be performed. Set blocks and feeler or thickness gauges ar
used with fixtures to reference the cutter to the work.

A fixture ought to be firmly mounted to the table of the machine upon that the work is
completed. Though' for the most part used on edge machines, fixtures are designed to carry work
for varied operations on most of the quality machine tools.
 Fixtures vary in design from comparatively easy tools to dear, sophisticated devices.
Fixtures additionally facilitate to change shaping operations performed on special instrumentality

CLASSES OF JIGS

Jigs could also be divided into 2 general classes: boring jigs and drill jigs. Boring jigs are
accustomed bore holes that either are overlarge to drill or should be created associate odd
size .Drill jigs are accustomed drill, ream, tap, chamfer, bit, countersink, reverse spot face, or
reverse countersink (Figure 2–3). The essential jig is nearly a similar for either machining
operation. the sole distinction is within the size of the bushings used.

TYPES OF JIGS

Drill jigs could also be divided into 2 general sorts, open and closed. Open jigs ar for
easy operations wherever work is completed on only 1 facet of the half. Closed, or box, jigs ar
used for components that has to be machined on More than one facet. The names accustomed
establish these jigs confer with however the tool is made. Guide jigs are commonly used for
accuracy rather Than speed. This sort of jig fits over, on, or into the work and isn't sometimes
clamped (Figure 2–4). Templates are the smallest amount dear and simplest kind of jig to use.
they'll or might not have bushings. Once bushings aren't used, the entire jig plate is generally
hardened.
 Plate jigs are just like templates (Figure 2–5). the sole distinction is that plate jigs have
constitutional clamps to carry the work. These jigs may be created with or while not bushings,
looking on the amount of components to be created. Plate jigs are generally created with legs to
boost the jig off the table for big work.
 This vogue is named a table jig (Figure 2–6). Sandwich jigs are a design of plate jig with
a back plate (Figure 2–7). This sort of jig is right for skinny or soft components that would bend
or warp in another variety of jig. Here again, the utilization of bushings is set by the amount of
components to be created.

Angle-plate jigs are accustomed hold components that are machined at right angles to
their mounting locators (Figure 2–8). Pulleys, collars, and gears are a number of the components
that use this sort of jig. A variation is that the changed angle-plate jig, that is employed for
machining angles then again ninety degrees (Figure 2–9). Both of these examples have clearance
issues with the cutlery. because the drill exits the merchandise being trained, it's very little or no
area for the drill purpose to clear the product fully, turn out a spherical hole all the approach
through the half wall, and avoid drilling the half surveyor. This can be most noticeable in Figure
2–9, where an angled hole needs extra clearance to the mitigated portion of the half surveyor.
Extra clearance here would enable the drill to finish the opening and avoid drilling the mitigated
portion of the surveyor. The half surveyor can possibly be hardened and also the drill is going to
be lost as results of any tried drilling.

Additional clearance on the mitigated diameter of the half surveyor could also be
attainable. a bigger clearance hole within the surveyor may even be additional if the mitigated
diameter can't be reduced. the extra design thought additional to the surveyor would come with
the feature to supply the right orientation of this clearance hole or machined relief to line up with
the bushing location.

Box jigs, or tumble jigs, sometimes whole surround the half (Figure 2–10). This variety
of jig permits the half to be fully machined on each surface without the requirement to reposition
the add the jig Channel jigs are the best design of box jig (Figure 2–11). The work is control
between 2 sides and Machined from the third aspect. In some cases, where jig feet are used, the
work is machined on 3 sides. Leaf jigs area unit tiny box jigs with a hinged leaf to allow for
easier loading and unloading (Figure 2–12). The most variations between leaf jigs and box jigs
are size and half location. Leaf jigs area unit ordinarily smaller than box jigs and area unit
generally created in order that they are doing not fully surround the half. They’re sometimes
equipped with a handle for easier movement.
 Indexing jigs are wont to accurately area holes or alternative machined areas around a
neighborhood. To do this, the jig uses either the half itself or a reference plate and a plunger
(Figure 2–13). Larger compartmentalization jigs area unit referred to as rotary jigs.

Trunnion jigs are a design of rotary jig for terribly giant or odd-shaped components
(Figure 2–14). The half is initial place into a box-type carrier then loaded on the Trunnion. This
jig is well matched for giant, significant components that have to be machined with many
separate plate type jigs.

Pump jigs area unit commercially created jigs that has to be custom-made by the user
(Figure 2–15). The lever-activated plate makes this tool in no time to load and unload. Since the
tool is already created and solely has to be changed, a great deal of your time is saved by
mistreatment this jig. Multi-station jigs is created in any of the forms already mentioned (Figure
2–16). the most feature of this jig is however it locates the work. Whereas one half is trained,
another is reamed and a 3rd counter bored. The ultimate station is employed for unloading the
finished components and loading recent components. This jig is usually used on multiple-spindle
machines. It may additionally work on single-spindle models. There area unit many alternative
jigs that are combos of the kinds delineate. These advanced jigs area unit usually therefore
specialized that they cannot be classified. Despite the jig selected, it should suit the half, perform
the operation accurately, and be straightforward and safe to control.
TYPES OF FIXTURES

The names wont to describe the varied forms of fixtures are determined principally by
however the tool is made. Jigs and fixtures are created primarily constant approach as so much as
locators and positioners’ area unit involved. The most construction distinction is mass. owing to
the exaggerated tool forces, fixtures area unit designed stronger and heavier than a jig would be
for constant half. Plate fixtures are the only design of fixture (Figure 2–17). the essential fixture
is formed from a flat plate that contains a design of clamps and locators to carry and find the
half. The simplicity of this fixture makes it helpful for many machining operations. Its ability
makes it widespread.

The angle-plate fixture may be a variation of the plate fixture (Figure 2–18). With this
tool, the half is often machined at a right angle to its locater. whereas most angle-plate fixtures
area unit created at ninety degrees, there area unit times once alternative angles area unit
required. In these cases, a changed angle-plate fixture is used (Figure 2–19). Vise-jaw fixtures
area unit used for machining tiny components (Figure 2–20). With this kind of tool, the quality
holding device jaws area unit replaced with jaws that area unit fashioned to suit the half. Vise-
jaw fixtures area unit the smallest amount overpriced variety of fixture to form. Their use is
restricted solely by the sizes of the vises offered.

These fixtures are used for machining components that has to have machined details
equally spaced The components shown in Figure 2–22 are samples of the uses of associate
compartmentalization fixture. Multi-station fixtures area unit used primarily for high-speed,
high-volume production runs, where the machining cycle should be continuous. Duplex fixtures
are the only design of multistation fixture, mistreatment solely 2 stations (Figure 2–23). This
manner permits the loading and unloading operations to be performed whereas the machining
operation is ongoing. For instance, once the machining operation is complete at station 1, the tool
is turned and therefore the cycle is perennial at station two. At constant time, the half is blank at
station one and a recent half is loaded.

Pro-filing fixtures area unit won’t to guide tools for machining contours that the machine
cannot ordinarily follow. These contours are either internal or external.

Since the fixture incessantly contacts the tool, associate incorrectly cut form is nearly not
possible. The operation in Figure 2–24 shows however the cam is accurately cut by maintaining
contact between the fixture and therefore the relating the edge cutter. This bearing is a very
important a part of the tool and should always be used.
CLASSIFICATION OF FIXTURES

Fixtures are ordinarily classified by the kind of machine on that they're used. Fixtures
also can be known by a sub classification. to Illustrate, if a fixture is meant to be used on a
shaping machine, it's referred to as a edge fixture. If the task it's meant to perform is straddle
edge, it's referred to as a straddle milling fixture. An equivalent principle applies to a shaper
fixture that's designed to machine radii. it's referred to as a lathe-radius fixture.
The Frame Jig

Many potential frame builders have the mistaken concept the frame jig should be
extraordinarily correct, designed sort of a preciseness measuring system and nonetheless possess
vast strength for bending and holding the conduit sections in position for fastening however of
course the base structure of the jig, typically referred to as the backbone, bed, table, base table,
face table or frame face are often virtually any relative rigid structure.

As long because the frame bed or backbone is level all told directions the $64000
preciseness and accuracy can occur through the fabrication of the fixtures that attach to the
current substructure or backbone and so are adjusted and secured to position and hold the conduit
and elements in situ throughout the fabrication of the frame or chassis.

Figure one illustrates a typical jig assembly with the bed or backbone being fabricated
from 2 segments of box conduit with the assorted fixtures locked into position.

Figure 1

This form of frame jig is brought up as being a ‘bottom-up’ arrangement and whereas it's
some disadvantages it's out and away the foremost common type of jig utilized in custom
motorbike frame construction. the subsequent footage illustrate a good type of frame jigs starting
from easy and crude home-brewed units to extraordinarily sophisticated absolutely adjustable
units factory-made for big chassis retailers. Though the vary of sophistication is wide, all of the
pictured jigs will manufacture terribly accurately aligned tube frames. Of course the preciseness
of the ultimate product is additional smitten by the builders ability than the frame jig being
employed and there square measure many custom frame builders United Nations agency don’t
use a frame jig to start with.

In figure two we tend to see a typical jig backbone, this instance is created from channel
and raised to knee height on fragment blocks.

Figure 2
 Another comparatively easy layout below in figure three shows 2 longitudinal rails
forming the backbone or bed framework.

Another typical horizontal rail or bed form of jig is shown in figure four. Note that during this
example, designed to fabricate one specific form of frame, the fixtures aren't adjustable however
square measure welded into position on the jig bed rail made of 3x3 sq. conduits.
 CHAPTER 2

INTRODUCTION TO PRO-E

Because the world's one in every of the provider of software package, specifically meant
to support a completely Integrated development method. constant quantity Technology
Corporation (PTC) is recognized as a strategic partner which may facilitate a manufacturer to the
flip a method into competitive advance, bigger market share and better profits and industrial and
mechanical design to purposeful simulation producing and knowledge management.

PRO-E mechanical design answer can improve our design productivity. PRO-E may be a
suit of programs that square measure utilized in design, analysis and producing of a just about
unlimited varies of the merchandise.

"Feature based” implies that we tend to produce elements and assemblies by process
feature like extrusion, sweeps, cuts, holes, spherical so on rather than specifying low level pure
mathematics like lines, areas and circles. This suggests that the designer will think about the pc
model at a really high level and leave all low pure mathematics detail for PRO-E to work out.

"Parametric” implies that the physical form of the half as assembly is driven by the worth
assigned to the attributes of its options. We tend to might outline or modify a feature dimension
or alternative attributes at any time. Any changes can mechanically propagate through the model.

"Solid modeling” implies that the pc model we tend to produce is ready to contain all the
data that a true solid object would have. it's volumes and thus, if you offer a price for the density
of the fabric it's mass and inertia
Modules in PRO-E

Following are the vital module of PRO-E:

5.1 Sketch module:

Sketcher module allows US to make sections. Sketcher technique is employed in

several areas of PRO-E. exploitation sketcher mode, we are able to produce pure mathematics
while not relevance the precise relationships between elements of sketch or the precise price of
dimensions, once we generate the sections, PRO-E makes specific assumptions. To illustrate if
we tend to draw nearly horizontal line, it becomes precisely horizontal and everyone these
assumptions square measure displayed diagrammatically.

Part module:

This starts by adding a group of default data point planes and making the primary
solid and surface options, then still increase deliver the goods the designed form by making
varied construction options and protrusions, slots and cuts, holes, shafts, ribs, chamfer, etc.

ALL COMPONENTS
1. Base Part: This part is created by using following features.
a. Revolve
b. Extrude cut
c. Sweep cut
d. Pattern(Axis)

Revolve sketch

Revolved Body
Extrude cut sketch

Extrude cut body

Sweep cut trajectory

Sweep cut
Pattern (Axis Method)
2. Cover part: It is created with the following features.

a. Revolve
b. Extrude cut1 with Pattern
c. Extrude cut2

Revolve sketch

Revolved Cover
Extrude cut Body with Axis Pattern each 1200 with 10 dia. With 86 PCD

Extrude Cut sketch

Extrude Cut hole

3. Plate: This part is created by using following features.
a. Revolve
b. Extrude cut with Pattern

Revolve Sketch

Revolved Body

Extrude cut Body with Pattern each 1200 with 16 dia. With 86 PCD
4. Stud: This part is created by using following features.

a. Revolve
b. Helical cut

Revolve sketch

Revolved body
 Helical cut(threading)

Revolved body with threading (helical cut)

4. Special washer: This part is created by using following features.
a. Extrude
b. Round tool

Extrude sketch

Extrude part
Extruded part with applying round tool on it.

Finished special washer part

6. Washer: This part is created by using following features.

a. Extrude
b. Round tool

Extrude sketch
Extruded part with applying round tool on it.

Finished washer part

7. Bush1: This part is created by using following feature.

a. Extrude

Extruded bush

8. Bush2: This part is created by using following feature.

a. Extrude

Extruded bush 2
9. Steel pin: This part is created by using following feature.

a. Extrude

Extruded steel pin

9. Nut: This part is created by using following feature.

a. Extrude
b. Helical sweep(cut)
c. Revolve

Extruded part
Extruded part with helical sweep (cut)

Revolved sketch on the extruded part with helical cut (internal threading)
 Revolve
d cut on the extruded part with helical cut
 CHAPTER 3

ASSEMBLY MODULE:

Few design s incorporates simply one half. Most design s square measure
combination of many thousands of elements as assembly drawing for documentation is
historically a multi-view drawing to complete design showing every element in its relative
position and known by name. Typically over all dimensions within the assembly drawing for
additional complicated design s, the assembly is split into purposeful sub-assemblies, that square
measure known within the assembly drawing. Individual elements square measure then known at
the assembly level. Assembly shows all the elements each commonplaces and non standard. a
typical half is one, that we tend to merely purchase from manufacture and use because it is. A
non-standard or custom half is one we tend to should design for the present project.

1. During this assembly to insert the elements one by one, we tend to used the desired
constraints they are:

a. Default for the primary element and for the remaining all elements insert, mate and align
constraints square measure used and created the element absolutely constraint.
Final Assembly of Drill Jig
 CHAPTER 4

INTRODUCTION TO FINITE ANALYSIS METHOD:

The finite part method represents associate degree extension of the matrix strategies for
the analysis of framed structures to the analysis of the time structures. The fundamental
philosophy of the strategy is to interchange the structure of the time having an infinite or infinite
range of unknowns at bound chosen separate points. The strategy is extraordinarily powerful
because it helps to accurately analyze structures with advanced geometrical properties and
loading conditions. within the infinite technique, a structure or time is discretized and perfect by
employing a mathematical model that is an assembly of subdivisions or separate components,
referred to as finite part, are assumed to be interconnected solely at the joints referred to as
nodes.
 Straightforward functions love polynomials are chosen in terms of unknown
displacements at the nodes to approximate the variation of the particular displacements over
every finite part. The external loading is additionally reworked in to equivalent forces applied at
the nodes. Next, the behavior of every part severally and later as an assembly of those
components is obtained by relating their response thereto of the nodes in such how that the
subsequent basic conditions are happy at each node:

• Equations of equilibrium

• The compatibility of displacements

• The material organic relationship

The equations, that are obtained victimization the higher than conditions, are
within the kind of force-displacement relationship. Finally, the force-displacement equations are
resolved to get displacements at the nodes that are the fundamental unknowns within the finite
part technique.

The fundamental plan within the finite part technique is to search out resolution of an
advanced drawback by exchange it by less complicated one. Since an easier one find the answer
replaced the particular drawback, we are going to be able to realize solely Associate in nursing
approximate resolution instead of actual resolution. In finite part technique, it'll usually be doable
to boost or refine the approximate resolution by causing a lot of machine effort.

This is often a numerical resolution for getting solutions to several of the issues
encountered in engineering analysis. During this technique, the body or the structure is also
divided into little components of finite dimensions referred to as finite components. The initial
body or time is then thought of as assemblage of those components connected at a finite range of
joints referred to as nodes.

4.1. ENGINEERING APPLICATIONS OF FEM:

The final nature of its theory makes it applicable to a large form of boundary price issues
in engineering. A boundary price drawback is one amongst that an answer is sought-after in
domain (region) of a body subject to the satisfaction of the prescribed boundary (edge) condition
of the variable of their derivatives. Largely all engineering issues that are illustrated within the
table four.1 of the finite part technique comes underneath 3 classes of boundary issues, namely

1. Equilibrium or steady state or time freelance drawback,

2. Eagan price drawback,

3. Transient or propagation programs.

Table 4.1 various applications of Finite Element Analysis

Area of study Equilibrium problems Eagan value problems Propagation problems

1. Civil engineering Static analysis of the Natural frequencies and Propagation of stress waves
structures trusses, frames, folded modes of structures
plates, roofs, shear walls
2. Aircraft structures Static analysis of wings, Natural frequencies flutter Response of aircraft
rockets, fuselages, fins and stability of aircraft, structures to random loads,
and missile structures rocket. dynamic response of
aircraft.
3. Hydraulic and Analysis of potential Natural periods and Analysis of unsteady state
water resources flows, free surface flows, modes of shallow basins, fluid flow and wave
engineering viscous flows. lakes and harbors propagation problems

4.Nuclear Analysis of nuclear Natural frequencies and Response of reactor

Engineering pressure vessels and stability of containment containment structures to
containment structures structures dynamic loads.
5.Mechanical design Stress concentration Natural frequencies and Crack and fracture problems
 problems, stress analysis stability of linkages, gears under dynamic loads.
of pressure vessels, and machine tools.
pistons, gears.

4.2. GENERAL DESCRIPTION OF FEM

The stepwise procedure for static drawback will be declared as follows:

Step 1: Discretization of time

The primary step within the finite part is to divide the structure of resolution region in 2
subdivisions of components. The subdivision or Discretization method of the time is actually
associate in nursing exercise of engineering judgment. These subdivisions are referred to as
components, and are connected to the adjacent of the weather in such how that the initial body is
delineated by it as closely as doable. Hence, the final objective of such Associate in nursing
idealization is to discretize the body in to finite range of components sufficiently little in order
that the easy displacement models will adequately approximate verity resolution.

Step 2: choice of correct Interpolation model

Since the displacement (field variable) resolution of the advanced structure underneath
any specific load conditions can't be foreseen precisely, we tend to assume some appropriate
with in part to approximate the unknown resolution. The assumed resolution should be from
machine purpose of read and it ought to satisfy bound convergence necessities.

Step 3: by-product of part stiffness matrices (Characteristic matrices) and cargo vectors

From the assumed displacement model the stiffness matrix and cargo vector P(e) of the
part ‘e’ are to be divided by victimization either equilibrium conditions or an appropriate
variation principle.

Step 4: assemblage of part equation to get the general equilibrium equations

 Since the structure consists of many finite components, the individual part stiffness
matrices and cargo vectors are to be assembled in a very variable manner and therefore the
overall equilibrium equations ought to be developed as:

[K] =ɸ [P]

Wherever [K] is termed assemblage stiffness matrix,

ɸ is termed nodal displacement vector and

P is termed nodal vector for the entire structure.

Step 5: resolution of systems equations to search out nodal values of the displacement (field
variable):

The general equations ought to be changed, to account for the boundary conditions of the
matter, when the incorporation of the boundary conditions, the equilibrium equations is resolved.

4.3. BENEFITS OF FEM:

1. Its ability to use varied size and form and to modal a structure of absolute pure
mathematics.

2. Its ability to accommodate absolute boundary conditions, loading, together with

thermal loading.

3. Its ability to modal composite structures involving completely different structural

elements appreciate stiffening member on a shell and combination of plates, bars and
solids, etc.,

4. The finite component structure closely resembles the particular structure rather
than being quite completely different obstruction that's arduous to check.
 5. The FEM is tested with success in representing varied forms of sophisticated
material properties and material behavior (nonlinear, aeolotropic, time dependent or fixed
supportdependent material behavior).

6. It pronto accounts for non-homogeneity of the fabric by distribution completely

different properties to different components or maybe it's potential to vary the properties
inside part in keeping with a pre-determined polynomial pattern.

4.4. DISADVANTAGES OF FEM:

Specific numerical results obtained for a selected drawback

1. Expertise and judgment square measure needed so as to construct a decent finite

component model.

2. an enormous laptop and a reliable malicious program (software) square measure

essential. Input and output knowledge square measure tedious to organize and interpret.

4.5. FINITE COMPONENT ANALYSIS:

Finite component analysis was initial developed for the employment of region and
nuclear industries wherever the protection of structure is important. Nowadays growth within the
usage of methodology is directly thanks to the speedy advances in engineering. As a result
business finite component packages exist that square measure capable of resolution the foremost
subtle issues, not simply in structural analysis, except for big selection of phenomena appreciate
steady state and dynamic fixed supportdistributions, fluid flow and producing processes
appreciate injection molding and metal forming.

Finite component analysis is employed in new product design, and existing

product refinement. Modifying AN existing product or structure is used to qualify the
merchandise or structure for a brand new service condition. Just in case of structural failure,
Finite component Analysis is also wont to facilitate in determinant the look modifications to
satisfy the new conditions.

Types of Analysis: There square measure differing kinds of study that square measure employed
in industry: Structural, Modal, Harmonic, Transient and Spectrum.

Structural Analysis consists of linear and non-linear models. Linear models square
measure easy parameters and assume that material isn't plastically malformed. Non-linear models
comprise stressing the fabric past its elastic capabilities. The stresses within the material then
vary with the quantity of deformation.

Vibration analysis is employed to check the fabric against random vibrations, shock and
impact. Every of those incidents might act on the natural vibration frequency of the fabric that
successively, might cause resonance and succeeding failure. Thus analysis is finished on the
fabric to predict the lifetime of the fabric. Heat-Transfer Analysis models the thermal physical
phenomenon or thermal fluid dynamics of the fabric or structure. This could comprise a gentle
state or transient transfer. Steady-state transfer refers to constant thermo properties in material
that yield linear heat diffusion.

FINITE COMPONENT ANALYSIS METHOD

The structure to be analyzed is divided in to mesh of finite sized components of

easy form. Inside every component, the variation of displacement is assumed to be determined
by easy polynomial form functions and nodal displacements. Equations for strain and stresses
square measure developed in terms of unknown nodal displacements. From this, the equations of
equilibrium square measure assembled in a very matrix kind, which may be simply programmed
and resolved, on a laptop. When applying acceptable boundary conditions, the nodal
displacements square measure found by resolution the matrix stiffness equation. Once the nodal
displacements square measure noted, component stresses and strains is calculated.
 CHAPTER 5:

INTRODUCTION TO ANSYS SOFTWARE

Computer code the aim of a finite component analysis is to model the behavior of a
structure underneath a system of masses. So as to try and do thus, all influencing factors should
be thought-about and determined whether or not their effects square measure significant or
negligible on the ultimate result. Several computer code square measures used for this purpose.
ANSYS, Pro-E, Uni graphics, NISA, MSC, NASTRAN etc.

The ANSYS program is self-contained general purpose finite component program

developed and maintained by Gloria May Josephine Svensson Analysis Systems Iraqi National
Congress. The program contains several routines, all reticulated and every one for main purpose
of achieving a solution to an engineering drawback by Finite component methodology.

ANSYS provides an entire resolution to design issues. It consists of powerful design

capabilities like full constant quantity solid modeling, design optimization and automotive
vehicle meshing, which provides engineers full management over their analysis.

The following square measure the special options of ANSYS software:

• It includes linear components.

• Heat flow analysis, fluid flow and component flow analysis is done.

• Graphic package and intensive preprocessing and post process.

The following shows the transient description of steps followed in every phase:

Table 4.2. Various stages of ANSYS.

PRE- PROCESSOR PHASE SOLUTION PHASE POST PROCESSOR PHASE

Geometry definitions Element matrix formulation Post solution operation

Mesh generation Overall matrix triangulation Post data print out

Materials definition Wave front Post data display

5.1: MESHING

Manual Meshing:

In manual meshing the weather square measure smaller at joint. this is often called mesh
refinement, and it allows the strain to be captured at the geometric separation. Manual meshing is
long and tedious method for models with any degree of geometric complication, however with
great tool rising in pre-processes, the task is changing into easier.

Meshing controls:

The default meshing controls that the program uses might manufacture a mesh that's
adequate for the model we tend to square measure analyzing. during this case, we want not
specify any meshing controls. but if we tend to do use meshing controls we tend to should set
them before meshing the solid model.

Meshing controls permit North American nation to determine the part form, midside node
placement and part size to be employed in meshing the solid model, this step is one in every of
the foremost necessary of the complete analysis for the choices we have a tendency to build at
this stage within the model development can deeply have an effect on the accuracy and economy
of the analysis.

5.2: GOOD SIZING OF COMPONENT

Good component filler (Smart sizing) may be a meshing feature that makes initial part
sizes free meshing operations. Good filler provides the mesher a more robust probability of
making fairly formed parts throughout automatic mesh generation.

5.3: FREE AND MAPPED MESH

A free mesh is one that has no restrictions in terms of part shapes and no specific
pattern applied to that. Compared to a free mesh, a mapped mesh is restricted in terms of the part
form it contains and therefore the pattern of the mesh. A mapped mesh contains solely
quadrilateral (area) or solely polyhedron (volume) parts. If this kind of mesh is desired, the user
should build the pure mathematics as series of fairly regular volumes and/or areas which will
settle for a mapped mesh.

6.4: PRE-PROCESSOR

 The pre-processor stage in ANSYS package involves the following:

 Specify the title that is the name of the matter.
 Set the kind 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 house within the applicable units
(m, mm, in, etc). The model could also be created in pre-processor, or it may be foreign
from another CAD drafting package through a neutral file format9 like IGES, STEP,
ACIS, Para solid, DFX, ETC., ). a similar units ought to be applied altogether directions,
otherwise results are going to be troublesome to interpret, or in extreme cases the result
won't show up mistakes created throughout loading and restraining of the model.
 Define the part sort, this might be 1D, 2D or 3D, and specify the analysis sort being
meted out.
 Apply mesh – Mesh generation is the method of dividing the analysis time in to variety of
separate elements or finite parts. The finer the mesh, the higher the result, however the
longer the analysis time. Therefore, the compromise between accuracy and resolution
speed is sometimes created.
 Assign the properties – Material properties (Young’s Modulus, Poisson’s magnitude
relation, density, and if applicable constant of growth, friction, thermal physical
phenomenon, damping result, heat, etc.,) have to be compelled to be outlined.

5.5: RESOLUTION

 Apply the masses. Some variety of loads is really applied to the analysis model. The
loading could also be within the kind of some extent load, pressure or a displacement
during a stress analysis, a fixed supportor total deforamation during a thermal analysis
and a fluid pressure or speed during a fluid analysis. The masses could also be applied to
some extent, an edge, a surface or maybe to an entire body.
  Applying the boundary conditions. When applying load to the model so as to prevent it
fast infinitely through the pc just about either a minimum of one stipulation should be
applied.
 FE convergent thinker may be logically divided in to 3 main elements, the pre-solver, the
mathematical-engine and therefore the post-solver. The pre-solver reads the model
created by the pre-processor and formulates the mathematical illustration of the model
and calls the mathematical-engine that calculates the results. The result came back to the
convergent thinker and therefore the post-solver is employed to calculate the strains,
stresses, etc., for every node at intervals the element or time.


6.6: POST-PROCESSOR

During this module, the results of the analysis square measure browse and understood.
All post-processor embody the calculation of stress and strain altogether of the X, Y, or Z
directions, or so within the direction at AN angle to the coordinate axes. The principle stress and
strain may be premeditated.

6.7: STRUCTURAL ANALYSIS

Structural analysis is maybe the foremost common-application of the FEM. The term
structural implies not solely technology structures reminiscent of bridges and buildings, however
conjointly armed service, natural philosophy, and mechanical parts reminiscent of pistons,
machine elements and tools. the first unknowns (nodal degree of freedom) calculated during a
structural analysis square measure displacements different qualities, reminiscent of strains,
stresses and reaction forces square measure derived from the nodal displacements.

6.8: MODAL ANALYSIS

 Definition: we have a tendency to use Modal Analysis to see the vibration characteristics
(Natural frequencies and mode shapes) of a structure of a machine element whereas it's being
designed. It can also be a place to begin for an additional, a lot of elaborate, Dynamic Analysis,
reminiscent of a transient dynamic, a harmonic response analysis, or a spectroscopic analysis.

Uses for Modal Analysis: The Natural frequencies and mode shapes square measure
necessary parameters within the design of a structure for Dynamic loading conditions. They’re
conjointly needed if you would like to try and do a spectroscopic analysis or a mode
superposition harmonic or transient analysis.

We are able to do modal analysis on a pre stressed structure, such as a spinning rotary
engine blade. Another helpful feature is modal cyclic symmetry, that allows you to review the
mode shapes of a cyclically symmetry structure by modeling simply a sector of it.

Modal Analysis within the ANSYS family of product may be a linear analysis.
Any nonlinearity, reminiscent of physical property and contact (gap) parts, are neglected
notwithstanding they're outlined. you'll be able to make a choice from many mode extraction
methods: topological space, Block Lanczos, Power Dynamics, reduced, unsymmetrical, and
damped. The damped methodology permits you to incorporate damping within the structure.
Details regarding mode extraction ways square measure coated later during this section.

6.9: STRUCTURAL STATIC ANALYSIS

Definition: A static analysis calculates the consequences of steady loading conditions on

a structure, whereas ignoring inertia and damping effects, akin to those caused by time-varying
loads. A static analysis will, however, embody steady inertia loads (such as gravity and motility
velocity), and time-varying masses that may be approximated as static equivalent loads (such
because the static equivalent wind and seismal loads normally outlined in several building
codes).
 Loads in a very Static Analysis: Static analysis is employed to see the displacements,
stresses, strains and forces in structures or parts caused by loads that don't induce important
inertia and damping effects. Steady loading and response conditions square measure assumed;
that's, the loads and also the structure’s response square measure assumed to vary slowly with
reference to time. The sorts of loading that may be applied in a very static analysis include:

• Externally applied forces and pressures

• Steady-state mechanical phenomenon forces (such as gravity or rational
velocity)
• Imposed (non-zero) displacements
• Temperatures (for thermal strain)
• Fluencies (for nuclear swelling)

A static analysis calculates the consequences of steady loading conditions on a structure,

whereas ignoring inertia and damping effects, akin to those caused by time-varying masses. A
static analysis will, however, embody steady inertia loads (such as gravity and motility velocity),
and time varied loads that may be approximated as static equivalent masses (such as static
equivalent wind and seismal masses normally outlined in several building codes.

Loads in a very Static Analysis: - Static analysis is employed to see the displacements,
stresses, strains, and forces in structures or parts caused by loads that don't include important
inertia and damping effects. Steady loading and response conditions square measure assumed;
that's, the masses and also the structure’s response square measure assumed to vary slowly with
reference to time. The sorts of loading that may be applied in a very static analysis

Include: -

• Externally applied forces pressures

• Steady-state internal forces (such as gravity or motility velocity)
• Imposed (non-zero) displacements
• Temperatures (for thermal strain)
• Fluencies (for nuclear swelling)
Linear vs. nonlinear Static Analysis: - a static analysis are often either linear or non linear.
every kind of nonlinearities are allowed-large deformations, plasticity, creep, stress stiffening,
contact (gap) parts, hyper elastic parts etc.

Overview of steps in a very static analysis: -

The process for static analysis consists of 3 main steps: -

1. Build the Model: - to create the model, specify the task name, analysis title then outline
the component varieties, component real constants, material properties, and also the model pure
mathematics. The structural parts are often linear or nonlinear. Material properties are often
linear or nonlinear, identical or writing, and constant or temperature-dependent. The Young’s
modules ought to even be outlined.

2. Apply the loads get the solution: - during this step, outline the analysis kind and
choices, apply loads, specify load step choices, and start the finite component resolution. the
loads that may be applied square measure :

Displacements- degree of freedom, constraints typically given at modal boundaries to outline

rigid support points.

 Forces- targeted loads typically given on the model exterior, moments.

 Pressures- surface loads typically applied on the model exterior, temperatures.
 Fluencies- applied to stuffy the consequences of swelling or creep.

3. Review the results: - Results from a static analysis include the nodal displacements,
nodal and component stresses, nodal and component strains, component forces, nodal reaction
forces etc.

Chapter 6

ANALYSIS PROCEDURE:

6.1 MODELANALYSIS:
 In this model analysis the total deformation on the drill jigs by applying required boundary
conditions. In the model analysis initial fixed supports applied and within the specified time the
total deformation will be generated..

Open ansys workbench 15.0, it opens a project schematic window with tool box,
graphical user interface with some other important tools.

Use import tool to import the geometry with STEP or IGES file format.

After importing the geometry file we do the required analysis.

Now on our model analysis was done. From the tool box select model analysis tab and drop on
gui.

Now link the imported geometry to the model analysis tab and double click on model to open
analysis window as shown below in the project schematic window.

MAIN WINDOW OF ANSYS WORKBENCH 15.0

Importing of the drill jig will be done after opening the workbench. For the supporting
purpose of the geometry, the file format of catia will be changed to step format. This is to match
up the graphical properties of the catia v5 to ansys workbench 15.0.
 The full form of the step is standard for the exchange of product model data which itself
states that will exchange the graphical properties of models.

The material properties are the important factor which will be considered as the second
preference after importing or creating the geometry. The procedure of material application,
double click on the engineering data which will appear on the top of the analysis system. The
analysis system which we are using in this project is MODEL analysis. After opening the
window of engineering data the material application will be done by selecting the add symbol in
the general materials. In this project we are working on two materials namely steel and gray cast
iron. These materials are available in thermal materials from engineering data source and select
the above mentioned material, and reset layout from view menu and update project.

MATERIAL PROPERTIES

MODEL ANALYSIS:

After importing the model into project schematic window drag and drop the MODEL tab
on to the screen from the toolbox window and link the geometry to geometry both will be linked
together. Double click on the model it opens the mechanical window with object.
 Model with Analysis tools

Mesh: To generate the meshing, there are two methods one is automatic mesh generation and the
other is with required size meshing. In this we used auto meshing with medium meshing.

Meshed Geometry

Assigning of material:

From the outline tab – select the geometry – Part – from the bottom detailed window- material –
Assignment – Select required material. Here we are considering the four materials
In model :

Set the initial fixed support

Right click on Analysis settings – Insert – Fixed support–and select as shown below

Solution:

Right Click on solution – Insert total deformation support- Right Click on solution – Solve. The
results window looks as below.
 Project schematic

Modal analysis:
For material structural steel:

1st & 2nd mode of deformation and natural frequency

 3rd & 4th mode of deformation and natural frequency

5th & 6th mode of deformation and natural frequency

Results
For material aluminum alloy:

1st & 2nd mode of deformation and natural frequency

3rd & 4th mode of deformation and natural frequency

5th & 6th mode of deformation and natural frequency
For material cast iron:

1st & 2nd mode of deformation and natural frequency

3rd & 4th mode of deformation and natural frequency

5th & 6th mode of deformation and natural frequency
:

6.1 STATIC STRUCTURAL ANALYSIS:

In this model analysis the stress an strain deformation on the drill jigs by applying required
boundary conditions. In the model analysis initial fixed supports applied and within the
specified time the total deformation will be generated..

Open ansys workbench 15.0, it opens a project schematic window with tool box,
graphical user interface with some other important tools.

Use import tool to import the geometry with STEP or IGES file format.

After importing the geometry file we do the required analysis.

Now on our model analysis was done. From the tool box select model analysis tab and drop on
gui.

Now link the imported geometry to the model analysis tab and double click on model to open
analysis window as shown below in the project schematic window.

MAIN WINDOW OF ANSYS WORKBENCH 15.0

Importing of the drill jig will be done after opening the workbench. For the supporting
purpose of the geometry, the file format of catia will be changed to step format. This is to match
up the graphical properties of the catia v5 to ansys workbench 15.0.
 The full form of the step is standard for the exchange of product model data which itself
states that will exchange the graphical properties of models.

The material properties are the important factor which will be considered as the second
preference after importing or creating the geometry. The procedure of material application,
double click on the engineering data which will appear on the top of the analysis system. The
analysis system which we are using in this project is static structural analysis. After opening the
window of engineering data the material application will be done by selecting the add symbol in
the general materials. In this project we are working on two materials namely steel and gray cast
iron. These materials are available in thermal materials from engineering data source and select
the above mentioned material, and reset layout from view menu and update project.

MATERIAL PROPERTIES

STATIC STRUCTURAL ANALYSIS:

 After importing the model into project schematic window drag and drop the static
structural tab on to the screen from the toolbox window and link the geometry to geometry both
will be linked together. Double click on the model it opens the mechanical window with object.

static structural with Analysis tools

Mesh: To generate the meshing, there are two methods one is automatic mesh generation and the
other is with required size meshing. In this we used auto meshing with medium meshing.

Meshed Geometry

Assigning of material:
From the outline tab – select the geometry – Part – from the bottom detailed window- material –
Assignment – Select required material. Here we are considering the four materials

IN STATIC STRUCTURAL:

Set the initial fixed support

Right click on Analysis settings – Insert – Fixed support–50 kN force or pressure and select as
shown below

Solution:
Right Click on solution – Insert Fixed support- Right Click on solution – Solve. The results
window looks as below.

Project schematic
STATIC STRUCTURAL ANALYSIS:

Project schematic

For structural steel:

For aluminum alloy:

For cast iron:

RESULTS:

MODAL ANALYSIS:

S.NO TYPE OF MATERIAL TOTAL DEFORMATION (MM)

1 2 3 4 5 6

1 STRUCTURAL STEEL 42.14 44.57 24.82 74.69 74.70 93.71

2 ALUMINUM ALLOY 75.42 75.96 39.50 184.91 135.57 75.30

3 CAST IRON 46.97 47.36 24.49 123.85 89.84 46.01

STATIC STRUCTURAL ANALYSIS:

EQUIVALENT
TOTAL STRAIN
DEFORMATION
S.N TYPE OF FORC EQUIVALENT x 10-4
O MATERIAL E x 10-3 MM STRESS MPA MM/MM

STRUCTURA
1 L STEEL 50KN 3.016 32.98 1.857

ALUMINUM
2 ALLOY 50KN 8.5231 31.48 5.032

3 CAST IRON 50KN 5.4677 33.94 3.456

CONCLUSION:

Modeling and analysis was completed by using advanced modeling software system catia
v5 and ansys 15 respectively. Static structural and MODAL analysis was done on DRILL JIG for
3 completely different materials and results are achieved. in line with the results stress is nearly
shut for 3 materials however considering deformation is a smaller amount for steel compared
with grey forged iron and aluminum alloy. Thus the steel is best material for the producing.