DESIGN AND FABRICATION OF ASSEMBLY FIXTURE

(FOR A PETROL BRACKET WITH ALIGNMENT)

A PROJECT REPORT Submitted by

P.DINESHKUMAR N.C.PRASAD M.SATHESH KUMAR G. SHANKAR

090111105013 090111105038 090111105053 090111105057

In partial fulfillment for the award of the degree Of

BACHELOR OF ENGINEERING
IN MECHANICAL ENGINEERING Dr. N.G.P INSTITUTE OF TECHNOLOGY, COIMBATORE

ANNA UNIVERSITY: CHENNAI 600 025

APRIL 2013

ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE
Certified that this project report DESIGN AND FABRICATION OF ASSEMBLY FIXTURE is the FOR A PETROL work of BRACKET WITH

ALIGNMENT

Bonafide

P.DINESHKUMAR,

N.C.PRASAD, M.SATHESH KUMAR, G.SHANKAR who carried out the project work under my supervision.

SIGNATURE

SIGNATURE

Dr.C.Selvaraj
HEAD OF THE DEPARTMENT

Mr.V.Sivaraman
SUPERVISOR

Associate Professor
Dept. of Mechanical Engineering Dr.N.G.P Institute of Technology Coimbatore- 48. Dept. of Mechanical Engineering Dr.N.G.P Institute of Technology Coimbatore- 48.

Submitted during the university examination held on April 2013

------------------------------------Internal Examiner

---------------------------------------External Examiner

ACKNOWLEDGEMENT

We express our deepest gratitude to Our Management for providing us with an environment to complete our project successfully. We are very grateful to our Principal Dr.V.Porkumaran and Dr.S. Dhandapani, Advisor for their valuable guidance and blessings. We would like to thank our Head of the Department Dr.C.Selvaraj for his unwavering support during the entire course of this Major project work and who modeled us both technically and morally for achieving greater success in this major project work. We thank our Project coordinator Prof.V.M.Manivasagam., department of mechanical engineering for his help and innovative ideas in making this project a successful one. We express our sincere thanks to our internal guide Mr.V.Sivaraman., Associate professsor for his constant encouragement and support throughout our course, especially for the useful suggestions given during the course of the project period and being instrumental in the completion of our project with his complete guidance. We also thank Sakthi Auto Component Limited and our external guide Mr.K.G.mohanasundaram.,senior manager-quality assurance for their help and innovative ideas in making this project a successful one. Finally, we take this opportunity to extend our deep appreciation to our family and friends, for all that they meant to us during the crucial times of the completion of our project.

COMPANY PROFILE:

Sakthi Auto Component Limited, established in the year 1983 was founded by Dr.Mahalingam. They are the major supplier of critical components to passenger car manufacturers. The components are Steering knuckles, Brake drums, Brake discs, Hubs, Brake calipers, Brackets, Carriers, Differential cases and Manifolds etc. Presently the supplies of these components are made to MarutiUdyog Ltd., Hyundai India Auto Ltd., Ford, Honda, Volkswagen, Volvo, etc., the quantum of exports per month ranges between 250 MT to 500 MT. It is likely to go up to 1000 MT in near future. Sakthi Auto Component Limited has been awarded the industrial safety awards for three consecutive years. It has also been recognized by MarutiUdyog Limited as a First class critical Component Vendor.

ABSTRACT: Fixtures are the work holding devices, to reduce the cost of manufacture in mass production. The main aim of our project is to design and fabricate an assembly fixture for a petrol bracket without error committed for stud assembly. During the assembly of stud in petrol bracket there is a chance of human error leads to improper screwing of stud which results in loss of time and rejection of component. Thus, we have designed an assembly fixture which eliminates the chance of human error during assembly. Fixtures are mainly designed to save production time and also to ensure the dimensional accuracy and also to facilitate quick and interchangeable assembly during mass production.

TABLE OF CONTENTS CHAPTER.NO TITLE PAGE NO

I II III 1.

ABSTRACT . (v) LIST OF FIGURES (viii) LIST OF TABLES... INTRODUCTION... 1.1. INTRODUCTION... 1.2. INTRODUCTION TO COMPONENT (PETROL BRACKET) 1.2.1. Drive shaft ...... 1.3. INTRODUCTION TO WORK HOLDING DEVICES 1.3.1 Jigs and Fixtures- Introduction.. 1.4. INTRODUCTION TO LOCATING AND CLAMPING DEVICES 1.4.1 PRINCIPLE OF LOCATION ... 1.4.1.1. Principle of Pin Location 1.4.1.2. Principle of Mutually Perpendicular Planes . 1.4.1.3 Principle of Extreme ... 1.4.2. LOCATING METHODS AND DEVICES .... 16 14 15 11 11 14 5 7 2 4 (x) 1 1

1.4.3. PINS AND BUTTON LOCATORS ... 1.4.3.1 Locating Pins . 1.4.3.2 Conical Locating Pins .... 1.4.3.3 Cylindrical Locating Pins .. 1.4.4. CLAMPING INTRODUCTION 1.4.4.1. Clamping device .. 1.4.4.1.1. Bridge Clamp . 1.5. INTRODUCTIONS TO SENSORS . 1.5.1. PROXIMITY SENSOR ... 1.5.2 PROXIMITY LIMIT SWITCH 2. METHODOLOGY . 2.1. WORKING 2.2. DESIGN OF ASSEMBLY FIXTURE.. 2.3. FIXTURE MANUFACTURING PROCESS 2.4. COST ESTIMATION .. 2.5. COMPARISON OF EXISTING FIXTURE AND NEW DESIGNED FIXTURE... 2.6. ADVANTAGES.

16 17 17 17 18 21 21 23 24 25 26 26 28 48 51

52 54

3.

CONCLUSION

...

55 56

REFERENCES ...

LIST OF FIGURES FIG NO 1.1 1.2 1.3 1.4 1.5 DESCRIPTION PAGE NO 2 10 12 12

PETROL BRACKET... A SIMPLE DESIGN OF JIG AND FIXTURE WORKPIECE IN SPACE ............... WORKPIECE LOCATED IN A FIXED BODY PRINCIPLE OF MUTUALLY PERPENDICULAR PLANES ....

15 17 19 20 21

1.6 1.7 1.8 1.9 3.1(A)

LOCATING PINS .. METHOD OF CLAMPING ... POSITION OF CLAMP BRIDGE CLAMP 3D-BOTTOM BASE PLATE WITH SENSOR STAND ....................

28

3.1 (B)

2D-BOTTOMS BASE PLATES WITH SENSOR STAND ....................... 29

3.2(A)

3D-BOTTOM BASE PLATE WITH LIMIT SWITCH 30

3.2 (B)

3D-BOTTOM BASE PLATES WITH LIMIT SWITCH 31

3.3(A) 3.3(B) 3.4(A) 3.4(B) 3.5(A) 3.5(B) 3.6(A) 3.6(B) 3.7(A) 3.7(B) 3.8(A) 3.8(B) 3.9(A) 3.9(B) 3.10(A) 3.10(B) 3.11

3D-TOP BASE PLATE .. 2D-TOP BASE PLATE . 3D-SENSOR STAND 2D-SENSOR STAND . 3D-PLUNGER 2D-PLUNGER ... 3D-SPACER 2D-SPACER 3D-SENSOR PIN ... 2D-SENSOR PIN 3D-SLIDING CLAMP 2D-SLIDING CLAMP 3D-ANGULAR BLOCK 2D-ANGULAR BLOCK . 3D-FINAL ASSEMBLY OF A FIXTURE . 2D-FINAL ASSEMBLY OF A FIXTURE PICTORIAL REPRESENTATION OF EXISTING FIXTURE AND NEW DESIGNED FIXTURE

32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47

52

LIST OF TABLES TABLE NO DESCRIPTION PAGE NO

2.1 2.2

COST ESTIMATION... . 51 COMPARISION OF EXISTING FIXTURE AND NEW DESIGNED FIXTURE 53