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IJIRAE::Combined load analysis of rotary cage fixture by FEA and Experimental approach

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The project idea basically developed from trunnion tables which are one type of fixture having ability to rotate about its axis and able to fix the component at any angle. There is no requirement of angle plate and sine plates, drilling process is also computer controlled so no guide bush is required, So robust design for extra rigidity, flexibility and simple to use. In this project task is difficult as design rotary cage fixture for component like cylinder block, which is heavy of 76 kg. It is not possible to rotate or handle component manually and proceed on them to make this process accident proof and automated for this purpose we are designing a rotary cage which rotate 360 degree and allow indexing to process on the component. Processes are to be operated on the component are drilling tapping and air blow washing ,Since drilling don’t need clamping here components self weight will enough to carry drilling force and tapping force coming through power tools. Therefore, rotary cage type fixture is critical importance. Due to these factors, the Rotary cage type fixture has been the topic of research for different aspect such as simulation, bending stress analysis and experimental validation done.
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    International Journal of Innovative Research in Advanced Engineering (IJIRAE) ISSN: 2349-2163   Volume 1 Issue 8 (September 2014 )   www.ijirae.com _________________________________________________________________________________________________ © 2014, IJIRAE- All Rights Reserved Page - 386 Combined load analysis of rotary cage fixture by FEA and Experimental approach. 1 V.S.Jakukore 2 L.B.Raut 1 PG Student, Mech Dept, 2 M.E.Coordinator, Mech Dept, SVERI Engg College, SVERI Engg College,   Abstract— The project idea basically developed from trunnion tables which are one type of fixture having ability to  rotate about its axis and able to fix the component at any angle. There is no requirement of angle plate and sine  plates, drilling process is also computer controlled so no guide bush is required, So robust design for extra rigidity,  flexibility and simple to use. In this project task is difficult as design rotary cage fixture for component like cylinder  block, which is heavy of 76 kg. It is not possible to rotate or handle component manually and proceed on them to  make this process accident proof and automated for this purpose we are designing a rotary cage which rotate 360  degree and allow indexing to process on the component. Processes are to be operated on the component are drilling  tapping and air blow washing ,Since drilling don’t need clamping here components self weight will enough to carry  drilling force and tapping force coming through power tools. Therefore, rotary cage type fixture is critical importance.  Due to these factors, the Rotary cage type fixture has been the topic of research for different aspect such as  simulation, bending stress analysis and experimental validation done .  Keywords— Combined load analysis, rotating fixture I.   I NTRODUCTION   In this research component engine block go inside the cage along with fixture trolley and going to be fixed inside the cage by using 3-2-1 principle and cage start rotate by using chain drive and stop at 0, 90,180,270,360 degree rotation by using proxy sensors and dogs, the stress analysis of cage is carried out for drilling force is also calculated and combined with cylinder block weight and use for strain stress analysis by using FEA and Experimental approach. Figure show operational lay out for understanding the concept . Fig: 1 Operation layout II.   D ESIGN R EQUIREMENTS : Design requirements are as follows.   a)   A load transmit the symmetrically to fixture.  b)   A fixture is strong enough to sustain the load of engine block and drilling force. c)   Fixture is designed for long life. d)   A material of fixture AISI304 is use to carry heavy load and corrosion resistant. e)   Typically the design process by which such fixtures are created has major four phases such as fixture planning, fixture layout, fixture element design, fixture body design. f)   The drilling feed force is obtained from standard formulae available on Sandvick website which is the leading tool manufacturer company in India. Fig. 2 Coro drill Total load on cage = Cylinder block load+ Drilling feed force= 940 + 570=1510 N    International Journal of Innovative Research in Advanced Engineering (IJIRAE) ISSN: 2349-2163   Volume 1 Issue 8 (September 2014 )   www.ijirae.com _________________________________________________________________________________________________ © 2014, IJIRAE- All Rights Reserved Page - 387   III.FEM   ANALYSIS The solid model as constructed from the drawing was used as to construct the finite elements models for the rotary cage fixture assembly. The main advantage of building a model of the complete rotary cage fixture assembly lies in the accurate weight distribution and representation that the model provides, each of these factors could influence the stress result obtained during the rotation. The model of the rotary cage fixture is shown in above Figure note the different colours used on model surface to represent stress distribution. Fig. 3 Von mises strain distribution of fixture for 0   0 cage position for drilling Fig. 4 : Von mises stress distribution of fixture for 0 0 cage position for drilling Fig. 5 Von mises strain distribution of fixture for 90 0 cage position for drilling Fig. 6 Von mises stress distribution of fixture for 90 0 cage position for drilling Fig. 7    Von mises strain distribution of fixture for 180 0 cage position for drilling   Fig. 8    Von mises stress distribution of fixture for 180 0 cage position for drilling      International Journal of Innovative Research in Advanced Engineering (IJIRAE) ISSN: 2349-2163   Volume 1 Issue 8 (September 2014 )   www.ijirae.com _________________________________________________________________________________________________ © 2014, IJIRAE- All Rights Reserved Page - 388   Fig. 9 Von mises strain distribution of fixture for 270 0 cage position for drilling Fig. 10 Von mises strain distribution of fixture for 270 0 cage position for drilling Fig. 11 Von mises strain distribution of fixture for 360 0 cage position for drilling Fig. 12 : Von mises stress distribution of fixture for 360   0 cage position  for drilling TABLE   I   FEM   RESULTS   COMBINED   LOAD   OF   CYLINDER   BLOCK   AND   DRILLING Name of Component Angles (FEA RESULTS FOR DRILLING) Angle 0 0  90 0  180 0  270 0  0 0  Strain and Stress µ Strain Stress (Mpa) µ Strain Stress (Mpa) µ Strain Stress (Mpa) µ Strain Stress (Mpa) µ Strain Stress (Mpa) Stress in track rod at centre 12.01 2.53 1.76 0.54 0.19 0.046 9.45 1.73 12.01 2.53 Rotary cage  joining plate 0.085 0.014 27.68 5.27 31.5 5.93 19.5 3.88 0.085 0.014 Stress in ring 1 6.69 1.37 1.61 0.321 1.01 0.19 6.57 1.01 6.69 1.37    International Journal of Innovative Research in Advanced Engineering (IJIRAE) ISSN: 2349-2163   Volume 1 Issue 8 (September 2014 )   www.ijirae.com _________________________________________________________________________________________________ © 2014, IJIRAE- All Rights Reserved Page - 389   IV.EXPERIMENTAL   SET   UP   AND   READINGS   The drilling feed force is calculated for 12 mm drilling tool of Coro drill of sandvik by using standard formulae available on sandvik website the calculated force is 570N added force on cylinder block is 285N because the experimental model is scaled by 50% following figure shows experimental strain readings for different cage positions Fig13: Strain measurement for track rod 0 0  position Fig14: Strain measurement for track rod 90 0  position TABLE   III   EXPERIMENTAL   READINGS V.RESULT   AND   DISSCUSSION A.   Combination load of engine block and drilling feed force The stress values obtained from finite element models for the positions where the stain gauges were applied were compared to the stress values obtained from the strain gauge readings considering Combination load of engine block and drilling feed force. The comparison is done for 0, 90,180,270,360 degree cage rotation. A stress plot for each rotation of the von mises stress in complete cage can be seen in chapter no. 4. For the stress value comparison the track rod, rotary cage joining plate and cage ring shown in following figures. The deviation between the stress value at the maximum stress value is approximately 3% for track rod, for rotary cage joining plate and cage ring 11% and for cage ring 13% there slight deviation in stress plot between two data sets. The data therefore indicate the method of accurate representation of actual stress obtained during 0, 90, 270, 360 degree cage rotation. I.A.1   Stresses in track rod for drilling It is observe that when cylinder block and trolley come in the cage and drilling feed force is applied stress is maximum but when cage move to 90 degree position stress is going to be reduce and at 180 degree stress is negligible, when cage come to its srcinal position a stress generated increase   Name of Component Angle (Experimental Readings for Drilling) Angle 0 0  90 0  180 0  270 0  360 0  Strain and Stress µStrai n Stress (Mpa) µStrain  Stress (Mpa) µStrain  Stress (Mpa) µStrain  Stress (Mpa) µStrain  Stress (Mpa) Stress in track rod 14 2.8 2 0.4 Out of rang Out of range 9 1.8 14 2.8 Rotary cage  joining plate Out of range Out of range 32 6.4 27 5.2 21 4.2 Out of range Out of range Stress in ring 1 13 2.6 3 0.6 2 0.4 9 1.8 13 2.6
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