Inhouse PRACTICAL

DESIGNING AND MANUFACTURING OF FIXTURE
IN-HOUSE TRAINING REPORT
A Project Report on
Designing and Manufacturing of fixture

Submitted in partial fulfilment of the requirement for the degree of
BACHLEOR OF TECHNOLOGY
In
Tool Engineering
By
Nitesh kumar
(Roll no. 02370208615)
UNDER THE GUIDANCE OF
MR. VAIBHAV CHANDRA
MR. M.S. RAWAT
Department of Tool Engineering,
Delhi Institute of Tool Engineering,
Okhla Industrial Area, Phase-II, New Delhi-110020
1
CANDIDATE DECLARATION
I hereby declare that the work which is being presented in this thesis entitled “Designing and
Manufacturing of Fixture” my own work carried out under the guidance of Vaibhav
Chandra ,Assistant Professor (Training Coordinator), Delhi Institute of Tool Engineering, Delhi
And M S Rawat, Technical officer (Training Supervisor ) , New Delhi.
I further declare that the matter embodied in this thesis has not been submitted for the award of
any other degree or diploma.
( )
Signature of the Student
Place: Delhi
Date:
2
ACKNOWLEDGEMENT
In-House training from 22 December 2017 to 5 January, 2018(2 Weeks) in workshop, Delhi
Institute Of Tool Engineering was a learning experience for me working in such encouraging
atmosphere which gives me great sense of pleasure to present the project report of in-house
training which had held after 5th semester on “DESIGNING AND MANUFACTURING OF FIXTURE”.
I would like to express my deepest sense of gratitude and sincere thanks to my highly respected
and esteemed guide MS Rawat (Technical Officer) for their valuable guidance, encouragement
and help for completing this work.
I would like to express my sincere thanks to Vaibhav Chandra (Assistant professor) for giving me
this opportunity to undertake this project. I would also like to thanks our Director-cum-principal
Dr S.Maji for whole hearted support.
I also wish to express my gratitude to Assistant professor Kanwarjeet Singh HOD (Tool
Engineering) for his kind hearted support. I am also grateful to Sumer Singh Attri (Senior
Technician); Guddu Tiwari (Technician); Subhash Chand Sharma (Technician) for their constant
support and guidance.
I also wish to express my indebtedness to my parents as well as my family member whose

blessings and support always helped me to face the challenges ahead. At the end I would like to
express my sincere thanks to all my friends and others who helped me directly or indirectly
during this project work.
( )
Nitesh kumar
02370208615
3
ABOUT DITE
Delhi institute of tool engineering formally known as tool room and training centre is the govt.
university and have centre of excellence in tool engineering. It is established in 1978. DITE
have two branches, TRTC (tool room and training centre) at wazirpur and Hi- tech vocational
training centre (HTVTC) have been merge and renamed as Delhi institute of tool engineering
(DITE). DITE has come into existence w.e.f. 28 th nov.2007. And it’s functioning from wazirpur
and okhla industrial area as campus 1 and campus 2 respectively.
DITE is affiliated to all India council for technical educational (AICTE) and Guru Govind
Indraprastha University and approved by govt. of NCT Delhi. DITE provides the following
courses:-
1. M.Tech (Tool Engineering)

2. B.Tech (Tool Engineering)
3. B.Tech (Mechatronics)
4. Diploma in Tool & Die Making (4Years)
5. Diploma in Mechanical Engine
DITE has been playing a vital role in the development of micro, small and medium industries
through supply of trained manpower in the field of tool making and tool designing and supply of
sophisticated tools such as dies, molds, press tool etc.
4
Table of Contents
Title Page No.
CANDIDATE DECLARATION................................................................................................................................ 2
ACKNOWLEDGEMENT............................................................................................................................... 3
ABOUT DITE....................................................................................................................................................... 4
ABSTRACT.......................................................................................................................................................... 8
INTRODUCTION.................................................................................................................................................. 9
Chapter:-2........................................................................................................................................................ 19
About DITE Workshop...................................................................................................................................... 19
PLANT LAYOUT......................................................................................................................................... 20
COMPONENT DRAWING................................................................................................................................. 35
PROCESS SHEET OF DITE.................................................................................................................................. 39
OPERATION FOR FIXTURE MANUFACTURING AND CUTTING TOOL USED......................................................42
CONCLUSION................................................................................................................................................... 59
s List of tables
Table no. Table Name Page no.
1.1 Material used in the fixture 13
1.2 Difference between jig and fixture 15
2.1 Various machines at the DITE workshop. 24
2.3 Panther lathe specification 26
2.4 Milling machine specification 28
2.5 Grinding Machine specification 31
2.6 CNC Milling machine specification 32
2.7 CNC Turning machine specification 34
5
LIST OF FIGURE
Figure no. Figure name page no.

1.1 Fixture 10
2.1 Workshop image 14
2.2 lathe machine 26
2.3 Milling machine 27
2.4 Shaper machine 29
2.5 Grinding machine 31
2.6 CNC Milling machine 33
2.7 CNC turning machine 34
5.1 cutting stock material 42
using hacksaw
5.2 Hacksaw 42
5.3 Rough dimensioning on 45
Shaper machine
5.4 Single point cutting tool 48
5.5 finishing operation on 49
Milling machine
5.6 End mill cutter 49
5.7 collet 50
5.8 Vernier caliper 51
5.9 grinding operaton 52
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ABSTRACT
The project gave a detailed about designing and manufacturing of fixtures, and also identified
the numerous advantages that are associated with the use of fixtures in manufacturing to
include: production increase, cost reduction, interchangeability and high accuracy of parts,
reduction of the need for inspection and quality control expenses, reduction of accident as
safety is improved, automation of machine tool to an appreciable extent, easy machining of
complex and heavy components, as well as low variability in dimension which leads to
consistent quality of manufactured products. Study of work piece and finished component size,
component drawing, process sheet of fixture, Plant layout of workshop (2d/3d design),
Specification of various machine at workshop, Provision of locating devices in the machine,
Various stages of manufacturing fixture, Available clamping arrangements in the machine,
Machining time, Safety precaution etc., Required level of the accuracy in the work.
In machining fixtures, minimizing work piece deformation due to clamping and cutting forces is
essential to maintain the machining accuracy. The various methodology used for clamping
operation used in different application by various authors are reviewed in this paper. The fixture
set up for component is done manually. For that more cycle time required for loading and
unloading the material. Fixtures reduce operation time and increases productivity and high
quality of operation is possible.
Keywords: fixture, accuracy, clamping, machine tool, productivity
GROUP-V
1. Rashmi Rani (027) 7. Sudhanshu (424)
2. Nitesh Kumar (023) 8. Sachin Goyal (030)
3. Amit (404) 9. Subham Kumar Nehra (031)
4. Rahul Kumar (427) 10. Anil Kumar (408)
5. Sushil (428) 11. Aman (005)
6. Vivek Kumar (037)
7
CHAPTER-1
INTRODUCTION
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1.1 Fixture
Fixture hold the work piece securely in the correct position with respect to the
machine/cutter during operation. There is sometime provision in fixture for setting the tool
with respect to the work piece/fixture, but the tool is not guided as in a jig. Fixtures are often
clamped to the machine table. There are many standard work holding devices such as jaw
chucks, machine vises, drill chucks, collets, etc. which are widely used in workshops and are
usually kept in stock for general applications. Fixture are most often identified by machine
tool where they are used.
Figure 1.1 a typical fixture

1.2 Purpose
A fixture's primary purpose is to create a secure mounting point for a work piece, allowing
for support during operation and increased accuracy, precision, reliability, and
interchangeability in the finished parts. It also serves to reduce working time by allowing
quick set-up, and by smoothing the transition from part to part. It frequently reduces the
complexity of a process, allowing for unskilled workers to perform it and effectively
transferring the skill of the tool maker to the unskilled worker. Fixtures also allow for a
higher degree of operator safety by reducing the concentration and effort required to hold a
piece steady.
Economically speaking the most valuable function of a fixture is to reduce labor costs.
Without a fixture, operating a machine or process may require two or more operators; using
a fixture can eliminate one of the operators by securing the work piece.
9
1.3 Elements of Fixture

 Locator
A locator is usually a fixed component of a fixture. It is used to establish and
maintain the position of a part in the fixture by constraining the movement of the
part. For work pieces of greater variability in shapes and surface conditions, a locator
can also be adjustable.
 Clamp
A clamp is a force-actuating mechanism of a fixture. The forces exerted by the
clamps hold a part securely in the fixture against all other external forces.
 Support
A support is a fixed or adjustable element of a fixture. When severe part
displacement/deflection is expected under the action of imposed clamping and
processing forces, supports are added and placed below the work piece so as to
prevent or constrain deformation. Supports in excess of what is required for the
determination of the location of the part should be compatible with the locators and
clamps.
 Fixture Body
Fixture body, or tool body, is the major structural element of a fixture. It maintains
the spatial relationship between the fixturing elements mentioned above, viz.,
locators, clamps, supports, and the machine tool on which the part is to be processed.
1.4 Selection of Materials
There are a wide range of materials from where jigs and fixtures could be made, to resist
tear and wear, the materials are often tempered and hardened. Also, phosphor bronze and
other non-ferrous metals, as well as composites, and nylons for wear reduction of the
mating parts, and damage prevention to the manufacturing part is also used. Some of the
materials are discussed below:
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Material Description
Contains (<0.3% carbon). Most suitable for most jigs applications as it is

Mild steel
the economical and most widely used material in jigs and fixtures.
Contain carbon (0.85%~1.18%). Most suitable for work pieces like

Carbon Steel woodwork and hand-tools such as files and chisels. It can be hardened to
serves as locator and bushings.
Contains tungsten (18% ~22%) for toughness and cutting strength,

High Speed chromium (4.3%) for hardening and wear resistance, vanadium (1%) for
Steel(HSS) retention of hardness at high temperature. Most suitable for cutting tools
like drills , reamers and cutters
Contain carbon (0.45% ~ 0.65%) and alloys Ni2Cr1M028 (40%). Most

High Tensile Steel
suitable for fasteners as well as high stress like ram press.
Contains carbon (1.5%~2.3) for hardness, high chromium (12%) but

alloyed with molybdenum (1%) and vanadium (0.3%~1%) for hardness
Die Steel
retention used at high temperatures. Most suitable for forging, casting and
extrusion.
Oil Hardening Contain carbon (0.9%~1.1%), tungsten (0.5%~2%) and carbon

Non-Shrinking (0.45%~1%). Most suitable for engraving tools and intricate pressing
Tool Steels jigs.
Contain carbon (2%~2.5%). Most suitable for milling fixture as it can

Cast Irons
withstand vibrations, machine slides and guide ways.
Nylon & Fiber Most suitable for used in soft lining for lever press/clamps to prevent dent
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Material Description
to work pieces under high pressure force
Phosphor Bronze Most suitable in corrosive resistance such as boiler valve
Table1:-Materials used in fixture
1.5 Fixture Design Fundamentals
Fixture design consists of a number of distinct activities: fixture planning, fixture layout
design, fixture element design, tool body design, etc. They are listed in Figure 1.4 in their
natural sequence, although they may be developed in parallel and not necessarily as a series
of isolated activities in actual execution. Fixture design deals with the establishment of the
basic fixture concepts:
 Fixture layout is an embodiment of the concepts in the form of a spatial
configuration of the fixture,
 Fixture element design is concerned with the concrete details of the locators, clamps
and supports,
 Tool body design produces a structure combining the fixture elements in the desired
spatial relationship with the machine tool.
1.6 Fixture Design Procedure:-

Fixtures must always be designed with economics in mind. The principle of location or the 3-2-1
principle, CAD tools (like ProE), and FEA tools (like ANSYS) are used for the design of the jigs
as well the fixtures. In the design of a fixture, a definite sequence of design stages is involved.
They can be grouped into three broad stages of design development.
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Stage one deals with information gathering and analysis. These include product analysis such as
the study of design specifications, process planning, examining the processing equipment and
considering operator safety and ease of use.
Stage Two involves the consideration of clamping and locating schemes. A clamping scheme is
devised in such a way that it will not interfere with the tools or cutters and are fully compatible
with proposed locating surfaces or areas.
Stage Three is the design of the structure of the fixture body frame. This is usually built around
the work piece as a single element which links all the other elements used for locating, clamping
tool-guiding, etc. into an integral frame work.
The following outputs are included in the fixture plan:
 Fixture type and complexity

 Number of work pieces per fixture
 Orientation of work piece within fixture
 Locating datum faces
 Clamping surfaces Support surfaces, if any.
 Economy of fixture
1.7 Advantage of fixture:-

 They improve productivity.
 It gives rapid production work and thus good for mass production.
 It reduced manufacturing costs.
 Complex and heavy components can be easily machined.
 Interchangeability.
 Jigs and fixtures are increased machining accuracy.
 It reduces in the expenditure due to inspection and quality control of finished
components.
1.8 Disadvantage of fixture:-
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 They have very tough and complicated design.
1.9 How fixture is differ from jig:-
S.No. Jigs Fixtures

Fixture holds the component being
Jigs incorporate bushes that machined with the cutters working
1. guide the tools. independently.
Jigs are used on drilling, They are used in connection with
reaming, tapping and counter turning, milling, grinding, shaping,
2. boring operations. planning, and boring operation.
Fixtures are dependent on specific
3. Jigs are depended on operation. machine tools.
Fixture are heavier in construction
and bolted rigidly on the machine
4. They are lighter than fixture. table.
They are more costly compare
5. to fixture. They are less costly.
They are not fixed on machine
6. table. They are fixed on machine table.
Table 1.2:-Difference between jig and fixture
1.10 Types of fixture:-

The fixture must be designed to withstand the forces generated by the machining process.
Allowances in fixture design, as well as part design, must be made with respect to firm clamping
of the work and in the robustness of the fixture itself. Additionally, the forces generated by the
tool should be directed toward the clamping whenever possible.
14
Fixtures are generally divided into five groups:

 Plate Fixtures – Plate fixtures are constructed from a plate with a variety of locators,
supports and clamps. They are the most common type of fixture because their versatility
makes them adaptable to a wide range of machine tools. They are made from many
different kinds of materials, which are governed only by the part being machined and the
process being performed.
 Angle-Plate Fixtures – Angle-plate fixtures are a modification of plate fixtures in that
rather than a reference surface parallel to the mounting surface, it is set perpendicular to
the mounting surface.
 Vice-Jaw Fixtures – Vice-jaw fixtures are modified inserts for vices designed to
accommodate a particular work-piece. These fixtures are the least expensive and
simplest to modify. The only limitations to these types of fixtures are size of the part and
capacities of available vices.
 Indexing Fixtures – Indexing fixtures are used to reference work-pieces that need
machining details set at prescribed intervals. Indexing fixtures must have a positive
means to accurately locate and maintain the indexed position of the part.
 Multi-Part or Multi-Station Fixtures – Multi-part or multi-station fixtures are normally
used for either machining multiple parts in a single setup, or machining individual parts
in sequence, performing different operations at each station.
In addition to their basic construction, fixtures may be classified in respect to the process or
machine tool to be used in the machining process. The primary types include:
 Milling Fixtures – Milling fixtures are the most common type of fixture and include
standard vices and clamps. However, as the work-piece size, shape and complexity
become more sophisticated so does the fixture. Tombstones, which are commonly
used on horizontal machining centre, come in a wide variety of configurations to hold
multiple parts on up to four sides of the fixture. The t-slots of the machine table are
standardized in size and spacing and are the primary means of holding work and
fixturing devices for machining. Fixtures are typically mounted to the table using a
variety of accessories such as clamps, straps, t-slot bolts, nuts and jacks.
 Lathe Fixtures – The same basic design principles that apply to milling fixtures also
apply to lathe, or turning, fixtures, with one major difference. In most milling
15
operations, the cutting tool rotates during machining, while with turning the part
rotates. This situation creates another condition the tool designer must deal with -
centrifugal, or rotational, force. Work-holding devices include two to six jaw chucks
and collets of varying shapes and diameters. Work may also be held between the head
and tail stock of the lathe or “between centers.”
 Grinding Fixtures – Grinding fixtures are a family of fixtures rather than a single
classification. The two major types of grinding fixtures are those used for surface
grinding and cylindrical grinding. The magnetic table is the preferred work-holding
device on surface grinders. Cylindrical grinding is usually a secondary operation after
turning. Often the same centre holes used for between-centres turning may be used for
grinding the part. As friction is more of a factor in grinding than in other processes,
fixture design must allow for coolant flow and swarf removal. If not built into the
grinding machine itself, the fixture design should include wheel dressing capability as
well.
 Broaching Fixtures – Broaching fixtures hold and locate the part in relation to the
broaching tool. Internal and external broaching requires different approaches to their
respective designs. Internal broaching requires less clamping because the process tends
to keep the part firmly seated on the fixture. External broaching requires resistance to
both pull and push forces that are exerted on the part, requiring more sophisticated
fixturing.
1.11 Safety consideration while designing and manufacturing fixture:-
Some of the factors that needs to be considered in designing and manufacturing fixtures are:
1. Clear sighting surfaces- worker should be able to see the work piece clearly without
bending or leaning towards the machine.
2. No sharp corners.
3. Bolts and nuts within the body and not protruding out.
4. Sufficiently stiff and rigid construction, must be attached firmly.
5. Controls and adjustment if any, should be located convenient to the operator to
preclude the necessity of reaching over or around, particularly where fixture is used on
power cutting machine.
6. Fixture should be strong enough for the job.
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7. The designs should incorporate standard clamping devices such as star hand wheels,
wing nuts, cam clamps, and lever clamps to avoid the necessity for handling wrenches,
thus eliminating many mishaps that usually accompany the use or misuse of this hand
tool.
8. The line of the clamping pressure should fall on or between stops to prevent spring
in the work. The clamping strain should fall within the fixture.
9. Locating points should be visible and easily accessible to the operator for cleaning
purposes when reloading.
10. Jigs should be of proper size to be readily handled.
11. On jigs that must be lifted frequently during the process, adequate handles should be
provided.
12. Care should be taken to design the jig so that the hands are clear of the cutting
blades during loading, cutting, and reloading cycles.
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Chapter:-2
About DITE Workshop
2.1 DITE workshop:-
A workshop is a building or room which contains work piece, tools or machinery for making
or repairing things, especially using wood or metal. The workshop in our college is of process
layout type, in its machines with similar functions are grouped together. The institute has
workshop equipped with latest machines. Workshop faculty of the Delhi institute of tool
engineering are very helpful which gives lots information related to manufacturing and guided us
so that no accident have been occur while machining.
Workshop Faculty:-
 MS Rawat (Technical officer)

 Sumer Singh Attri (Senior Technician)
 Guddu Tiwari (Technician)
 Subhash Chand Sharma (Technician)
A 2 dimensional layout of the DITE workshop is attached in the report file. Numbers of different
machines are given below in table 2.1.
Machine at DITE Number

Lathe M/c 5
Milling M/c 2
Shaper M/c 1
Grinding M/c 2
Drilling M/c 1
Tool & Cutter Grinder 1
Hydraulic Surface Grinder 1
CNC Universal Milling M/c 1
CNC Turning Centre 3
CNC Machine Centre 1
CNC Copying Milling M/c 1
Table 2.1:-Various machines at the DITE workshop.
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2.2 PLANT LAYOUT

Plant layout is an important part of an industry. Plant layout can be defined as ‘’“the plant
layout is the optimum arrangement of facilities including non-machine equipment, showing
the space allocated for material movement, storage, and all the supporting activities from the
receipt of raw materials to the shipping of finished goods”. The basic objectives of plant layout
are -
1. Simplification of production process in terms of maximum utilization (man, machine and

equipment), and the minimization of delays and cost of production.
2. Overall integration of all the activities to achieve the best flow of material in a sequence
that saves floor space and increases output with reduced inventories.
3. Achievement of better working conditions, supervision, control, higher flexibility and
adaptability to changing conditions.
Types of layout:-
1. Product or Line Layout:
If all the processing equipment and machines are arranged according to the sequence of
operations of the product, the layout is called product type of layout. In this type of layout, only
one product of one type of products is produced in an operating area. This product must be
standardized and produced in large quantities in order to justify the product layout.
The raw material is supplied at one end of the line and goes from one operation to the next quite
rapidly with a minimum work in process, storage and material handling.
Fig. 2.1 shows product layout for two types of products A and B
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Merits:-1.Flexibility of equipment and personnel.
2. Higher utilization of production facilities.
Demerits:-1.Increased production planning and control
2. More floor space is required in process layout than other types of plant layouts.
2. Process layout
The process layout is particularly useful where low volume of production is needed. If the
products are not standardized, the process layout is more low desirable, because it has creator
process flexibility than other. In this type of layout, the machines and not arranged according to
the sequence of operations but are arranged according to the nature or type of the operations.
This layout is commonly suitable for non-repetitive jobs.
Same type of operation facilities are grouped together such as lathes will be placed at one place,
all the drill machines are at another place and so on.
Figure 2.2:-Process layout
Merits:-1.Lowers total material handling cost and is less work in process.
2. Total production time is also minimized.
Demerits: - 1.No flexibility which is generally required is obtained in this layout.

2. A single machine breakdown may shut down the whole production line
3. Specialized and strict supervision is essential.
3. Fixed layout:-
20
This type of layout is the least important for today’s manufacturing industries. In this type of
layout the major component remain in a fixed location, other materials, parts, tools, machinery,
man power and other supporting equipment’s are brought to this location.
The major component or body of the product remain in a fixed position because it is too heavy or
too big and as such it is economical and convenient to bring the necessary tools and equipment’s
to work place along with the man power. This type of layout is used in the manufacture of
boilers, hydraulic and steam turbines and ships etc.
Merits
1. Material movement is reduced

2. Capital investment is minimized
Demerits
1. Highly skilled man power is required.
2. Movement of machines equipment’s to production centre may be time consuming.
3. Complicated fixtures may be required for positioning of jobs and tools. This may
increase the cost of production.
4. Combination Layout:-
Now a days in pure state any one form of layouts discussed above is rarely found. Therefore,
generally the layouts used in industries are the compromise of the above mentioned layouts.
Every layout has got certain advantages and limitations. Therefore, industries would to like use
any type of layout as such.
Flexibility is a very important factory, so layout should be such which can be molded according
to the requirements of industry, without much investment. If the good features of all types of
layouts are connected, a compromise solution can be obtained which will be more economical
and flexible
The type of layout of the workshop in our course of training was process layout.
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2.3 Image of DITE workshop:-
CNC TURNING CNC COPYING

CENTRE MILLING MACHINE
DRILLING
MACHINE
TOOL AND CUTTER
GRINDER MACHINE
MILLING
MACHINE ENTRY/EXIT
CNC UNIVERSAL CNC MACHINING SHAPER HYDRAULIC SURFACE
DOOR
MILLING MACHINE CENTRE MACHINE GRINDER MACHINE
LATHE MACHINE
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STAFF ROOM
GRINDER MACHINE
BENCH ROOM
SHAPING MACHINE
figure2.3 1:-Workshop of DITE
2.4 Specification of machine at DITE:-

 CNC Machining Centre
Machine institution year:-1993
Operator:-Fanuc
Under maintenance
 CNC Universal Milling Machine
NOVAR SPA
NAK:-Machine Automatic Centre
 CNC Copying Milling Machine
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FAGOR
 CNC Turning Centre (2)
Machine institution year:-1993 (DUPLD Standard)
E.E.C.S-231Z
Modello LX
 Turning Centre
Graziano Italy
Sag. 605
 Cons Lathe Machine (5)
Panther
Model:-1650/2
Serial Number:-538
 Cons Milling Machine (2)
Serial Number:-JY16081401
 Shaper Machine
Padam HS-18
 Tool and Cutter Grinding machine
 Hydraulic Surface Grinding Machine
ROSA Model Number:-8
Marposs
 Surface Grinder(2)
SGMT:-1224
2.5 Detail description about the machine at DITE:-
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1. Lathe machine:-
Working Principle: The lathe is a machine tool which holds the work piece between two
rigid and strong supports called centers or in a chuck or face plate which revolves. The
cutting tool is rigidly held and supported in a tool post which is fed against the revolving
work. The normal cutting operations are performed with the cutting tool fed either
parallel or at right angles to the axis of the work.
A lathe is a tool that rotates the work piece about an axis of rotation to perform various
operations such as cutting, sanding, knurling, drilling, deformation, facing, and turning,
with tools that are applied to the work piece to create an object with symmetry about that
axis.
Specification:-
MODEL 1650 / 2
Height of Centres mm 215
Swing over Bed mm 410
Swing over Slide mm 250
Between Centres mm 1500
Slide Movement mm 250
BED
Bed Type 2 Flat & 2V
mm
Bed Width 265
MAIN SPINDLE
Type & Size of Spindle Nose
Taper Bore in Center Sleeve MT A 2 Size 4
Spindle Bore mm 4
42
TAIL STOCK
Spindle Diameter mm
Taper Bore in Spindle Sleeve MT 45
4
SPEEDS
No. of Speeds
Range / RPM mm 8 / 16
45-938 / 30-1250
ELECTRICALS
HP 3
Main Motor
Power Supply 3 Phase
OTHER DATA
25
Kg 1550
Gross Weight
FLOOR SPACE
Occupied (L x W) 2350 x 1100 3350 x 1150

Packing Dimension 1750 x 1000 x 1300 2750 x 1050 x 1350
Table 2.2:- Panther lathe machine model 6050/2
Figure2.2:-lathe machine
2. Milling machine:-
Introduction: Milling is the cutting operation that removes metal by feeding the work against a
rotating, cutter having single or multiple cutting edges. Flat or curved surfaces of many shapes
can be machined by milling with good finish and accuracy. A milling machine may also be used
for drilling, slotting, making a circular profile and gear cutting by having suitable attachments.
Working Principle: The work piece is holding on the worktable of the machine. The table
movement controls the feed of work piece against the rotating cutter. The cutter is mounted on a
spindle or arbor and revolves at high speed. Except for rotation the cutter has no other motion.
As the work piece advances, the cutter teeth remove the metal from the surface of work piece
and the desired shape is produced.
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Figure2.3:-Milling machine
27
Specification:-
Model1 Model2 Model3 Model4
Technical 9" x 40" 10.5" x 48" 13" x 60" Automatic for
Specifications 220 x 975 mm 260 x 1200 mm 325 x 1470 mm Multi-purpose
of Ram Turret
Milling
Machine
Table size of 220 x 975 260 x 1200 325 x 1470 325 x 1470
Vertical Drive
Milling
Machine
Vertical Travel 345 440 480 480
Longitudinal 535 675 780 780
Travel Manual
Cross Travel 245 340 396 396
Table to 0 Min. 0 Min. 0 Min. 0 Min.
Spindle
Power Feed 526 640 785 785
Head Tilt 45º ...do.. ...do.. ...do.. ...do..
Up & Down
Head move 90º ...do.. ...do.. ...do.. ...do..
Left & Right
Horizontal
Quill spindle 86 mm 86 mm 90 mm 90 mm
diameter Hardened & Hardened & Hardened & Hardened &
Grinded Grinded Grinded Grinded
Head & Ram 360º 360º 360º 360º

Rotate Parallel
on body
Ram Travel 250 300 440 480

Overall Height, 1800x1200x130 2100x1500x180 2200x1764x200 2200x1764x2000
Width & 0 0 0
Length
Table2.3:-Milling machine specification
Technical Features:-
 Duly seasonal alloyed heavy duty casting.

 High quality steel is used in shafts & gears.
 Interchangeability of parts ensured through standardization & quality control.
28
 All sliding screws fitted with Bronze Bushes & bearing for smooth running & easy
interchangeability.
 Ram, Cross Slide. Main Working Table all alignments with Taper gib strips.
 The machines table accuracy is within one two Micron, plus host of other features like
Vibration free precision, honed head hardened & grinded, seasonal cast steel body
4. Shaper machine:-
Introduction: The shaper is a machine tool used primarily for:
1. Producing a flat or plane surface which may be in a horizontal, a vertical or an angular

plane.
2. Making slots, grooves and keyways
3. Producing contour of concave/convex or a combination of these
Working Principle: The job is rigidly fixed on the machine table. The single point cutting
tool held properly in the tool post is mounted on a reciprocating ram. The reciprocating
motion of the ram is obtained by a quick return motion mechanism. As the ram reciprocates,
the tool cuts the material during its forward stroke. During return, there is no cutting action
and this stroke is called the idle stroke. The forward and return strokes constitute one
operating cycle of the shaper.
Figure2.4:-Shaper Machine
29
Specification:-
24" 30" 36"

Length of stroke(in mm) 675 825 975
Max. Horizontal travel of table(in mm) 690 765 840
Max. Vertical travel of table(in mm) 365 415 465
Minimum Distance table to Ram(in mm) 40 40 40
Minimum Distance table to Ram(in mm) 405 405 405
Max. Vertical travel of tool slide(in mm) 152 152 152
Length & Width of table top(in mm) 600x335 675x335 750x335
Length & Depth of table slide(in mm) 600x410x370 675x410x370
750x410x370
Number of Ram cycles per minute 3 3 3
Range of Ram cycles per minute 20 to 60 15 to 60 15 to 60
Feed per pick up(in mm) 0.12 0.12 0.12
Tool Size(in mm) 32x25 32x25 32x25
Power of Motor(in kw) 2 5 5
Approximate Net weight(in kg) 1700 2000 2030
Floor Space(in mm) 2000x1250 2150x1250 2300x1250
Table2.4:-Specification of shaper machine.
5. Grinding Machine:-
The grinding machine consists of a bed with a fixture to guide and hold the work piece,
and a power-driven grinding wheel spinning at the required speed. The speed is
determined by the wheel’s diameter and manufacturer’s rating. The grinding head can
travel across a fixed work piece, or the work piece can be moved while the grind head
stays in a fixed position. Fine control of the grinding head or table position is possible
using a Vernier calibrated hand wheel, or using the features of numerical controls.
Grinding machines remove material from the work piece by abrasion, which can generate
substantial amounts of heat. To cool the work piece so that it does not overheat and go
outside its tolerance, grinding machines incorporate a coolant. The coolant also benefits
the machinist as the heat generated may cause burns. In high-precision grinding machines
(most cylindrical and surface grinders), the final grinding stages are usually set up so that
they remove about 200 nm (less than 1/10000 in) per pass - this generates so little heat
that even with no coolant, the temperature rise is negligible.
30
Figure2.6:-Surface grinding machine
Specification:-
31
Table 2.5:-surface grinding machine specification
5.CNC Milling machine:-
Milling is the machining process of using rotary cutters to remove material[1] from a work piece

by advancing (or feeding) the cutter into the work piece at a certain direction [2]. The cutter may
also be held at an angle relative to the axis of the tool. [3] Milling covers a wide variety of
different operations and machines, on scales from small individual parts to large, heavy-duty
gang milling operations. It is one of the most commonly used processes for machining custom
parts to precise tolerances.
Milling can be done with a wide range of machine tools. The original class of machine tools for
milling was the milling machine (often called a mill). After the advent of computer numerical
control (CNC), milling machines evolved into machining centers: milling machines augmented
by automatic tool changers, tool magazines or carousels, CNC capability, coolant systems, and
enclosures. Milling centers are generally classified as vertical machining centers (VMCs) or
horizontal machining centers (HMCs).
Specification:-
Table 2.7 CNC milling machine specification
32
Figure2.7: - CNC milling machine.
6. CNC Turning Machine:-
CNC turning refers to the automated machining process of shaping material, such as
metal, wood or plastic, using a computer numeric control (CNC) machine. In contrast to
traditional turning utilizing a lathe, which usually requires continuous operator attention,
CNC turning allows for multiple cutting actions to be completed under computer control.
During the CNC turning process, a piece of material (wood, metal or plastic) is rotated
and a cutting tool is moved parallel to the axis of rotation to produce precise diameters
and depths. CNC turning can be performed on the outside of the work piece or the inside
(also known as boring) to produce tubular components to various geometries.
CNC machine tool is in accordance with the preparation of a good pre-processing

procedures, automatic processing of parts to be processed. We have the parts of the
processing process line, process parameters, tool movement trajectory, displacement,
cutting parameters (spindle speed, feed, back to eat knife, etc.) and auxiliary functions
(tool change, spindle forward, Cutting fluid on, off, etc.), in accordance with the NC
machine tool specified by the instruction code and program format written into the
processing program, and then the contents of this program recorded on the control
medium (such as perforated tape, tape, disk, ), And then input to the CNC machine tool
CNC device, which command machine parts processing.
33
Specification:-
Table2.7:-CNC turning machine
Figure2.7:-CNC turning machine
CHAPTER:-3
34
COMPONENT DRAWING
2 NAME DATE DELHI INSTITUTE OF TOOL

2010 ENGINEERING
DRN. RASHMI 27/12/17 OKHLA INDS. AREA
RANI NEW DELHI-110020
CHD.
APD. MILLING FIXTURE DRG.NO:-1
SCALE 1:1 (DETAIL DRAWING)
ALL DIM.ARE IN MM SHEET (1) OFF (5)
35

2010 ENGINEERING
CHD.
36

2010 ENGINEERING
CHD.
37

2010 ENGINEERING
CHD.
38
CHAPTER:-4
PROCESS SHEET OF DITE

4.1 Process Planning:-
• Process planning is also called: manufacturing planning, process planning, material processing,
process engineering, and machine routing.
• Which machining processes and parameters are to be used to convert (machine) a piece part
from its initial form to a final form predetermined from an engineering drawing. The act of
preparing detailed work instructions to produce a part.
4.2 Product Realizations at DITE:-
Product design
Process,
Machine
Knowledge
Process planning
Sequence of operation
Verification
Scheduling
Knowledge
Scheduling
Execution
39
DESIGN
PROCESS PLANNING
MACHINE TOOL SCHEDULING AND
PRODUCTION CONTROL
4.3 FACTOR AFFECTING PROCESS PLAN SELECTION:-
 Shape
• Tolerance
• Surface finish
• Size
• Material type
• Quantity
• Value of the product and Urgency
• Manufacturing system itself
4.4 STEPS FOR PROCESS PLANNING FOR MANUFACTURING OF

FIXTURE
 Study the overall shape of the part. Use this information to classify the part and determine
the type of workstation needed.
 Thoroughly study the drawing. Try to identify every manufacturing features and notes.
40
• If raw stock is not given, determine the best raw material shape to use.
• Identify datum surfaces. Use information on datum surfaces to determine the setups.
• Select machines for each setup.
• For each setup determine the rough sequence of operations necessary to create all the
features.
• Sequence the operations determined in the previous step.
• Select tools for each operation. Try to use the same tool for several operations if it is
possible. Keep in mind the trade off on tool change time and estimated machining time.
• Select or design fixtures for each setup.
• Evaluate the plan generate thus far and make necessary modifications.
• Select cutting parameters for each operation.
• Prepare the final process plan document.
4.5 SEQUENCE OF OPERATION FOR MANUFACTURING OF

FIXTURE:
RAW MATERIAL SELECTION TO GET THE REQUIRED SHAPE

CUTTING THE RAW MATERIAL AND SURFACE FINISHING
ACCORDING TO THE
REQUIRED DIMENSION
SHAPER MACHINE
MILD STEEL HACKSHAW/POWER MILLING MACHINE
HACKSHAW GRINDING MACHINE
DEBURRING
ASSEMBLE ALL THE MAKING HOLE AND

COMPONENT TO GET TAPPING ACCORDING TO GIVE THE SHAPE TO THE
MILLING FIXTURE THE INFORMATION GIVEN WORKSHIP AS SHOWN IN
IN THE DESIGN THE DESIGN AND THEN
SURFACE FINISHING
ASSEMBLE MILLING MACHINE
MILLING FIXTURE DRILLING MACHINE MILLING MACHINE
TAPPING GRINDING MACHINE
41
CHAPTER:-5
OPERATION FOR FIXTURE MANUFACTURING AND

CUTTING TOOL USED
5.1Material Selection and cutting Stock material:-
5.1.1Raw material selection and how we cut the workpeice:

 Firstly we had studied the component design and then make a process sheet for further
going of work.
 Stock material available for machining the locating block for the milling fixture was MS.
We took the stock material available to us from the inventory.
 After the selection of material, we have gone to the bench room for cutting the
workpeice according to the dimension.
 We took rough marking on the top surface of stock material of size ‘65x71’ for back
plate and of size ‘72 x 95’for clamping plate using a steel rule and a pencil.
 We had hold the stock material in bench vise in the bench room
 We have cut the stock material using hacksaw giving some extra margin in the stock
material while rough marking so that we can compensate if there is any change in the
workpeice size.
Figure 5.1:- Cutting the Stock material using hacksaw.
42
5.1.2 Cutting tool used:-
5.1.2.1 Hacksaw:-
Figure 5.2:- Typical full-size hacksaw frame, with 12" blade

A hacksaw is a fine-toothed saw, originally and mainly made for cutting metal. The equivalent
saw for cutting wood is usually called saw. Most hacksaws are hand saws with a C-shaped frame
that holds a blade under tension.
5.1.2.1.1 How to use hacksaw and its safety precaution:-
Saws are made in various shapes and sizes and for many uses. Use the correct saw for the job.
 Wear safety glasses or goggles, or a face shield (with safety glasses or goggles).
 Select a saw of proper shape and size for stock being used.
 Select a saw with the number of teeth per inch (TPI) in order to get the desired finish. For
example: a coarse tooth blade (e.g., 2 or 3 TPI) should be used for thicker stock. 18 to 32
TPI should be used on thinner metals or plastic (0.5 cm or 1/4 inch). General Wood
cutting typically requires about 4 TPI.
 Choose a saw handle that keeps wrist in a natural position in the horizontal plane.
 Choose saw with a handle opening of at least 12 cm (5 in.) long and 6 cm (2.5 in.) wide
and slanted at a 15° angle.
43
 Check the stock being cut for nails, knots, and other objects that may damage or buckle
saw.
 Start the cut by placing your hand beside the cut mark with your thumb upright and
pressing against blade. Start cut carefully and slowly to prevent blade from jumping. Pull
upward until blade bites. Start with partial cut, then set saw at proper angle.
 Apply pressure on down stroke only.
 Use a helper, a supporting bench or vise to support long stock if required.
 Keep teeth and blades properly set.
 Protect teeth of saw when not in use.
5.1.2.1.2 What should I know about using a hacksaw?
 Select correct blade for material being cut.

 Keep blade rigid, and frame properly aligned.
 Cut using steady strokes, directed away from you.
 Use entire length of blade in each cutting stroke.
 Use light machine oil on the blade to keep it from overheating and breaking.
 Cut harder materials more slowly than soft materials.
 Clamp thin, flat pieces requiring edge cutting.
 Keep saw blades clean and lightly oiled.
 Do not twist when applying pressure.
 Do not use when the blade becomes loose in the frame.
5.1.3 Measurement:-
5.1.3.1 Scale:-
We had used scale for the rough marking and measuring of stock material for back plate and
clamping plate.
5.1.4 Cutting Time:-
44
Cutting time is about 2-3 hour for each back plate and clamping support plate.
5.2Roughening operation:-
5.2.1 Giving rough size to the “back plate” and “clamping plate” in the
Shaper Machine:-
 Firstly mark the rough size of ‘62x68’ for back plate and ‘69x92’ for clapping
support plate.
 Then for providing support block to the stock material so that it is rigidly held on
the in vise or clamped directly on the table.
 Single point cutting tool held properly on in the tool post is mounted on
reciprocating ram
 Before starting the machine, we had assured about positioning and clamping.
 Start the machine and stop at appropriate position so that depth of the cut is
adjusted by moving the tool downwards towards the workpeice.
 As the ram reciprocates, the material cuts in forward stroke.
 Repeating this operation until we did not got the mark size.
Figure 5.3:-
Giving rough dimension to the stock material in the Shaper Machine
45
5.2.2 Safety precautions:-

 No alteration or adjustment should be done on the machine parts while the machine is on.
 Clamps holding the work should not be adjusted while the machine is on.
 The machine is to be stopped before cleaning the metal.
 The sharp edges of the work should be handled with hand.
 The measuring of the work should be done only after the machine is switched.
 The operator should not seek the assistance of others for starting and stopping the
machine.
 Machining of precise parts and internal surfaces of the work piece are to be carried out
with great care
 The operator should stay away from direction of the ram.
5.2.3.1 Single point cutting tool:-
It is simplest form of cutting tool & it have only one cutting edge. A single point
cutting tool consists of a sharpened cutting part and the shank and main parts or elements which
are:
1: Shank
It is the main body of the tool.
2: Flank:
The surface or surfaces below the adjacent to the cutting edge is called flank of the tool.
3: Face
The surface on which the chip slides is called the face of the tool.
4: Heel
It is the intersection of the flank and the base of the tool.
5: Nose
It is the point where the side cutting edge and end cutting edge intersect.
6: Cutting Edge
46
It is the edge on the face of the tool which removes the material from the work piece. The cutting
edge consists of the side cutting edge (major cutting edge) and cutting edge (minor cutting edge)
and the nose.
47
Figure 5.4:- single point cutting tool
Tool signature:-
The seven elements that comprise the signature of a single point cutting tool are always
stated in the following order:
1. Back rake angle

2. Side rake angle
3. End relief angle
4. Side relief angle
5. End cutting edge angle
6. Side cutting edge angle and
7. Nose radius
5.2.3 Measurement:-
5.2.3.1 Scale:-
We had used scale for the rough marking and measuring of stock material according to
the requirement for back plate and clamping plate.
5.2.4 Machining Time:-
Machining time of shaper machine for complete shaping was about 1-2 hour for each back plate
and clamping support plate Apart from total volume of material ,feed rate ,cutting velocity, depth
of cut etc. ,quick return ratio also affect the machining time
48
5.3 finishing operation:-
5.3.1 Finishing of back plate and clamping plate in milling machine:-
 Firstly mark the rough size of ’60.5x66.5’ for back plate and ’67.5x90.5’ for clapping
support plate.
 And the we had rigidly clamp the workpeice on the milling vise and held it on the milling
table.
 We had use small blocks, so that workpeice is rigidity clamped and provide support to it.
 End milling cutter is held properly on its position using collet.
 Start the machine and stop at appropriate position so that depth of the cut is adjusted by
moving the tool downwards towards the workpeice and move the table using transverse
handle and cross traverse handle accordingly.
 Sufficient amount of coolant is given over the workpeice and tool.
 Repeating this operation until we did not got the mark size.
 Surface finishing in it is better than the shaper machine.
Figure 5.5:-Performing finishing operation on milling machine while manufacturing the milling
fixture
49
5.3.2 Safety Precaution:-
 Do not make contact with the revolving cutter.
 Place a wooden pad or suitable cover over the table surface to protect it from possible
damage.
 Use the buddy system when moving heavy attachments.
 Do not attempt to tighten arbor nuts using machine power.
 When installing or removing milling cutters, always hold them with a rag to prevent
cutting your hands.
 While setting up work, install the cutter last to avoid being cut.
 Never adjust the work piece or work mounting devices when the machine is operating
 Chips should be removed from the work piece with an appropriate rake and a brush.
5.3.3.1 End milling cutter:-
An end mill is a type of milling cutter, a cutting tool used in industrial milling applications. It is
distinguished from the drill bit in its application, geometry, and manufacture. While a drill bit
can only cut in the axial direction, a milling bit can generally cut in all directions, though some
cannot cut axially. End mills are used in milling applications such as profile milling, tracer
milling, face milling, and plunging.
50
END MILL
CUTTER
Figure 5.6:- End mill cutter
5.3.4 Tool holder:-
Collet:-
It is a subtype of chuck that forms a collar around an object to be held and exerts a strong
clamping force on the object when it is tightened, usually by means of a tapered outer collar. It
may be used to hold a work piece or a tool. An external collet is a sleeve with a (normally)
cylindrical inner surface and a conical outer surface. The collet can be squeezed against a
matching taper such that its inner surface contracts to a slightly smaller diameter, squeezing
the tool or work piece to hold it securely. Most often this is achieved with a spring collet, made
of spring steel, with one or more kerf cuts along its length to allow it to expand and contract.
Figure 5.7:-Collet
5.3.5 Measurement:-
5.3.5.1 Scale:-
51
We had used scale for the rough marking and measuring of stock material according to
the requirement for back plate and clamping plate.
5.3.5.2 Vernier Caliper

It is a precision instrument that can be used to measure internal and external distances
extremely accurately. The example shown below is a manual caliper. Measurements are
interpreted from the scale by the user. This is more difficult than using a digital Vernier caliper
which has an LCD digital display on which the reading appears. The manual version has both an
imperial and metric scale. Manually operated Vernier calipers can still be bought and remain
popular because they are much cheaper than the digital version. Also, the digital version
requires a small battery whereas the manual version does not need any power source.
Figure 5.8 Vernier caliper
5.3.6 Machining time:-

Machining time is the time when a machine is actually processing something. Generally,
machining time is the term used when there is a reduction in material or removing some
undesirable parts of a material.
Here machining time is less than 1 hour for each back plate and clamping support plate. The total
volume of material, feed rate, cutting velocity, depth of cut etc. affect the machining time.
5.5:-Grinding Operation:-
52
5.5.1 Steps involved in grinding operation:-

 Firstly remove the burr of nest plate and workpeice on the side which to place in the
magnetic chuck, so both are deburred using oil stone.
 Nesting is required in case of base plate because of small size where it provide support to
side where size is small.
 Nesting is not required in clamping support plate as it have sufficient strength to
overcome cutting force of grinding wheel.
 We had sure that workpeice is properly clamp to the magnetic chuck.
 Initially we had given small depth of cut so that it just touches the grinding wheel.
 Movement across transverse side is automatic while the cross transverse wheel is used to
control movement in cross traverse direction.
 Process is repeated until we did not get dimension given in design sheet.
 Surface finishing is very nice as it remove the chip from it which is in micron.
NESTING PLATE
Figure 5.9:-performing grinding operation for surface finishing in grinding machine.
5.5.2 Safety precaution:-
53
 Check the Speed.

 Check Grinding wheel and Grinding Guard.
 Ensure proper assembly of flanges and other parts.
 Use Right Wheel Dimension.
 Always Test Before Running
 Always Wear Personal Protective Equipment.
 Carry Out Maintenance at Regular Intervals of Time.
5.5.3 Cutting tools used:-
Grinding wheels:-
It is a wheel composed of an abrasive compound and used for various grinding (abrasive
cutting) and abrasive machining operations. Such wheels are used in grinding machines. The
wheels are generally made from a composite material consisting of coarse-particle aggregate
pressed and bonded together by a cementing matrix (called the bond in grinding wheel
terminology) to form a solid, circular shape. Various profiles and cross sections are available
depending on the intended usage for the wheel. They may also be made from a solid steel or
aluminum disc with particles bonded to the surface. Today most grinding wheels are artificial
composites made with artificial aggregates, but the history of grinding wheels began with
natural composite stones, such as those used for millstones.
Figure5.10:-Grinding wheel
5.5.4 About deburring operations:-

Deburring operation being performed to remove the burr in the workpeice. The tool being used
for the removal of burr called deburring tool. In our workshop, the “Oil stone” is used to remove
the burr. We had performed this operation when we need to nesting plate to remove the burr in
the side which is need to be over the magnetic chuck .If the burr had not removed then their
54
chance of severe accident and it can destroy the workpeice, so deburring is very important
operations which should not be neglected.
Figure5.11:-Oil stone
5.5.5 Measurement:-
1. Scale
2. Vernier caliper
It takes about more than 1 hour for finishing each of the base plate and clamping support
plate.The total volume of material, feed rate, cutting velocity, depth of cut etc. affect the
machining time.
5.6 Cutting slot in the “Clamping support block” on the milling machine:-
5.6.1 Steps for cutting slot in Milling machine:-
 Firstly marks the line for angular cutting using the dimension given in the component
drawing.
 Now note down the angle at which slot is being cut.
 Initially cut using end mill cutter of diameter 8mm until their have same height being cut.
 And we had rotate the milling machine head of angle 30degree and the fixed at that place
 Be assured that machine is rigidly mounted on the vise and held it on the machine table.
 Now giving depth of cut of about 0.2-0.4 depth of cut we give the angular cut step wise
and using traverse and cross-traverse handle move the cutting tool over the workpeice i.e.
Using manual feed.
 We had provided the coolant on the tool and workpeice so that there should not be any
wear and tear on the workpeice.
55
 We had repeated the above step to get the desired shape as in the component design
5.6.2 Safety Precaution:-
 Carefully rotate the head of milling machine.

 After rotating, head of the milling machine is rigidly mounted.
 Coolant should be given sufficient amount.
56
Figure5.12:-Performing angular and slot cutting operation in the Milling machine.

In this operation 1-2 hours taken in the manufacturing of clamping support block
57
5.7 Drilling operation:-
5.7.1 Steps for the drilling hole on the milling machine

 Firstly mark the two perpendicular line on the workpeice to get the center of the circle.
 Then we mark all the center on the workpeice.
 We had make hole of diameter 8mm and 6mm.
 Threaded hole are being made by using standard for the conversation of metric into mm.
 Then we had made hole using standard for threaded hole.
Figure5.13:-Drilling on the milling Machine
Drill bits
They are cutting tools used to remove material to create holes, almost always of circular cross-
section. Drill bits come in many sizes and shapes and can create different kinds of holes in many
different materials. In order to create holes drill bits are usually attached to a drill, which
powers them to cut through the work-piece, typically by rotation. The drill will grasp the upper
end of a bit called the shank in the chuck.
58
Figure5.14 Drill Bit
5.7.3 Machining Time:-

It take 30-45 minute to complete the operation.
5.8 Tapping operation:-

Tapping operation to complete thread in the hole where required.
Figure5.15 Tap
Taps
A tap cuts or forms a thread on the inside surface of a hole, creating a female surface which
functions like a nut.
59
Figure5.16:- Base plate
Figure5.17:-
Clamping support plate
60
CONCLUSION
After undergoing a 2 week of In house training in the college I had learnt machining learnt how
to operate shaper machine, grinding machine, milling machine etc. I found myself enjoying this
project throughout the process. Especially when remembering my experiment with the strings in
the workshop and how much it annoyed me every time I was entering workshop, I feel I engaged
really well with the subject. For this project I have done things that I’ve never done, like I used
to learn every single thing which make my project more beautiful and tried to record everything.
In this training we had learnt about manufacturing and designing of fixture.
All faculty of workshop are very cooperative, they always helps us during machining of job.
They gave me a lot of exposure on the terms of reference and procedure related to the process of
my work.
Exposure that where given to me by this college workshop can provide the picture on a real life
industrial situation, the task and responsibility that would be carried by me on the field.
Although, I feel there are improvements to be made on how the viewer perceive what I am
trying to communicate. I’m thankful to each and every student and teacher staff who helped me
in every aspect of my training. I’m so happy that will recommend further upcoming students who
will give exam in ipu to recommend to take admission in this college.
61

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DESIGNING AND MANUFACTURING OF FIXTURE

IN-HOUSE TRAINING REPORT

Designing and Manufacturing of fixture

(Roll no. 02370208615)

UNDER THE GUIDANCE OF

MR. VAIBHAV CHANDRA

MR. M.S. RAWAT

Department of Tool Engineering,

Delhi Institute of Tool Engineering,

Okhla Industrial Area, Phase-II, New Delhi-110020

I also wish to express my indebtedness to my parents as well as my family member whose

1. M.Tech (Tool Engineering)

About DITE Workshop...................................................................................................................................... 19

PROCESS SHEET OF DITE.................................................................................................................................. 39

OPERATION FOR FIXTURE MANUFACTURING AND CUTTING TOOL USED......................................................42

1.2 Difference between jig and fixture 15

2.1 Various machines at the DITE workshop. 24

2.3 Panther lathe specification 26

2.4 Milling machine specification 28

2.5 Grinding Machine specification 31

2.6 CNC Milling machine specification 32

2.7 CNC Turning machine specification 34

Figure no. Figure name page no.

2.1 Workshop image 14

2.2 lathe machine 26

2.3 Milling machine 27

2.4 Shaper machine 29

2.5 Grinding machine 31

2.6 CNC Milling machine 33

2.7 CNC turning machine 34

5.1 cutting stock material 42

5.3 Rough dimensioning on 45

5.4 Single point cutting tool 48

5.5 finishing operation on 49

5.6 End mill cutter 49

5.8 Vernier caliper 51

5.9 grinding operaton 52

1. Rashmi Rani (027) 7. Sudhanshu (424)

2. Nitesh Kumar (023) 8. Sachin Goyal (030)

3. Amit (404) 9. Subham Kumar Nehra (031)

4. Rahul Kumar (427) 10. Anil Kumar (408)

5. Sushil (428) 11. Aman (005)

6. Vivek Kumar (037)

Figure 1.1 a typical fixture

1.3 Elements of Fixture

1.4 Selection of Materials

Contains (<0.3% carbon). Most suitable for most jigs applications as it is

Contain carbon (0.85%~1.18%). Most suitable for work pieces like

Contains tungsten (18% ~22%) for toughness and cutting strength,

Contain carbon (0.45% ~ 0.65%) and alloys Ni2Cr1M028 (40%). Most

Contains carbon (1.5%~2.3) for hardness, high chromium (12%) but

Oil Hardening Contain carbon (0.9%~1.1%), tungsten (0.5%~2%) and carbon

Contain carbon (2%~2.5%). Most suitable for milling fixture as it can

to work pieces under high pressure force

Phosphor Bronze Most suitable in corrosive resistance such as boiler valve

Table1:-Materials used in fixture

1.5 Fixture Design Fundamentals

1.6 Fixture Design Procedure:-

The following outputs are included in the fixture plan:

 Fixture type and complexity

1.7 Advantage of fixture:-

1.8 Disadvantage of fixture:-

 They have very tough and complicated design.