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DESIGN AND FABRICATION OF ASSEMBLY FIXTURE

(FOR A PETROL BRACKET WITH ALIGNMENT)

A PROJECT REPORT

Submitted by

P.DINESHKUMAR 090111105013

N.C.PRASAD 090111105038

M.SATHESH KUMAR 090111105053

G. SHANKAR 090111105057

I n partial ful fi llment for the award of the degree

Of

BACHELOR OF ENGINEERING

I N

MECHANICAL ENGINEERING

Dr. N.G.P INSTITUTE OF TECHNOLOGY, COIMBATORE

ANNA UNIVERSITY: CHENNAI 600 025

APRIL 2013


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ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report DESIGN AND FABRICATION OF

ASSEMBLY FIXTURE FOR A PETROL BRACKET WITH

ALIGNMENT is the Bonafide work of P.DINESHKUMAR,

N.C.PRASAD, M.SATHESH KUMAR, G.SHANKAR who carried out the

project work under my supervision.

SIGNATURE SIGNATURE

Dr.C.Selvaraj Mr.V.Sivaraman

HEAD OF THE DEPARTMENT SUPERVISOR

Associate Professor

Dept. of Mechanical Engineering Dept. of Mechanical Engineering

Dr.N.G.P Institute of Technology Dr.N.G.P Institute of Technology

Coimbatore- 48. Coimbatore- 48.

Submitted during the university examination held on April 2013

------------------------------------- ----------------------------------------

Internal Examiner External Examiner


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ACKNOWLEDGEMENT

We express our deepest gratitude to Our Managementfor 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 assurancefor 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.


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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 awardsfor three consecutive years. It has also been recognized by MarutiUdyog

Limited as a First class critical Component Vendor.


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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.


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TABLE OF CONTENTS

CHAPTER.NO TITLE PAGE NO

I ABSTRACT . (v)

II LIST OF FIGURES (viii)

III LIST OF TABLES... (x)

1. INTRODUCTION... 1

1.1. INTRODUCTION... 1

1.2. INTRODUCTION TO COMPONENT

(PETROL BRACKET) 2

1.2.1. Drive shaft ...... 4

1.3. INTRODUCTION TO WORK HOLDING

DEVICES 5

1.3.1 Jigs and Fixtures- Introduction.. 7

1.4. INTRODUCTION TO LOCATING

AND CLAMPING DEVICES 11

1.4.1 PRINCIPLE OF LOCATION ... 11

1.4.1.1. Principle of Pin Location 14

1.4.1.2. Principle of Mutually

Perpendicular Planes . 14

1.4.1.3 Principle of Extreme ... 15

1.4.2. LOCATING METHODS AND

DEVICES .... 16


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1.4.3. PINS AND BUTTON LOCATORS ... 16

1.4.3.1 Locating Pins . 17

1.4.3.2 Conical Locating Pins .... 17

1.4.3.3 Cylindrical Locating Pins .. 17

1.4.4. CLAMPING INTRODUCTION 18

1.4.4.1. Clamping device .. 21

1.4.4.1.1. Bridge Clamp . 21

1.5. INTRODUCTIONS TO SENSORS . 23

1.5.1. PROXIMITY SENSOR ... 24

1.5.2 PROXIMITY LIMIT SWITCH 25

2. METHODOLOGY . 26

2.1. WORKING 26

2.2. DESIGN OF ASSEMBLY FIXTURE.. 28

2.3. FIXTURE MANUFACTURING PROCESS 48

2.4. COST ESTIMATION .. 51

2.5. COMPARISON OF EXISTING FIXTURE

AND NEW DESIGNED FIXTURE... 52

2.6. ADVANTAGES. 54

3. CONCLUSION ... 55

REFERENCES ... 56


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LIST OF FIGURES

FIG NO DESCRIPTION PAGE NO

1.1 PETROL BRACKET... 2

1.2 A SIMPLE DESIGN OF JIG AND FIXTURE 10

1.3 WORKPIECE IN SPACE ............... 12

1.4 WORKPIECE LOCATED IN A FIXED BODY 12

1.5 PRINCIPLE OF MUTUALLY

PERPENDICULAR PLANES .... 15

1.6 LOCATING PINS .. 17

1.7 METHOD OF CLAMPING ... 19

1.8 POSITION OF CLAMP 20

1.9 BRIDGE CLAMP 21

3.1(A) 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


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3.3(A) 3D-TOP BASE PLATE .. 32

3.3(B) 2D-TOP BASE PLATE . 33

3.4(A) 3D-SENSOR STAND 34

3.4(B) 2D-SENSOR STAND . 35

3.5(A) 3D-PLUNGER 36

3.5(B) 2D-PLUNGER ... 37

3.6(A) 3D-SPACER 38

3.6(B) 2D-SPACER 39

3.7(A) 3D-SENSOR PIN ... 40

3.7(B) 2D-SENSOR PIN 41

3.8(A) 3D-SLIDING CLAMP 42

3.8(B) 2D-SLIDING CLAMP 43

3.9(A) 3D-ANGULAR BLOCK 44

3.9(B) 2D-ANGULAR BLOCK . 45

3.10(A) 3D-FINAL ASSEMBLY OF A FIXTURE . 46

3.10(B) 2D-FINAL ASSEMBLY OF A FIXTURE 47

3.11 PICTORIAL REPRESENTATION OF

EXISTING FIXTURE AND NEW

DESIGNED FIXTURE 52


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LIST OF TABLES

TABLE NO DESCRIPTION PAGE NO

2.1 COST ESTIMATION.... 51

2.2 COMPARISION OF EXISTING

FIXTURE AND NEW DESIGNED

FIXTURE 53

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