CHAPTER 1

INTRODUCTION

A Vise or Vice is known as a mechanical screw which is primarily used to

hold or clamp a work piece in order to allow work to successfully perform on it
with tools that include planes, mills, saws, drills, sandpaper, and screwdrivers, to
name a few. A vise generally has a fixed jaw, with another, parallel, jaw that then
moves away or towards the fixed jaw by a screw.

When it comes to a machining vise there are many styles available

depending on what it is you want such as woodworking vises and metalworking
vises.

Wood working Vises:

The wood working vise generally has jaws that are either made of plastic,
wood, or even from metal. However, when made from metal, they are generally
faced with wood, which helps to avoid destroying the work piece. The edges of the
jaws at the top are brought flush against the bench top by the extension of the
wooden face, which is above the top of the iron moveable jaw.

The jaw in question may also include a dog hole that is used to hold a bench
dog. The modern wood working vises use a split nut. This nut allows the screw to
rotate in two different parts, whereby, the nut can be taken from the screw while
the jaw that is moveable can then be inserted swiftly into a workable position. The
nut at this point is then closed over the screw, so that the vise is firmly closed onto
the work.

1
Metal working Vises:

These vises have jaws that are made from metal. They can also have a
hardened steel that has a rough finish. It is also a common sight to see removable
soft jaws which offer a quick change to suit a fast change over on set ups. In
addition, where appropriate, they are used to also protect any work from potential
damage.

The metal working vises, or also known as engineers’ or even fitters’ vises,
are subsequently locked into place on the top surface of a bench. The faces of jaws,
that are fixed, are to the front edge of the bench. The height of the bench should be
so that the top of the vise jaws are either flush or slightly below the elbow height of
the user when they are standing straight.

In the metal working vises, the nut is similar to that in the wood working
vises. It may be serrated, so that with the assistance of a lever, it can be taken from
the screw, so that the screw and jaw can be inserted into an ideal position, to then
place the nut once again onto the screw.

Vise screws are generally either of a buttress thread form or a Acme thread.
However, those who use a quick release nut will ultimately use a buttress thread.

The style of a machining vise is of course extensive, and depending on what

it is you want to achieve, there is one available. However, it is also important to
remember to heed the safety instructions before using a machining vise, making
sure to be aware of your working area and to clear any objects that may prove to be
a potential risk factor while you work.

2
 CHAPTER 2

COMPONENTS DESCRIPTION

The main components of the machine vice are as follows:

 Fixed jaw
 Movable jaw
 Screw rod
 Clamping plate
 Lock nut

3
2.1 FIXED JAW

It is the main component of the machine vice which houses the movable jaw,
clamping plate, screw rod. It is a stationary component. It clamped with a jaw grip.

It has guide ways with polished surface to ensure free movement of the
movable jaw. It has provisions such that it can be clamped on the bed of a machine
vice. It is made of mild steel.

4
2.2 MOVABLE JAW

The movable jaw can freely move on the fixed jaw. It is connected with the
screw rod. The rotary motion of the screw rod forces the linear motion of the
movable jaw. It has grips clamped on its face with the help of screws. These grips
hold the work piece rigidly. The movable jaw is made up of mild steel. The
distance between the two faces of the grip is the working length.

5
2.3 SCREW ROD

A lead screw (or lead screw), also known as a power screw or translation

screw, is a screw designed to translate radial motion into linear motion.

It is the main part which aids the movement of the movable jaw. The rotary
motion is given to the screw rod which has suitable screw thread. The phenomenon
is that when rotary movement given to the screw thread the output is got in the
form of a linear movement. A rod is inserted into the hole at the end of the screw
rod in the perpendicular axis and given rotary movement. It is made up of

2.4 JAW PLATES

6
 Vise jaw plates and matching work piece holders cooperate to reliably
secure an odd-shaped object in a preferred orientation between the plates. At least
one of a plurality of work piece holders are disposed throughout the jaw in a
uniform orthogonal pattern with the plate holes precisely aligned in rows and
columns and spaced apart a same distance such that a selected work piece holder
with one or more mount posts matching the jaw holes is mountable equally well
throughout the plate.

2.5 LOCK NUT

7
 A locknut, also known as a locking nut, prevailing torque nut, stiff
nut or elastic stop nut, is a nut that resists loosening under vibrations and torque.
Elastic stop nuts and prevailing torque nuts are of the particular type where some
portion of the nut deforms elastically to provide a locking action.

CHAPTER 3

8
 DESIGN CALCULATIONS

3.1 DRILLING TORQUE CALCULATIONS

Diameter of the hole, D = 20 mm

Speed of the drill spindle, N = 100 rpm.

Specific cutting force, kc = 4550 N/mm2

Feed per rotation, f = 0.4 mm

Tool diameter, d = 20 mm

The co-efficient depends on the

geometry of the tip of the tool, k = 0.5

πDN
Peripheral velocity, v=
1000
π ×20 × 100
¿
1000

= 6.28 m/min

k c × f ×d × v
Power required, P=
240000
4550 ×0.4 × 20 ×6.28
¿
240000

= 0.9525 kW
P × 60
Drilling torque, T=
2 πN

9
 0.9525× 103 × 60
¿
2 π ×100

= 90.953×103 N-mm

k ×k c × f ×d
Cutting force, F=
2
0.5× 4550 × 0.4 ×20
¿
2

= 9100 N

3.2 PRESSURE ON THE WORK PIECE

Diameter of the screw rod = 24 mm
Cutting force = Pressure ×Area
π
9100 = p × 4 × 242

p = 20.1154 MPa

Actual resisting force

π
Obtained, Fr = 20.1154× 4 × 242

Fr = 9100 N

3.3 MATERIAL OF THE VICE

10
 3.3.1 CHEMICAL COMPOSITION:

Material Selected is Mild Steel:

Table 3.1 Chemical composition of mild steel

Material name
Chemical composition
and designation
Element Weight, %
Fe 99.3
C 0.08-0.3
Mild steel
Mn 0.4

3.3.2 MECHANICAL PROPERTIES:

Table 3.2 Mechanical properties

S.NO PROPERTIES VALUES Density, kg/m

1 Ultimate tensile strength 555Mpa
7861.093
2 Yield strength 480MPa

3.4 DESIGN OF JAW

Total eq. load acting

11
 1
on the jaw, F = 2 ¿ ]
1 2 2
= 2 [9100+ √ 9100 + 9100 ] ]

= 14724.11 N

Width of the jaw, = 77 mm

Height of the jaw, = 90 mm
Compressive strength, σy = 480 MPa
Taking factor of safety n =4

Therefore design stress, [σ] = (480/4)

= 120 MPa
Stress = Total eq. load / Area
Load, F = 14724.11 N
14724.11
Stress, σ = 77 ×90

= 2.1247 MPa < 120MPa

σ < [σ]
Therefore the design is safe.

12
3.5 DESIGN OF SCREW ROD

Direct compressive stress induced in the body of screw rod

4F
σ n=
π d 2s

4 × 14724.11
¿
π × 242

= 32.55 N/mm2
Ls
α=
p ds

280
¿
3× 24

= 3.89°
φ=tan−1 μ

¿ tan−1 0.1 [Initially assume 0.1]

= 5.71°
F d s tan ( φ+ α )
T=
2

14724.11× 24 × tan ( 5.71+3.89 )

¿
2

= 29881.24 N-mm
Torsional shear stress,
16 T
σ s=
π d 3s

16× 29881.24
¿
π ×24 3

13
 = 11.01 N/mm2
Since the screw rod is subject to direct and shear stress, the maximum principle
stress can be obtained as
1
σ pl= [s n + √ s 2n+ 4 s2s ]
2

1
¿ [32.55+ √ 32.552 + ( 4 ×11.012 ) ]
2

= 35.92 N/mm2

Maximum shear stress,

1 2
σ sm= s + 4 s2s
2√ n

1
¿ √ 32.552+ ( 4 × 11.012 )
2

= 19.65 N/mm2

14
3.6 DIMENSIONS:-
The dimensions of the vice are as follows:
Width of the jaw, B = 75mm
Thickness of the jaw, t = 47mm

Width of the base plate, b = 77mm

Length of the base plate, l = 279mm

Height of the jaw, h = 90mm

15
 CHAPTER 4
OPERATIONS, FABRICATION AND WORKING

4.1 OPERATIONS

Gas cutting

In oxy-fuel cutting, a cutting torch is used to heat metal to kindling

temperature. A stream of oxygen then trained on the metal combines with the
metal which then flows out of the cut (kerf) as an oxide slag.

Torches that do not mix fuel with oxygen (combining, instead, atmospheric
air) are not considered oxy-fuel torches and can typically be identified by a single
tank (Oxy-fuel welding/cutting generally requires two tanks, fuel and oxygen).
Most metals cannot be melted with a single-tank torch. As such, single tank torches
are typically used only for soldering and brazing, rather than welding.

Shaping

Shaping is a material removal process in which a cutting tool takes mass and
shapes a stationary object to produce a sculpted or plane surface.

Drilling

Drilling is a cutting process that uses a drill bit to cut or enlarge a hole in

solid materials. The drill bit is a multipoint, end cutting tool. It cuts by
applying pressure and rotation to the work piece, which forms chips at the cutting
edge. One study showed that drilling accounts for nearly 90% of all chips
produced.

16
Milling

Milling is one of the most widely used machining processes in the industry. It
allows a great variety of shapes to be created thanks to a cutting tool comprised of
several cutting edges, which is subjected to a rotational movement and a feed
motion.

4.2 FABRICATION

Initially the top of the fixed jaw is machined for good surface finish. A slot
is machined in the centre of the fixed jaw for the movable jaw to move correctly.
Now the movable jaw is machined for the required dimensions and a T-shape
machining is done at the bottom to exactly fit into the slot of the fixed jaw. A
tapping operation is done at the underside of the T-shape to fix the clamping plate
using fastener.

The screw rod is machined in a lathe. A cylindrical rod is taken and thread
cutting operation is done on it to match the pitch on the fixed jaw. A bore is made
on the end of the screw rod to insert the handle. The screw rod is inserted into the
right side of the fixed jaw and clamped with the movable jaw using a fastener that
exactly in the slot made on the front end of the screw rod.

17
4.3 WORKING

The machine vice placed on the bed of the machine vice. The vice is
adjusted to get an approximate centre of the tool on the work piece. Then the vice
is clamped with the bed ways by means of bolts on the clamping plates welded to
the vice. The work piece to be machined is held in between the two jaws. The
screw rod is rotated clock wise to move jaw in the forward direction. The work
piece is held to the requirement of machining process. The jaw is tightened over
the surface of the work piece to ensure no movement of the work piece because the
tangential and radial forces acting on it are very large. The force on the screw rod
varies according to the labour working on it. It also depends on the speed of the
motor and type of machining. When the job is done the screw rod is rotated in the
anticlockwise direction to loosen the grip. The work piece is then removed from
the vice. Then the vice is cleaned and removed from the bed ways by removing the
bolts.

18
 CONCLUSION

The fabricated machine vise based on calculations, functions properly. It is

used in clamping the work piece in milling and drilling operations. The clamping
force of vise can withstand the cutting force of the operations performed.

FURTHER DEVELOPMENT:

1. Improvements can be made on conventional vice by means of providing

swivel base for angular movements.
2. Sensors can be used behind the jaw so that the movement of jaw can be
restrained up to the safe limit and the impact on the work piece is reduced.
3. Pneumatic circuits can be used for automatic operations.
4. Hydraulic circuits can also be used for operations involving high cutting
force.

19
 CHAPTER – 5
COST ESTIMAION
5.1 COST OF THE COMPONENTS

The cost of the components are listed in the table below

Table 5.2 cost of the components

S.NO. COMPONENTS COST IN Rs/-

1 Fixed jaw
2 Movable jaw
3 Screw rod
4 Jaw plate
Total material cost

S.NO. Machining COST IN Rs/-

1
2
3
4

20