© 2017 IJNRD | Volume 2, Issue 4 April 2017 | ISSN: 2456-4184
DESIGN AND FABRICATION OF MECHANICAL
FIXTURE FOR HMC MACHINE
1
Harish P. Jorvekar, 2 Kedar S. Kawnaikar
1
UG Student, 2UG Student
1,2
Department of Mechanical Engineering,
Sir Visvesvaraya Institute of Technology, Nashik-422102, India.
Abstract—Fixture is a device which secures a single object to a location in space relative to a specific reference plane and/or point by
limiting at least four of its possible six degrees of movement in space (along the x, y and z axis and rotation about said axis). In existing
set up the workpiece is manufactured on conventional machining operations, so the aim of this project is to replace with fixture for HMC
machine to increase production rate of workpiece.
Index Terms—Fixture, Productivity, Improve Accuracy.
I. INTRODUCTION
The fixture is a special tool for holding a work piece in proper position during manufacturing operation. For supporting and clamping the
work piece, device is provided. Frequent checking, positioning, individual marking and non-uniform quality in manufacturing process is
eliminated by fixture. This increase productivity and reduce operation time [1]. Fixture design plays an important role at the setup planning
phase. Proper fixture design is crucial for developing product quality in different terms of accuracy, surface finish and precision of the
machined parts In existing design the fixture set up is done manually on conventional lathe and milling machines. So the aim of this project is
to replace with mechanical fixture to save time for loading and unloading of component [3].
A fixture consists of a set of locators and clamps. Locators are used to determine the position and orientation of a workpiece, whereas
clamps exert clamping forces so that the workpiece is pressed firmly against locators. Clamping has to be appropriately planned at the stage of
machining fixture design. A fixture is a production tool that locates, holds, and supports the work securely so the required machining
operations can be performed. A fixture should be securely fastened to the table of the machine upon which the work is done [4].
II. PROBLEM STATEMENT
In company, currently the operation on workpiece (32-A cylinder) is carried on conventional machineries. These are time consuming and
sometimes non economical. In this process 8 workpieces were produced during the time span of 12 hours.
Conventional machines include:
Simple drill machine
Radial drill machine
Milling machine
Four axis VMC (Vertical Machining Centre)
Figure1 : Conventional Machining Operations
III. OBJECTIVE
The objective of mechanical fixture is to transfer the conventional machining operations to modern and high-tech machine i.e. HMC
(MORI SEIKI NHX 6300 DCG-2).
The name of job/workpiece is 32-A cylinder.
Material used is cast iron.
It is a pneumatic cylinder used in Atlas Copco.
IJNRD1704017 International Journal of Novel Research and Development (www.ijnrd.org) 64
© 2017 IJNRD | Volume 2, Issue 4 April 2017 | ISSN: 2456-4184
Figure 2: 32-A-Cylinder (workpiece)
After analyzing operations performed on conventional machines, we came across a machine called HMC (MORI SEIKI NHX 6300
DCG-2). This machine was vacant and after studying we found that the machine is suitable for 32-A cylinder.
Hence operations that can be performed on HMC are as follows:
Facing
Boring
Counter boring
Drilling
Grooving
Chamfering
Threading
Hence most of the operations performed on conventional machines could be easily replaced by designing the appropriate fixture for
HMC.
IV. HORIZINTAL MACHINING CENTRE (HMC)
Name of Machine: MORI SEIKI NHX 6300 DCG-2
Figure 3: Actual machine and its internal structure.
Specifications of NHX 6300
DDM (Direct Drive Motor) on the B-axis (option).
Rapid traverse rate (X/Y/Z): 60 m/min.
High-rigidity spindle with a large-diameter bearing.
Ring type magazine (60 tools) offers high-speed indexing.
The reduction in standby power.
V. DESIGN AND FABRICATION OF FIXTURE
Important considerations while designing jigs and fixtures. Designing of and fixtures depends upon so many factors. These factors are
analyzed to get design inputs for and fixtures [3].
The list of such factors is mentioned below:
a. Study of workpiece and finished component size and geometry.
b. Type and capacity of the machine, its extent of automation.
c. Provision of locating devices in the machine.
d. Available clamping arrangements in the machine.
e. Available indexing devices, their accuracy.
f. Evaluation of variability in the performance results of the machine.
g. Rigidity and of the machine tool under consideration.
h. Study of ejecting devices, safety devices, etc.
i. Required level of the accuracy in the work and quality to be produced
IJNRD1704017 International Journal of Novel Research and Development (www.ijnrd.org) 65
© 2017 IJNRD | Volume 2, Issue 4 April 2017 | ISSN: 2456-4184
Figure 4: CAD Design and Actual Fixture.
Graphical representation for increment in Production rate.
Figure 5: Comparison of conventional machining operation vs operation on HMC w.r.t. Time
ADVANTAGES
High productivity.
Time consumption less.
High accuracy
Corrosion resistant.
Less or negligible errors.
High surface finish.
Low maintenance cost.
Less wear of fixture material.
Economical then conventional.
No lubrication is required.
DISADVATAGES
High initial cost.
Difficult in handling.
Programming of the machine was difficult.
Due to thick cutting chips, the safety glass of the machine broke.
CONCLUSIONS
The efficiency and reliability of the fixture design has enhanced by the system and the result of the fixture design has made more
reasonable.
Hence we have completed the fixture and a successful trial has been done.
The production rate of the workpiece (32-A cylinder) increased.
Elimination of human errors.
Reduction in cycle time of operations.
ACKNOWLEDGEMENT
The authors are grateful to the Management of Grandeur Engineering Pvt. Ltd. for providing the permission to carry out the work. Sincere
thanks are also due to Mr. Rajesh Ban, our industry project guide for helping our team in the shopfloor. The authors also thank head of the
department of mechanical engineering Prof. Saurabh Kerhalkar and our college project guide Prof. V.S. Thete for their help in research
assistance.
REFERENCES
[1] Shailesh S Pachbhai , Laukik P Raut, “A Review on Design of Fixtures”, International Journal of Engineering Research and General
Science Volume 2, Issue 2, Feb-Mar 2014 ISSN 2091-2730.
[2] Hamad Mohammed Abouhenidi, “Jig and Fixture Design”, International Journal of Scientific & Engineering Research, Volume 5,
Issue 2, February-2014 Page-142, ISSN 2229-5518.
[3] Shivaji Mengawade, Vaibhav Bankar, Pratik P Chaphale, “A Review on Design and Analysis of Work Holding Fixture”,
International Journal of Engineering Research and General Science Volume 4, Issue 2, March-April, 2016, ISSN 2091-2730.
[4] Satyajeetsinh Raijada, Amit Dudhatra, “Design of a Fixture of Connecting Rod for Boring Operation” IJSRD - International Journal
for Scientific Research & Development| Vol. 2, Issue 09, 2014 | ISSN (online): 2321-0613.
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