[ANGULAR GRINDING FIXTURE FOR TRAINING MODEL]

NETTUR TECHNICAL TRAINING FOUNDATION

AN ISO 9001:2008CERTIFIED TRAINING INSITTUTION

A PROJECTREPORT
ON
MULTIPURPOSE ANGULAR GRINDING
FIXTURE
A Dissertation Submitted By,
ARUNKUMAR N
(1554/DTC/2014)
For the award of,
TRAINEE OFFICER IN GRADUATE ENGINEERING TRAINING
Under the valuable guidance of
Mr. A SHANKAR

NETTUR TECHNICAL TRAINING FOUNDATION,

KUMBAKONAM TRAINING CENTRE.
R.S.No.101/1,Venkatesha Nagar, Chettimandapam,
KUMBAKONAM- 612001

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NETTURTECHNICAL TRAINING FOUNDATION

ANISO9001:2008CERTIFIEDTRAININGINSTITUTION

CERTIFICATE
THIS IS TO CERTIFY THAT PROJECT TITLED
MULTIPURPOSE ANGULAR GRINDING
FIXTURE
It is a bona fide record of the project work done
by, ARUNKUMAR N

This is

to

Certify

that

the project work entitled MULTIPURPOSE ANGULAR

GRINDING FIXTURE is a bona fide work carried out by N.ARUNKUMAR

(1554/DTC/2014), in partial fulfillment for the award of trainee officer in NETTUR
TECHNICAL TRAINING FOUNDATION, BENGALURU during the year AUGUST
2014-2015.
It is certified that all corrections/suggestions indicated for Internal Assessment have been
incorporated in the Report .The project report has been approved as it satisfies the
academic requirements in respect of the work prescribed for the GRADUATE
ENGINEER TRAINING.

PROJECT GUIDE

PRINCIPAL

(A SHANKAR)

(A SHANKAR)

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PREFACE:
I am submitting this project report as a part of fulfillment of the course,
GRADUATE ENGINEER TRAINEE at NETTUR TECHNICAL TRAINING
FOUNDATION, BENGALURU, KARNATAKA during the year AUGUST 2014-2015.

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ABSTRACT:
Fixtures are considered to be one of the most prominent devices designed and used for higher
productivity and product quality in batch production.
One of the problems faced in machine shops is the cost of fixture.
.
Fixture setup is used to reduce the work load within the company. These are special work
holding and tool guiding device. Quality of the performance of a process is largely influenced
by the quality of fixture used for this purpose. What makes a fixture unique is that each one is
built to fit a particular part or shape.
The main purpose of a fixture is to locate and in the cases hold a work piece during an operation.
. Fixtures reduce operation time and increases productivity and high quality of operation is
possible.

The main aim of this project is to reduce cost of the fixture and used for training purpose.

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OBJECTIVES OF PROJECT:
The main objective of project is to design a multipurpose angular grinding fixture with
details. The fixture is for training students which are used for NTTF training purposes.
NTTF has designed quality objectives to achieve the overall goal and develop each
Individual undergoing training to expertise the trainees during the training period itself
NTTF formulated one of the objectives as TO INCULCATE THE CULTURE,
PRODUCE WHILE LEARNING AND LEARN WHILE PRODUCING.
The objective of the project that I have complete is to give an insight into the
Working of angular grinding fixture, reduction of manufacturing cost, and inspection
of the activities which helps to consistently deliver the components without fail;
throughout its life. One method of reducing manufacturing cost per component is to
reduce machining cycle time. The manufacturing cycle time can be reduced by
reducing nonproductive time like loading, unloading, and the placing of work piece
onto the machine. Here jig and fixture design has important role to play.
Productive time for a machine is the time required for surface grinding operation by
the machine.

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SYNOPSIS:
Fixture setup is used to reduce the work load within the company. These are special work
holding and tool guiding device. Quality of the performance of a process is largely influenced
by the quality of fixture used for this purpose. What makes a fixture unique is that each one is
built to fit a particular part or shape.
The main purpose of a fixture is to locate and in the cases hold a work piece during an
operation.
The main aim of this project is to reduce cost of the fixture and used for training purpose.
The objective of the project that I have complete is to give an insight into the
Working of angular grinding fixture, reduction of manufacturing cost, and inspection of the
activities which helps to consistently deliver the components without fail; throughout its life.
One method of reducing manufacturing cost per component is to reduce machining cycle time.
The manufacturing cycle time can be reduced by reducing nonproductive time like loading,
unloading, and the placing of work piece onto the machine. Here jig and fixture design has
important role to play.
Productive time for a machine is the time required for surface grinding operation by the
machine

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SCOPE OFTHEPROJECT:
To know the basics of fixture practically.
Design and Manufacturing of the grinding fixture.
Exposure in Auto CAD. Software
Exposure in functions like planning, routing, scheduling, follow up, inspection
of the tool and component
Exposure to basic machining.

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ACKNOWLEDGEMENT:
I would like to express my sincere gratitude to Managing Director Mr. N Reguraj for giving
me this lifetime opportunity in carving my career path.
I take the privilege to thank Mr. R Rajagopalan, Mentor Director for his timely support.
I owe my sincere gratitude to Mr. Arul Selvan, Deputy Managing Director Edutech NTTF and
Mr. K Venugopal, Director NTTF for all help and infrastructure provided to complete this
project successfully.
I express my sincere thanks to Mr. S. Stephen Louis, ASSOCIATE DIRECTOR (HR) NTTF,
BANGALORE, for his valuable support during the course of the project
I am highly indebted to Mr. T K Rajiv (GET coordinator) for all his untiring effort in steering
us in our Training Arena.
I express my thanks to our Principal Mr. A Shankar (Unit head, KTC) for his constant
encouragement and valuable suggestions in selecting and completing this Project.
I

thank

to

all

to

teaching

and

non-teaching

staff

of

NTTF-DHARWAD

and

NTTF-KUMBAKONAM and all my COLLEAGUES and well-wishers those who have helped
me directly or indirectly to perform the project.

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CONTENTS:
SL.NO

CONTENTS

PAGE NO

INTRODUCTION TO FIXTURES

10-12

DESIGN CONSIDERATIONS

12-16

TYPES OF FIXTURES

17-24

4
5

PROJECT SUMMARY DESIGN,

MANUFACTURING PROCESS
MATERIAL SELECTION OF

25-38
39-41

S6

MOULD DEFECTSANDREMEDIES

41-46

PROJECT SUMMARY DESIGN,

MANUFACTURING PROCESS

46-48

COST ESTIMATION

58-60

DRAWINGSANDPROCESSPLAN

61-67

10

TRAIL& INSPECTION

64

11

PHOTOGRAPHIC IMAGES OF FIXTURE

65-75

12
13

CONCLUSION
REFERENCES

14

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80-87
89

90

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INTRODUCTION:
Over the past century, manufacturing has made considerable progress. New machine
tools, high-performance cutting tools, and modern manufacturing processes enable today's
industries to make parts faster and better than ever before. Although work holding methods have
also advanced considerably, the basic principles of clamping and locating are still the same.
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. Fixture is widely used in the
Industry practical production because of feature and advantages.
To locate and immobilize work pieces for machining, inspection, assembly and other operations
fixtures are used. A fixture consists of a set of locators and clamps. Locators are used to
determine the position and orientation of a work piece, whereas clamps exert clamping forces so
that the work piece is pressed firmly against locators. Clamping has to be appropriately planned
at the stage of machining fixture design. The design of a fixture is a highly complex and
intuitive process, which require knowledge. 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, so the aim of this project is to replace with hydraulic fixture to save time
for loading and unloading of component. Hydraulic fixture provides the manufacturer for
flexibility in holding forces and to optimize design for machine operation as well as process
function ability.
HISTORY
The first manufactured products were made one at a time. Early artisans started with little
more than raw materials and a rough idea of the finished product. They produced each product
piece by piece, making each part individually and fitting the parts into the finished product. This
process took time. Moreover, the quality and consistency of products varied from one artisan to
the next. As they worked, early manufacturing pioneers realized the need for better methods and
developed new ideas.
Eventually, they found the secret of mass production: standardized parts. Standard parts
not only speeded production, they also ensured the interchangeability of parts. The idea may be
obvious today, but in its time, it was revolutionary.
These standard parts were the key to enabling less-skilled workers to replicate the skill of
the craftsman on a repetitive basis. The original method of achieving consistent part
configuration was the template. Templates for layout, sawing, and filing permitted each worker
to make parts to a standard design. While early templates were crude, they at least gave skilled
workers a standard form to follow for the part. Building on the template idea, workers
constructed other guides and work holders to make their jobs easier and the results more
predictable. These guides and work holders were the ancestors of today's jigs and fixtures.
Yesterday's work holders had the same two basic functions as todays: securely holding and
accurately locating a work piece. Early jigs and fixtures may have lacked modern refinements,
but they followed many of the same principles as todays work holder designs.
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DEFINITIONS
Often the terms "jig" and "fixture" are confused or used interchangeably; however, there
are clear distinctions between these two tools. Although many people have their own definitions
for a jig or fixture, there is one universal distinction between the two. Both jigs and fixtures
hold, support, and locate the work piece. A jig, however, guides the cutting tool. A fixture
references the cutting tool. The differentiation between these types of work holders is in their
relation to the cutting tool. As shown in Figure 1-1, jigs use drill bushings to support and guide
the tool. Fixtures, Figure 1-2, use set blocks and thickness, or feeler, gages to locate the tool
relative to the work piece.

A jig guides the cutting tool, in this case with a bushing.

A fixture references the cutting tool, in this case with a set block.

Jigs

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The most-common jigs are drill and boring jigs. These tools are fundamentally the same.
The difference lies in the size, type, and placement of the drill bushings. Boring jigs usually
have larger bushings. These bushings may also have internal oil grooves to keep the boring bar
lubricated. Often, boring jigs use more than one bushing to support the boring bar throughout
the machining cycle.
In the shop, drill jigs are the most-widely used form of jig. Drill jigs are used for drilling,
tapping, reaming, chamfering, counter boring, countersinking, and similar operations.
Occasionally, drill jigs are used to perform assembly work also. In these situations, the bushings
guide pins, dowels, or other assembly elements.
Jigs are further identified by their basic construction. The two common forms of jigs are
open and closed. Open jigs carry out operations on only one, or sometimes two, sides of a work
piece. Closed jigs, on the other hand, operate on two or more sides. The most-common open jigs
are template jigs, plate jigs, table jigs, sandwich jigs, and angle plate jigs. Typical examples of
closed jigs include box jigs, channel jigs, and leaf jigs. Other forms of jigs rely more on the
application of the tool than on their construction for their identity. These include indexing jigs,
turn-on jigs, and multi-station jigs.
Specialized industry applications have led to the development of specialized drill jigs. For
example, the need to drill precisely located rivet holes in aircraft fuselages and wings led to the
design of large jigs, with bushings and liners installed, contoured to the surface of the aircraft. A
portable air-feed drill with a bushing attached to its nose is inserted through the liner in the jig
and drilling is accomplished in each location.
Fixtures
Fixtures have a much-wider scope of application than jigs. These work holders are
designed for applications where the cutting tools cannot be guided as easily as a drill. With
fixtures, an edge finder, center finder, or gage blocks position the cutter. Examples of the morecommon fixtures include milling fixtures, lathe fixtures, sawing fixtures, and grinding fixtures.
Moreover, a fixture can be used in almost any operation that requires a precise relationship in
the position of a tool to a work piece.
Fixtures are most often identified by the machine tool where they are used. Examples
include mill fixtures or lathe fixtures. But the function of the fixture can also identify a fixture
type. So can the basic construction of the tool. Thus, although a tool can be called simply a mill
fixture, it could also be further defined as a straddle-milling, plate-type mill fixture. Moreover, a
lathe fixture could also be defined as a radius-turning, angle-plate lathe fixture. The tool
designer usually decides the specific identification of these tools.

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The hierarchy of work holding options.

DESIGN CONSIDERATIONS
The principal considerations when choosing among work holder varieties fall into three
general categories: tooling cost, tooling details, and tooling operation. Although each of these
categories is separated here, in practice they are interdependent. The following are some design
differences and considerations for permanent, general-purpose, and modular work holders.
Tooling Costs
The total cost of any jig or fixture is frequently the major area of consideration in many
work holder designs. Although initial cost is a major element, it should not be the basis for
accepting or rejecting any tooling option.
A more-proper economic evaluation of the work holder design takes into consideration
many other factors. As discussed previously, permanent fixtures have distinct advantages in the
production of high-volume and high-precision parts. They also typically reduce machine setup
time, machine cycle time, and the level of operator skill required to produce satisfactory quality
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output. Over a long production run, or a series of runs in the life of a tool, the average cost of
the tool per piece produced can be quite low.
General-purpose work holders are more expensive than temporary tools in most cases, but
their utility and flexibility often allow these work holders to be regarded as a capital cost to be
amortized over a period of time without regard to actual usage. Similarly, modular fixturing is
typically a capital investment to be amortized over a set lifespan, with an average cost assigned
to usage for each anticipated job.
Another cost to be considered is work holder disposition. Permanent fixtures require
storage and maintenance to keep them available for their next use. General-purpose tools are
reused extensively, but still incur some costs for maintenance and storage. Similarly, modular
fixtures will be disassembled, and the components maintained, stored, and reused frequently.
Tooling Details
Tooling details are the overall construction characteristics and special features incorporated
into the jig or fixture. Permanent work holders are designed and built to last longer than
temporary work holders. So, permanent jigs and fixtures usually contain more-elaborate parts
and features than temporary work holders.
There are several other differences between permanent and temporary work holders in this
area. These include the type and complexity of the individual tooling elements, the extent of
secondary machining and finishing operations on the tool, the tool-design process, and the
amount of detail in the work holder drawings. Since the elements for modular work holders are
usually part of a complete set, or system, only rarely will additional custom components need to
be made.
Permanent work holders contain different commercial tooling components based on
expected tool usage. Permanent jigs intended for a high-volume drilling operation, for example,
often use a renewable bushing and liner bushing together. A throwaway jig for a smaller
production run often uses a simple press-fit bushing.
The secondary operations normally associated with tooling include hardening, grinding,
and similar operations to finish the work holder. Usually, permanent work holders are hardened
and ground to assure their accuracy over a long production run. Since they are intended only for
short production runs, throwaway jigs and fixtures do not require these operations. Another
secondary operation frequently performed on permanent tools, but not temporary tools, is
applying a protective finish, such as black oxide, chrome plating, or enamel paint.
In designing a permanent work holder, the designer often makes detailed engineering
drawings to show the tool room exactly what must be done to build the work holder. With
temporary work holders, the design drawings are often sent to the tool room as simple freehand
sketches.
Permanent tools are normally designed for long-term use. This being the case, the
drawings and engineering data for the permanent jig or fixture then become a permanent record.
With modular work holders, the designer may either construct drawings or specify building the
work holder directly around the part. Here only a parts list and photographs or video tape are
kept as a permanent record.

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Certain work holding applications require special fixture characteristics. For example, a
particularly corrosive environment may require stainless steel components and clamps to deliver
a satisfactory life cycle. In other cases, variable work piece dimensions, as in a casting,
necessitate clamping devices which can compensate for these variations. Appearance of a
finished part might require the use of nylon, plastic, or rubber contact points to protect the part.
Similarly, the selection of tooling details can enhance the productivity of some permanent
tools. For example, utilizing small hydraulic clamps may allow loading many parts on a work
holder due to the compactness of the design. This would enhance productivity by reducing
load/unload time as a percentage of total cycle time. Duplicate fixtures are sometimes justified
for machining centers because they allow loading of parts on one pallet during the machining
cycle on the other pallet.
Tooling Operation
The performance of any work holder is critical to the complete usefulness of the tool. If the
work holder cannot perform the functions desired in the manner intended, it is completely
useless, regardless of the cost or the extent of the detail. As the performance of a permanent,
modular, or general-purpose work holder is considered, several factors about the machine tools
must be known. These factors include the type, size, and number of machine tools needed for
the intended operations.
Work holders are sometimes designed to serve multiple functions. For example, it is
possible to have a work holder that acts both as a drill jig and a milling fixture. These tools are
called combination tools or multiple-function work holders. Figure 1-6 shows a typical
temporary work holder for drilling and milling operations on the same part. In this example,
since the work holder has provisions for both milling and drilling, it is classified as both a drill
jig and milling fixture.

. A combination drill jig/milling fixture used for both types of operations on the same part.

Other machine considerations may come into play as well. On numerically controlled
machines, for example, care must be taken in fixture design to position clamps out of the cutting
tool's path. Pallet machines require different fixtures than other machines. Obviously, vertical
mills would be tooled differently than horizontal mills. Likewise, the way parts are loaded onto
the fixture has implications for fixture design.
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Despite the work holder design or the size of the production run, every jig or fixture must
meet certain criteria to be useful. These criteria include accuracy, durability, and safety.
Accuracy, with regard to jigs and fixtures, is the ability of a work holder to produce the desired
result, within the required limits and specifications, part after part, throughout the production
run.
To perform to this minimum level of accuracy, the work holder must also be durable. So,
the jig or fixture must be designed and built to maintain the required accuracy throughout the
expected part production. If part production is continuous, year after year, the jig or fixture must
be more durable than is necessary for only one production run.
The final consideration, safety, is actually the most important. No matter how good the
design or construction, or how well it produces the desired accuracy, if the work holder is not
safe, it is useless. Safety is a primary concern in the design of any work holder.
Safety, as well as speed and reliability of part loading, can often be improved by the use of
power clamping, either pneumatic or hydraulic. Once set, power clamps will repeatedly clamp
with the identical force. This is not always true with manual clamps, which depend on operator
diligence for the proper application of clamping force. In addition, power-clamping systems can
have interlocks to the machine control which will shut the machine down if the system loses
powera clear safety advantage for both operator and machine tool.
APPLICATIONS FOR JIGS AND FIXTURES
Typically, the jigs and fixtures found in a machine shop are for machining operations.
Other operations, however, such as assembly, inspection, testing, and layout, are also areas
where work holding devices are well suited. Figure 1-7 shows a list of the more-common
classifications and applications of jigs and fixtures used for manufacturing. There are many
distinct variations within each general classification, and many work holders are actually
combinations of two or more of the classifications shown.
EXTERNAL-MACHINING APPLICATIONS:
Flat-Surface Machining
Milling fixtures
Surface-grinding fixtures
Planning fixtures
Shaping fixtures
Cylindrical-Surface Machining
Lathe fixtures
Cylindrical-grinding fixtures
Irregular-Surface Machining
Band-sawing fixtures
External-broaching fixtures
INTERNAL-MACHINING APPLICATIONS:
Cylindrical- and Irregular-Hole Machining
Drill jigs
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Boring jigs
Electrical-discharge-machining fixtures
Punching fixtures
Internal-broaching fixtures
NON-MACHINING APPLICATIONS:
Assembly
Welding fixtures
Mechanical-assembly fixtures
(Riveting, stapling, stitching, pinning, etc.)
Soldering fixtures
Inspection
Mechanical-inspection fixtures
Optical-inspection fixtures
Electronic-inspection fixtures
Finishing
Painting fixtures
Plating fixtures
Polishing fixtures
Lapping fixtures
Honing fixtures

Miscellaneous
Layout templates
Testing fixtures
Heat-treating fixtures

TYPES OF FIXTURES:
The following is a partial list of production operations that use fixtures:
Assembling
Lapping
Boring
Milling
Broaching
Planning
Drilling
Sawing
Forming
Shaping
Gauging
Stamping
Grinding
Tapping
Heat treating
Testing
Honing
Turning
Inspecting
Welding

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TYPES OF FIXTURES:
The names used to describe the various types of fixtures are determined mainly by
How
the tool is built. Jigs and fixtures are made basically the same way as far as locators
and positioners are concerned. The main construction difference is mass. Because of the
increased tool forces, fixtures are built stronger and heavier than a jig would be for the
same part.
Plate fixtures
Plate fixtures are the simplest form of fixture. The basic fixture is made from a Flat plate that
has a variety of clamps and locators to hold and locate the part. The simplicity of this fixture
makes it useful for most machining operations. Its adaptability makes it popular.

Angle-plate fixture
The angle-plate fixture is a variation of the plate fixture. With this tool, the part is
Normally machined at a right angle to its locator.

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Modified angle-plate fixture

While most angle-plate fixtures are made at 90 degrees, there are times when
Other angles are needed. In these cases, a modified angle-plate fixture can be used.

Fig. modified angle-plate fixture

Vise-jaw fixtures
Vise-jaw fixtures are used for machining small parts. With this type of tool, the
Standard vise jaws are replaced with jaws that are formed to fit the part. Vise-jaw fixtures
are the least expensive type of fixture to make. Their use is limited only by the sizes of
the vises available.

Fig. Vise-jaw fixtures

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Indexing fixtures
Indexing fixtures are very similar to indexing jigs. These fixtures are used for
Machining parts that must have machined details evenly spaced. The parts shown in
Figures are examples of the uses of an indexing fixture.
Indexing fixtures

Parts machined with an indexing fixture.

Multi station fixtures

Multi station fixtures are used primarily for high-speed, high-volume production
runs, where the machining cycle must be continuous.
Duplex fixtures
Duplex fixtures are the simplest form of multi station fixture, using only two
stations. This form allows the loading and unloading operations to be performed while
the machining operation is in progress. For example, once the machining operation is
complete at station 1, the tool is revolved and the cycle is repeated at station 2. At the
same time, the part is unloaded at station 1 and a fresh part is loaded.
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Duplex fixtures
Profiling fixtures
Profiling fixtures are used to guide tools for machining contours that the machine
cannot normally follow. These contours can be either internal or external. Since the
fixture continuously contacts the tool, an incorrectly cut shape is almost impossible. The
operation in Figure shows how the cam is accurately cut by maintaining contact
between the fixture and the bearing on the milling cutter. This bearing is an important
part of the tool and must always be used.
.

MILLING FIXTURE

Milling Fixtures

Milling fixtures are the most common type of fixture in general use today.
The simplest type of milling fixture is a milling vise mounted on the machine table.
However, as the work piece size, shape, or complexity becomes more sophisticated, so
too must the fixture.
The design should permit as many surfaces of the part to be machined as possible.
Without removing the part.
Whenever possible, the tool should be changed to suit the part. Moving the part to
accommodate one cutter for several operations is not as accurate or as efficient as
changing cutters.

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Locators must be designed to resist all tool forces and thrusts. Clamps should not be
used to resist tool forces.
Clearance space or sufficient room must be allotted to provide adequate space to change
cutters or to load and unload the part.
Milling fixtures should be designed and built with a low profile to prevent unnecessary
twisting or springing while in operation.
The entire work piece must be located within the area of support of the fixture. In those
cases where this is either impossible or impractical, additional supports, or jacks, must
be provided.
Chip removal and coolant drainage must be considered in the design of the fixture.
Sufficient space should be permitted to allow the chips to be easily removed with a
brush.
Set blocks or cutter setting gages must be provided in the fixture design to aid the
operator in properly setting up the tool in production.

Lathe Fixtures
Similar to the design of milling fixtures.

In milling, the work piece is stationary and the cutting tool revolves. In turning
operations, the work piece revolves and the cutting tool is stationary.

Tool designer must deal with-centrifugal force. The complete fixture must be designed
and constructed to resist the effects of the rotational, or centrifugal, forces present in the
turning.

Since lathe fixtures are designed to rotate, they should be as lightweight as possible.

Lathe fixtures must be balanced. While perfect balance is not normally required for
slow-speed turning operations, high rotational speeds require the fixture to be wellbalanced.

Projections and sharp corners should be avoided since these areas will become almost
invisible as the tool rotates and they could cause serious Injury

Parts to be fixtured should, whenever possible, be gripped by their largest diameter, or

cross section.

The part should be positioned in the fixture so that most of the machine operation can be
performed in the first fixturing.

Clamps should be positioned on surfaces, or areas, which are rigid before and after
machining.

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As with other fixtures, some means of cutter setting should also be incorporated into the
design. However, since the work holder will be rotating, this setting device should be
removed.

Whenever possible, standard lathe accessories should be adapted in the design of turning
fixtures. Lathe faceplates are an ideal method to mount large fixtures. Likewise, a
standard lathe chuck, or collets, can and should be modified for many fixturing
applications.

Surface Grinding Fixtures

Surface grinding fixtures are similar in design to milling fixtures, but made to much
closer tolerances. Whenever practical, use magnetic chucks to hold the work piece.

Provide adequate room or slots to permit the escape of coolant and to allow easy
removal of built-up grinding sludge.

Provide coolant containment devices or splash guards to keep the fixture from spilling
coolant on the floor around the machine. Fixture elements which are in contact with the
magnetic chuck should be made from ferrous materials. Include provisions for rapid
wheel dressing and truing in the design of the fixture, if not built into the machine. All
locators must be accurately and positively positioned.

Boring Fixtures
These fixtures differ from boring normally used for large parts with large holes where
the boring bar is rigid enough to provide additional support. A pilot bushing is not
needed.
Boring fixtures, like milling fixtures, should have some provision for setting the
position of the cutting tool relative to the part.
In cases where a boring fixture is to be used on a very large machine, such as a boring
mill or vertical turrets lathe it is also good practice to include areas on the fixture to
insure proper alignment with the machine.

[NETTUR TECHNICAL TRAINING FOUNDATION, BENGALURU]Page 23

[MULTIPURPOSE ANGULAR GRINDING FIXTURE]

DOWEL PIN
Dowel pins are often used as precise locating devices in machinery. Steel dowel pins
are machined to tight tolerances, as are the Corresponding holes, Which are typically reamed.
A dowel pin may have a smaller diameter than its hole so that it freely slips in or a larger
diameter so that it must be pressed into its hole (interference fit).

FULCRUM PIN
A Lever is a rigid rod or bar capable of turning about a fixed point called fulcrum. or A shaft or
pin on which something turns.

[NETTUR TECHNICAL TRAINING FOUNDATION, BENGALURU]Page 24

[MULTIPURPOSE ANGULAR GRINDING FIXTURE]

ALLEN SCREW
A screw with a hexagonal hole in the head with a tapered threaded shank and slotted head .
It is turned by an axial hexagonal hole in its head.

BEVEL EDGE

A beveled edge refers to an edge of a structure that is not

perpendicular to the faces of the piece. The words bevel and chamfer overlap in usage; in
general usage they are often interchanged, while in technical usage they may sometimes be
differentiated as shown in the image at right.

[NETTUR TECHNICAL TRAINING FOUNDATION, BENGALURU]Page 25

[MULTIPURPOSE ANGULAR GRINDING FIXTURE]

PURPOSE AND ADVANTAGES OF JIGS AND FIXTURES
(a) It reduces or sometimes eliminates the efforts of marking, measuring and setting of work
piece on a machine and maintains the accuracy of performance.
(b) The work piece and tool are relatively located at their exact positions before the operation
automatically within negligible time. So it reduces product cycle time.
(c) Variability of dimension in mass production is very low so manufacturing processes
supported by use of jigs and fixtures maintain a consistent quality.
(d) Due to low variability in dimension assembly operation becomes easy, low rejection due to
les defective production is observed.
(e) It reduces the production cycle time so increases production capacity. Simultaneously
working by more than one tool on the same work piece is possible.
(f) The operating conditions like speed, feed rate and depth of cut can be set to higher values
due to rigidity of clamping of work piece by jigs and fixtures.
(g) Operators working become comfortable as his efforts in setting the workpiece can be
eliminated.
(h) Semi-skilled operators can be assigned the work so it saves the cost of manpower also.
(i) There is no need to examine the quality of produce provided that quality of employed jigs
and fixtures is ensured.
IMPORTANT CONSIDERATIONS WHILE DESIGNING JIGS AND FIXTURES.
Designing of jigs and fixtures depends upon so many factors. These factors are analyzed to get
design inputs for jigs and fixtures. The list of such factors is mentioned below:
1) Study of work piece and finished component size and geometry.
2) Type and capacity of the machine, its extent of automation.
3) Provision of locating devices in the machine.
4) Available clamping arrangements in the machine.
5) Available indexing devices, their accuracy.
6) Evaluation of variability in the performance results of the machine.
7) Rigidity and of the machine tool under consideration.
8) Study of ejecting devices, safety devices, etc.
9) Required level of the accuracy in the work and quality to be produced.

[NETTUR TECHNICAL TRAINING FOUNDATION, BENGALURU]Page 26

[MULTIPURPOSE ANGULAR GRINDING FIXTURE]

PROJECTSUMMARY:
STEPS INVOLVING IN MANUFACTURING PROCESS:

[NETTUR TECHNICAL TRAINING FOUNDATION, BENGALURU]Page 27

JOB DETAILS:
NAME

: TRI SQUARE

MATERIAL

: MILD STEEL

THICKENESS

: 5mm

SCALE

: 1:1

All Dimensions are in

mm

Machining time calculations:

The major aim and objectives in machining industries generally are:
Reduction of total manufacturing time,
Increase in MRR, i.e., productivity
Reduction in machining cost without sacrificing product quality
Increase in profit or profit rate, i.e., profitability.
The total time required to perform a machining operation consists of following elements:
Set-up time,
Handling time,
Machining time,
Allowances.

(a) Set-up time:

This is the time taken to prepare the machine for operation. The set-up time includes
the time taken to:
(i) Study the component drawing.
(ii) Draw tools from tool crib, and
(iii) Install and adjust the tools, jigs and fixtures on the machine.

(b) Handling Time:

It is the time taken by the operator in preparing a part for machining and for disposing
the part
After operation has been completed. The handling time includes the time for loading
and unloading
The component on the machine, making measurements on parts during machining, etc.

(c) Machining Time:

It is the time for which the machine works on the component, i.e. from the time when
the tool touches the work piece to when the tool leaves the component after
completion of operation. The machining time depends on the type and extent of
machining required, material being machined, speed, feed, depth of cut and number
Of cuts required.

(d) Allowances:
In additions to the elements of time described above, the total time to perform an
operation includes a number of allowances like time for personal needs of the
operator, time for checking, time for tool sharpening etc.

Lathe:
The factors that govern machining time will be understood from a simple case of
machining. A steel rod has to be reduced in diameter from D1to D2 overall length L by
straight turning in a centre lathe.
TC= (Lc ( Ns0))xnp
Where
L=required length of cut
TC= cutting time
LC= actual length of cut
=L+A+O
A, O= approach and over run

Estimation of machining time in turning. A,

O= approach and over run as shown
N =spindle speed, rpm
so = feed (tool), mm/rev
np=number of passes required

Speed N, is determined from cutting velocity, VC

VC=D N(1000)
Where, D =diameter of the job before cut
The number of passes, npis mathematically determined from,
np=( D1-D2) 2 t
Where,
t is the depth of cut in one pass in mm.

Milling:
Milling time TC= (l+a) / F
Where
l is the length of work piece in the direction of feed
a is the approach length a=d (D -d)
d depth of cut in mm
D Diameter of milling cutter in mm (18mm carbide insert cutter)
F Table feed in mm/min (~100 mm/min)

Surface grinding:
Machining time t m = 2xLxBxi
V x1000xS
L=l+ (2 x over travel)
Where,
L=grinding length in mm l
= length of work piece
i = number of cuts
V=Speed of table in m/min
S=lateral feed in mm/stroke
B=Width of work piece

Drilling:
Ex: For 18mm,
V=dn/1000m/min
N=1000X25/18
=442.09rpm.
Feed=0.5mm/rev
Machining time:
Tm=L/SrXN
Tm=machining time
L =Length of the tool travel
Sr =feed
N =speed in rpm.

MILLING TIME CALCULATIONS FOR TOP PLATE:

SPEED:
Dia of cutter=20mm; v=20m/min
N=VX1000/D
=20X1000/20
=318.31rpm

FEED:
Fm=FtXZXN

[N=No. of tooth sin cutter]

=0.1X6X318.31 [Ft=feed/tooth]
=190.98mm/min

DEPTH OF CUT:
0.5mm/pass

Machining time:

Tm =L+a/f
a=d (D-d)
=0.5(15-10)
=3.535mm
Tm =115+10.94/160
=0.7783min
=46.68secper pass
=46.68x2.5

= 10.12min
Other side,
=46.68X2=93.36sec/side
Breadth wise,
Tm=46.68x2
=93.36 sec/side
Tm=46.68x1.5
=70.02sec/side
So, estimated time for bottom plate, cavity plate, top plate=40+40+40mins
Totally2hrs.
Similarly,
For spacer or heel block
Estimated time =44mins

DRILLING TIME CALCULATIONS FOR FIXED, PLATE:

V=DN/1000m/min.
For =4mm
N=1000XV/D
=1000X20/ X4
=1591.54rpm
For =6mmN=1000x20/ X6
=1061.0rpm

Feed=0.5mm/rev
Machining time,
Tm=18/0.5x2000
=1.08min
Tm=18/0.5X550
=3.5min.

DRILLING TIMECALCULATIONS FORBOTTOMPLATE:

V=DN/1000m/min.

Feed=0.5mm/rev

For =4mm
N=1000XV/D
=1000X20/ X4
=1591.54rpm
For =8.5mmN=1000x20/ X8.5
=748.96rpm
For =14.5mmN=20000/ X14.5 =439.04rpm
For =15.5mmN=20000/X15.5 =410.72rpm

Machining time,
Tm=20/0.5x2122.00
=1.18min
Tm=20/0.5X994.71
=2.5min.
Tm=20/0.5X544
=3min.
Tm=8/0.5X578
=1.6min.

DRILLING TIMECALCULATIONS FORCORE BACK PLATE:

V=DN/1000m/min.

Feed=0.5mm/rev

For=3mm
N=1000XV/D
=1000X15/ X4
=1193.66rpm
For=6mmN=1000x15/ X6
=795.77rpm
For=6.8mmN=15000/X6.8 =702.15rpm
For=10mmN=15000/X10 =477.46rpm

Machining time,
Tm=8/0.5x2122.00
=0.45min
Tm=8/0.5X1224.2
=0.78min.
Tm=8/0.5X1500
=0.64min.

For=15mmN=15000/X15 =318.30rpm
Tm=4/0.5X578
=0.87min.

Estimated time for different machining operations:

SL.NO Part name Milling
(hr)

Surface
Grinding
(hr)

Lathe Drilling Bench

Total

(hr)

(hr)

(hr)

(hr)

Fixed Plate

2:00

2:00

1:00

2:00

7:00

Sliding Plate

2:00

2:00

1.00

2:00

7:00

Top Plate

2:50

2:00

1:00

2:00

7:50

Base Plate

3:50

3:00

1:00

2:00

9:50

Fulcrum Pin

2:00

0.5

2:50

Tri Square

1:00

2:00

3:00

10:00

2:00

10:50

36:50

Total (hr)

10:00

4:00

COST ESTIMATION:
Estimation is the art of determining the cost which is likely to be incurred on the
manufacturer of article, before it is actually manufactured.
Actually estimation is necessary to complete in the market and be sure if the manufactured
article is profitable or not .Here we have considered the approximate value of the following
1. Machine hour rate
2. Machining time
3. Cost of material

Machining cost estimation:

Total
amount

Machine

Machine

Description

Utilization

Machining
rate/hour

Milling

10:00

80/hr

800.0

Surface grinding

10:00

90/hr

900.0

Lathe

2:00

50/hr

100.0

Drilling

4:00

120/hr

360.0

Bench work

10:50

70/hr

735.0

SL
NO

Total cost (Rs)

Material cost estimation:

(Rs)

2895/-

SL.NO

Material description

Quantity

(Rs)

Total
Amount
(Rs)

60

445.0

Rate

MS Flat

MS Round rod

105

562.0

Allen screw

20

10

196

Dowel pin

2 Nos

10

20

Total Cost(Rs)

1218.0/-

Total cost estimated =2417.50 +1218.0

Rs =3657.50/-

Selection of Raw Materials:

SL.NO

Description

Material

Quantity

Fixed Plate

M.S

Sliding Plate

M.S

Top Plate

M.S

Base Plate

M.S

Fulcrum Pin

M.S

Dowel pin

M.S

Remarks

PROCESS PLAN FOR FIXED PLATE:

Sl.No

Process

Interpretation of diagram

Tools used

Machine

2
3
4
5
6
7
8

Check the raw material size,

Parallelism and thickness.

Vernier caliper,
Micrometers, vernierheight
gauge.

Clamp the work piece in milling vice

remove the excess stock and machined
the references in SG.

Vernier Caliper, 20 end

mill cutter, fly mill cutter.

Marking and Punching.

Vernier height gauge, dot

punch, ball peen hammer.

Use4, 6, 9.7, 10, 13, 14.5,

15.5 mm drills.

Drill chucks, drill bits.

Sensitive and Radial

drilling machine.

15H7 and 16H7

machine reamer.

Radial Drilling
Machine.

Countersink tool.

Drilling machine.

6 flat file.

Bench vice.

Tools used

Machine

Do the machine reaming forgetting

15H7 and 16H7 finished hole.
Do the countersinking for all the
holes.
Do the chamfering on the plate as
per the drawing.

Milling machine,
Surface Grinding
Machine.
Surface table and
Anvil.

PROCESS PLAN FOR SLIDING PLATE:

S.No

Process

Interpretation of diagram

Check the raw material size,

parallelism and thickness.

Vernier caliper,
micrometres,vernierheight
gauge.

Clamp the work piece in milling vice

remove the excess stock and machined
the references in SG.

Vernier Caliper, 20 end

mill cutter, fly mill cutter.

Marking and Punching.

vernier height gauge, dot

punch, ball peen hammer.

Use4, 6, 9.7, 10, 13, 14.5,

15.5 mm drills.

Drill chucks, drill bits.

Sensitive and Radial

drilling machine.

15H7 and 16H7

machine reamer.

Radial Drilling
Machine.

Countersink tool.

Drilling machine.

6 flat file.

Bench vice.

3
4
5
6
7
8

Do the machine reaming forgetting

15H7 and 16H7 finished hole.
Do the countersinking for all the
holes.
Do the chamfering on the plate as
per the drawing.

Milling machine,
Surface Grinding
Machine.
Surface table and
Anvil.

PROCESS PLAN FOR TOP PLATE:

S.No

Process

Interpretation ofdiagram

Check the raw material size,

parallelismand thickness.

Clamptheworkpiecein milling
viceremove the excess stock and
machined the references in SG.

Toolsused
Vernier
calliper,
micrometres,vernierheight
gauge.
Vernier Caliper, 20 end
mill cutter, fly mill cutter.

Machine

Milling machine,
Surface Grinding
Machine.
Surface table and
Anvil.
Sensitive and Radial
drilling machine.

Marking and Punching.

Vernier height gauge, dot

punch, ball peen hammer.

Use4, 6, 6.8, 9, 12, 15,

22mm drills.

Drill chucks, drillbits.

Do the profile cutting of insert by

boring tool in lathe.

Boring tool, R5 radius tool.

Lathe machine.

Dothehandreamingforgetting6H7
hole and do the tapping of M8.

Tap wrench,hand reamer

and M8 tap.

Bench vice.

Countersink tool.

Drillingmachine.

6 flat file.

Bench vice.

Toolsused

Machine

8
9

Do the countersinking for all the

Holes.
Dothechamferingon theplateas
per thedrawing.

PROCESS PLAN FOR BASE PLATE:

S.No

Process

Interpretation ofdiagram

Check the raw material size,

parallelism and thickness.

Vernier
calliper,
micrometres,vernierheight
gauge.

Clamptheworkpiecein milling
viceremove the excess stock and
machined the references in SG.

Vernier Caliper, 20 end

mill cutter, fly mill cutter.

Marking and Punching.

Use4, 6.2, 8.5mm drills.

Do the countersinking for all the
Holes.
Do the chamfering on the plate as
perthedrawing.

6
7

Vernier height gauge, dot

punch, ball peen hammer..
Drill chucks, drillbits.

Milling machine,
Surface Grinding
Machine.
Surface table and
Anvil.
Drilling machine.

Countersink tool.

Drillingmachine.

6flat file.

Bench vice.

PROCESS PLAN FOR FULCRUM PIN:

S.No

Process

Interpretation of diagram

Check the raw material size,

Parallelism and thickness.

Vernier caliper,
micrometres, vernier height
gauge.

Clamp the work piece in milling vice

remove the excess stock and
machined the references in SG.

Vernier Caliper, 20 end

mill cutter, fly mill cutter.

Marking and Punching.

Vernier height gauge, dot

punch, ball peen hammer.

Use4, 6, 6.8, 9, 12, and

14.5 drills.

Drill chucks, drill bits.

Do the profile cutting of insert by

boring tool in lathe.

Boring tool, R5 radius tool.

Lathe machine.

Dothehandreamingforgetting6H7
hole and do the tapping of M8 and
M16.

Tap wrench, hand reamer

and M8, M16 tap.

Bench vice.

Countersink tool.

Drilling machine.

6 flat file.

Bench vice.

7
8
9

Do the countersinking for all the

Holes.
Do the chamfering on the plate as
per the drawing.

Tools used

Machine

Milling machine,
Surface Grinding
Machine.
Surface table and
Anvil.
Sensitive and Radial
drilling machine.

Planning the sequence of operations for all the positions. The operations, which can be done
at our tool room.

Placing Order for Materials:

Indent was placed in the purchasing department for the material required for the production.

Tool manufacturing:
Manufacturing of tool was started after receiving the material as per the operation sequence.

Bench work and Assembly:

Once all the components were finished I started with final assembly of the tool. Before
doing assembly bench work like tapping, chamfering etc were done.

Inspection and trial:

Inspection means measurement of quality of a product other prescribed standard. For the
approval of fixture, the job is inspected .All the elements of the tool were inspected as and

when it was machined using vernier caliper and micrometer etc .Finally after try-out, the job
was centrally inspected after visual inspection near the machine itself.

MACHINES UTILISED:
LATHE
MILLING MACHINE
DRILLING
SURFACE GRINDING

LATHE
The main function of lathe is to remove metal from a piece of work to give it the requires
shape and size. This is accomplished by holding the work securely and rigidly on the machine
and then turning it against cutting tool which will remove metal in the form of chips.

Operations involved:

Turning
Facing
Chamfering
Threading.

MILLING:
Milling machine is used for removing excess material from a work piece with a
Rotating cutting tool. The rotating cutting tool is called themillingcutter.The cutter rotates
at a high speed and because of the multipoint cutting edge it removes metal at a very fast rate.
The machine can also hold number of cutters at a time.
Milling process is used for producing flat ,contoured or helical surfaces, for cutting
thread and tooth edges and for making helical grooves.
Operations involved
Face milling
End milling

DRILLING:
Drilling machine is used to originate or cut a hole where none previously existed.
This is an extensively used machine for through or blind holes. The hole is produced by
axially feedingtherotatingdrillintotheworkpiecewhichisheldonthetableofthedrilling machine.

Operation involved
Drilling
Chamfering

GRINDING:
Grinding operation is a method of machining work pieces by use of rotary abrasive
Tool, called grinding wheel. The grinding operation can be rough
Grinding or finishing grinding (precision grinding).Rough grinding is a commonly used
method for removing excess material from castings, forgings etc.
Precision grinding is the principal production method of cutting materials that are too
hard to be machined by other conventional tools and a finer surface finish as compared to
other manufacturing method.

Surface grinding machine:

It is used for producing accurately machined surface by removing material in small
quantity. The material is removed by the rotating wheel which is made of abrasive particles. It
is used in my project for machining of all the plates.

Inspection report:
NETTUR TECHNICAL TRAINING FOUNDATION
INSPECTIONREPORT

DESCRIPTION: FIXED PLATE

S.NO

DRG.SIZE

160

90

15.00

45.00

75.00

17.50

47.0

62.00

98.00

10

118.0

11

142.50

12

15H7

13

16H7

14

6H7

15

5X45

16

2X45

17

13

18

10.0

19

8.5

20

Surface finish

DRG NO:1

ACTUALSIZE

QTY:2
REMARKS

21

Flatness

22

Parallelism

23

Perpendicularity

ACCEPTED:YES
REJECTED:

INSPECTION:
SECTION HEAD:

REWORK:

F/COM/7526

Inspection report:
NETTURTECHNICAL TRAINING FOUNDATION
INSPECTIONREPORT

DESCRIPTION: SLIDING PLATE

S.NO

DRG.SIZE

160

90

15.00

45.00

75.00

17.50

47.0

62.00

98.00

10

118.0

11

142.50

DRG NO:2

ACTUALSIZE

QTY:2
REMARKS

12

15H7

13

16H7

14

6H7

15

5X45

16

2X45

17

13

18

10.0

19

8.5

20

Surface finish

21

Flatness

22

Parallelism

23

Perpendicularity

ACCEPTED:YES
REJECTED:
REWORK:

F/COM/7526

INSPECTION:
SECTION HEAD:

Inspection report:
NETTURTECHNICAL TRAINING FOUNDATION
INSPECTION REPORT

DESCRIPTION: TOP PLATE

S.NO

DRG.SIZE

90

15.00

45.0

75.00

12.0

27.00

45.0

63.00

78.0

10

90

11

6H7

12

R5.0

13

20.0

14

25.0

15

40.3

16

2X45

17

5X45

18

R3

19

3.0

20

M8X20

DRGNO:4

ACTUALSIZE

QTY:1
REMARKS

21

Surface finish

22

Flatness

22

Parallelism

23

Perpendicularity

ACCEPTED:YES
REJECTED:

INSPECTION:
SECTION HEAD:

REWORK:

F/COM/7526

Inspection report:
NETTURTECHNICAL TRAINING FOUNDATION
INSPECTION REPORT

DESCRIPTION: BASE PLATE

S.NO

DRG.SIZE

90

15.00

45.0

75.00

12.0

27.00

45.0

63.00

78.0

10

90

DRGNO:5

ACTUALSIZE

QTY:1
REMARKS

11

20.0

12

M8X20

13

M16X20

14

6H7

15

2X45

16

5X45

17

Surface finish

18

Flatness

19

Parallelism

20

Perpendicularity

ACCEPTED:YES
REJECTED:
REWORK:

F/COM/7526

INSPECTION:
SECTION HEAD:

Inspection report:
NETTURTECHNICAL TRAINING FOUNDATION
INSPECTION REPORT

DESCRIPTION:FULCRUM PIN DRGNO:6

S.NO

DRG.SIZE

90

15.00

45.0

75.00

12.0

27.00

45.0

63.00

78.0

10

90

11

8.5

12

6H7

13

5x45

14

1x45

15

Filing finish

16

Surface finish

17

flatness

18

parallelism

19

perpendicularity

ACTUALSIZE

QTY:1
REMARKS

ACCEPTED:YES
REJECTED:
REWORK:
F/COM/7526

Inspection report:

INSPECTION:
SECTION HEAD:

PHOTOGRAPHIC IMAGES OF FIXTURE:

FIXED PLATE:

SLIDING PLATE:

TOP PLATE:

BASE PLATE:

FULCRUM PIN:

ALLEN SCREW

EJECTORPIN:

RETURNPINS:

CORE INSERT:

OVERALL TOOLS:

ASSEMBLY VIEW:

COMPONENT:

OUTCOME OF THE PROJECT:

Learned

about

design

software such

as AUTOCAD.

Known about PROCESS PLAN FOR SEQUENCE OF

OPERATION Involving in PRODUCTION.
Got hands on experience operating in basic Machines.
Assembly of fixtures ,trail and trouble shooting.
Learnt about INSPECTION process.

CONCLUSION:
The grinding fixture was successfully completed and assembled on. It
took three months for completion of the tool. All that was involved in the
project is good design, systematic work and the co-operation and coordination
from all staff members to me, which fetched outstanding result at the end.
Though we have taken all care to complete the project to the best of our
ability, some errors may have crept in due to over sight or ignorance or trial and
error methods .There is definitely scope for improvement in the different
aspects of this project.
It really persuades me to do more & more, perhaps in better ways in my
future. I take this opportunity to thank everyone, who contributed directly or
Indirectly to the success of my project.

[MULTIPURPOSE ANGLE GRINDING FIXTURE]

REFERENCES:
Fixture

design

Edward Hoffman

Technology

NTTF Master File

Design PPTs

PG School

Production

Fixture

Engineering

Chemistry

Jain

[ANGULAR GRINDING FIXTURE FOR TRAINING MODEL]

[ANGULAR GRINDING FIXTURE FOR TRAINING MODEL]

[ANGULAR GRINDING FIXTURE FOR TRAINING MODEL]

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