J.

ANISH RAJA-412512114012
A.DEV ANANDH-412512114036
R.GOWRI SHANKAR-412512114051
B.GOWTHAM-412512114052

Mr.M.C.ANAND CHAKARAVARTHI,
Assistant Professor,
Department of Mechanical Engineering
The design of a fixture depends a lot on the designer’s expertise and
experience and hence no solution is optimal or near optimal for a given
work piece. For a Gear hobbing fixture also there are multiple designs
possible. This paper is about redesigning of a hobbing fixture to make it
common for the other gears’ manufacturing and reduce the no of
settings of the fixture on the hobbing machine. There by reducing
company’s cost & time. The design was checked and validated for
safety under the action of cutting forces.
Setup change time reduction

EEI reduction

Variation due to setups reduction

Machine availability improved

Cam Gear G4 G6 Comp Drive G6
G4

G5

OPD Gear G3 FIP Gear G5

G3
G2

G1
Crank Gear G1 Idler Gear G2
LA10841
LA10842
LA10843
LA10844
LA10845
LA10846
Machine : P254 3 Axis CNC Hobbing M/C
Component : Various H Timing Gears
Process : Hobbing-Conventional
Material : 16MnCr5
Hob material : HSS M35 Coated
Job Holding : Expansion collet draw bar
Holding method : Hydraulic actuated draw bar
Coolant : Castrol Ilocut 1945
Hydraulic Oil : Servo AW68
 SMED PROCEDURE

STEP ( A ) – Observe the current Methodology

STEP ( B ) - Separate Internal, External & Waste Activities

STEP ( C ) – Convert Internal Activities into External Activities

STEP ( D ) – Improve Internal & External Activities

DOCUMENT NEW PROCEDURE & DO IT ALL AGAIN

 Ranking matrix of problem (Scale : 1 to 10)
Tool Setup Quality Machine Work area Material
Members change change time problems breakdown 5S condition
K Sabapathy 4 9 3 3 2 2
PV Ramsuresh 4 9 3 3 2 2
Franklin 4 9 3 3 2 2
Prakash 4 9 3 3 2 2
C Krishnamoorty 4 9 3 3 2 2
Total 20 45 15 15 10 10

Higher points given for ‘Setup change Time’

Large time loss due to setup change
in Hobbing.
Expensive High tech CNC machines
idle during the setup change.
Entire line will become idle during this
time.
Delay in delivering the product due to
huge setup time delay

Variation in meeting the quality

standards between setup changes
To reduce Setup change Time loss in
Hobbing operation from 420 Minutes
to 60 Minutes within 2 months.
H Timing Gear Soft Operations

Mini Hob Wash Deburring

Output
Market Opn.20 Opn.30 Opn.40
to HT
(BOSF)
Drilling
Opn.50
 Process flow diagram
BOSF
BLANKS To HT
20 30 40 50

To Shop 1

90 80 70

To
Engine
100 110 115 120 125 127 Assembly
Opn no Description 100 Grind bore & Boss face
20 Hob gear teeth 110 Grind other face
30 Washing 115 Intermediate wash
40 Break sharp corners Prepared by:
120 Grind gear teeth
50 Radial slot milling and chamfer 125 Final washing
70 Heat treatment 127 Timing Mark punching
80 Shot Blast Approved by :
90 Inspection
 Component Setup loss in
Operation no Machine name
process Minutes

20 Premier Hobbing Teeth Hobbing 420

30 Grind Master Teeth Deburring 15

40 Protel Key Way Broaching 20

 Baseline Target Duration
Aspects
Minutes Minutes Months
2
Setup
420 60 (JAN &
Change time
FEB’16)
Cause & Effect Diagram
Men Machine
Improper Auto cycle
Lack of erratic
loading Hydraulic
training
Pressure
Improper
tools less Process High Speed
knowledge & Feed Machine stalls
On load

Higher
setup time
Material
Ineffective Hardness
Fixture design
Clamping For different jobs Excess
Allowance
Sequence
Wrong loading Not maintained Hard
Of component spots Unsuitable
Tool material
Component
Location

Method Material
 Fixture design for different jobs

 Component location
 Enabler Diagram to reduce the setup change

Redesign the fixture to To provide separate

accommodate both type bung to suit every
of ACD Gear component OBJECTIVE
To reduce Setup
ENABLERS
Change time

Change the Procure new machines

Hobbing process for every component
Redesign the fixture to accommodate both type of
components
Existing M/C construction is not suitable for this
solution

Change the hobbing process

Existing hobbing process can not be avoided

Procure new machines for every component

Will need huge capital investment

To provide separate bungs to suit the height variation

This can be possible with out any investment