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EXAM SEAT NO
1. KHEMNAR PRADEEP
B80690814
2. LASALKAR SARVESH
B80690816
3. PATIL BY
BHUSHAN
SPONSORED
MAHINDRA SONA LTD.
SATPUR, NASHIK-422007
B80690818
PROF. M. A. AHIRE (INSTITUTE GUIDE)
Mr. S.V. BHUSAL &
Mr. D.J. BHADANE (COMPANY GUIDE)
Broaching
Keyway Milling
Broaching
Keyway Milling
P- 0.060% ;
S-0.08-0.35%
Heat Treatment - HND & TEM :-229-269 BHN
0.3d
Fig no. 1. Drill bit
Side butting
blocks
VBlock
Jig
Plate
Drill
Bush
Support
Plate
Support
Plate
Main Hole
Locater
CWasher
Base
Plate
Thrust = 1702.02 N
4)LOCATION:-
From Clamping Force range Screw/Bolt size is selected from book is,
Material Chart
Component No
Component Number
Component Material
1.
Base Plate
Mild-Steel
2.
Support Plate
Mild-Steel
7.
Washer
Mild-Steel
9.
C-washer
Mild-Steel
11.
Jig plate
Mild-Steel
Composition in %
C
Si
Mg
0.2-0.3
0.25
0.05
0.05
0.57
Properties
Density
Hardness
Modulus of Elasticity
(Kg/m^3)
(BHN)
(Gpa)
7850
140
190
Breaking Strength
(N/mm^2)
430
Remarks
Above mentioned parts are not subjected to much stresses & wear. Hence Mild-steel is selected for these
components. Mild-Steel have following advantages: Easily available, Cheap cost, Economical,
Most widely used.
Material Chart
Component No
Component Number
Component Material
3.
Vee-Block
SAE 8620
4.
SAE 8620
8.
Hinge pin
SAE 8620
12.
SAE 8620
Composition in %
C
Mn
Si
Ni
Cr
Mo
0.17-0.23
0.60-0.95
0.20-0.35
0.35-0.75
0.35-0.65
0.15-0.25
Properties
Density
(Kg/m^3)
7859
Hardness
(BHN)
220
Modulus of Elasticity
(Gpa)
210
Breaking Strength
(N/mm^2)
690
(N/mm^2)
821.8
Remarks
Above mentioned parts are subjected to the stresses & friction, hence material have wear resistance property.
Thus, SAE8620 materials selected for these components.
SAE 8620 have following advantages: Used for high resistance surface, High hardness .
Resist shock load, High strength.
Material Chart
Component No
Component Number
Component Material
5.
Drill Bush
EN 31
6.
Linear Bush
EN 31
Composition in %
C
Mn
Si
Cr
0.9-1.2
0.3-0.75
0.10-0.35
1-1.6
0.5
0.5
Properties
Density
(Kg/m^3)
7810
Hardness
Modulus of Elasticity
(BHN)
(Gpa)
229
210
Breaking Strength
(N/mm^2)
(N/mm^2)
1102.45
1158
Remarks
Above mentioned parts Drill bush, Linear bush required to be hardened material, for that we have selected EN
31 Material. It has following advantages: High hardness,
Used for high resistance surface,
Resist shock load,
High strength.
COST ESTIMATION
Raw Material Cost = Rs 2273
Operation Cost
= Rs 11545
= 500 Parts
= 75 parts/hr
= 8.50 Rs/part
= 638 Rs/hr
= 4250 Rs
= 4785 Rs/day
= 14,35,500 Rs/year
= 17000 Rs/year
Time Analysis for Broach Re-pass : Operation Time for Single Batch (Ot)
= 7 hr
Job Handling Time (Ht)
= 0.5 hrs
Total Time Saved Per Batch
= 10.5 hrs
Total Time Saved Per Year
= 42 hrs
Total Time Saving/Year in Terms of money =18900 Rs/year
Total Yearly Benefits
= Rs 35900
Payback Period
Break Even Point
= 4 Months
= 1664 Parts
Ref : Jig & Fixture Design; By Edwrd.G. Hoffman; Pg no. 91,94
CONCLUSION
Yearly profit earned by company is actually of Rs.
35,900/ If parts are continuously manufactured for whole year;
then profit will be of Rs. 14,35,500/ The total machining time saved for a batch of 500 parts is
around 10.5 Hrs.
Rejection tends to zero & productivity increases.
Customers satisfaction by obtaining their required surface
finish & dimensions.
REFERENCES
1. Jig and Fixture Design, By Edwrd G. Hoffman; Delmar Cengage Learning; 5th Edition;
2. Production Technology, By HMT; TATA McGraw Hill; 24th Edition2006;
3. Westermann Tables, By Hermann Jutz &Eduard scharkus; New Age International(P)Ltd.; 3rd Edition
2008;
4. Design Data, By PSG College of Technology; Kalaikathir Achchagam; 2nd Edition 2010;
5. Material science & Metallurgy, By O. P. Khanna; Dhanpat Rai Publications; 11th Edition; 2007;
6. Jigs and fixtures, By P.H.Joshi; Tata Mc-GrawHill company limited; 6th Edition 2010;
7. Material Analysis, By Mahindra & Mahindra Steel Division; Industrial and Engg Journals;
8. Design of a 5-Axis Fixture System, By Brian Dorchik, Steven Feroli, Ryan McGlone, Ryan McLaughlin;
Worcester Polytechnic Institute, Worcester, Massachusetts; 2007;
9. Dedicated Fixture Design for Polishing of Silicon, By Taufif Bin Zakaria; Report submitted in partial
fulfillment of the requirements for the award of the degree of Bachelor of Mechanical Engineering;
November 2008;
10. Manufacturing Tooling (Jig Design) By Nageswara Rao Posinasetti; February 12, 2008;
11. Introduction of Jig & Fixture (Pdf).
12. Care lane cutting & clamping forces (Pdf).
13. http://www.mahindrasona.com/about.htm
THANKS