ijirae::combined load analysis of rotary cage fixture by fea and experimental approach
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8/10/2019 IJIRAE::Combined load analysis of rotary cage fixture by FEA and Experimental approach
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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 andExperimental approach.1V.S.Jakukore
2L.B.Raut
1PG Student, Mech Dept,
2M.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 sineplates, 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 tomake 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 drillingtapping and air blow washing ,Since drilling dont 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 assimulation, bending stress analysis and experimental validation done.
Keywords Combined load analysis, rotating fixture
I.INTRODUCTIONIn 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 showoperational lay out for understanding the concept
.Fig: 1 Operation layout
II.DESIGN REQUIREMENTS:
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 toolmanufacturer company in India.
Fig. 2 Coro drill
Total load on cage = Cylinder block load+ Drilling feed force= 940 + 570=1510 N
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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 -387
III.FEMANALYSIS
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 stressresult 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 00 cage position for
drilling
Fig. 4 : Von mises stress distributi on of fixture for 00 cage position for
drilling
Fig. 5 Von mises strain distribution of fixture for 900cage position for
drilling
Fig. 6 Von mises stress distribution of fixture for 900cage position for
drilling
Fig. 7Von mises strain distribution of fixture for 180 0 cage position fordrilling
Fig. 8Von mises stress distribution of fixture for 180 0 cage position fordrilling
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8/10/2019 IJIRAE::Combined load analysis of rotary cage fixture by FEA and Experimental approach
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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 -388
Fig. 9 Von mises strain distribution of fixture for 2700 cage position for
drilling
Fig. 10 Von mises strain distribut ion of fixture for 2700 cage position for
drilling
Fig. 11 Von mises strain distribution of fixture for 360
0
cage position fordrilling
Fig. 12 : Von mises stress distribution of fixture for 3600 cage position
for drilling
TABLEI FEMRESULTSCOMBINEDLOADOFCYLINDERBLOCKANDDRILLING
Name of
Component
Angles
(FEA RESULTS FOR DRILLING)
Angle 00 90
0 180
0 270
0 0
0
Strain and
Stress
Strain
Stress
(Mpa)
Strain
Stress
(Mpa)
Strain
Stress
(Mpa)
Strain
Stress
(Mpa)
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 cagejoining 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
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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 -389
IV.EXPERIMENTALSETUPANDREADINGSThe 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 00position Fig14: Strain measurement for track rod 90
0position
TABLEIII EXPERIMENTALREADINGS
V.RESULTANDDISSCUSSION
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 werecompared to the stress values obtained from the strain gauge readings considering Combination load of engine block anddrilling 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 maximumstress 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 accuraterepresentation of actual stress obtained during 0, 90, 270, 360 degree cage rotation.
I.A.1 Stresses in track rod for drill ing
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 original position a stress generated increase
Name of
Component
Angle
(Experimental Readings for Drilling)
Angle 00 90
0 180
0 270
0 360
0
Strain and Stress Strain
Stress(Mpa)
Strain Stress(Mpa)
Strain Stress(Mpa)
Strain Stress(Mpa)
Strain Stress(Mpa)
Stress in trackrod
14 2.8 2 0.4 Out ofrang
Out ofrange
9 1.8 14 2.8
Rotary cagejoining plate Out of
rangeOut ofrange
32 6.4 27 5.2 21 4.2 Out ofrange
Out ofrange
Stress in ring 1
13 2.6 3 0.6 2 0.4 9 1.8 13 2.6
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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 -390
0
0.5
1
1.5
2
2.5
3
0 90 180 270 360
Stress(MPa)
Cage Rotation in Degree
FEA
Strain gauge
values
Fig.15 Stress comparision for back strain gauge on track rod and FEA for Drilling
I.A.2 Stresses on rotary cage joining plate for drilling
Initially on zero degree position cage joining plate stress generated is negligible as shown in figure 6.5. The reasionis the load is acting vertically downword direction but at 90 degree position stress is increase because drilling feed force,
at 180, 270 degree position stress is slightly decreses. Hear it shoulde be noted that there are two cage joining plate butwe are measure stress on only one plate on which strain gauge is mounted.
0
1
2
3
4
5
6
7
0 90 180 270 360
Stress(MPa)
Cage Rotation in Degree
FEA
Strain gauge
values
Fig. 16 Stress comparision for strain gauge on cage joining plate and FEA for drilling
I.A.3 Stresses in cage ring for drilling
The cage ring is the strongest part of the fixture initially cylinder block come inside the cage then drilling force is
applied on the cylinder block the net effect on the cage ring is shown in figure
0
1
2
3
0 90 180 270 360
Stress
(MPa)
Cage Rotation in Degree
FEA
Strain gauge
values
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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 -391
Fig17. Stress comparision for strain gauge on cage ring and FEA for drilling
VI.CONCLUSIONS
The various conclusions obtained during this work are listed below.1. In this work the material used for cage is stainless steel(AISI 304) ,yield strength 210 Mega Pascal and factor of safety
3 so maximum allowable stress is 70 Mega Pascal which is far greater than stress observed by FEM analysis and
experimentation by cage rotation So the given fixture is safe for drilling operation.
2. After manufacturing of rotary cage fixture, observed that it is possible to operate cage fixture successfully and scaling
of model used for experimentation.3. The study further established that the rotational operation of rotary cage or similar structure can be accurately
simulated by menace of structural analysis.4. The stress data obtained from FEA result are very close to the experimental readings of strain and stress.
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[4] Sandeep Soni & Ravindra Mane Design and Modeling of Fixture for Cylinder. Liner Honing Operation,
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