Design Of Fixture For Full Bore Gate
Valve
PRESENTED BY
ANTONY RAJ .C (Reg. No. 960614114016)
ARUN B (Reg. No. 960614114022)
ASHOK KUMAR . A (Reg. No. 960614114025)
BERLIN VINCE .E (Reg. No. 960614114027)
Under the Guidance of,
Mr. VIJAY WIILLS M.E., (Supervisor)
Assistant Professor,
Department of Mechanical Engineering,
DMI Engineering college,
Aralvaimozhi - 603 130.
1
BHEL INTRODUCTION
“A GLOBAL ENGINEERING ENTERPRISE SOLUTION FOR A BELLER
TOMORROW” presented by the Barath Heavy Electrical Limited (BHEL). The
origination is one among the top ten power generation equipment manufacturer. The
industry produces Gas Turbines, Steam Turbines, Turbo Generators, Boilers, Pumps,
Heat Exchangers, Pulverizes and Electrical Switch Gears. BHEL references in around
60 countries of the world. Its certifications to Quality Management Systems(ISO 9001),
Environment Management(ISO14001), Occupational Health and Safety Management
Systems(OHSAS 18001). The BHEL Trichy also engaged in design, engineering,
manufacture, construction, testing, commissioning and servicing for power,
transportation(railway) and renewable energy industries. They developing technology
for Integrated Gasification Combined Cycle(IGCC) power plants. It included with
Nano tech, fuel cells superconductivity and thin film solar cells. The organization
focused on innovation and R&D.
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ABSTRACT
Jigs and fixture are commonly called as work holding devices. They holds
the workpiece during machining processes. The purpose of work holding
devices for mass production.
The project is mainly aimed to produce fixture for “full bore gate valve”.
The process is to locate and clamp the gate for machining process.
3
LITRATURE REVIEW
ANTONY RAJ .C, ARUN B, ASHOK KUMAR . A, BERLIN VINCE .E
“DESIGN OF FIXTURE FOR FULL BORE GATE VALVE” IN THE JOURNAL
OF “ VALVE DESIGN AND ANALYSIS” reported that the gate valves are used for
safety shut down of stream to reduce the colloidal damage. There are different types of
gate valve available depends on the usage. FBV is the one of the widely used gate valve
and manufacturing of FBV is complicated. So, methods and manufacturing processes
are analyzed to adaptation of suitable process contacted for increasing of production.
Best production process improve the life time and economical value. Concluded with
the concept of using fixture for production. The fixture is made of steel material which
is available in economically dependent value.
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FULL BORE GATE VALVE
The FBV is Bi-Directional on-off control valve. The valve might able to
resist the high pressure flow to prevent leakage to control the damage.
Gate valves are used to isolate the flow or fully stop. To prevent the leak
the valve might be hydro tested. If the defect is found rework of valve
manufacturing is needed.
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PICTURE OF FBV
FBV
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PICTURE OF GATE
GATE OF FULL BORE GATE VALVE
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ALTERNATIVE METHODS
Laser Machining
High concentric laser beam is used to cut the metal. It is kind of
CNC machining. But compare with VMCs laser is high cost method.
Mold with closer tolerance
Molding the desired shape using casting is cheaper and easier
method. But formation of cavity, cracks and other defects may included.
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TYPE OF MACHING PROCESS
ANALYSED
VMC MACHINE
• The VMC states that “Vertical Milling Centre”. The operation of
machine controlled by computer. So, machining is precise and
expensive.
• The spindle runs in z-axis. Because the tool is mounded vertically on
the machine. Also, the VMC can change tool automatically.
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NECESSITY OF FIXTURE
FOR FBV
The machining can be done by VMC.
• Drawback
o High machining hour rate.
o Setting time.
o Reduced output.
• Overcome problem
o Fixture must be designed.
Setting time reduced.
Accuracy improved.
10
DIFFERENT FIXTURE DESIGNS
Choosing the best fixture design is essential to improve the Dimensional
accuracy.
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METHODOLOGY
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PROBLEM IDENTIFICATION
Widely avalible work holding devices are used to hold circular hollow
components. So, the unique design might be able to hold both horizontally
and vertically.
Strap locking mechanism is essential to holding the work during machining
processes. And the base metal should have better rigidity and withstand
vibration.
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MATERIAL SELECTION
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CUTTING FORCE CALCULATION
Boring
Speed N = 100 rpm
Feed rate = 1.25 mm/min
= 75 mm/rev
Width of cut = 20 mm
Depth of cut = 2 mm
Cutting power
cutting power = (Ap x Ac x vd x kc)/(60 x 10^6 x n)
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CALCULATION
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CUTTING FORCE CALCULATION
Clamping force
Clamping force = (Force/ Coefficient of friction)
Cutting force
Cutting force (Fc) = A.Kc = b.h.Kc
Where,
Ap = Depth of cut (mm)
Ac = Cutting width (mm)
Vd = Table feed per mm (mm/min)
Kc = Specific cutting force (Mpa)
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CALCULATION
Clamping force
= 854.08/0.15
= 5693.3 N
Cutting force
Specific cutting force (Kc) = 2280 N
Cutting cross section (A) = 2 mm^2
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CALCULATION
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BASE PLATE
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FABRICATION
Turning process
Facing process
Drilling process
Boring process
Stellate welding & centerless grinding
Polishing process
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STELLATE WELDING
Stellate alloys are composed of various amounts of cobalt, nickel, iron,
aluminum, boron, carbon, chromium, manganese, molybdenum,
phosphorus, sulfur, silicon, and titanium, in various proportions, most
alloys containing four to six of these elements.
The work piece surface is welded with stellate material in order to get a
hard surface. Then the welding surface is smoothened with grinding
operation.
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WORKING PRINCIPLE
The work piece is welded with a stellate material. This is because to
improve the hardness of the work piece.
The surface of the work piece is so rough due to stellate welding. This
surface can be smoothened by surface finish operation.
Then the work piece is drilled in the downside and the hole is also drilled
perpendicularly to the work piece.
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WORKING PRINCIPLE
This happens too much time in milling machine. By using fixture. The time
can reduced for producing a work piece.
This fixture contains stopper, holder(strap) which holds the work piece
tightly with the fixture.
Also there is a locating pin which is used to fix the fixture with lathe
machine. By removing the face plate in the lathe and then fixture this
instead of face plate. Easily work piece can be loaded and unloaded.
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PARTS REQUREMENTS
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COST ESTIMATION
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CONCLUSION
It is concluded that the design of fixture component overcome the difficulty
of producing FBV. And using this component will improve the accuracy.
Also, dimensional stability is more.
The replacement of lathe base plate by fixture able to increase the mass
production in industries. Comparing with manual method production this
design reduce the consumption of material. So, the reducing of
manufacturing cost leads to high production rate.
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FABRICATED FIXTURE
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FIXTURE HUGE SIZE
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REFERANCE
“Module 8 jigs and fixture for Machine shops” version -2 ME. IIT
Kharagpur.
Dr. G.K. Vijayaragavan, S.Sundharavalli “Design of jig, Fixture and
Press Tools” A.R.S Publications (2014).
P.H.Joshi “jigs and fixtures”, Tata McGraw Hill Education Pvt. Ltd.
Publications, 3rd Edition.
Donaldson C., LeCain G. H., Gold V. C., Ghose J., “Tool Design”
India, Tata McGraw-Hill, p. 495, (2002).
“DESIGN DATA, Data book of engineers” by PSG College of
Technology, Coimbatore- Kalaikathir Achchagam Publications.
Wilson F.W., Konecny A.R., and Potthof W.J., “Fundamentals of
tool design”, ASTME, Prentice-Hall, NJ, (1962).
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REFERANCE
International Journal of Engineering Research and General Science
Volume 2, Issue 2, Feb-Mar 2014 ISSN 2091-2730.
Benhabib, B (2003). Manufacturing-Design, Production,
Automation AND Integration. Marcel Dekker, New York, New York.
Boyes, William E (1982).Jigs and Fixtures. Society of Manufacturing
Engineers, Marketing Services Dept., Dearborn Mich.
Cincinnati T35 Specifications and Manuals.
Drozda, Tom. (1989). Jigs and Fixtures. Society of Manufacturing
Engineers, Publications Development Dept., Dearborn Mich.
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