A PROJECT REPORT ON

DESIGN ANALYSIS AND MANUFACTURE OF AN INDEXING

AND TURNING FIXTURE FOR A REAR COVER COMPONENT

REPORT SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR

THE AWARD OF THE DEGREE OF

BACHELOR OF ENGINEERING IN MECHANICAL ENGINEERING

SUBMITTED BY
YOGESHRAM.S (732321114345)

Under the Guidance of

DEPARTMENT OF MECHANICAL ENGINEERING
SSM COLLEGE OF ENGINEERING
KOMARAPALAYAM – 638183
EROD DT, TAMILNADU, INDIA
AUGEST 2024
 DEPARTMENT OF MECHANICAL ENIGEERING
SSM COLLEGE OF ENGEERING
KOMARAPALAYAM

CERTIFICATE
This is to certify that the report entitled “DESGIN ANALYSIS AND
MANUFACTURE OF AN INDEXING AND TURNING FIXTURE FOR A REAR COVER
COMPONENT “REPORT submitted by S.YOGESHRAM (732321114345) to a
department of mechanical engineering toward partial fulfilled of the
requirement for the award of bachelor of engineering in mechanical
engineering is a Bonafede record of the work carried out by him under MY
supervision and guidance.

MR NANDAKUMAR MR.KL.KUMAR
ASSISTANT PROFESSOR HEAD OF DEPARTMENT
MECHANICAL DEPARTMENT ASSISTANT PROFESSOR
MECHANICAL DEPARTMENT

PLACE:
DATE:
 DECLARATION
I Have by declare that I have undergone internship training at SSM
college of engineering anna university between 8 July 2024 to August
8 2024 and that this internship report is the result of work done at
the SSM College of engineering, Anna university during the period. A
copy certificate issued by the organization is enclosed hereby.

Yogeshram.S
(732321114345)
Mechanical department
DESIGN AND ANALYSIS OF AN INDEXING FIXTURE:

The modern manufacturing system demands for

increase in productivity, safe operations with
fewer efforts in less cost of operation. In industrial
sectors, in India, placement of component is a
major factor. It affects the production rate, cost
and hence the profit of the company.
Placement/mounting of products requires time.
Hence, to make the process of workability easier,
we design an Indexing Fixture which will work in
less available space and thus reduce the time
required to rotate the engine block from one
position to another and carry out operations. The
project discusses the mechanism used to rotate a
6-cylinder Truck engine along its horizontal axis of
rotation. This project gives an idea about the
designing of this Indexing Fixture by considering
Ergonomics and safety
Key Words: Engine Block, Productivity, Indexing
Fixture, Axis of Rotation, Workability, Ergonomics.
INTRODUCTION:
Earlier for lifting and tilting any heavy engine
components was done by hoist and weight
lifting chain arrangement. Due to this it was
very risky for the workers to complete any
process related to movement of engine.
Working on the engine was done manually on
a suitable lathe machine, requiring highly
skilled operator. For a steady demand
(medium demand as compared to today
scenario) loaded in the CNC machine for
various processes to be carried out. This
increased the work load on the CNC and
decreased efficiency and also was seen to be
nonprofitable. Various other problems like
Time loss, Ergonomic considerations were
present. So, to overcome these shortcomings
a new concept of “INDEXING DEVICE” was
initiated. An Indexing Fixture is a device used
to rotate (index) any object through a specific
angle. We are using the indexing machine to
index a 6 cylinder engine through various
degrees about a horizontal axis of rotation.
 This machine provides various benefits like
safety for user, easy handling, time saving etc.
So the main problem of rotating a heavy
engine is overcome using indexing device.

Fig -1: Engine block on which reworking is

done
 Ergonomic risk reduction:
Earlier for reworking on the engine block at
various angular positions the block cannot be
moved at particular angular position and thus the
tool needs to be used at an angle on the engine
block surface which results in poor finish as well
as more time is required and thus decreasing
production efficiency. Indexing Machine would
essentially negate all these disadvantages and we
can achieve better working conditions

 Easy handling Indexing

Machine ensures that the process becomes easy
as there are no complications at the workers end.
 Operators safety
Earlier process involved lot of risky operations
which were harmful for the worker. Whenever the
engine was lifted and tilted by chain and hoist the
motion of engine could not be controlled so
wayward motion of engine caused lot of problems
for the workers. Chances of engine colliding with
the worker or any object were present which
would definitely have an adverse impact on the
working environment.
 Time saving
As lifting and tilting of engine required lot of time,
patience as well as concentration the process took
certain time. Indexing Machine will reduce the
process time as well as no skilled labor will we
required for the process.
Table -1: Engine Specifications Engine Family QSK-
23 Engine configuration In line,4-Cycle, 6 cylinder
Displacement 23.2 L HP Range Diesel 760 – 950
Gas N/A Fuel system Pressure Time (PT)
Dimensions(mm) 1859 X 940 X 1656 mm (length x
width x height) Weight(Kg) 2858 kg Emission Non-
Certified(Industrial) IMO Tier II (Marine) Markets
Earth movers Excavators Road paver
TORQUE AND POWER CALCULATIONS WEIGHT
OF BASIC COMPONENTS:
 WEIGHT OF FRAME: 63 Kg
 WEIGHT OF LH HOUSING: 80 Kg
 WEIGHT OF FIXTURE BASE: 280 Kg
 WEIGHT OF LH INDEX PLATE: 80 Kg
 WEIGHT OF RH INDEX PLATE: 80 Kg
 WEIGHT OF RH HOUSING: 95 Kg
 TOTAL WEIGHT OF INDEXING MACHINE
AFTER MACHINING= 1302.81 Kg
 WEIGHT OF ENGINE BLOCK= 700 Kg
First we need to find the centre of mass of
the whole system with engine and indexing
machine combined. For the calculation of
centre of mass we need to consider a
reference axis. The components that are
rotating only contribute to the calculation of
centre of mass. The rotating components are
the fixture base and the engine block and the
right and left hand side housing. The basic
requirement to calculate the torque is the
moment due to the weights of indexing
machine and the engine that is located on the
machine about the centre of mass. Then, we
need to calculate the centre of mass of
indexing machine and the engine. Centre of
mass of indexing machine is calculated
through CATIA In which the assembly is done
and then centre of mass is calculated. The
centre of mass co-ordinates of engine is given
as input variables
Design and Selection of Components Design
calculations are according to Indian Standards
used for cranes and hoists and standard
papers. Some Indian Standards have the
direct guidelines for some components.
Above components are available with
standard sizes. Hence, we have to select the
suitable size from the calculated values.
Mechanism components are checked
depending on the ultimate strength by
verifying that the calculated stress does not
exceed a permissible stress dependent on the
breaking strength of the material used.
Following general components are to be
Designed, Analyzed and Selected.
Overview
Overview gives us basic idea about how the
Indexing machine appears and also we have
made a 3D model to get a good
understanding of indexing machine structure.
Modeling has been done in CATIA V5
considering the actual dimensions and
constraints in the Indexing Machine. Whole
structure is designed to get maximum output
and also has ergonomic shape which reduces
risk for the worker.
Hoist
An electro-mechanical appliance whose
principal function is the lifting or lowering or
both, of loads and having a wire rope fixed
between the rope drum and the load block
used for lifting the load is called as an electric
wire rope hoist. A Hoist is a type of a device
used for lifting an object and moving it from
one place to another with ease. A hoist is an
assembly of rope drum, motor, and hook
block. It travels over the girder. The function
of the hoist is to provide the main hoisting
motion i.e. to rise and lower the weight.
Previously this type of hoist and pulley
mechanism was used to turn the engine from
vertical to horizontal position. This method
had certain disadvantages as discussed earlier
hence this mechanism has been replaced
 Indexing Plates
The index plates are made of Cast Iron. Both
plates are of the same dimensions. The index
plates have numerous through holes according
to the indexing angles required. The stopper is
used to lock a particular indexing position. The
holes are of same diameter. The RH index plate
is fixed the rotating shaft and the Fixture
Base(bed).

Shafts
The Index Plates are being given drive by two
Shafts. These shafts are made from Mild Steel.
They are undergoing Bending stress and Torsion
stress. They are transmitting torque from input to
the fixture. They are varying in diameter in
successive steps to increase load carrying capacity
without increasing weight.

Frame Support
There are two supports given to the frame of the
Indexing Machine.1st is located on the right hand
side and 2nd is located on the left hand side of the
Fixture Housing.1st structure supports the Right
hand housing.2nd structure supports the left hand
housing
Design and selection of Belt Drive
Belts are used to transmit power between two
shafts by means of friction. A belt drive consists of
three elements – driving and driven pulleys and an
endless belt, which envelopes them. Belt drives
can transmit power over considerable distance
between the axis of driving and driven shafts.
They are simple to design and have low initial
cost. For our purpose we have selected V-belts as
it offers following advantages over Flat belts
 The force of friction between the surfaces of the
belt and V-grooved pulley is high due to wedge
action. This wedging action permits a smaller arc
of contact, increases the pulling capacity of the
belt and consequently results in increase in the
power transmitting capacity.
 V-belts have short Centre distance, which results
in compact construction.
 They permit high speed reduction even up to
7:1.  Flat belts are hinged, while V-belts are
endless which results in smooth and quiet
operation even at high operating speeds.
 The drive is positive because the slip is negligible
due to wedge action
 V-belt drive can operate in any position when
belt is vertical. V-belts are made of polyester
fabric and cords, with rubber reinforcement. The
cross-section of v-belt is shown in figure. It
consists of following three parts:
 The central load carrying layers of polyester
cords or polyester fabric, which are located on
horizontal lines near the center of gravity of the
belt cross-section.
The manufacturers and the bureau of Indian
standards have standardized the dimensions of
the cross-section. The cross-sectional dimensions
are given in table below.

The selection of the cross-section depends upon

two factors, namely, the power to be transmitted
and speed of the faster shaft. Figure below shows
the range of speed and power for various cross-
sections of the belt. Depending upon the power
and speed of the faster pulley, a point can be
plotted on this diagram and the corresponding
cross-section selected

Design and selection of Gear Drive Worm gear

drives are used to transmit power between two
non intersecting shafts which are in general at
right angles to each other. A speed reduction as
high as 100:1 can be obtained with a single pair of
worm gears. Worm gear drives are compact with
small overall dimensions compared with
equivalent spur or helical gear drives having same
speed reduction. The operation is smooth and
silent. Provision can be made for self locking
operation, where the motion is transmitted only
from the worm to the worm wheel. Single
threaded worm gives large speed reduction,
however the efficiency is low and multi threaded
worm gives high efficiency however the speed
reduction is low. The terminology for worm and
worm wheel is :
 Z1= NUMBER OF STARTS ON THE WORM
 Z2= NUMBER OF TEETH ON WORM WHEEL
 Φ = PRESSURE ANGLE
 ϒ = LEAD ANGLE
 P1 = AXIAL PITCH OF WORM
 P2= CIRCULAR PITCH OF WORM WHEEL
 L = LEAD
 D1 = DIAMETER OF WORM
 D2 = DIAMETER OF WORM WHEEL
 C = CENTRE DISTANCE
 i = GEAR RATIO(Z2/Z1)
 m = Module
Φ = 20 degrees Power to be transmitted(P) = 2.2
KW
Maximum lead angle = 25 degrees Lewis form
factor(y) = 0.125
Modified Lewis form factor(Y) = 0.393
The maximum lead angle ,Lewis form factor and
modified Lewis form factor are preferred.
i = (350/5)= 70:1
We have chosen single start threads because the
velocity ratio is more than 20.
Z1=1 ; Z2= i*Z1 = 70 w1 = (2*3.14*350)/60 =
36.65 rad/s Centre distance of 250 mm is
assumed.
The condition for ;
D1 is : (C^0.875)/3 ≤ D1≤ (C^0.875)/1.7 D1≥
42mm and D1≤75 mm Therefore D1 = 60 mm is
taken Axial pitch of the worm should be equal to
the circular pitch of worm wheel
Helix angle = 90 – ϒ = 85.46
degrees Helix angle should be limited to 6 degrees
per thread therefore there should be at least 14
threads.

ERGONOMICS
Ergonomics is a scientific discipline, which is
concerned with improving the productivity,
health, safety and comfort of people, as well as
promoting effective interaction among people,
technology and the environment in which both
must operate. By studying previous method we
found out various drawbacks relating to it and by
designing Indexing Machine we can eliminate all
these drawbacks. Indexing Machine helps to
eliminate:
(a)Errors in machining
(b) Awkward position of working block
(c) Poor access or inadequate clearance and
excessive reach,
(d) Increased time in setting up of tool for various
angular positions
Therefore, the Indexing Fixture that is selected
should be suitable for the types of tasks
performed and be adaptable to multi-purpose
use. Office workstations must be designed
carefully to meet the need of the staff and to
accomplish the goals of the facility.
ANALYSIS
Substance into smaller parts in order to gain a
better understanding of it. The technique has
been applied in the study of mathematics and
logic since before Aristotle, though analysis as a
formal concept is a relatively recent development.
Analysts in the field of engineering look at
requirements, structures, mechanisms, systems
and dimensions. Electrical engineers analyze
systems in electronics. Life cycles and system
failures are broken down and studied by
engineers. It is also looking at different factors
incorporated within the design. Engineering
analysis involves the application of scientific
analytic principles and processes to reveal the
properties and state of a system, device or
mechanism under study. Engineering analysis is
decomposition; it proceeds by separating the
engineering design into the mechanisms of
operation or failure, analyzing or estimating each
component of the operation or failure mechanism
in isolation, and re-combining the components
according to basic physical principles and natural
laws. 3.1 Analysis of Index Plates a) Left Hand Side
Index Plate Analysis Conditions:
 Maximum Force acting on Plate = 6916.45 N
 Supports = Bearings on Shafts. Results Obtained:
 Displacement = 6.23 * 10-2 mm
 Stress = 2.091N/mm2

The index plate is safe from failure as the stress in

it does not exceed the ultimate tensile strength
(250MPa). As the stress induced is less than the
cyclic stress (154 MPa) of the material i.e. Cast
Iron, the chances of Fatigue Failure is negligible.
The index plate is safe from failure as the stress in
it does not exceed the ultimate tensile
strength(250MPa).As the stress induced is less
than the cyclic stress(154 MPa) of the material i.e.
Cast Iron, the chances of Fatigue Failure is
negligible. As the machine undergoes cyclic
loading chances of Fatigue Failure are present but
as crosschecked by analysis, the life of the
component will be more than 106
Analysis of Shafts
a) Right Hand Side Shaft (Driven Shaft) Analysis
All the parts are safe from failure as the stress
in them does not exceed the ultimate tensile
 strength.As the stress induced is less than the
respective cyclic stresses of the material, the
chances of Fatigue Failure is negligible. As the
machine undergoes cyclic loading chances of
Fatigue Failure are present but as crosschecked
by analysis, the life of the components will be
more than 106.Hence we arrive to the
conclusion that the design will be safe 
Maximum Torque acting on shaft = 4254.66
Nm 
b) Supports = Bearings on Shafts.
c) Results Obtained:  Displacement = 3.72 * 10-5
mm
d)  Stress = 4.89 * 10-2 N/mm

STRESS ANALYSIS
 DISPLACEMENT ANALYSIS

b) Left Hand Side Shaft (Driving Shaft)

Analysis Conditions:
 Maximum Torque acting on shaft = 4254.66
Nm
 Supports = Bearings on Shafts. Results
Obtained:
 Displacement = 6.67 * 10-2 mm

All the parts are safe from failure as the stress

in them does not exceed the ultimate tensile
strength.As the stress induced is less than the
respective cyclic stresses of the material, the
chances of Fatigue Failure is negligible. As the
machine undergoes cyclic loading chances of
Fatigue Failure are present but as crosschecked
by analysis, the life of the components will be
more than 106.Hence we arrive to the
conclusion that the design will be safe

Productivity of a production system is

analogous to the efficiency of a machine. Just
as it is desired to increase the efficiency of a
machine, it is also aimed to raise the
productivity within the available
resources .Productivity may be defined as the
ratio between output and input. Output
means the amount produced or the number of
 items produced and inputs are the various
resources
machine and also reducing the manual fatigue[1].
In this case the device that caters our needs is the
use of jigs. Let us take one example. Let us
consider that one gets an order of say 1000
products. There need to be three holes drilled on
this product. In such a case the designer tries to
draw out every single hole with the help of
square, strengtheners, scribers and center hole[2].
Hence using of jig to position and guide the tool to
its right path is preferred rather than using
scribers, square, strengtheners or center punch
etc. Thus the productivity is increased which is
done by eliminating individual positioning,
marking and frequent checking. Interchangeability
is the chief advantage here[3]. The successful
running of any mass production depends upon the
interchangeability to
facilitate easy assembly and reduction of unit
cost. Mass production methods demand a
fast and easy method of positioning work for
accurate operations on it[4].
DESIGN CONSIDERATIONS:
The points that are taken into consideration
for designing a product are as following:
o Jig must be so strong that the deflection
in the jig should be as less as possible.
The deflection that is mentioned
includes the forces of cutting, clamping
of workpiece to the machine table. The
frame of the fixture should have
sufficient mass to prevent vibrations
during the machining of the job[5].
o Another important design consideration
is the clamping which should be fast
enough and require less amount of
effort.

o Arrangement of clamps should be such

that they are easily available[6]. They
should also have the arrangement for
easy removal as well.
o Is swinging of clamp system is provided
for removal of workpiece the clamp
 should swing as far as possible for
unclamping the device.
o There should also be provision for easy
removal of chip. This will prevent the
interference of the chip with the
operation on the workpiece i.e. cutting
operation[7].
o The clamps and support points which are
to be adjusted in due course of time
should be preferred of same size. It will
be better if the clamps and adjustable
support points can be operated from the
front of the fixture.

PROBLEM IDENTIFICATION AND PROPOSED

CONCEPT:
EXISTING METHOD;
Indexing is a necessary kind of motion.
Usually when the word indexing is used, it
refers specifically to rotation. That is, indexing
is most often the quick and easy but precise
rotation of a machine part through a certain
known number of degrees[8]. The existing
 indexing drill jig is of the rotating type where
the indexing head has to be pulled and
rotated.

Fig 3.1 Existing Indexing Drill Jig with

mandrel.
PROPOSED METHODOLOGY:
Modification of existing drill jig which is
operated by an indexing mechanism, by the lever
operated indexing mechanism considering the
three orders of lever. This jig is being modeled by
the calculation of Torque, Thrust Force, Leverage
and Spring loading for the improvement in
productivity.

DESIGN OF COMPONENTS:
Jig Plate:
Jig plate is a machined product, with flat
surfaces and a surface finish equal to 32
microinches or better on both sides[9]. It is
readily machined with very little distortion.
Using proper aluminum machining methods,
tolerances in the thousandths can be
maintained. The dimensions of the jig plate
used here are as follows
length=100
Width = 150mm
Thicknenss=20mm

Angle Plate:
An angle plate is a work holding
device used as a fixture in metalworking. The
angle plate is made from high quality material
(generally spheroidal cast iron) that has been
stabilized to prevent further movement or
distortion[10]. The dimensions of the angle
plate used here are as follows:
Length = 150mm
 Width=150mm

Base Plate:
A solid piece of material that has enough strength
and sturdiness to serve as the surface to which
other things are attached to be supported[11].
The dimensions of the base plate used here are as
follows:
Length = 190mm
Width = 150mm
Thickness = 20mm
Mandrel:
A mandrel is a round object against which
material can be forged or shaped, or a tool
component such as a chuck that grips or clamps
materials to be machined in a lathe[12]. The
dimensions of the mandrel used here are as
follows:
Length = 72mm
Larger Diameter = 63.4mm
Smaller Diameter = 24.8mm ; Taper Angle = 150 .

Indexing Plate:
An indexing plate is a specialized tool that allows a
workpiece to be circularly indexed; that is, easily
and precisely rotated to preset angles or circular
divisions[13]. The dimensions of the indexing
plate used here are as follows:
Diameter = 80mm
Angle = 22.50
Thickness = 20mm
Depth = 15mm ,Pitch = 10mm

Lever:
A lever is a machine consisting of a beam or rigid
rod pivoted at a fixed hinge, or fulcrum. A lever is
a rigid body capable of rotating on a point on
itself[14]. The major categories of them are Class
1,2,3 lever. The mechanical advantage of the lever
is given by the equation,
F*A=Q*b
 F*160=600*400
F=150N
Bush:
A bush is a mechanical fixing between two,
possibly moving, parts, or a strengthened fixing
point where one mechanical assembly is attached
to another[15]. The dimensions of the bush used
here are as follows:
Length = 20mm
Top diameter = 20mm
Bottom diameter= 16mm

Dowel pin:
A dowel is a solid cylindrical rod, usually
made from wood, plastic, or metal. In its
original manufactured form, a dowel is
called a dowel rod[16]. Dowel rods are
often cut into short lengths called dowel
pins.
Diameter = 4mm
Length = 30mm
Allen screw:
A hex key, Allen key or Allen wrench is a tool used
to drive bolts and screws with hexagonal sockets
in their heads[17].Metric hex wrench sizes are
sometimes referred to using the designation "M"
followed by the size in millimeters of the tool or
socket. The alen screws used here are M5 and M6
Stud:
The stud pin is used to hold the latch at one end
of it. Two stud pins are used in this jig which has
the latch which is used to hold the workpiece
firmly with the mandrel[18].

Latch:
A latch is a type of mechanical fastener that is
used to join two or more objects or surfaces
together[19]. Depending upon the type and
design of the latch, this engaged bit of hardware
may be known as a keeper or strike. The
calculation for the moment of inertia of latch is
shown below
L=bd/12
 T=1.5*11/12
L=1663.75mm
The calculation for the deflection of latch is shown
below:
𝛿l=PL/48EL
𝛿l=300*110/48*2.1*10*1663.75
𝛿l=0.0238mm
Pressure pad:
A pressure pad presses against the material during
bending, and is used for preventing the springing
back of the material and the sliding of the
material during forming[20]. The dimensions of
the pressure pad used here are as follows: Max.
Diameter = 25mm Min. diameter = 18mm Height
= 15mm Screw thread = M12
ACKNOWLEDGEMENT
It would have been very difficult for us to make
this project alone. We are dutifully obliged to all
the people who helped us directly or indirectly in
making this project successful. We received
helping hand from many people who were eager
to help us out through our queries.
CONCLUSION:
In this project, a complete model of work holding
and tool guiding indexing drill jig was
manufactured in the special machines laboratory.
The device is operated by using the lever setup
provided with the indexing plate. The newly
designed drill jig helps to simplify the operation
and reduces the risk of the operator during
loading and unloading. This project helped us to
gain decent exposure to various Engineering fields
like: Ergonomics, Design, Analysis, Manufacturing
and Safety. It helped us to get familiar with the
actual industrial condition.