PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

CHAPTER NO 1
COMPANY PROFILE

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

COMPANY PROFILE
HISTORY

The company has long history which dates back to the year 1985, when m/s
Turner Hoare & co started it’s activity in imports and exports of traditional Indian
consumer goods. I n 1968, m/s Turner Hoare & Corporate. Took over another company,
m/s east Asiatic Corporate. and realizing market potential entered into execution of
engineering project like hydro pneumatic ash handling system, mechanical cleaning
rakes, vibroscreen travelling water screens and bagged import substitution award
twice.

In 1977, with equity participation of DANA corporation USA, the company

went into technical collaboration to manufacture automotive components like
propeller shafts, UJ kits, automotive clutches. For this purpose the plant was set up
in Nashik. In line with the tradition followed by DANA corporation the company
was rechristened by name Mahindra Spicer limited, Spicer being the worldwide trade
name of DANA Corporate.

MAHINDRA SONA LTD.

The company is situated at Nashik at 180 kms. North east of Mumbai and employs
about 350 people. The constructed area is over 11000 sq meters. The company engaged in
designing and manufacturing a wide range of auto ancillary products such as
propeller shafts, clutches, UJ kits, steering joints, steering system parts, axles and
components thereof. The company is original supplier to almost all vehicles
manufacture in India.

The companies prestigious customers include Arvin motor, USA ( commercial

vehicles ), Ashok Leyland, Tata motors, Mahindra & Mahindra ltd, forces motors,
Rane TRW steering , ZF steering & JCB India & UK.

The products are supplied as proprietary and for many of its products; the
company enjoys confidence of customers, under self-certification scheme. The
company also caters to spare parts market demands.

The unit has EOH & S management system to maintain the performance of EOH
& S and implement continual improvements. Manufacturing facilities include many CNC

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

machines and SPM. Inspection is carried out by latest inspection techniques & testing
equipments. The company firmly believes that the EOH & S policy and objectives
can only be achieved through the direction given by its management and the
involvement of its people. The plans now in places, which are supported by its
people, will secure a successful future for the company as for its customers.

MILESTONES OF MSL

1968 collaboration agreement between Mahindra (MUV & tractor mfr,

2003 incomes $1 billion) and Dana co. USA for manufacturing
Of clutches.
1976 Collaboration agreement between Mahindra and Dana co. for
Manufacturing propeller shafts, axle shafts and universal joints
In a joint venture company Mahindra Spicer ltd.
1979 Inauguration of Nashik works.
1984 Merger of Mahindra Spicer ltd. With Mahindra & Mahindra ltd.
Becomes MSL divisions of Mahindra & Mahindra ltd.
1986 Dana collaboration ends.
1994 Formation of Mahindra sona ltd. Restructure of MSL divisions as
MSL.
1995 ISO9001 certification by RWTUV, Germany.
1996 Scientific work measurement technique (MOST) adopted.
1999 QS9000 certification by RWTUV, Germany.
1999 Exports to USA begin.
2002 Exports to Indonesia begin.
Group kaizen activity launched.
2003 Exports to Egypt & UK begin.
2004 TPM kicks off.
2005 QMS up gradation to ISO/TS16949.

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PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

CHAPTER NO 2
INTRODUCTION

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

INTRODUCTION

The lathe is one of the oldest machine tools and came into existence from the early tree
lathe which was then a device for rotating and machining a piece of work held between two
adjacent trees. A rope wound round the work with its one end being pulled by a man caused
the job to rotate intermittently with its further development a strip of wood called “lath” was
used to support the rope and that is how the machine came to be known as “lathe”.
This device continued to develop through centuries and in the year 1797, HENRY
MAUDSLAY an Englishman, designed the first screw cutting lathe which is the forerunner
of the present day high speed heavy duty production lathe, a machine tool which has
practically given shape to the present day civilization by building machines and industries.
Eccentric work is work that is turned off center, or not on the normal center axis. An engine
crankshaft is a good example of an eccentric workpiece. Crankshafts normally have a main
center axis, called a main journal, and offset axes, which produce the throw and the
eccentric diameters of the mechanism. An eccentric shaft may have two or more diameters
and several different center axes. The amount of eccentricity, or half of the throw, is the
linear distance that a set of center holes has been offset from the normal center axis of the
workpiece. Eccentric turning on the lathe is used for the following eccentric turning
situations. When the throw is large enough to allow all centers to located on the workpiece
at the same time. When the throw is too small allow all centers to fit into the end of a
workpiece at the same time. When the throw is largethen all centers cannot be located on
the work, or in other words, a throw larger than the largest diameter of the workpiece.

The company” MAHINDRA SONA PVT. LTD” were producing the part called flange
yoke by conventional method. For manufacturing the flange yoke they were using 5
machines

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

The company” MAHINDRA SONA PVT. LTD” were producing the part called
flange yoke by conventional method. For manufacturing the flange yoke they were
using 5 machines. The operations done on it are as follows:-

 Cross-hole drilling
 Boring
 Pilot diameter turning
 Bolt hole drilling
 Spot facing
 Bolt hole reaming
 Cross hole grooving
 Chamfering
 Deburring

The machines are used as follows:-

 CNC Auto Lathe Machine

 CNC Boring and Grooving Machine
 Vertical Milling Machine
 Chamfering Machine
 Deburring Machine.

So as to increase the productivity we have to manufacture the part using

minimum machines. For that they have chosen the all path to be manufacture a
flange yoke 1310. Our aim is to re-generate a simple path for flange yoke.

According to the requirement we suggest a some machines for the eliminate

the trial & error method using for a placing pilot diameter turning tool in tool holder,
designing the fixture at chamfering machine to hold the flange yoke. In view of the

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

high investment and tooling cost of a CNC machine, the cutting and ideal time should be
optimize by considering the tool consumption and the non machining time cost components.

The aim this project is to be determining optimum machining conditions, operation

sequence, and critical path for operational activity to minimize non machining time. The
project is carried out by applying the fish bone method of root cause analysis on planning
and manufacturing process of flange yoke 1310. Finding of this project shows that wrong
process planning and routing of process in misalignment conditions .Modified process
planning and sequence of manufacturing operations with the use of CNC machines as well
as SPM.

In boring and grooving the part has create more chips which is to be accomplished
effect to the tool whenever the tool life is goes decreasing. We suggest a lubrications by the
forcefully damped and also the pneumatic air gun is to be used to clean the fixture for a
improving the productivity and high quality level of product.

In company the final operation performed on flange yoke 1310 is Deburring

operation which required more power and from which more fatigue to operator is create
then we suggest some small equipment for doing Deburring operation it not required power
and also it is manually operated by using that equipment less fatigue to operator and it is
easy to handle.

Objective of the Study:

The following objectives could be achieved by using the advanced techniques:

 Reduction in operator Fatigue.
 Reduce the throughput time.
 Increase in production.
 Prevention of workers accidents.
 High accuracy obtained.
 Reduction in material handling
 Reduction in cost of production.

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

CHAPTER NO 3
NEED OF PROJECT

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

NEED OF PROJECT
The company has to create a challenge for whom to study the whole process
which manufactures a flange yoke 1310.We studied that the process is to be carried by
conventional machine on flange yoke 1310. The main need of project is to plan the process
in easy way for performing the operation on flange yoke 1310.which required less time and
also increasing the productivity of the company.

In an organization the intention behind every task is to increase in the

profit and to increase productivity. Productivity can be increased by using modern
version of machines and using some different process plans & techniques. Also used
some fixture for reduction in process time of operation.

Mahindra sona is the largest manufacturer of automobile accessories the

company manufactures universal joint kits, propeller shafts, Carden shafts, Drive shafts,
Flange yoke 1310 ,Flange yoke 1350, Axles, Sliding joints, clutches etc.

From these products one part of universal joints (flange yoke) was
manufactured by using conventional machines. There are nine process involved in
manufacturing of flange yoke. The process is

 Cross-hole drilling
 Boring
 Pilot diameter turning
 Bolt hole drilling
 Spot facing
 Bolt hole reaming
 Cross hole grooving
 Chamfering
 Deburring

As all machines are conventional consumes more time to manufacture the part, as
cycle time of each part is increased hence it hampers productivity. Minimizing the
use of conventional machines we can increase productivity.

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

Here comes the need of our project as decided the product should be manufactured
in minimum cycle time, so to fulfil this requirement. We have designed one or
more than fixture which helps in combining the operations i.e. in past after each
operation part has to be loaded and unloaded from one machine to another. Now
company fixture uses at chamfering machines, due to which loading & unloading
time is eliminated and suggest a machines or tool used for the pilot diameter
turning operation.

Man:-
Machine:-
Five operators deployed
Operation wise five
hence chance of individual
different machines
mistake/ error

(1310 F) flange
yoke
improvement in
quality,
productivity

Material:
Method:-
No effect.
Each of five machines & each operation has its
own process chart. Loading & unloading,
setting involved. Time consuming process.

Fig. no.:- 1 Fish Bone Method

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PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

CHAPTER NO 4
COMPANY
SPECIFICATIONS

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

COMPANY SPECIFICATIONS

Everything, which is manufacture under given specifications, completely fulfils

the requirement of the concern. Our project in Mahindra sona was also having some
specifications. For the specifications we have to be considered:

 Job on which machining should be done.

 The VMC on which job is manufactured.

As the job has freedom to move in six directions, for proper machining on it,
these all motions should be restricted. Following are some parts of fixture with their
specifications.

 Base plate :- specifications of company was the dimensions of bed of VMC

on which base plate is fixed.
 Pilot locator :- specifications of company was the diameter of flange.
 Bracket :- specifications given was the overall height of flange yoke.
 Alignment mandrel: - specifications were the diameter of cross hole.

Above discussed specifications are taken by considering flange yoke, now some
specifications of overall fixture by considering VMC

 The specifications give to height of fixture is the distance between the tool
and table of machine.
 Width related specifications considering according to width of bed.

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PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

CHAPTER NO 5
PROJECT
SPECIFICATIONS

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

PROJECT SPECIFICATIONS

To accomplish the project, there are certain specifications put forward to the
company on the basis of which the project is to be designed, which are as follows,

Sr. No. Particulars Specifications

Problem faced:- Manufacture the part using

1 More machines being used, cycle time is minimum number of
also more & material handling is high. machines.

2 Manual working:- Manufacture a part having

Causes less accuracy, more handling time good accuracy
& more cycle time.

3 Need of project:- Use fixture to improve

To plan the process path & reduce the productivity & high
manufacturing & material handling time. accuracy

4 Solution suggested Use fixture & Craig lathe

for pilot diameter turning
operation
5 Type of fixture Four hole-Chamfering

6 Operation Easy & less fatigue to

operator.

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

CHAPTER NO 6
EXISTING
MANUFACTURING
PROCESS

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

EXISTING MANUFACTURING PROCESS

Existing Manufacturing Operation of Flange Yoke
Operation no Description

- Forging (c-45) as per Forging drawing.

1 Cross hole drilling

2 Rough cutting

3 Finish cutting

4 Pilot diameter turning

5 Boring and grooving

6 Four hole facing

7 Four hole drilling

8 Four hole tapping

9 chamfering

10 Deburring

11 Inspection and packing

12 Dispatch

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

Flow Diagram of Existing Manufacturing Process:

Forging

Operation
OperationNo.1:-
no.1:-Cross
cross Hole
hole drilling
Drilling

Operation No. 2:- Rough Cutting

Operation No. 3:- Finish Cutting

Operation No. 4:- Pilot Diameter Turning

Operation No. 5:- Boring and Grooving

Operation No. 6:- Four Hole Facing

Operation No. 7:- Four Hole Drilling

Operation No. 8:- Four Hole Tapping

Operation No. 9:- Chamfering

Operation No. 10:- Deburring

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

Operation No. 11:- Inspection And Packing

Dispatch

METHODOLOGY
The methodology adopted for present work was as follows:
 Studying the existing manufacturing process of flange yoke 1310 used in light
commercial vehicle which is the assembly for in universal joint kits and also the
propeller shafts.
 Determination of process plan for flange yoke 1310 in which the fault is to be
recommended at which the time will be consumed and the increase productivity.
 Types of processing causing the defect in the part:
 Tool used at the CNC auto lathe machine for pilot diameter turning
operation,
 Suggested design fixture for chamfering machine
 Deburring equipment for removing the burr from the part
 Suggest process plan for the flange yoke 1310.

ANALYSIS OF DEFECTS
Analysis of data is an important task. The production data was collected of six
months and analysis of defects was for the two processes as given below:

Tool Used At the CNC Auto Lathe Machine for Pilot Diameter Turning Operation
In pilot diameter turning process, the rejection occurred due to:
 Incorrect setting up of tool on the machine,
 Incorrectly ground tool angles such as rake angle, clearance angle and nose
radius,
 Wear of cutting tool,
 Incorrect cutting conditions such as depth of cut and feed rate,
 Quality of tool.
 Skilled operator is required
 Prevent number of accidents.
 Quality of coolant.

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

 Cost of tool.

The table 1 shows the month wise description of defectives pieces of flange yoke 1310 in
pilot diameter turning process.

Months Aug Sept Nov Dec Jan Feb

Number of
components
Production 3000 3000 3000 3000 3000 3000
Defective parts 41 30 36 32 28 21
% Defective parts 1.366667 1 1.2 1.06667 0.93333 0.7
Average 1.04444

Table no 1: Defective Components in Pilot Diameter Turning Operation

Deburring Equipment for Removing the Burr from the Part

In Deburring process, process the rejection was due to high, mishandling of component and
less skilled operator.
 Incorrectly ground tool angles such as rake angle, clearance angle and nose
radius,
 Wear of cutting tool,
 Incorrect cutting conditions such as depth of cut and feed rate,
 Quality of tool.
 Skilled operator is required
 Prevent number of accidents.
 Quality of coolant.
 Cost of tool.

Months Aug Sept Nov Dec Jan Feb

Number of
components
Production 3000 3000 3000 3000 3000 3000
Defective parts 50 60 62 59 48 45
% Defective parts 1.666667 2 2.06667 1.96667 1.6 1.5
Average 1.8

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

Table no 2: Deburring Equipment for Removing the Burr from the Part

CHAPTER NO 7
MODIFYING
MANUFACTURING
PROCESS

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

MODIFYING MANUFACTURING PROCESS

In the modified process, boring and grooving, and Deburring process is done after
the cross hole drilling operations i.e. the component is for rough cutting, finish cutting, pilot
diameter turning operation is carried out on CNC auto lathe machine. Next operation is to
be carried at vertical milling machine which includes the four hole facing, drilling, tapping
operations. The part is to send on chamfering operation.

Modifying Manufacturing Operation of Flange Yoke

Operation no Description

- Forging :( c-45) as per Forging drawing.

1 Cross hole drilling

2 Boring and grooving

3 Deburring

4 Rough cutting

5 Finish cutting

6 Pilot diameter turning

7 Four hole facing

8 Four hole drilling

9 Four hole tapping

10 Chamfering

11 Inspection and packing

12 Dispatch

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

Flow Diagram of Modifying Manufacturing Process:

Forging

Operation No.1:- Cross Hole Drilling

Operation No. 2:- Boring and Grooving

Operation no. 3:- Deburring

Operation No. 4:- Rough Cutting

Operation No. 5:- Finish Cutting

Operation No. 6:- Pilot Diameter Turning

Operation No. 7:- Four Hole Facing

Operation No. 8:- Four Hole Drilling

Operation No. 9:- Four Hole Tapping

Operation no. 10:- Chamfering

Operation No. 11:- Inspection And Packing 22

Dispatch
 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

COMPARISION OF MANUFACTURING PROCESS

Forging Forging

Operation No.1:- Cross Hole Drilling Operation No.1:- Cross Hole Drilling

Operation No. 2:- Rough Cutting Operation No. 2:- Rough Cutting

Operation No. 3:- Finish Cutting

Operation no. 3:- Deburring

Operation No. 4:- Pilot Diameter Operation No. 4:- Rough Cutting
Turning

Operation No. 5:- Boring And Grooving Operation No. 5:- Finish Cutting

Operation No. 6:- Four Hole Facing Operation No. 6:- Pilot Diameter
Turning

Operation No. 7:- Four Hole Drilling Operation No. 7:- Four Hole Facing

Operation No. 8:- Four Hole Tapping Operation No. 8:- Four Hole Drilling

Operation No. 9:- Chamfering Operation No. 9:- Four Hole Tapping

Operation no. 10:- Deburring Operation No. 10:- Chamfering

Operation No. 11:- Inspection and Packing Operation No.11:- Inspection and Packing

Dispatch Dispatch

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

CHAPTER NO 8
TIME CALCULATION
ACTIVITY CHARTS

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

TIME CALCULATION ACTIVITY CHART

CNC Boring and Grooving Machine time calculation

Sr.No Operation Time In Sec

1 Job Loading 8

2 Boring 30

Job Shift For Internal

3
Grooving
8

4 Internal Grooving 28

5 Job Unloading 2

6 Inspection 10

The production rate:

1 hour = 58 parts produce

The shift operator will be produce 500 parts/shift

The daily production is that company is 1000 parts

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

CNC AUTO LATHE MACHINE TIME CALCULATION

Sr.No Operation Time In Sec

1 Job Loading 14

2 Rough Cut 19

3 Finish Cut 10

4 Pilot Dia.and Chamfering 10

5 Job Unloading 7

6 Inspection 10

The production rate:

1 hour = 72 parts produce

The shift operator will be produce 500 parts/shift

The daily production is that company is 1000 parts

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

VERTICAL MILLING MACHINE TIME CALCULATION

Sr.No Operation Time In Sec

1 Job Loading 47

2 For Hole Facing 75

3 For Hole Drilling 32

5 Job Unloading 20

6 Inspection 27

The production rate:

1 hour = 53 parts produce

The shift operator will be produce 450 parts/shift

The daily production is that company is 900 parts

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

CHAMFERING MACHINE TIME CALCULATION

Operation
Sr.No Time In Sec

1 Job Loading 3

2 Chamfering 8

3 Job Unloading 3

4 Inspection 3

The production rate:

1 hour = 95 parts produce

The shift operator will be produce 750 parts/shift

The daily production is that company is 1500 parts

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

CHAPTER NO 9
MULTIPLE ACTIVITY
CHARTS

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

MULTIPLE ACTIVITY CHART

Multiple Activity Chart for CNC Boring and Grooving Machine

Operation Time Operator Machine Operation

1
2
3
Load 4
5
6
7
8
Unload 9
10
11
12 Operation
13
14
Inspection 15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

Multiple Activity Chart for CNC Auto Lathe Machine

Operation Time Operator Machine Operation
1
2
3
4

Job Loading(14 Sec)

5
6
7

Rough Cut(19sec)
8
9
10
11
12
13
14
15
Unloading(7sec)

16
17
Job

18
19
20
21
22

Finish Cut(10)
23
Inspection(10sec)

24
25
26
27
28
29
30
Pilot Ø & Chamfering

31
32
33
34
35
36
37
38
39

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

Multiple Activity Chart for Vertical Milling Machine

Operation Time Operator Machine Operation
0
2
4
6
8
10
12
14
16
18 Facing And
20 Drilling
22
Load 24 Operation
( 48 Sec) 26 ( 107 Sec)
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
Unload 58
(28 Sec) 60
62
64
66
68
70
72
74
76
78
Inspection 80
( 24 Sec) 82
84
86
88
90
92
94
96
98
100
102
104
106
108
Idle 110
( 39 Sec) 112
114
116
118
120 Pallet And Tool
122 Change
124 (26 Sec)
126
128
130
132
134

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

Multiple Activity Chart for Chamfering Machine

Operation Time Operator Machine Opertion

1

Unloadin Loading
g (3sec) (3sec)
Job
2

Chamfering(8sec)
3
4

Job
5
Inspection 6
(2sec) 7
8
9

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PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

CHAPTER NO 10
FLOW CHARTS

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

FLOW CHART
Flow Chart for CNC Boring and Grooving Machine

Task: Boring and Grooving Operation

Chart Begins: Load the component

Chart End: Unload the component

Charted By:

Date:

Boring Operation
1

1 Shift for internal grooving

Internal Grooving Operation

2
2 Transport Summary
2
2
2 = Operation = 2
21
Inspection
= Inspection =1

Storage = Storage = 1
1
= Transport =2

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

Flow Chart for CNC Auto Lathe Machine

Task: Pilot Diameter Turning

Chart Begins: Load the component

Chart End: Unload the component

Charted By:

Date:

1 Rough Cut

2
Finish Cut

Pilot Diameter Cut

3
Summary

1 Transport

Inspection
1
1 = Operation = 3

= Inspection = 1
Storage
1 = Storage = 1

= Transport = 1

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

Flow Chart of Vertical Milling Machine

Task: Chamfering Operation

Chart Begins: Load the component
Chart End: Unload the component
Charted By:
Date:

Four hole facing

1

1 Shift for next operation

Four hole drilling

2

2 Transport
Summary
1
Inspection

= Operation = 1
1 Storage
= Inspection = 1

= Storage = 1

= Transport = 1

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

Flow Chart of chamfering Machine

Task: Chamfering Operation

Chart Begins: Load the component

Chart End: Unload the component

Charted By:

Date:

Chamfering
1
Transport
1
Summary

1 Inspection
= Operation = 1

Storage = Inspection = 1
1
= Storage = 1

= Transport = 1

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

CHAPTER NO 11
SUGGEST FIXTURE
DESIGN

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

SUGGEST FIXTURE DESIGN

Principles of jigs and fixture design
Following are the essential factors which must be considered in designing of fixture

 Study the work piece

 Study the machine tool
 Study of the locating elements
 Study of the loading and unloading system
 Study of clamping arrangement
 Study of indexing system and devices
 Study of tool setting and guiding elements
 Study of ejection system
 Study of table firing arrangement
 Study the methods by which the fixtures are manufactured.

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

Principal of Designing:
Locating principal:

The question of properly location the supporting, and clamping the work is important since the
overall accuracy is primarily dependant on the accuracy with which the work piece is consistently
located within the fixture. There must be no movement of work piece while machining locating
surface to the establishment of proper relationship between work piece and the fixture. The function
of clamping is to exert the force to press the work piece against the locating surface and holds it
there against the action of cutting force.

The six degree of freedom:

The fix illustrate the body is in the free space. A body in this condition has six degree of freedom;
three of those are freedoms of translations and three are freedom of rotations. Consider the possible
movements of the free body shown, with respect to the three mutually perpendicular axes ‘X-X’, ‘Y-
Y’ and ‘Z’

It has three freedom of translation

Move along ‘X-X’

Move along ‘Y-Y’

Move along ‘Z-Z’

Three freedoms of rotation

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

Rotate about ‘X-X’

Rotate about ‘Y-Y’

Rotate about ‘Z-Z’

The duty of locating system:

The locating system must in conjunction with the clamping system, completely

constrained the work piece or eliminate as many of the six degree of freedom to complete

operation with accuracy.

The six point locating principle (3-2-1 principle):

The work piece is resting of the tree pins 1, 2, and 3 which are inserted in the base of
body of the work. The work piece cannot rotate about the axis ‘X-X’ and ‘Z-Z’ it also cannot move
down. In this way five types of motion are restricted. Two more pins 4 and 5 are inserted in a fixed
body, in a plane perpendicular to the plane containing pins 1, 2, 3. Now the work piece cannot rotate
about the 'Y-Y' axes and also cannot move towards the left. Hence the addition of pins 4 and 5
restrict the three more types of motion. Another pin 6 the second vertical faces of the fixed body
arrest one more motion thus 9 motions are restricted. The remaining motion are restricted by
clamping devices the above method of location the work piece in a fixture is called 3-2-1 principle
of "six point" location principle.

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

CHAMFERING MACHINE TOOL HEADS

Fig.no.2: Chamfering Machine

Multiple spindle chamfering heads can be fixed in mostly all chamfering

machines. The machine should a quill feed or like radial chamfering machine in
which the external spindle for longitudinal as well as radial movement and internal
for rotary action of the spindle. Multiple spindle heads will increase the production
as many spindle you add in head and also depends upon the components. It can
double or triple your chamfering/drilling/tapping/reaming operations by
simultaneously chamfering countersinking, reaming or tapping two or more holes in
one operation. Multi-spindle heads have proved to be the most versatile method to
chamfer / tap / ream/ chamfer in numbers of holes. Multi chamfer heads (Multiple
Spindle Chamfer Head) can be mounted on any standard chamfering machines with
suitable adapters and drive dogs. Main housing is made up of Aluminium casting
which is precisely machined. All rotating parts are hardened and ground.
Changeover of PCD of the spindle can be set easily and accurately by jigs. Spindle
run on needle and thrust bearings. IN multi spindle chamfering heads chamfer
revolution is usually identical with machine rpm.

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

Functional Layout

VMC CNC

CNC Auto
VMC Lathe

Boring
VMC And
Grooving

Boring
VMC And
Grooving Chamfering

VMC
Deburring

VMC

Table no. 3: Functional Layout

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

LINE/ PROCESS LAYOUT

CNC Drilling
Machine

CNC Auto Lathe

Machine

CNC Boring and

Grooving
Machine

Vertical Milling
Machine

Chamfering
Machine

Deburring
Machine

Table no. 4: Line Layout

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

CHAPTER 12
MATERIAL SELECTION

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

MATERIAL SELECTION

Component Material
Sr. No. Requirement & Properties
Name

Its function is to carry the

Base Plate
assembly. Whole weight of Mild steel
1 &
component is acting it.
Base

It is locating part it is subjected to

bear hence material should have
2 Locator high wear resistance properties so Mild steel
it must be harden

To hold the object at a fixed

3 Stud position. Mild steel

To clamping the device for

4 Clamp particular operation. Mild steel

To hold the object at a fixed

5 Vertical Plate position vertically. Mild steel

To provide specific height to base

6 Clamp Height plate. Mild steel

Table no.5: Material Selection

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

CHAPTER NO 13
CONCLUSION

CONCLUSION

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

Operation Existing Process Modifying Process

Part Production 1000 1200

Labours 6 4

Machining Time 6.73 6.02

Material Handling More Less

Chances of More Less

Accidents

Operator More Fatigue Less Fatigue

Labour cost More Less

Table No. 6: Productivity Improvement Table

From our Project we conclude that, the existing process required more time for
performing the various operations on Flange Yoke 1310.It required more material handling,
more machining time, and more chances of accident and more fatigue to operator. Then we
suggest the Modifying process for improving the productivity. Reduce the material handling
time and also reduce the chances of accident in company. We suggest the design of fixture
for Chamfering operation.

We learnt from this project improving the productivity and also the various time,
quality and quantity chart for any component like as Multiple activity chart, Gantt chart,
Flow charts, Time calculation chart etc.

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PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

CHAPTER NO 14
REFERENCES

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

REFERENCES
 P.C.Sharma,”A Text Book of Production Engineering”, S. Chand & CO., New
Delhi, 1990.

 N.S.Salunke,” A Text Book of Production Technology”, Tech Max Publications,

Pune .Edition 2013.

 M.Selim Akturk & Selcuk Avci,”And Integrated Process Planning Approach For
CNC Machine Tools”, The International Journal Of Advance Manufacturing
Technology, London, 1996.

 B.Vijay Ramath,” Design of jig and fixture”,

 B.S.Raghuwanshi,”Workshop Technology (Volume-1)”, Dhanpat Rai & co.(P)

Limited, Educational & Technical Publishers, New Delhi,16 Edition,2005.

 PSG college of Technology, “Design Data Book of Engineering”, Kalaikathir

Achchagam, Coimbatore, 1978 & Reprinted July 2004.

 V.B.Bhandari,”Design of Machine Element”, Nirali Publications, Pune. Edition

2013.

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PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

DETAILED
PHOTOGRAPHS

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

MAHINDRA SONA LIMITED NASHIK

Fig.no.3: Mahindra Sona Limited

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

Vertical milling machine

Fig.no.4: Vertical Milling Machine

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

Deburring machine

Fig.no.5: Deburring Machine

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

CNC Auto Lathe Machine

Fig.no.6: CNC Auto Lathe Machine

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 PROCESS PLANNING APPROACH FOR FLANGE YOKE 1310 2013

FLANGE YOKE 1310

Fig.no.7: Flange Yoke 1310

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