Rear Forward Axle Housing Snorkel Boring Position Capability Improvement

CHAPTER 1
INTRODUCTION
1.1 AXLE
Axle is the important part of the differential. The axle is a straight shaft that is
fixed in a location; it is combined with bearing or brushing use to mount rotating wheel or
gears. The wheel or gear can be attached to it with a built in gearing or bushing. A bearing
or brushing fits inside the center of the wheel and allow it to rotate without affecting the
axle itself. The purpose of axle is to secure the wheels or gears to specific locations
relative to other wheels or gear. The wheels would not remain in fixed position and the
force and vehicle would make the wheel bend flat. In automobile two types of differential
are used which are front axle and rear axle. The power developed by the engine is
transferred to the wheels through clutch, gear box, universal joints, propeller shaft, final
drive, differential and rear axles.

Fig 1.1: Axle

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Rear Forward Axle Housing Snorkel Boring Position Capability Improvement

1.2 AXLE HOUSING
An axle assembly on a car or truck is the set of components that allow the wheels
to rotate freely. Two wheels are usually connected by a shaft known as an axle. It sits
inside axle housing, and is held in place by bearings or bushings that allow it to rotate
within the axle housing. Damage to the axle itself can cause the entire assembly to fail, so
the housing acts as a protective layer for the spinning axle. Lubrication of the axle is also
made possible because of the housing.
The axle housing may also contain other components that allow for steering, driving, or
load bearing. If axle housing is intended primarily for bearing a load it may be called a
dead axle because it is not used to propel the vehicle forward. Many front wheel drive
vehicles feature a rear dead axle that is meant only for load bearing and for keeping the
left and right rear wheels on track. If the axle is part of the drive system, it may be known
as a drive axle.
Sometimes an axle is not a solid piece, but instead two pieces that connect within the axle
housing. This allows the wheels to rotate at different speeds the gears that drive these
wheels will be contained within the axle housing, as will the two separate axle pieces. A
driveshaft may also enter the housing at its front, usually in the center, to connect with
any drive gears for the wheels. The housing allows these components to be protected from
impacts, and it also allows lubrication to be contained within the space, preventing
premature breakdown of the axle components.
Larger trucks may feature more than one axle to help support the weight of the vehicle
without causing excess strain on the axle itself. One axle is devoted entirely to supporting
the truck's weight, while the other axle is not weight-bearing at all and allows the axle
shaft to spin with far less stress. This is sometimes known as a full float axle system, and
it is common on dump trucks, tractor trailers, and other large, load-bearing vehicles.
Semi-floating axles will still end up supporting some of the weight of the vehicle, and
non-floating axles are usually responsible for supporting the entire load of the vehicle.
1.3 REAR AXLE
Rear axle transmits power from differential to the wheels so that vehicle may turn.
Rear axle isnt a single part but it consist two parts which are connected to the

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Rear Forward Axle Housing Snorkel Boring Position Capability Improvement

differential. Outer end of the rear axle carries the wheel while inner end is connected by
sun gear of the differential.
The propeller shaft is provided with two universal joints and also a sliding joint. The
spring is fixed rigidity in the middle, to the rear axle. The front end of the spring is fixed
rigidly on the frame, while the rear end is supported in a shackle. The driving thrust is
transmitted to the frame by the front half the springs. Due to the torque traction, the
spring deflects. The up down movement of the rear axle induces. Variation in the length
of propeller shafts which gets compensated by the slip joint. Consequence of the rear axle
movement and deflection of the spring is, to alter the position of the final drive shafts
also. This shafts position may result in bending of the propeller shafts which is avoided
by using a universal joint at the rear end of the propeller shaft.
1.4 SNORKEL BORE

Fig 1.2: Snorkel Bore

The above figure shows snorkel bore in axle housing. This type of axles is used in heavy
duty vehicles. A front engine rear axle drives heavy capacity vehicles requires snorkel
bore to connect a forward rear axle to backward rear axle. One end of the shaft is
connected to snorkel bore and other end is connected to rear end axle.

1.5 PROCESS CAPABILITY

Process Capability refers to the uniformity of the process.

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Rear Forward Axle Housing Snorkel Boring Position Capability Improvement

It is judged by Comparing process performance with process requirements. Since meeting
Specification limits is one of the basic requirements, capability analysis. Usually involve
the specification limits in their calculation.
Process capability analysis is a vital part of an overall quality-improvement Program.
Among the major uses of data from a process capability analysis are the following:
1.
2.
3.
4.
5.
6.

Predicting how well the process will hold the tolerances.

Assisting product developers/designers in selecting or modifying a process
Assisting in establishing an interval between sampling for process monitoring
Specifying performance requirements for new equipment.
Selecting between competing vendors.
Planning the sequence of production processes when there is an interactive effect of
processes on tolerance

7. Reducing the variability in a manufacturing process.

1.5.1 CAPABILITY INDICES:
There are several statistics that can be used to measure the capability of a process:
Cp, Cpk, Pp and Ppk.
1.
2.
3.
4.

The statistics assume that the population of data values is normally distributed.
Variability can be stated as either short-term or long-term.
Cp and Cpk are based on short term variability.
Pp and Ppk are based on total variability.

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Rear Forward Axle Housing Snorkel Boring Position Capability Improvement

Short term variability is defined as the average within subgroup variability.
Total variability is estimated by treating the data as one big sample using only the overall
mean and looking at how the data points vary around this one overall mean
Cp: It simply relates the Process Capability to the Specification Range and it does not
relate the location of the process with respect to the specifications. Values of C p exceeding
1.33 indicate that the process is adequate to meet the specifications. Values of C p between
1.33 and 1.00 indicate that the process is adequate to meet specifications but require close
control. Values of Cp below 1.00 indicate the process is not capable of meeting
specifications.
Cpk: It considers process average and evaluates the process spread with respect to where
the process is actually located. Generally, a CPK greater than 1.33 indicates that a process
is capable in the short term. Values less than 1.33 tells that the variation is either too wide
compared to the specification or that the location of the variation is offset from the center
of the specification. Cpk = Cp only when the process is perfectly centered. Cp represents the
highest possible value for Cpk.
1.6 FIXTURE
A fixture is a production tool that locates, holds, and supports the work securely so
the required machining operations can be performed. Set blocks and feeler or thickness
gauges are used with fixtures to reference the cutter to the work piece.
A fixture should be securely fastened to the table of the machine upon which the work is
done. Though largely used on milling machines, fixtures are also designed to hold work
for various operations on most of the standard machine tools. Fixtures vary in design
from relatively simple tools to expensive, complicated devices. Fixtures also help to
simplify metal working operations performed on special equipment.
1.6.1 TYPES OF FIXTURE
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 petitioners 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.
These are commonly used product processing stage. It depends on the type of operation
i.e. being performed on the work piece and classified as,

Simple fixture: It is employed for simple operations.

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Rear Forward Axle Housing Snorkel Boring Position Capability Improvement

Milling fixture: It is specially employed for milling operations.
Lathe fixture: It is employed for holding the work piece during lathe operation.
Boring fixture: It is employed in boring operation to hold the work piece for
enlarging the hole.
Profiling fixture: These 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.
1.6.2 CLAMPING
The various forces acting upon the w/p during a machining operation necessitate a
means of clamping it in position after it has been correctly located. The method of
clamping will depend upon the type of locating device and vice-versa. The selection of
locating and clamping methods and devices will depend upon the machining operation
and configuration of the part.
FACTORS TO BE CONSIODERED IN CLAMPING
The following are the some of the factors to be considered in clamping.

The clamping pressure should not be too much.

The clamping pressure should be exerted to avoid distortion.
The movement of the work must be limited.
The clamps must be simple and foolproof.
The design must be so as to enable the clamp to be completely lifted out of work

while unloading.
Clamps should be quick in operation i.e., clamping time should be minimum.
Position of the clamps should not disturb work piece loading or unloading and cutting
tool paths.
The clamps should be arranged on the work so as to perform as many operations are
possible.
1.6.3 LOCATION
Location refers to the establishment of the desired relationship between the work
pieces and jigs and fixtures. Correct location influences the accuracy of the finishing
products.

3-2-1 principle of location

We have two objectives when mounting a part in a fixture for machining:
1. Accurately position the part at the desired coordinates.
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Rear Forward Axle Housing Snorkel Boring Position Capability Improvement

2. Restrict all six degrees of freedom so that the part cannot move.
A widely used method of accomplishing these two objectives uses the 3-2-1 principle, socalled because it entails three steps that employ three, then two, then one fixed points of
known location. Since that adds up to six fixed points, its also known as the six point
method.
In the three steps of the 3-2-1 method, three mutually perpendicular planes, called datum
planes, are introduced, one at each step. These three planes define the work piece
position, and together with opposing clamping forces fully constrain the part.
For a fixture designer, the major portion of design time is spent deciding how to locate the
work piece in the fixture. You know that any free body has a total of twelve degrees of
freedom as below: 6 translational degrees of freedom: +X, -X, +Y, -Y, +Z, -Z and 6
rotational degrees of freedom:
Clockwise around X axis (CW -X)
Anticlockwise around X axis (CCW -X)
Clockwise around Y axis (CW -Y)
Anticlockwise around Y axis (CCW -Y)
Clockwise around Z axis (CW -Z)
Anticlockwise around Z axis (CCW-Z)
We must fix all the 12 degrees of freedom except the three transitional degrees of
freedom (-X, -Y and -Z) in order to locate the work piece in the fixture. So, 9 degrees of
freedom of the work piece need to be fixed.
By using the 3-2-1 method as shown below
1

Rest the work piece on three non-collinear points of the bottom surface (XY), and
able to fix the +Z, CROT-X, ACROT-X, CROT-Y and ACROT-Y degrees of

freedom.
Now, rest the work piece at two points of side surface (XZ), and able to fix the +Y

and ACROT-Z degrees of freedom.

Now, rest the work piece at one point of the adjacent surface (YZ), and able to fix
the +X and CROT-Z degrees of freedom. So, successfully 9 required degrees of

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freedom can be fixed by using the 3-2-1 principle of fixture design and the 3-2-1
method is the fundamental principle for all types of fixture design.

CHAPTER 2
LITERATURE SURVEY
The literature review has been carried out to identify the effort made in the field of
designing of jigs and fixture to the focal area of present work.
1. Xiumeikung et all have studied about fixture planning. Fixture planning determines
precise locating the rigid clamping of a work piece according to work pieces design and
process requirements. Locating surfaces are classified as plane, pin holes and external
profiles. Commonly used fixtures locating methods on the primary locating method
include 1)3-2-1 point locating for prismatic; it uses 3 locations on the primary locating
surface, 2 locators on the secondary locating surface and 1 locator on the tertiary locating
plane.
2) 1 plane ad 2 planes locating for general parts with 2 holes. it uses a primary locating
rate locating of plane, a primary pin and secondary pin to restrict the freedom of a work
piece.
3) v-block locating for external cylindrical parts. 1 wide v-block or 2 short v-pads may be
used to hold the work piece. The clamping planning determines clamping surfaces and
points on the work piece and clamping components, the magnitude of each clamping
force and the clamping sequence when the stability of the work piece becomes a concern.
To bold a specific part, several design constraints may be applied. Among them, 4 main
constraints in the fixture planning are as follow.
(1)Geometrical constraints: accurate locating of a work piece should be ensured to meet
machining accuracy requirements of a work piece.
(2)Accessibility constraints: There should be no interference among fixture components,
work piece and machining tools during assembly and machining. In addition, it should be
easy to load and unload the work piece.
(3)Force constraints: The fixtures should be strong enough to resist the forces and
moments produced by clamps and machining tools. A minimum clamp force should be
specified for the work piece stability.
(4)Deformation constraints: The stiffness of a fixture system should be sufficient to keep
the work piece deformation with in the design interference.
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Rear Forward Axle Housing Snorkel Boring Position Capability Improvement

2. Parvesh Kumar et all., conducted the process capability analysis for boring operation
by understanding the concepts methodologies and making critical assumptions. As
Process-capability analysis has become an important integrated part in the applications of
statistical techniques for quality assurance. Quality assurance in mass production is
achieved using statistical process-control techniques. The process-capability analysis,
which is a SPC Technique, helps to determine the ability for manufacturing between
tolerance limits and engineering specifications. The capability analysis gives information
about the changes and tendencies of the systems during production. In this study, Control
charts for variables are implemented to achieve a good control over the process. SPC
technique was used to evaluate machines capability (cp) and process centering ( cpk) of
manufacturing process to find whether the process is capable or not. The number of
nonconforming part was determined in observed values, in short and long periods of time.
After monitoring the process a significant improvement has been experienced in terms of
increase in process capability indices and reduction in defective parts per million (ppm).
The Ishikawa Diagram for critical defeats is drawn, the root causes for each are identified
and the suitable remedial measures are suggested. Faults regarding manufacturing out-oftolerance limits were eliminated, the variability in the process and the cost due to lowquality production were reduced in the particular company. In todays competitive
market, SPC is not the most frequently used technique in small and medium-sized
companies. The most important problems in Business are that there are no trained
employees to apply it and there is insufficient investment. Consequently, SPC must be
applied widely and continuously to achieve quality improvement.
3. SHAILESH S PACHBHAI, have investigated about fixture design and assembly. In
machining fixtures, from clamping work piece deformation can be minimize and it is
essential to maintain the machining accuracy. In recent times hydraulic techniques are
usually adopting to save time and increase accuracy. Loading and unloading of work
piece in manual clamping is the time consuming process so is to reduce the set up time
and process time is the main aim of the process. Hence now days in all industry hydraulic
clamps are adopting to reduce the time consumed and increase the productivity from that
best quality of product can be obtained. The main aim for adopting the hydraulic cylinder
is to reduce the processing time and reduction in position variation while machining of a
part taking place. All the values of deformation and von misses stress calculated with
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Rear Forward Axle Housing Snorkel Boring Position Capability Improvement

ANSYS software is comparatively lower than standard values and hence, we can
conclude that design is safe. As per calculation, the proposed fixtures have a direct impact
on product quality, productivity and cost.
4. Qiang Li, M.A has investigated about fixture design and assembly, a typical fixture
design for prismatic parts consists of 3 essential elements: locators, clamps and
supporters. Locators are employed to position the work piece in the static equilibrium so
as to remove all degrees of freedom. Clamps are used to hold the work piece firmly
against the locators during the machining process. The primary design factors of fixture
clamps comprising external cuttings force and tool direction etc.., have to be taken into
account during a fixture design process. As machining fixtures subjected to external
emitting forces, the 2 fixture elements have to guarantee that the work piece is rigidly
located and assure it respectively. Representatively refers to the work piece and the
subsequent work piece can be precisely located in the same position by the fixture.

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CHAPTER 3
PROBLEM DEFINITATION

3.1 STATISTICAL QUALITY CONTROL

Statistical quality control involves the use of various methods to measure and analyze
a process. The overall objectives of SQC are
To improve the quality of process output
To reduce process variability and achieve process stability
Solving processing problem
3.1.1 THE SQC TOOLS
Quality tools can be used in all phases of production process, from the start of
product development up to product marketing and customer support. The 7 QC Tools are
simple statistical tools used for problem solving. These tools were developed by the
Quality preceptors such as Deming and Juran. Ishikawa has stated that these 7 tools can
be used to solve 95 percent of all problems. The following are the 7 QC Tools:
1) Histogram
2) Check Sheet
3) Pareto Diagram
4) Defect Concentration Diagram
5) Cause & Effect Diagram
6) Control Charts
7) Scatter Diagram
From the above 7 QC tools we make use of cause and effect diagram as it is a tool that is
useful for identifying and organizing the known or possible causes of quality, or the lack
of it. The structure provided by the diagram helps to think in a very systematic way. Some
of the benefits of constructing a Cause-and-Effect Diagram are that it
Helps determine the root causes of a problem or quality characteristics using a
structured approach.
Encourages group participation and utilizes group knowledge of the process.
Uses an orderly, easy-to-read format to diagram cause-and-effect relationships.
Indicates possible causes of variation in a process.

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Increases knowledge of the process by helping everyone to learn more about the
factors at work and how they relate.
Identifies areas where data should be collected for further study.
3.1.2 CAUSE & EFFECT DIAGRAM
A graphic tool that helps identify, sort, and display possible causes of a problem or quality
characteristic. It consists of a central stem leading to the effect (problem) with multiple
branches coming off the stem listing various groups of possible cause of the problem. In a
typical manufacturing problem, the groups may consist of five Ms - Men, Machines,
Materials, Method and Measurement. The six M Money may be added if it is relevant. In
some cases Environment is one of the main groups. Important subgroups in each of these
main groups are represented on the middle bones and these branch off further into
subsidiary causes represented as small bones. The arrows indicate the direction of the
path from the cause to the effect. Owing to its characteristic appearance it is known as
Fisherbone Diagram.

Fig 3.1: Cause and Effect Diagram

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3.2 PROBLEM DEFINITION

Fig 3.2: Rear Axle Housing

As shown in the figure there are two axes in the component
Axis of snorkel bore
Axis of axle shaft
The x and y distance between these two axis is 100.60mm and 106.66mm respectively
with the tolerance limit of 190 microns.
At the present scenario, there is a variation in the distance between the two axes due to
which the desired position of snorkel bore is not achieved with the dimensions mentioned
above.
This variation is due to the clearance in the existing u-block (0.1 mm) and bore locator
(0.5mm). Our work is reduce this clearance in order to achieve position of the snorkel
bore from the reference plane
The below figure shows the clearance that exists in various components of the machine

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1. U- Block

Fig 3.3: U-Block

2. BORE LOCATOR

Fig 3.4: Bore Locator

3.3 METHODOLOGY

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Study of the complete process of operations that are carried out in the bay.
Study of the component which is actually having a problem of varying position.
Study of the existing fixture which is causing the problem in the component.
To overcome that above problem design of a new fixture is recommended by

including ejector pins to restrict the movement of the component.

By doing the above process we would conclude that the process under consideration
of CNC machine can be improved.
3.3.1 STUDY OF COMPONENT
The casting is supplied to AAL from outside by vendors. Once the AAL receives
the component AAL personals inspect the component. If there are any problems the
component is rejected, otherwise it is accepted and it is taken through the different
process such as welding two housing halves, machining process which includes boring,
face milling, drilling etc,.
Axle housing is made up of carbon steel casting of 450Mpa tensile strength
Main chemical composition of carbon steel casting
ELEMENTS

WEIGHT(%max)
Table 3.1:

Chemical

CARBON

0.25

MANGANESE

1.20

PHOSPHOROUS

0.040

SULPHUR

0.035

SILICON

0.60

composition

Residual elements:
ELEMENTS

WEIGHT(%max

NICKEL

)
0.40

CHROMIUM

0.35

COPPER

0.40

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MOLYBDENUM

0.15

Table 3.2: Residual elements

3.3.2 STUDY OF EXISTING FIXTURE

Fig 3.5: Bore Locator

Fig 3.6: U-Block

The above figure shows the fixture which is currently used for machining
operation of axle housing. As mentioned in the problem definition the desired distance
between the axis of the shaft and the axis of snorkel bore to be achieved cannot be done
using this fixture due to clearance between the component and the fixture body. Therefore
it is necessary to design a new fixture which provides all the requirements in order to
overcome these problems and to achieve desired position of snorkel bore.
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3.4 OBJECTIVE
The current bore locator and U-block in use leads to above mentioned problems.
So the main objective of our project is to eliminate this problem and

To improve the process capability.

To optimize the clearance between the component and U-block.
To optimize clearance between component and bore locator.
To achieve accuracy in dimensional position of the snorkel bore.
To obtain repeatability in tolerance.

CHAPTER-4
DESIGN OF FIXTURE

4.2 DESIGN AND MODELLING OF BORE LOCATOR AND V-BLOCK

The current project work is aimed at designing fixture to carryout boring and surface
milling operations
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The important objective of this fixture is to reduce the clearance between the component
and the fixture body, hence it is necessary ejector pins to the bore locator and V shaped
block instead of U shaped block.
The successful design of fixture is the result of designers ability to analyze all the
operations performed on the component to incorporate design feature in the fixture that
eliminates the difficulties or problems associated with such operations
FACTORS TO BE CONSIDERED BEFORE DESIGNING
The successful design of a fixture depends upon the analysis of several factors which
have to be carefully studied before the actual work is taken ahead.

Study of component
Study the type and capacity of machine
Study the locating element
Study the clamping elements
Study the ejecting devices
Study the power devices for operating clamping elements
Study clearance required between fixtures
Study safety devices
Study of rigidity and vibration problems
Study the method of manufacturing of fixture base, body or frame.

4.1.2 FACTORS CONSIDERED FOR DESIGN

There are 5 factors considered in design of fixture,
1. Location
Ensure that work is given with desired constraint.
Introduce fool proofing devices such as fouling pins, projections etc, to prevent
incorrect positioning of work piece
Make location progressive.
2. Clamping
Position of clamper to be best resistance to cutting forces without causing deformation

3.

4.

5.

to work piece.
If possible make the clamps integral with fixture body.
Stability and Rigidity
Make fixture as rigid as required for operation.
Provide means of positioning and bolting the equipment to machine tool.
Clearance
Allow ample clearance to allow for variation of work piece size.
Allow ample clearance for operators to handle.
Handling
Make equipment easy to handle and ensure that no sharp corners are present and
providing lifting points.

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4.2 V BLOCK
PART 1: BASE PLATE

Figure 4.1: Base Plate

PART - 2 : GUIDE ROD

Figure 4.2: GUIDE ROD

PART- 3: V-BLOCK BODY

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Figure 4.3: BLOCK BODY

PART - 4: WEAR PAD

Figure 4.4: WEAR PAD

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4.2.1 V- BLOCK ASSEMBLY

Figure 4.5: V-Block assembly

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4.2.2 BILL OF MATERIALS FOR V-BLOCK
A bill of material (BOM) is a list of the raw materials, sub-assemblies, sub-components,
components, parts and quantities of each needed to manufacture an end product. No
physical dimension is described in a BOM.

PART NO

DESCRIPTION

MATERIAL

QUANTITY

Base Plate

Mild Steel

Guide Rod

EN 31

V-Block Body

Mild Steel

Wear Pad

EN 31

Nut

Mild Steel

Table 4.1: Bill of materials for V-block

4.3 FIXTURE
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PART-1: PISTON CAM ATTACHMENT

Figure
PISTON

4.6:
CAM

ATTACHMENT
PART-2: SLIDE SHAFT GUIDE

Figure 4.7: SLIDE SHAFT GUIDE

PART-3: LOCKING PLATE

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Figure 4.8: LOCKING PLATE

PART-4: PLATE

Figure 4.9: PLATE

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PART-5: SLIDE SHAFT CHANGE PART

Figure 4.10: SLIDE SHAFT CHANGE PART

PART-6: TOP PLATE

Figure 4.11: TOP PLATE

PART-7: BASE PLATE
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Figure 4.12: BASE PLATE

PART - 8: SLIDE SHAFT

Figure 4.13: SLIDE SHAFT

Part 9: SLIDE SHAFT BUSH
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Figure 4.14: SLIDE SHAFT BUSH

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4.3.1 FIXTURE ASSEMBLY WITH COMPONENT

Figure 4.15: FIXTURE ASSEMBLY WITH COMPONENT

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4.3.2 BILL OF MATERIALS FOR FIXTURE
PART NO

DESCRIPTION

MATERIAL

QUANTITY

Piston Cam Attachment

EN 353

Slide Shaft Guide

EN 353

Locking Plate

Mild Plate

Plate

Mild Steel

Slide Shaft Change Part

EN 353

Top Plate

Mild Steel

Base Plate

Mild Steel

Slide Shaft

EN 353

Slide Shaft Guide Bush

EN 353

Table 4.2: Bill of materials for fixture

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4.4 FINAL ASSEMBLY OF COMPONENT WITH FIXTURE AND V-BLOCK

Figure 4.16: ASSEMBLY OF COMPOMEMT WITH FIXTURE AND V-BLOCK

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CHAPTER 5
COST AND ESTIMINATION

5.1 WEIGHT CALCULATION OF A FIXTURE

ITEM
NUMBE

COMPONENT

R
1

QUANTITY VOLUME
(mm3)

DENSITY*10
6

WEIGHT

(Kg/mm3)
1

1413700

7.85

11.09

Base Plate
Vertical body
outside

1060287

7.85

83.23

Vertical body

570200.2

7.85

17.7

Top plate
Piston cam

706858.3

7.85

5.54

Attachment

712540.6

7.85

5.59

162601.4

7.85

7.62

30766.21

7.85

1.449

171051.59

7.85

5.37

22790.6

7.85

1.43

1590431.6

7.85

12.48

6
7
8
9

Slide shaft
guide
Slide shaft
Slide Shaft
Guide bush
Slide shaft

10

Change part
Rough locator

11

V block

239601.6

7.85

1.88

12

Guide Rod
V block Base

273220.48

7.85

4.285

714924.35

7.85

5.61

3000.44

7.85

0.471

12000.56

7.85

0.3768

13
14

plate
Wear Pad

15

Nut

Table 5.1: Weight calculation of fixture

Department of Mechanical Engineering, MIT, Mysore.

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Rear Forward Axle Housing Snorkel Boring Position Capability Improvement

5.2 COST CALCULATION OF FIXTURE
ITEM
NUMBE

VOLUME
COMPONENTT QUANTITY (mm3)

COST

(Kg/mm3)

R
1

DENSITY*10

1413700

7.85

Base Plate
Vertical body
outside

1060287

7.85

Vertical body

570200.2

7.85

885.6

Top plate
Piston cam

706858.3

7.85

277

Attachment

712540.6

7.85

4246.8

162601.4

7.85

34477.9

30766.21

7.85

8714.64

171051.59

7.85

16198.52

22790.6

7.85

8627.55

6
7
8
9

Slide shaft
guide
Slide shaft
Slide Shaft
Guide bush
Slide shaft
Change part

554.5
4161.5

9414.614

10

Rough locator

1590431.6

7.85

11

V block

239601.6

7.85

456.44

12

Guide Rod
V block Base

273220.48

7.85

2059.22

714924.35

7.85

1346.08

3000.44

7.85

113.04

12000.56

7.85

180.64

13
14

plate
Wear Pad

15

Nut

Table 5.2: Cost calculation of fixture

SPECIMEN CALCULATION:
FIXTURE COST ESTIMATION
Total Cost of Fixture = Material Cost + Labour Cost+ Cylinder Cost
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Rear Forward Axle Housing Snorkel Boring Position Capability Improvement

=85531.32+12000+8500=106031.32
V-BLOCK COST ESTIMATION
Total Cost of V-block = Material Cost + Labour Cost
=4155.42+1500=5655.42

5.3 PROCESS SHEET:

OPERATIONS

PROCESS OF OPERATIONS

Department of Mechanical Engineering, MIT, Mysore.

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Rear Forward Axle Housing Snorkel Boring Position Capability Improvement

Shot Blasting
Tack Welding
Seam Welding
Straddle Facing
Ring and Cover
Cold Swage
Flange Facing
Friction Welding
Flange Welding
Strengthening
Centre less Grinding
Deburring

It is the process used to polish the metal surface

It is the temporary weld used to create initial joint Between
two housing halves
It is the process in which the 2 halves are completely welded
It is a process in which material of both sides are removed by
multiple tools mounted on the saddle
In this process the ring is welded to one side of the housing
and cover is welded to the other end of the housing.
In this process outer edge of the housing is pressed to
required Flange diameter
In this process removal of material is carried out at both the
faces of the housing
In this process the spindle is welded to the housing. Due to
the friction between spindle and housing end.
This is a process in which the flange is welded to the housing
It is a process of testing strength of a welded joint by applying
heavy load on the welded part.
It is the machining process which removes the material from
the Work piece using abrasive cutting
It is the process of removing burrs remains on the surface of
the Housing
Table 5.3: Process Sheet

Department of Mechanical Engineering, MIT, Mysore.

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Rear Forward Axle Housing Snorkel Boring Position Capability Improvement

CONCLUSION
A rear axle with a snorkel bore part number C-3121-N-C612 is used in heavy duty
vehicles. Snorkel bore is present in forward rear axle through which the power is
transmitted to the backward rear axle.
At the present scenario, there is a variation in the distance between the two axes due to
which the desired position of snorkel bore is not achieved, as there was some clearance
between the component and the fixture due to which it is unable to machine the
component as per required dimensions and tolerance limit, thus a new fixture is to be
designed to eliminate the clearance and to obtain the desired position of the snorkel bore.
By introducing the new Fixture and V-Block following advantages can be achieved.
Machining dimensional deviations eliminated and component is as per drawing
Required tolerance and accuracy achieved
Operation time is reduced and productivity is increased.

Department of Mechanical Engineering, MIT, Mysore.

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Rear Forward Axle Housing Snorkel Boring Position Capability Improvement

REFERENCES
1. XiumeiKang and Qingjin Peng Fixture Feasibility: Methods and Techniques for
Fixture Planning, Volume 5, Issue 1-4, January 2008, pages 424-433
2. Parvesh Kumar Rajvanshi , Dr. R.M.Belokar, Improving the Process Capability of a
Boring Operation by the Application of Statistical Techniques, International Journal of
Scientific & Engineering Research Volume 3, Issue 5, May-2012 1 ISSN 2229-5518
3. Shailesh S Pachbhai, Laukik P Raut, Design and Development of Hydraulic Fixture
for Machining Hydraulic Lift Housing, Intl journal of Mechanical Engineering and
Robotics, Vol. 3, No. 3, July, 2014. ISSN 2278 0149.
4. Qiang Li, M.A Virtual Reality for Fixture Design and Assembly, University of
Nottingham October 2008.

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Rear Forward Axle Housing Snorkel Boring Position Capability Improvement

Contents
INTRODUCTION...............................................................................................................1
1.1 AXLE.........................................................................................................................1
1.2 AXLE HOUSING......................................................................................................2
1.3 REAR AXLE..............................................................................................................2
1.4 SNORKEL BORE......................................................................................................3
1.5 PROCESS CAPABILITY..........................................................................................4
1.5.1 CAPABILITY INDICES.........................................................................................4
1.6 FIXTURE...................................................................................................................5
1.6.1 TYPES OF FIXTURE.........................................................................................6
1.6.2 CLAMPING........................................................................................................6
1.6.3 LOCATION.........................................................................................................7
LITERATURE SURVEY.....................................................................................................8
PROBLEM DEFINITATION.............................................................................................11
3.1 STATISTICAL QUALITY CONTROL...................................................................11
3.1.1 THE SQC TOOLS.............................................................................................11
3.1.2 CAUSE & EFFECT DIAGRAM......................................................................12
3.2 PROBLEM DEFINITION.......................................................................................13
3.3 METHODOLOGY...................................................................................................15
3.3.1 STUDY OF COMPONENT..............................................................................15
3.3.2 STUDY OF EXISTING FIXTURE..................................................................16
3.4 OBJECTIVE............................................................................................................17
DESIGN OF FIXTURE.....................................................................................................18
4.2

DESIGN AND MODELLING OF BORE LOCATOR AND V-BLOCK...........18

FACTORS TO BE CONSIDERED BEFORE DESIGNING....................................18

4.1.2 FACTORS CONSIDERED FOR DESIGN......................................................18
4.2 V BLOCK.............................................................................................................20
4.2.2 BILL OF MATERIALS FOR V-BLOCK.........................................................23
4.3 FIXTURE.................................................................................................................24
4.3.1 FIXTURE ASSEMBLY WITH COMPONENT...............................................29
4.3.2 BILL OF MATERIALS FOR FIXTURE..........................................................30
4.4 FINAL ASSEMBLY OF COMPONENT WITH FIXTURE AND V-BLOCK....31
COST AND ESTIMINATION...........................................................................................32
5.1 WEIGHT CALCULATION OF A FIXTURE..........................................................32
5.2 COST CALCULATION OF FIXTURE...................................................................32
5.3 PROCESS SHEET:..................................................................................................35
CONCLUSION..................................................................................................................36
REFERENCES...................................................................................................................37
Department of Mechanical Engineering, MIT, Mysore.

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Rear Forward Axle Housing Snorkel Boring Position Capability Improvement

Department of Mechanical Engineering, MIT, Mysore.

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