Sample Soft

DESIGN A FIXTURE FOR ANNULUS RING GEARS TO
REDUCE SETUP TIME ON VERTICAL SHAPER MACHINE

A
REPORT
SUBMITTED IN PARTIAL FULFILLMENT OF THE
INDUSTRIAL PROJECT (4ME31) COURSE
For the award of
Bachelor of Technology
(Mechanical Engineering)
Submitted by
Krish Vataliya 19ME423
Soham Patel 20ME307
Under the guidance of
Er. Jinesh Patel
Prof. J. R. Koisa
At
Birla Vishvakarma Mahavidyalaya

Engineering College,
Vallabh Vidyanagar – 388 120
Affiliated to Gujarat Technological University
[An Autonomous Institution]
May 2023
CERTIFICATE
Date: 03 / 05 / 2023
This is to certify that the Industrial Project (4ME31) entitled “DESIGN A FIXTURE FOR
ANNULUS RING GEARS TO REDUCE SETUP TIME ON VERTICAL SHAPER
MACHINE.” has been carried out by Krish Vataliya and Soham Patel in the 8th semester
under my guidance in partial fulfillment of the degree of Bachelor of Technology in
Mechanical Engineering, Birla Vishvakarma Mahavidyalaya, Vallabh Vidyanagar, during
the academic year 2022-23.
Er. Jinesh Patel Dr. P. M. George

Industrial Guide, Head of the Department,
Elecon Engineering. BVM Engineering College.
Prof. J. R. Koisa
College Guide,
BVM Engineering College.
i
PROJECT PERMISSION LETTER
JJ
ii
ORIGINALITY REPORT CERTIFICATE
It is certified that Industrial Project (4ME32) - Report entitled “DESIGN A FIXTURE

FOR ANNULUS RING GEARS TO REDUCE SETUP TIME ON VERTICAL SHAPER
MACHINE.” has been carried out by Krish Vataliya and Soham Patel has been examined
by us. We undertake the following:
[1] Project has significant new work / knowledge as compared already published or
are under consideration to be published elsewhere. No sentence, equation,
diagram, table, paragraph or section has been copied verbatim from previous work
unless it is placed under quotation marks and duly referenced.
[2] The work presented is original and own work of the author (i.e., there is no
plagiarism).No ideas, processes, results or words of others have been presented as
Author own work.
[3] There is no fabrication of data or results which have been compiled / analyzed.
[4] There is no falsification by manipulating research materials, equipment or

processes, or changing or omitting data or results such that the research is not
accurately represented in the research record.
[5] The report has been checked using DUPLICHECKER (copy of originality report
attached) and found within limits, (i.e., permitted similarity index <= 20 %).
Soham Patel 20ME307
iii
ACKNOWLEDGEMENT
We would like to express our sincerest gratitude to Er. Jinesh Patel, Er. V. B. Senjaliya,
Er. Sachin Bhavsar, Er. Kiran Patel, Er. Nilesh Patel and along with other Elecon
Engineering personnel, and Prof. J. R. Koisa, Mechanical Engineering Department,
B.V.M Engineering College, for their guidance, time, and support. We consider ourselves
extremely fortunate to be able to work with such thoughtful and encouraging engineers
and professors as them. They have guided us throughout the project by sharing their
experience, expertise and other mandates. We also value their broad range of skills and
attention to every detail of our project; we would not have been able to complete the
project work without their offer to complete it.
We would also like to thank Dr. Vishal Pandya and Prof. Chintan Mazmudar, project
coordinators, along with Dr. P. M. George, Head of the Department of Mechanical
Engineering, B. V. M Engineering College, Vallabh Vidyanagar, for the opportunity to
work on this Industrial Project.
Soham Patel 20ME307
iv
ABSTRACT
Elecon Engineering is one of pioneers and leading designer and manufacturer of planetary
gear boxes for industry applications in material handling, sugar, marine, defense, cement,
chemical, food, power, agriculture and other applications. A planetary gearbox, which is
also referred to as an epicyclic gearbox is a gearbox configuration consisting of a planetary
carrier, sun gear as a sub assembly that meshes inside an annulus gear. The Annulus gear
is a type of gear that has teeth on the inside of a circular ring-shaped structure i.e., internal
gear. Elecon Engineering manufactures wide ranges of size of annulus gear on vertical
gear shaper machine and on Hobbing machine via internal milling attachment. Vertical
Gear Shaping is a versatile process for machining gear teeth on such a complex monolithic
component, which cannot otherwise be produced using other methods (like Hobbing) due
to geometric constraints. Nevertheless, the vertical shaper machines at Elecon
Engineering, Gear Division, (Machine Model - CJMT YKM51160C/28, CJMT
YKM51250C/7), have limitation of stroke length of the spindle, that the minimum stroke
is fixed and has adjustable maximum stroke, leading to a time-consuming and arduous
setup process when handling different job order components. Longer setup time have an
immediate impact on machine utilization and production time.
This report demonstrates the work of designing an offloading fixture, which is capable of
accommodating ranges of job order components for internal gear teeth generation i.e.,
annulus gear ring of varying diameters and face widths. The offloading fixture is designed
by an integrated methodology approach and with taking into account several factors. The
modeling of fixture and its elements are designed by considering the cutting force and
weight loads to which it will experience while in process. To ensure optimal properties
and manufacturing capabilities, different materials such as AISI 1010, AISI 1020, AISI
321, AISI 1045, AISI 361 are designated to different elements of fixture. The detailed
fixture is modelled in SOLIDWORKS. In order to validate safe design integrity of fixture,
it is statically analyzed and examined in SOLIDWORKS. The static structural analysis of
the fixture and its elements using Finite Element Analysis (FEA) determines the
displacements, stresses, strains, and factor of safety induced in structures or components
by applied loading condition. Multiple design alternatives for the fixture are presented,
most suitable design is selected to minimize setup time and improve manufacturing
efficiency.
v
TABLE OF CONTENT
CERTIFICATE .................................................................................................................. I
PROJECT PERMISSION LETTER ............................................................................. II
ORIGINALITY REPORT CERTIFICATE ................................................................III
ACKNOWLEDGEMENT .............................................................................................. IV
ABSTRACT ...................................................................................................................... V
TABLE OF CONTENT .................................................................................................. VI
LIST OF TABLES ........................................................................................................... X
LIST OF FIGURES ........................................................................................................ XI
NOMENCLATURE ..................................................................................................... XIII
1. INTRODUCTION ....................................................................................................... 1
1.1 FIXTURE SIGNIFICANCE ...................................................................................... 2
1.2 SHAPING PROCESS ................................................................................................ 4
1.3 CURRENT SHAPING FIXTURE ARRANGEMENT ............................................. 5
1.4 TIME STUDY OF MAIN LOSSES........................................................................... 6
2. LITERATURE REVIEW ........................................................................................... 8
2.1 LITERATURE REVIEW ........................................................................................... 8
2.1.1 DESIGN CONSIDERATIONS ........................................................................... 8
2.1.2 METHODOLOGY PHASES ............................................................................... 8
2.1.3 CONSIDERATION OF TOOL OVER RUN ...................................................... 8
2.1.4 3-2-1 PRINCIPLE ................................................................................................ 9
2.1.5 LOCATING PINS .............................................................................................. 10
2.1.6 CUTTING FORCE ............................................................................................ 10
2.1.7 V- BLOCK ......................................................................................................... 10
2.1.8 POWER SCREW ............................................................................................... 11
2.1.9 MATERIAL SELECTION ................................................................................ 11
2.1.10 GD&T STANDARDS ....................................................................................... 12
2.2 RESEARCH GAP .................................................................................................... 13
2.3 PROBLEM DEFINITION ....................................................................................... 14
2.4 OBJECTIVES .......................................................................................................... 14
3. METHODOLOGY .................................................................................................... 15
3.1 METHODOLOGY FLOW CHART ....................................................................... 15
3.2 CALCULATION ..................................................................................................... 16
vi
3.2.1 CUTTING FORCE CALCULATION ............................................................... 16
3.2.2 V – BLOCK CALCULATION .......................................................................... 17
3.2.3 POWER SCREW DESIGN USING MITCALC SOFTWARE ......................... 18
3.2.4 POWER SCREW MANUAL CALCULATIONS ............................................. 19
4. OBSERVATIONS...................................................................................................... 22
4.1 MACHINE INFORMATION .................................................................................. 22
4.2 PRINCIPLE OF MACHINE TOOL ........................................................................ 24
4.3 MANUFACTURING PROCESS AND SEQUENCE FOR ANNULUS GEAR .... 25
5. SET – UP PLANNING .............................................................................................. 28
5.1 RECORDING OF ANNULUS GEAR SPECIFICATIONS .................................... 28
5.2 OPERATION VARIABLES .................................................................................... 32
5.3 FIXTURING ELEMENTS REQUIRED ................................................................. 32
6. FIXTURE PLANNING ............................................................................................. 34
6.1 FIXTURE REQUIREMENT ................................................................................... 34
6.1.1 DESIGN OF ELEMENTS FOR LOWER PORTION OF FIXTURE ............... 35
6.1.1.1 SUPPORTING BLOCKS .............................................................................. 35
6.1.1.2 BASE PLATES ............................................................................................. 37
6.1.1.3 LOCATING PIN ........................................................................................... 38
6.1.2 DESIGN OF ELEMENTS FOR UPPER PORTION OF FIXTURE................. 38
6.1.2.1 SELF-CENTERING CHUCK ....................................................................... 38
6.1.2.2 STEPPED JAWS ........................................................................................... 40
6.1.2.3 V - BLOCK ................................................................................................... 41
6.1.2.4 POWER SCREW .......................................................................................... 42
6.2 FIXTURE LAYOUTS ............................................................................................. 43
6.2.1 FIXTURE LAYOUT 01 .................................................................................... 43
6.2.2 FIXTURE LAYOUT 02 .................................................................................... 44
6.3 FIXTURE LAYOUTS WITH MACHINE .............................................................. 46
6.4 MATERIAL LISTING ............................................................................................ 47
7. FIXTURE ELEMENTS DRAWING ....................................................................... 48
7.1 DRAWING SHEETS OF FIXTURE LAYOUT 01 ................................................ 48
7.1.1 DRAWING SHEETS OF FIXTURE COMPONENTS FOR GSP05................ 48
7.1.1.1 BASE PLATE................................................................................................ 48
7.1.1.2 SUPPORTING BLOCKS ............................................................................. 49
7.1.1.3 STEPPED JAWS .......................................................................................... 50
7.1.1.4 LOCATING PIN .......................................................................................... 51
vii
7.1.2 DRAWING SHEETS OF FIXTURE COMPONENTS FOR GSP07................ 52
7.1.2.1 BASE PLATE............................................................................................... 52
7.1.2.3 STEPPED JAWS .......................................................................................... 54
7.1.2.4 LOCATING PIN .......................................................................................... 55
7.2 DRAWING SHEETS OF FIXTURE LAYOUT 02 ................................................ 56
7.2.1 STEPPED V – BLOCKS ................................................................................... 56
7.2.2 POWER SCREW ............................................................................................... 57
7.2.3 POWER SCREW SUPPORTS .......................................................................... 58
8. FIXTURE DESIGN ANALYSIS .............................................................................. 59
8.1 STATIC ANALYSIS OF FIXTURE LAYOUT 01 ................................................. 60
8.1.1 STATIC ANALYSIS OF FIXTURE ELEMENTS OF GSP05 ......................... 60
8.1.1.2 LOCATING PINS ........................................................................................ 61
8.1.1.3 BASE PLATE AND JAW ............................................................................ 62
8.1.1.4 WORKPIECE CLAMPED ON BASE PLATE ........................................... 63
8.1.2 STATIC ANALYSIS OF FIXTURE ELEMENTS OF GSP07 ......................... 64
8.1.2.2 LOCATING PINS ........................................................................................ 65
8.1.2.3 BASE PLATE AND JAW ............................................................................ 66
8.1.2.4 WORKPIECE CLAMPED ON BASE PLATE ........................................... 67
8.2 STATIC ANALYSIS OF FIXTURE LAYOUT 02 ................................................. 68
8.2.1 STEPPED V – BLOCK JAWS .......................................................................... 68
8.2.2 WORKPIECE CLAMPED ON BASE PLATE USING STEPPED V –
BLOCK .............................................................................................................. 69
9. RESULTS AND DISCUSSION ................................................................................ 70
10. CONCLUSIONS ........................................................................................................ 71
10.1CONCLUSION 01 ................................................................................................... 71
10.2CONCLUSION 02 ................................................................................................... 71
10.3CONCLUSION 03 ................................................................................................... 72
REFERENCES ................................................................................................................ 73
PLAGIARISM REPORT ............................................................................................... 75
INTRODUCTION ........................................................................................................... 75
LITERUATRE REVIEW ................................................................................................ 75
METHODOLOGY .......................................................................................................... 75
viii
OBSERVATION ............................................................................................................. 75
SET – UP PLANNING ................................................................................................... 75
FIXTURE PLANNING ................................................................................................... 75
FIXTURE ELEMENTS DRAWING .............................................................................. 76
FIXTURE DESIGN ANALYSIS .................................................................................... 76
RESULT AND DISCUSSION ........................................................................................ 76
CONCLUSION ............................................................................................................... 76
ix
LIST OF TABLES
TABLE 1: SPECIFICATION OF GSP 05 MACHINE CJMT YKM51250C/7. [3] ......... 22

TABLE 2: SPECIFICATION OF GSP 07 MACHINE CJMT YKM51160C/28. [3] ....... 23
TABLE 3: ANNULUS GEAR SPECIFICATION. ........................................................... 31
TABLE 4: RANGES OF ANNULUS GEAR FACE WIDTH. ......................................... 31
TABLE 5: OPERATION VARIABLES. .......................................................................... 32
TABLE 6: AISI 1010 MATERIAL. [11] .......................................................................... 47
TABLE 8: AISI 321 MATERIAL. [9] .............................................................................. 47
x
LIST OF FIGURES
FIGURE 1: PLANETARY GEAR BOX. ............................................................................ 1

FIGURE 2: GEAR SHAPING CUTTER. [17].................................................................... 4
FIGURE 3: GEAR SHAPING PROCESS. [17] .................................................................. 4
FIGURE 4: FIXTURING ARRANGEMENT. .................................................................... 5
FIGURE 5: ELEMENTS OF CURRENT FIXTURING SETUP ARRANGEMENT. ....... 5
FIGURE 6: TIME STUDY OF GSP-05. ............................................................................. 7
FIGURE 7: TIME STUDY OF GSP-07. ............................................................................. 7
FIGURE 8: OVER RUN OF TOOL. [17] ........................................................................... 8
FIGURE 9: RESEARCH GAP FOR FIXTURE DESIGN. ............................................... 13
FIGURE 10: METHODOLOGY. ...................................................................................... 15
FIGURE 11: V - BLOCK WIDTH CALCULATION. ..................................................... 17
FIGURE 12: POWER SCREW CALCULATION IN SOFTWARE. ............................... 18
FIGURE 13: SQUARE THREADS. [20] .......................................................................... 19
FIGURE 14: TERMINOLOGY OF POWER SCREW. [20] ............................................ 19
FIGURE 15: DEVELOPMENT OF THREAD. [20] ........................................................ 19
FIGURE 16: FORCE DIAGRAM FOR LIFTING LOAD. [20] ....................................... 20
FIGURE 17: FORCE DIAGRAM FOR LOWERING LOAD. [20] ................................. 20
FIGURE 18: TORQUE MOVEMENT. [20] ..................................................................... 21
FIGURE 19: CUTTER BACK-OFF MOTION. [16] ........................................................ 24
FIGURE 20: ANNULUS GEAR MACHINING ROUTE. ............................................... 25
FIGURE 21: GEAR NOMENCLATURE. [15] ................................................................ 28
FIGURE 22: CLAMPING ELEMENTS. [14]................................................................... 32
FIGURE 23: FIXTURE CLAMPING ELEMENTS. [14] ................................................. 33
FIGURE 24: SUPPORTING BLOCK - GSP05. ............................................................... 35
FIGURE 25: SUPPORTING BLOCK - GSP07. ............................................................... 37
FIGURE 26: BASE PLATE - GSP05 & GSP07. .............................................................. 37
FIGURE 27: LOCATING PIN - GSP05 & GSP07. .......................................................... 38
FIGURE 28: SELF CENTERING STEPPED JAW CHUCK. .......................................... 39
FIGURE 29: STEPPED JAWS - GSP05 & GSP07........................................................... 40
FIGURE 30: STEPPED V - BLOCK. ............................................................................... 41
FIGURE 31: POWER SCREW. ........................................................................................ 42
FIGURE 32: FIXTURE LAYOUT 01. .............................................................................. 43
xi
FIGURE 33: FIXTURE LAYOUT 02. .............................................................................. 44
FIGURE 34: 3-2-1 PRINCIPLE FOR STEPPED V BLOCKS. ........................................ 45
FIGURE 35: FIXTURE LAYOUT 01 AND 02 WITH MACHINE. ................................ 46
FIGURE 36: BASE PLATE DRAWING SHEET GSP05. ............................................... 48
FIGURE 37: SUPPORT DRAWING SHEET GSP05. ..................................................... 49
FIGURE 38: STEPPED JAW DRAWING SHEET GSP05. ............................................. 50
FIGURE 39: LOCATING PIN DRAWING SHEET GSP05. ........................................... 51
FIGURE 40: BASE PLATE DRAWING SHEET GSP07. ............................................... 52
FIGURE 41: SUPPORTS DRAWING SHEET GSP07. ................................................... 53
FIGURE 44: STEPPED V-BLOCK DRAWING SHEET................................................. 56
FIGURE 45: POWER SCREW DRAWING SHEET. ...................................................... 57
FIGURE 46: POWER SCREW & BEARING SUPPORT DRAWING SHEET. ............. 58
FIGURE 47: SUPPORTING BLOCK STATIC ANALYSIS GSP05. .............................. 60
FIGURE 49 BASE PLATE AND JAW STATIC ANALYSIS GSP05. ........................... 62
FIGURE 50: WORKPIECE CLAMPED ON BASE PLATE GSP05. .............................. 63
FIGURE 52: LOCATING PIN STATIC ANALYSIS GSP07. ......................................... 65
FIGURE 53: BASE PLATE AND JAW STATIC ANALYSIS GSP07. .......................... 66
FIGURE 54: WORKPIECE CLAMPED ON BASE PLATE GSP07. .............................. 67
FIGURE 55: STEPPED V BLOCK JAW STATIC ANALYSIS. ..................................... 68
FIGURE 56: WORKPIECE CLAMPED ON BASE PLATE, STATIC ANALYSIS. ..... 69
xii
NOMENCLATURE
Symbol Definition Units
𝐹𝑐 Cutting force 𝑁
ℎ Thickness of cut 𝑚𝑚
𝑧 Material exponent ~
𝑁
𝑘𝑐1,1 Specific cutting force
𝑚𝑚2
𝑏 Width of cut 𝑚𝑚
𝐾𝛾 Correction factor for rack angle ~
𝐾𝑉 Correction factor for cutting speed ~
𝐾𝑣𝑒𝑟 Wear factor ~
𝐾𝑠𝑡 Correction factor for chip compression ~
𝑑 Nominal diameter 𝑚𝑚
𝑑𝑐 Core diameter 𝑚𝑚
𝑑𝑚 Mean diameter 𝑚𝑚
𝑝 Pitch 𝑚𝑚
𝑙 Lead 𝑚𝑚
 Coefficient of friction ~
 Helix angle °
 Friction angle °
xiii
𝛽 Angle of V - block °
𝑃 Effort N
𝑀𝑡 Torque 𝑁𝑚𝑚
𝑁
𝑐 Compressive stress
𝑚𝑚2
𝑁
 Shear stress
𝑚𝑚2
𝑁
𝑚𝑎𝑥 Principal maximum shear stress
𝑚𝑚2
𝑊 Load 𝑁
 Pie ~
 Efficiency 
𝜂𝑚𝑎𝑥 Maximum efficiency 
[] References ~
𝑓𝑜𝑠 Factor of safety ~
𝐹𝐸𝐴 Finite element analysis ~
GSP Gear Shaping Process Machine ~
xiv
1. INTRODUCTION
Ishwarbhai B. Patel founded Elecon Engineering in Goregaon, Mumbai in 1951. The

company's initial focus in India was on Engineering, Procurement, and Construction
projects. It began by producing custom manufacturing conveyor systems. On January 11,
1960, the company was formed as a private limited company and relocated to its current
location in Vallabh Vidyanagar, Gujarat. The company later went public on the Bombay
Stock Exchange and the National Stock Exchange.
ELECON Engineering is one of the largest Asian manufacturers of industrial gear

systems, having a global presence. The company is also a pioneer in manufacturing of
shafts and pinions for power transmission gearboxes. Elecon Engineering mainly
manufactures two types products: Catalogue products and Engineering products.
Catalogue products are well established in the design practice and Engineering products
are specially designed as per customer requirements for industry applications in sugar,
marine, defence, cement, chemical, food, power, agriculture.
We were provided the opportunity to perform project in the workshop of ELECON

Industry's Gear Division. The workshop was divided into various zones, from which we
carried out our project in the planetary zone (Helical-P). Elecon Engineering is India's
leading manufacturer of Planetary Gearboxes for material handling, sugar, marine,
defence, cement, chemical, food, power, agriculture, and other industries. Planetary
gearboxes for vertical roller mill drive, bucket wheel drive, slew drive, roller press drives,
and sugar mill drives with foot and shaft mounted are among the applications. It is a type
of gearbox composed of a gear carrier on which planet gears are assembled. As shown, a
sun gear center gear is assembled into a carrier assembly and the entire one into an annulus
ring gear.
Figure 1: Planetary Gear Box.
1
The annulus ring gear is an essential part of the gear box, with internal teeth of specific
dimensions (Module, tooth depth, pressure angle, and so on). Internal annulus ring gear
teeth are manufacture on the vertical shaper machine CJMT (GSP 05 & 07). This CJMT
vertical shaper machine has the limitation of requiring more setup time, which can be
reduced by designing a fixture while enhancing manufacturing time. This report work
shows the design and analysis of an offline loading fixture for a vertical gear shaper
machine, which is used to generate straight internal gear teeth for components such as
annulus ring gears, gear casing, carrier, and hollow shaft. The design is carried out with
an objective of enhancing manufacturing time and minimizing setup time. The fixture has
been designed to set up job order annulus ring gear that have different diameters and face
widths of components.
1.1 Fixture Significance
A machine fixture is a device or tool used to hold and position a workpiece in a specific
orientation during a machining operation. Fixtures can be simple or complex, and they
may be modified to coordinate with a wide range of workpieces and machining operations.
Fixtures are commonly utilized in a number of industries, such as manufacturing,
automotive, aerospace, and engineering. The fixture used in machining operations can
have a significant impact on machine utilization.
Fixtures play an essential role in reducing setup time for workpieces in manufacturing and
machining operations. Fixtures, by securely holding and positioning the workpiece, can
help to reduce the amount of time required to set up and adjust the machine for each new
workpiece. Here are some of the primary advantages of using fixtures to reduce setup
time.
1. Consistency: With a fixture in place, the workpiece is held in a consistent position

and orientation, ensuring that each machining operation is performed accurately and
consistently.
2. Accuracy: Fixtures are designed to provide high levels of accuracy and repeatability,
ensuring that each workpiece is machined to the same specifications.
2
3. Speed: Once a fixture has been set up and adjusted, subsequent workpieces can be
quickly and easily loaded into the fixture, reducing the overall setup time.
4. Operator efficiency: The ease of use and ergonomics of the fixture can have a
significant impact on operator efficiency and productivity. A well-designed fixture
can reduce operator fatigue and improve overall efficiency.
5. Increase Efficiency: The fixture should be designed to optimize the cutting process
and reduce the time taken to perform the task. It should aim to reduce the setup time,
improve the accuracy of the cutting process and reduce the need for manual
intervention.
6. Reduce Costs: The fixture should be designed to minimize material and production
costs without compromising on quality. It should aim to use readily available
materials and standard components to reduce the cost of production.
7. Ease of Use: The fixture should be easy to set up, adjust and operate. The operator
should be able to quickly and easily load and unload the workpiece. The fixture
should also be designed with safety features to ensure that the operator is not at risk
of injury during operation.
8. Versatility: The fixture should be designed to accommodate a variety of workpieces

and be easily adaptable to different sizes and shapes. It should also be compatible
with different cutting tools and shaper machines.
9. Durability: The fixture should be designed to withstand the rigors of machining and
be capable of withstanding repeated use without degrading in quality. It should also
be resistant to wear and tear and require minimal maintenance.
10. Compliance with Standards: The fixture should be designed to comply with industry
standards and regulations. It should be designed to meet safety standards and be
compatible with other equipment used in the machining process.
3
In summary, fixtures are a necessary tool for reducing setup time in machining operations.
Fixtures help to ensure that each workpiece is machined efficiently and to the same
specifications by providing stability, accuracy, and repeatability, ultimately leading to
increased productivity and profitability for the manufacturing operation.
1.2 Shaping Process
Gear shaping is a machining process used to machine internal gears, which are cylindrical
gears with teeth on the inside. The teeth on the internal surface of the gear blank are
generated using a vertical shaping machine, also known as a gear shaping machine, which
employs a modified rotating shaping cutting tool. The process is used to create gears with
high precision and accuracy, making them suitable for use in a variety of applications
ranging from automotive transmissions to industrial machinery.
The vertical shaping process starts with selecting the appropriate tooling for the gear
blank, which is the raw material for the process. The gear blank is then mounted on the
machine and positioned relative to the cutting tool. Following that, the machine uses a
series of axially vertical strokes to reciprocate the shaping cutting tool across the internal
surface of the gear, removing material and generating the teeth.
Figure 2: Gear Shaping Cutter. [17]
Figure 3: Gear Shaping Process. [17]
4
During the cutting action, the cutter and workpiece continuously rotate, simulating the
rolling of two gears, and the cutter is radially fed into the workpiece at the start of the
process until it reaches the final depth of cut. Gear shaping is less productive than gear
Hobbing (which uses a worm gear cutter), but it is more versatile. Gear Hobbing, for
example, cannot generate internal gears or gears with geometric constraints that would
interfere with a gear hob. Gear shaping can also be used as a finishing operation on
hardened gears.
1.3 Current Shaping Fixture Arrangement
Figure 4: Fixturing Arrangement.
Strap
Workpiece Clamp
Supports Heel
Screw
Jack
Figure 5: Elements of Current Fixturing Setup Arrangement.
5
As per technical specific requirements of clients or customers, Elecon Engineering
designs and manufactures wide ranges of planetary gear boxes. Each new design of gear
box has variation in dimension of components, that job order production. Depending upon
design of gearbox therefore there may be variation in dimension of annulus ring gear. Due
to such circumstances, for each new annulus ring gear workpiece, it is necessary to alter
the fixture arrangement for each workpiece.
It is necessary to locate and clamp workpiece of annulus ring gear at certain height from
machine’s base table so that the cutting stroke length is shortened, for that following
fixturing elements are used:
1. Supports – For different size of workpiece, different supporting block of different

heights are available at that workshop, so that suitable supporting block can be used
for suitable size of workpiece.
2. Locating Pins – Locating pin’s function is similar to that of supports, only difference
is that it has smaller heights compared to supports, so that large heighten workpiece
can be located directly over machine’s base table.
3. Strap Clamps – Strap Clamps are used to restrict the rotational movement of
workpiece by friction and clamping force.
4. Heel Screw Jack and Fastening Elements – Heel screw jack act as pivot support to
rear end of strap clamps and provide proper clamping force on workpiece so that it
may not deflect.
1.4 Time Study of Main Losses
Time study is a technique used in manufacturing and other industries to measure and
analyses the amount of time required to complete a specific task or process. Manufacturers
can identify areas of inefficiency or waste and develop strategies to improve productivity
and reduce costs by conducting a time study.
6
A time study can be used to identify the main sources of waste, also known as the "7
losses" in lean manufacturing. Manufacturers, for example, can identify waiting,
transportation, and motion waste by tracking the time it takes to complete a specific
process. This data can be used to improve processes that reduce waste, such as changing
the layout of a workspace or streamlining the manufacturing process.
Time analysis can also be used to identify other waste sources, such as overproduction,
processing waste, or defects. Manufacturers can identify opportunities to reduce waste
and improve overall efficiency by analyzing the time it takes to complete a specific task.
Overall, time study is an important tool for identifying and addressing the primary waste
sources in manufacturing processes. A time study was conducted at the planetary zone,
and various losses were recorded, yielding the following results indicating losses.
Figure 6: Time Study of GSP-05.
Figure 7: Time Study of GSP-07.
7
2. LITERATURE REVIEW
2.1 Literature review
2.1.1 Design Considerations
Fixtures, which are components or assemblies used to hold a machining part, must be
designed with the part's shape and the type of machining in mind. A fixture can be
designed with production tools specifically for the job to make a standard machine tool
more versatile and work as a specialized machine tool. The process of designing and
manufacturing fixtures is complex and requires knowledge of many areas, including
geometry, dimensions, tolerances, procedures, and manufacturing processes. This article
defines fixtures in depth and discusses the design considerations associated with fixtures
in manufacturing. The fixture must also be simple to install and remove from the machine.
[1]
2.1.2 Methodology Phases
The proposed methodology for fixture design in this research paper integrates it with
process planning and includes three phases: predesign analysis (phase I), functional
analysis (phase II), and productivity improvement (phase III). During phase I, the initial
fixture design aspects are developed by analyzing the product design information. Phase
II involves addressing the clamping and location aspects of fixture design for the given
process sequence and product design information. The third and final phase, phase III,
focuses on increasing productivity, which can include using simultaneous machining
approaches and multi-clustering, which can involve utilizing simultaneous machining
approaches and multi-clustering. [2]
2.1.3 Consideration of tool over run
Main motion length (Over Run) is depended on the tooth

breadth of work cutting, it is longer than 1.1~1.2 times of
the tooth breadth. To ensure that the gear teeth have the
desired finish and geometry while minimizing the risk of
tool damage or workpiece. [3]
Figure 8: Over Run of Tool. [17]
8
For Ex.: Work Piece Tooth Breadth 𝐵 = 100𝑚𝑚
Cutting Length 𝐿 = 100 × 1.2 = 120𝑚𝑚
Over Run Length OL = 20𝑚𝑚 from both sides of faces.
2.1.4 3-2-1 Principle
The 3-2-1 principle is a common approach used in manufacturing for designing and
locating fixtures. This principle helps to ensure that the workpiece is held securely and
accurately during the manufacturing process. Here's how the 3-2-1 principle can be
applied to a hollow short cylinder:
1. Three Points of Contact: The first step is to establish three points of contact between
the fixture and the workpiece. For a hollow short cylinder, this can be achieved by
placing it on a one face of hollow cylinder. The support can be designed to fit the
shape of the cylinder precisely, ensuring that the points of contact are evenly spaced
and provide sufficient stability and preventing rocking.
2. Two Planes of Contact: The second step is to establish two planes of contact. This
can be done by using two additional supports that contact the circumference of
cylinder.
3. One Direction of Contact: The final step is to establish one direction of contact. This
can be achieved by using a clamp or other mechanism to hold the cylinder securely
in place against the supports and restrict rotational movement. The direction of
contact should be perpendicular to the two planes of contact, ensuring that the
cylinder is held securely and accurately in position during the manufacturing
process.
By following the 3-2-1 principle, you can ensure that the hollow short cylinder is securely
and accurately held in place during the manufacturing process. This helps to ensure that
the resulting product is of high quality and meets the required specifications. [4]
9
2.1.5 Locating Pins
A locating pin is a mechanical component used in manufacturing and assembly processes

to align and position two or more parts precisely. It is typically made up of a cylindrical
or conical-shaped shaft with precise diameter, length, and tolerances. The pin is inserted
into a hole or slot in one part before being used to precisely locate and align the mating
part. Locating pins are commonly used in industries where precision and accuracy are
critical, such as automotive, aerospace, and electronics manufacturing. They are also
found in consumer goods like furniture and appliances. Depending on the application,
locating pins can be made of a variety of materials such as stainless steel, hardened steel,
or plastic. [5]
2.1.6 Cutting Force
A shaper machine's cutting operation is determined by the stroke length and the force or
torque generated by the machine's ram. Because the cutting tool is attached to the ram, the
same force is applied to the workpiece. As a result, determining the type of operation that
can be performed requires selecting the appropriate type of cutting tool for a specific
operation on the workpiece. The cutting process should be designed with the cutting force
exerted by the tool in mind. Cutting force will aid in the statical analysis of the fixture to
determine whether or not it can withstand cutting forces. [6]
2.1.7 V- Block
V-blocks are precision tools used to securely hold cylindrical or round workpieces during
machining or inspection processes. They are designed with a V-shaped groove along their
length, which cradles and centers the workpiece. The V-groove can be cut at different
angles depending on the requirements of the application.
One commonly used V-block angle is 120°. This angle is often used in conjunction with
a matching 60° angle on the opposite V-block to create a stable platform for holding shafts
or cylinders that need to be aligned precisely. The 120°. V-block angle provides a wider
contact area with the workpiece compared to steeper angles, increasing the stability and
reducing the risk of slippage. [7]
10
2.1.8 Power Screw
Power screws are mechanical devices used to convert rotational motion into linear motion
or vice versa. They consist of a threaded rod or shaft and a nut that has matching threads,
which engage with each other. When the screw is rotated, the nut moves along the length
of the screw, creating linear motion.
Power screws are used in various applications, such as in machinery, automotive,

aerospace, and robotics. They are used for transmitting power, precise positioning, and
holding loads in place. The amount of linear motion produced per revolution of the screw
depends on the pitch of the threads, which is the distance between successive thread crests.
Power screws can be designed with different thread forms, such as square, buttress, or V-
threads, depending on the application's requirements. They can also be made from various
materials, including steel, brass, bronze, and plastic.
Overall, power screws are essential components in various mechanical systems, providing
reliable and efficient linear motion and power transmission. [8]
2.1.9 Material Selection
Material selection is an important consideration in fixture design. The material must be

strong enough to resist machining forces without deforming or breaking. The intended
use, environmental conditions, and required properties such as strength, durability, and
temperature tolerance must all be considered. It must also be worn and corrosion resistant.
Mild steel, HSS, cast iron, aluminum, and composite materials are common materials used
in fixture design. [4]
AISI 321 is a stainless steel with excellent high-temperature resistance and good
weldability. It is commonly used in aerospace and automotive applications where high-
temperature and corrosion resistance are required. [9]
AISI 316 is a type of stainless steel that contains molybdenum, which have good resistance
in non-oxidizing acids and chlorine-containing media. 316 is characterized by resistance
to high temperatures, high plasticity, ductility, and relatively good ductility. [10]
11
AISI 1010 is a low-carbon steel that is commonly used in cold-formed steel structural
components. It has good strength and ductility properties, making it suitable for
applications such as appliances and furniture. [11]
AISI 1020 is a low-carbon steel that is often used in the production of machine parts,
gears, and shafts due to its good machinability and weldability. It has a relatively low
tensile strength but good ductility and toughness. [12]
AISI 1045 is a medium-carbon steel that has good strength, toughness, and wear resistance
properties. It is commonly used in a variety of industrial applications, such as gears, shafts,
and axles. With a high tensile strength and good machinability, AISI 1045 is a versatile
material that can be easily heat-treated to achieve the desired properties for specific
applications. It is also known for its weldability, making it a popular choice for welded
structures. Additionally, AISI 1045 is a cost-effective material that offers good value for
its performance characteristics. [13]
2.1.10 GD&T Standards
The ASME y14.5 standard, also known as the Geometric Dimensioning and Tolerancing
(GD&T) standard, is widely used in the manufacturing industry. The standard provides a
framework for creating engineering drawings with clear, concise, and unambiguous
specifications for the allowable variation in the form, size, orientation, and location of
features on a part. The literature suggests that the ASME y14.5 standard is an effective
tool for improving the accuracy and efficiency of manufacturing processes. [14]
12
2.2 Research Gap
➢ There are many existing fixtures available for mass production components;
however, a fixture that can accommodate components of varying sizes, for which an
optimised fixture can be designed to minimise the time required to change out the
workpiece, is not developed or else not designed.
Figure 9: Research Gap for Fixture Design.
➢ As illustrated in Figure, annulus ring gears can have varying face widths based on
the different gearbox designs. To generate teeth in the shortest possible time, with
the shortest possible cutting stroke length, a gear blank must be placed and mounted
at a specific required height, with overrun taken into account. It takes about 2-3 hours
to set up such a system.
➢ As a result, for vertical shaper machines with such constraints, a fixture can be
designed to reduce setup time, resulting in an upsurge in production time. Also,
fixture which can accommodate workpieces of different sizes is yet not designed.
13
2.3 Problem Definition
Setting up annular ring gear of various sizes (different diameters and face widths) on a
vertical shaper machine to manufacture internal teeth typically takes 2 − 3 ℎ𝑜𝑢𝑟𝑠, which
can be reduced by developing a fixture, leading to gain in production time.
2.4 Objectives
→ To Design Fixture of Annulus Ring Gear, for vertical gear shaping machine GSP05
& GSP07.
→ Static analysis of the fixture designed.
→ Reduction in actual setup time to upsurge production time.
14
3. METHODOLOGY
3.1 Methodology Flow Chart
• Machine Information
• Machining Process
• Type of Workpiece and related
Observation
• Workpiece Specifications
Set-Up Planning • Operation Variables
• Fixturing Elements Required
• Fixture Requirements
• Locating and Clamping surface
Fixture Planning
and points
• Fixture Layout Plan
• Base Plate Modeling

• Supports Modeling
Fixture Configuration
• Step Jaw Modeling
• Complete Fixture arrangement
• Statical Analysis of Fixture

Elements
Fixture Design Analysis
• Deformation Analysis
• Tolerancing
Fixture Design Conclusion and

Material Listing
Figure 10: Methodology.
15
3.2 Calculation
3.2.1 Cutting Force Calculation
(𝟏 𝒎𝒎)𝒛
𝑭𝒄 = × 𝒌𝒄𝟏,𝟏 × 𝒃 × 𝒉 × 𝑲𝜸 × 𝑲𝑽 × 𝑲𝒗𝒆𝒓 × 𝑲𝒔𝒕 [6]
𝒉𝒛
𝐹𝑐 = Cutting force in 𝑁
ℎ = Thickness of cut in 𝑚𝑚
𝑧 = Material exponent
𝑁
𝑘𝑐1,1 = Specific cutting force in 𝑚𝑚2
𝑏 = Width of cut in mm
𝐾𝛾 = Correction factor for rack angle
𝐾𝑣 = Correction factor for cutting speed
𝐾𝑣 = 1.1 with high-speed steel tools
𝐾𝑣 = 1.0 with cemented carbide tools
𝐾𝑣𝑒𝑟 = Wear factor
𝐾𝑠𝑡 = Correction factor for chip compression
 Calculation for 8mm Module
(1 𝑚𝑚)0.24
𝐹𝑐 = × 1775 × 3 × 5 × 0.96 × 1.1 × 1.4 × 1.1 = 𝟐𝟗𝟒𝟐𝟓 𝐍
50.24
∴ Fc = 29425N = 29.425 kN
 Calculation for 12mm Module
(1 𝑚𝑚)0.24
𝐹𝑐 = × 1775 × 3 × 5 × 0.96 × 1.1 × 1.4 × 1.1 = 𝟑𝟐𝟑𝟔𝟎 𝐍
50.24
∴ Fc = 32360 = 32.360 kN
16
3.2.2 V – Block Calculation
Figure 11: V - Block Width Calculation.
𝑅𝑎𝑑𝑖𝑢𝑠
Width = 𝛽
𝑡𝑎𝑛( )
2
400
=
120°
𝑡𝑎𝑛 ( 2 )
400
=
𝑡𝑎𝑛(60°)
Width = 230.94 𝑚𝑚
17
3.2.3 Power Screw Design Using MITCalc Software
Figure 12: Power Screw Calculation in Software.
18
3.2.4 Power Screw Manual Calculations
Standard Screw Size:
Nominal Diameter, 𝑑 = 22𝑚𝑚
Pitch, 𝒑 = 𝟓𝒎𝒎
Core Diameter, 𝑑𝑐 = (𝑑 – 𝑝) Figure 13: Square threads. [20]

= (22 − 5)
𝒅𝒄 = 𝟏𝟕𝒎𝒎
Mean Diameter, 𝑑𝑚 = (𝑑 – 0.5𝑝)

= (22 – 0.5 ∗ 5)
𝒅𝒎 = 𝟏𝟕. 𝟓𝒎𝒎
Lead, 𝑙 = 𝑝 ∗ 𝑛𝑜. 𝑜𝑓 𝑠𝑡𝑎𝑟𝑡

𝒍 = 𝟓𝒎𝒎
Coefficient of friction, µ = 0.16

µ = 𝐭𝐚𝐧(∅)
Friction Angle ∅ = tan−1(0.16) Figure 14: Terminology of Power Screw. [20]

∅ = 𝟗. 𝟎𝟗°
𝑙
Helix angle, 𝑡𝑎𝑛𝛼 = 𝜋𝑑𝑚
5
𝛼 = 𝑡𝑎𝑛−1 (𝜋∗17.5)
𝜶 = 𝟒. 𝟔𝟑°
Effort, 𝑃 = 𝑊 𝑡𝑎𝑛 (∅ + 𝛼)
= 9810 ∗ 𝑡𝑎𝑛(9.09 + 4.63)
= 9810 ∗ 𝑡𝑎𝑛(13.72)
𝑷 = 𝟐𝟑𝟗𝟓. 𝟎𝟒𝟖 𝑵
Figure 15: Development of Thread. [20]
19
Figure 16: Force Diagram for Lifting Load. [20]
𝑊𝑑𝑚 𝑡𝑎𝑛 (∅ + 𝛼)
For raising the load, 𝑀𝑡 = 2
9810 ∗ 19.5 ∗ 𝑡𝑎𝑛(13.72)
=
2
𝑀𝑡 = 23351.721 𝑁. 𝑚𝑚
𝑴𝒕 = 𝟐𝟑. 𝟑𝟓𝟏 𝑵. 𝒎
Figure 17: Force Diagram for Lowering Load. [20]
𝑊𝑑𝑚 𝑡𝑎𝑛 (∅ − 𝛼)
For lowering the load, 𝑀𝑡 = 2
9810 ∗ 19.5 ∗ 𝑡𝑎𝑛(4.46)
= 2
𝑀𝑡 = 7460.437 𝑁. 𝑚𝑚
𝑴𝒕 = 𝟕. 𝟒𝟔𝟎 𝑵. 𝒎
For Self - Locking Screw,

∅ > 𝛼,
tan(∅) > tan(𝛼),
9.09 > 4.63
𝑙
µ>
(𝜋𝑑𝑚 )
tan (𝛼)
Efficiency, 𝜂 = 𝑡𝑎𝑛 (∅+𝛼)
tan (4.63)
= 𝑡𝑎𝑛 (9.09+4.63)
𝜼 = 𝟑𝟑. 𝟏𝟕%
20
1 – 𝑠𝑖𝑛(∅)
Maximum Efficiency, 𝜂𝑚𝑎𝑥 = 1+ 𝑠𝑖𝑛(∅)
1 – 𝑠𝑖𝑛(9.09)
= 1+ 𝑠𝑖𝑛(9.09)
𝜼𝒎𝒂𝒙 = 𝟕𝟐. 𝟕𝟏%
𝑊
Compressive Strength, 𝑐 = 𝜋
( 𝑑𝑐 2 )
4
9810
= 𝜋
( 172 )
4
𝑵
𝒄 = 𝟒𝟑. 𝟐𝟏𝟗 𝒎𝒎𝟐
16(𝑀𝑡 )𝑡
Shear Strength,  = 𝜋𝑑𝑐 3
16(23351.721)
= 𝜋∗ 173
𝑵
 = 𝟐𝟒. 𝟐𝟎𝟕 𝒎𝒎𝟐
 2
Maximum Shear Strength 𝑚𝑎𝑥 = √( 2𝑐) + 2
43.219 2
= √( ) + 24.2072
2
= √ 1052.949
𝑵
𝒎𝒂𝒙 = 𝟑𝟐. 𝟒𝟒𝟗 Figure 18: Torque Movement. [20]
𝒎𝒎𝟐
𝑆𝑦𝑡
Factor of Safety, 𝑓𝑜𝑠 = 
𝑚𝑎𝑥
180
= 32.449
𝒇𝒐𝒔 = 𝟓. 𝟓𝟒
 The results obtained from both the software and manual calculations are
consistent, confirming the selection of the Sq 22×5 square thread. This thread
specification has been chosen based on its compatibility with the fixture design
requirements.
21
4. OBSERVATIONS
4.1 Machine Information
 GSP 05 – Vertical Gear Shaper Machine, CJMT YKM51250C/7
Maximum external dia of

2500𝑚𝑚
workpiece
Maximum internal dia of
2800𝑚𝑚
workpiece
Maximum Module 20𝑚𝑚
Maximum face width of
430𝑚𝑚
workpiece
Maximum Stroke Length 460𝑚𝑚
Reciprocating motion stroke
number of main shaft of gear 15~ 200𝑡𝑖𝑚𝑒𝑠/𝑚𝑖𝑛
shaping tool
Amount of circular feed 0.05~ 0.50𝑚𝑚/𝑠𝑡𝑟𝑜𝑘𝑒
Amount of radial feed 0.005~ 0.50𝑚𝑚/𝑠𝑡𝑟𝑜𝑘𝑒

Fast moving speed of work
666𝑚𝑚/𝑚𝑖𝑛
table
Fast revolution speed of work
1 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛/𝑚𝑖𝑛
table
Adjusting amount of stroke
50𝑚𝑚
position of gear shaping tool
End face dia of worktable
1800𝑚𝑚
main shaft
Diameter of worktable main
350𝑚𝑚
shaft hole
Distance between center of 1400~ 240𝑚𝑚 𝑤𝑖𝑡ℎ𝑜𝑢𝑡 𝑎𝑑𝑑𝑖𝑡𝑖𝑜𝑛𝑎𝑙 𝑤𝑜𝑟𝑘𝑡𝑎𝑏𝑙𝑒
worktable and main shaft of
cutter 1400~ 600𝑚𝑚 𝑤𝑖𝑡ℎ 𝑎𝑑𝑑𝑖𝑡𝑖𝑜𝑛𝑎𝑙 𝑤𝑜𝑟𝑘𝑡𝑎𝑏𝑙𝑒
Distance between end-face of 1250~ 740𝑚𝑚 𝑤𝑖𝑡ℎ𝑜𝑢𝑡 𝑎𝑑𝑑𝑖𝑡𝑖𝑜𝑛𝑎𝑙 𝑤𝑜𝑟𝑘𝑡𝑎𝑏𝑙𝑒

work table and main shaft of
Gross power of machine 50 𝐾𝑊
Table 1: Specification of GSP 05 Machine CJMT YKM51250C/7. [3]
22
 GSP 07 – Vertical Gear Shaper Machine, CJMT YKM51160C/28
Maximum external dia of

1600𝑚𝑚
workpiece
Maximum internal dia of
2100𝑚𝑚
workpiece
Maximum Module 20𝑚𝑚
Maximum face width of

400𝑚𝑚
workpiece
Maximum Stroke Length 460𝑚𝑚
Reciprocating motion stroke

number of main shaft of gear 15~ 150𝑡𝑖𝑚𝑒𝑠/𝑚𝑖𝑛
shaping tool
Amount of circular feed 0.05~ 0.50𝑚𝑚/𝑠𝑡𝑟𝑜𝑘𝑒
Amount of radial feed 0.005~ 0.5𝑚𝑚/𝑠𝑡𝑟𝑜𝑘𝑒
Fast moving speed of work

444𝑚𝑚/𝑚𝑖𝑛
table
Fast revolution speed of work
0.5 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛/𝑚𝑖𝑛
table
Adjusting amount of stroke
50𝑚𝑚
position of gear shaping tool
Terminal surface dia of
1400𝑚𝑚
worktable main shaft
Diameter of worktable main
320𝑚𝑚
shaft hole
Distance between center of 950~ 0𝑚𝑚 𝑤𝑖𝑡ℎ𝑜𝑢𝑡 𝑎𝑑𝑑𝑖𝑡𝑖𝑜𝑛𝑎𝑙 𝑤𝑜𝑟𝑘𝑡𝑎𝑏𝑙𝑒

worktable and main shaft of
Distance between end-face of 950~ 480𝑚𝑚 𝑤𝑖𝑡ℎ𝑜𝑢𝑡 𝑎𝑑𝑑𝑖𝑡𝑖𝑜𝑛𝑎𝑙 𝑤𝑜𝑟𝑘𝑡𝑎𝑏𝑙𝑒

work table and main shaft of
Gross power of machine 35 𝐾𝑊
Table 2: Specification of GSP 07 Machine CJMT YKM51160C/28. [3]
23
4.2 Principle of Machine Tool
Generation method is regarded as the machining principle, so gear shaping tool and
workpiece are equivalent to a pair of toothing gear without clearance. Whether cutting
stroke or empty run, both circumrotate according to definite rolling proportion in order to
ensure the same peripheral velocity on the pitch circle. Module and pressure angle of the
gear shaping tool should be same as the processed gear.
The machine tool has four numerical control axes. The axis SP is main operating
transmission shaft and it reciprocates with the gear shaping tool which direction of
movement parallels with axes line of workpiece. The axis B is rotary movement of axes
of the worktable. The axis C is rotation axis of cutter and it circumrotates with the cutter.
The axis Y is radial feed axes and it slowly approaches to gear shaping tool along the lines
of level unto the requested depth with worktable by the action of the lead screw. Rotary
movement axes if the worktable (B axis) and rotation axis of the cutter (C axis) are the
requested for simultaneous movement and this movement’s realization relies on the
numerical control system and its control program. The machine tool has cutter back-off
organs, on the return stroke of cutting tool, gear shaping cutting tool retracts from surface
of workpiece by some amount in order to avoid fraying of cutting edges of cutter and
scraping the machining surface of workpiece.
1. Principle Cutting Stroke.

2. Withdrawal X.
1 3
3. Return Stroke.
4. Radial Feed.
Figure 19: Cutter Back-Off Motion. [16]
24
4.3 Manufacturing Process and Sequence for Annulus Gear
Shot Blasting & Peening.
Figure 20: Annulus Gear Machining Route.
25
- For the production of annulus gears, forged raw rings made from materials such as
18CrMo4, 32CrMo4, and 42CrMo4 are procured, depending on the gearbox design. The
use of forged materials offers several advantages. Firstly, forged materials exhibit a
consistent grain structure, which enhances their resistance to fatigue and wear over
extended periods of use. Additionally, forged materials possess greater density compared
to other materials, imparting increased resistance to cracking and other forms of damage.
By utilizing forged materials as the raw material for annulus internal gears, the resulting
product is more reliable and durable. These gears can effectively withstand the high levels
of torque and stress typically encountered in machinery applications. Overall, the choice
to use forged materials contributes to the production of annulus gears that offer enhanced
performance and longevity.
- The forged raw ring undergoes a turning process where it is carefully machined and
shaped to achieve the desired blank size, while considering the grinding allowance.
Subsequently, based on the weight and dimensions of the workpiece, a series of holes with
different sizes are drilled and tapped into the gear's face. These tapped holes serve the
purpose of securely fastening the workpiece using an eye bolt as an anchor.
- Once the gear blank is securely clamped onto the vertical shaper machine (GSP05 &
07), the internal teeth are generated using a specialized gear shaping cutter. To alleviate
any stress generated during the machining process, the gear blank undergoes a nitriding
treatment. Nitriding is a surface hardening process that involves the introduction of
nitrogen into the steel's surface, resulting in the formation of hard and wear-resistant
nitrides.
Nitriding is typically carried out at lower temperatures, typically around 500-600°C, in

the presence of ammonia gas. During the process, nitrogen atoms diffuse into the surface
of the steel and react with alloying elements like chromium and molybdenum to form
nitrides. These nitrides are dispersed throughout the surface layer of the steel. The depth
of the nitride layer can vary depending on the process time, temperature, and other factors,
ranging from a few microns to several hundred microns.
26
- After the heat treatment process, shot peening and shot blasting are performed on the
treated parts. Shot peening is typically conducted following carburizing or nitriding
treatments to enhance the fatigue life and overall durability of the parts. This process
involves bombarding the surface of the parts with small spherical particles, inducing
compressive residual stresses that help to prevent crack initiation and propagation.
On the other hand, shot blasting is carried out to remove burrs and clean the hardened
surface of the workpiece. This process entails propelling a high-velocity stream of
abrasive material against the surface, effectively smoothing out rough areas and
eliminating surface contaminants. It is a form of abrasive blasting that achieves a cleaner
and more refined surface finish.
- The heat treatment process imparts the desired properties to the workpiece, but it can
also lead to distortion of the workpiece shape. Therefore, grinding becomes necessary to
achieve the required dimensions and tolerance forms. Grinding involves the use of wheel
bonded of abrasive particles to remove material from the workpiece surface, allowing for
precise shaping and dimensional accuracy. This process helps to refine the workpiece
shape and bring it within the specified tolerances.
- Subsequently, the internal profile grinding process is conducted to achieve the desired
crowning of gear teeth and attain the designed surface profile. This step is crucial in
ensuring that the gear operates effectively throughout its intended lifespan. By precisely
shaping the gear teeth and creating the specified surface profile, the internal profile
grinding process enhances the functionality and durability of the gear.
- Once the annulus gear is machined, it undergoes inspection using a Coordinate

Measuring Machine (CMM) to ensure its dimensional accuracy and quality before being
assembled into the gearbox. This step is crucial in verifying that the gear meets the
required specifications and will function effectively within the gearbox assembly. By
utilizing advanced measurement technology, such as a CMM, the gear's dimensions and
features are precisely evaluated, providing assurance of its performance and reliability
during operation.
27
5. SET – UP PLANNING
Fixture setup planning involves choosing the best approach to setting up a workpiece on
fixture for a specific manufacturing process. As a result, fixture setup planning includes
keeping records of workpiece specifications, operation variables, and clamping fixturing
elements.
5.1 Recording of Annulus Gear Specifications
In this step of the methodology, past one year data of specifications of annulus gear are
recorded for the purpose to design fixture components that are capable to accommodate
different sizes of workpiece.
The following parameters were recorded:
1. Normal module
2. External diameter
3. Internal diameter
4. Face width
5. Shaping width
6. Tooth depth
Figure 21: Gear Nomenclature. [15]
28
From this following parameter, External diameters and Face widths are primarily
considered to design stepped jaws as fixturing element, that supports and locate annulus
gear.
 Workpiece Specifications
NORMAL EXTERNAL INTERNAL FACE NO. OF TOOTH SHAPING

SR. NO.
MODULE DIAMETER DIAMETER WIDTH TEETH DEPTH WIDTH
1 3 320 255 59 87 6.75 45

2 3.5 390 269.5 75 79 7.875 75
3 3 380 279 69 95 6.75 55
4 2.5 364.7 297.5 56 121 5.625 565
5 6 830 648 66 110 13.5 66
6 7 960 770 74 112 15.75 74
7 6 560 528 100 90 13.5 75
8 8 1090 880 70 112 18 70
9 6 830 678 66 115 13.5 66
10 6 830 660 66 112 13.5 66
11 7 960 735 74 107 15.75 74
12 4 440 352 89 90 9 75
13 4 440 352 89 90 9 75
14 4 440 369 89 94 8.5 75
15 7 960 714 74 104 15.75 75
16 4 525.17 448.2 95 114 9.6 90
17 6 624.11 528 100 90 13.5 75
18 6 700 555.6 100 94 13.1 90
19 7 970 756 74 110 15.75 74
20 3 379 291 69 99 6.75 55
21 3.5 400 325.5 95 95 7.875 75
22 7.5 760 599.5 63 111 12.37 63
23 7 970 756 74 110 15.75 74
24 5.5 760 572 63 106 12.375 63
25 3 320 234 140 80 6.75 52
29
26 4 440 328.4 105 84 8.8 85
27 7 840 707 130 103 15.75 130
28 10 1130 920 200 94 22.5 170
29 8 720 584 170 75 18 140
30 5 520 400 130 82 11.25 100
31 5 520 425 130 87 11.25 100
32 6 530 492 138 84 13.5 112
33 6 632.71 528 120 90 13.5 85
34 5 520 425 130 87 11.25 100
35 6 732 576 150 98 13.5 75
36 5 520 425 130 87 11.25 100
37 4 490 392 104 100 ~ 74
38 8 900 701.59 140 89 19.43 120
39 9 1010 793.81 140 90 19.55 128
40 5 520 425 130 87 11.25 100
41 5 630 496 150 101 109 100
42 10 906.85 671 180 67 21 130
43 6 760 564 150 96 13.5 75
44 8 900 701.59 140 89 19.43 120
45 4.5 560 444.83 135 101 10.82 85
46 8 810 720 150 90 18 100
47 6 681.74 575.923 175 98 13.5 75
48 7 1000 833 154 119 15.75 154
49 6.5 670 526.5 170 90 14.62 140
50 6.5 670 574 170 90 13.625 140
51 6.5 670 552.5 162 87 14.625 162
52 4 510 364.74 155 93 8.63 75
53 5 520 425 130 87 11.25 100
54 6 620 504 155 86 13.5 125
55 6 620 516 155 88 13.5 125
56 4.5 480 397 114 90 9.62 100
57 5 520 425 130 87 11.25 100
58 6.5 816 611 180 96 14.62 110
30
59 4 500 328.4 105 84 8.8 105
60 5 520 425 130 87 11.25 100
61 6 740 630 155 107 13.5 125
62 6.5 816.86 611 180 96 14.62 110
63 6 600 555.6 120 94 13.1 120
64 4 630 508 136 129 9 106
65 4 630 508 136 129 9 106
66 5 520 430 130 88 11.25 100
67 5 520 430 130 88 11.25 100
68 7 800 617.4 116 90 15.25 100
69 8 880 677.45 120 87 19.27 100
70 11 1210 1056 160 98 24.75 160
71 11 1100 946 270 88 24.75 240
72 12 1250 1032 280 88 27 250
73 3.5 585 423.48 377 123 7.88 82
74 6 585 478.18 377 82 14.41 110
75 3.5 560 389.2 350 113 7.68 65
76 4.5 560 444.83 350 101 10.825 75
77 4.5 560 444.83 345 101 10.82 75
78 3.5 560 389.2 345 ~ 7.68 65
79 3.5 560 389.2 345 113 7.68 65
80 4.5 560 444.83 345 101 10.83 75
81 6 1050 576 390 97 ~ 165
82 5 612 496 426 101 10.9 100
83 3.5 612 426 496 113 7.68 80
Table 3: Annulus Gear Specification.
Sr. No. Ranges of Face width

01 to 24 0-100
25 to 70 101-200
71 to 72 201-300
73 to 81 301-400
82 to 83 401-500
Table 4: Ranges of Annulus Gear Face Width.
31
5.2 Operation Variables
R1 Cutter Tooth Number 18
R2 Workpiece Tooth Number 101
R3 Cutter Tooth Module 5 𝑚𝑚
R4 Cooling in Circle 1
R5 Circle Time 1
R6 Internal/ External 0
R7 Rotation of Workpiece 1
R8 Quick Feed Speed 300 𝑚𝑚/𝑚𝑚
R9 Y Feed Speed 3.0 𝑚𝑚/𝑚𝑖𝑛
R10 B Feed Speed 0.5 𝑚𝑚/𝑆𝑡𝑟
R11 SP Feed Speed 30 𝑆𝑡𝑟/𝑚𝑖𝑛
R12 Y Feed Depth 0.5 𝑚𝑚
Table 5: Operation Variables.
5.3 Fixturing Elements Required
A fixturing element, also known as a fixture or workholding element, is a device or

component used to hold and position a workpiece securely during machining, assembly,
or inspection processes. Fixturing elements are essential in manufacturing and machining
operations to ensure accurate and consistent production. Following fixturing elements are
required to clamp annulus type of workpiece: 1
6 .
1. Strap clamps .
2. T – Nut 3
4
.
3. Stud .
2
4. Flanged Screw Jack (Heel)
.
5. T slot bolt
6. Washer and fastening elements Figure 22: Clamping Elements. [14]
32
Figure 23: Fixture Clamping Elements. [14]
A number of standard sizes of the mentioned fixturing elements are available at the
company’s workshop. Since the sizes of annulus gear vary according to gearbox design,
these standard sizes of fixture elements can be used to accommodate and clamp various
workpieces on the base table. The type, size, and shape of the workpiece, as well as the
specific machining or assembly operation being performed, all influence the selection of
a fixturing element. Fixturing elements serve as essential for ensuring precise positioning,
stability, and repeatability during manufacturing processes, all of which contribute to
increased productivity and accuracy.
Strap clamp are ultimately selected in order to clamp workpiece from above surface so
that it may not deflect while machining operation. Also, chucks are possible op to clamp,
but with consideration of large size of workpiece from recorded data, large size of chuck
(1600 mm) is required to be design and clamping force required to clamp annulus gear
on machine table would be large. With this consideration simple strap clamps are selected
for clamping purpose.
Other fixture elements, such as fasteners, screw jack as a heel, studs, and T-nuts, are
needed to support the strap clamp and clamp it to the base table. These remaining elements
enables the strap clamp to clamp annulus gear workpieces with varying face widths. [14]
33
6. FIXTURE PLANNING
In this stage of fixture design, the focus is on identifying the requirements for the fixture,
including the necessary elements, locating points, clamping points, and surfaces, as well
as determining the overall fixture layout. These requirements are derived from the
problem statement and the observations made previously. Components are designed with
consideration of locating and clamping requirements of workpiece and finally fixture
layout for machine is recognized. Finally, the overall fixture layout for the machine is
recognized and planned accordingly.
6.1 Fixture Requirement
As highlighted in the research gap and problem statement, machining workpieces with
varying diameters and face widths on a vertical shaper machine has time-consuming setup
process. Specifically, when generating gear teeth, the gear blanks need to be precisely
located and positioned at a specific height from the machine's base table. The current setup
procedure for this job is tedious, taking approximately 𝟐 − 𝟑 𝒉𝒐𝒖𝒓𝒔 to complete.
The setup time involves several steps, including the positioning and clamping of
supporting blocks onto the machine's base table and the subsequent adjustment of the
workpiece's concentricity with respect to the base table. Among these tasks, the locating
of the supporting blocks is particularly arduous and time-consuming. It entails lifting and
placing heavy blocks of various sizes on the table and shop floor repeatedly.
To address this challenge, it is essential to design a supporting block of a specific height

that eliminates the need for lifting and loading of supporting blocks during the setup
process. By doing so, the efficiency of the setup can be significantly improved, saving
valuable time and streamlining the overall operation.
During the time study, it was observed that approximately 𝟓 − 𝟔 𝒉𝒐𝒖𝒓𝒔 are required to
generate teeth on the workpiece, resulting in significant idle time for the operators. To
optimize productivity, the concept of offline loading can be introduced in the fixture
design. This involves setting up the subsequent workpiece on a separate base plate while
the preceding workpiece is being machined.
34
By implementing offline loading, the setup time for each workpiece can be overlapped
with the machining time of the preceding workpiece. This eliminates the idle time for the
operators and maximizes the utilization of the machine. The operators can efficiently
prepare the next workpiece on a separate base plate, allowing for seamless transitions and
improved overall productivity.
Through the design of supporting blocks, base plates, and locating pins to locate and
support the workpiece at a specific height, a significant aspect of fixture design is
accomplished. As a result, it is possible to categorize the fixture into two main portions:
the lower fixture and the upper fixture.
The lower fixture portion comprises the assembly of supporting blocks, base plates, and
locating pins. On the other hand, the upper fixture assembly consists of devices or
elements that are responsible for clamping and precisely locating the workpiece axis with
the machine's base table. These components play a crucial role in securing the workpiece
in place and ensuring its proper alignment for machining operations.
By dividing the fixture into these two distinct portions, it becomes easier to understand
and manage the various components and functionalities of the fixture system.
6.1.1 Design of Elements for Lower Portion of Fixture
6.1.1.1 Supporting Blocks
The primary function of the supporting blocks is to elevate the workpiece to a specific
height. Three supporting blocks are designed for each machine, specifically for the GSP
Figure 24: Supporting block - GSP05.
35
05 and GSP 07 models. Adhering to the 3-2-1 principle, the number of supporting blocks
is limited to three in order to prevent any rocking motion of the base plate that will be
placed on top of them. These supporting blocks are carefully designed, taking into account
the annulus workpiece's face width and the required space between the cutter and the
machine's base table. The supporting blocks feature slots that enable them to be securely
clamped onto the machine's base table. Additionally, they are equipped with standard-
sized T-slots, allowing for the attachment of an offline loading base plate onto the
supporting block.
 Dimensioning of supporting block for GSP 05:
 The distance between cutter and worktable is 1200 𝑚𝑚.
 From recorded data of specification of annulus gear, maximum observed face width
size of annulus gear is about 500 𝑚𝑚. (workpiece number 83).
 Distance of 50 𝑚𝑚 is considered for tool overrun so that tool engages smoothly in

workpiece while generating teeth.
 Distance of 50 𝑚𝑚 is considered for base plate thickness which will rest over the
supporting block.
 Distance of 200 𝑚𝑚 is considered as allowance for tool setup and face width more than
500 𝑚𝑚.
 ∴ Supporting Block Height = 𝟏𝟐𝟎𝟎 – 𝟓𝟎𝟎 – 𝟓𝟎 – 𝟓𝟎 – 𝟐𝟎𝟎 = 𝟒𝟎𝟎 𝒎𝒎
36
 Dimensioning of supporting block for GSP 07:
Figure 25: Supporting block - GSP07.
 The distance between cutter and worktable is 820 𝑚𝑚.
 For GSP 07, annulus gear with faces of 400 𝑡𝑜 500 𝑚𝑚 can be located.
 Distance of 50 𝑚𝑚 is considered for tool overrun so that tool engages smoothly in

workpiece while generating teeth.
 Distance of 50 𝑚𝑚 is considered for base plate thickness which will rest over the
supporting block.
 Distance of about 100 𝑚𝑚 is considered as allowance for tool setup and face width
more than 400 𝑚𝑚.
 ∴ Supporting Block Height = 820 – 400 – 50 – 50 – 100 = 220 mm

6.1.1.2 Base Plates
Two each base plate is designed for both of machines, GSP 05 & GSP 07. This pair of
base plate will act as offline pallet, one for setup and other for machining, utilized
Figure 26: Base Plate - GSP05 & GSP07.
37
subsequently. This base plate has 4 slots feature at 90° for installations of stepped jaws
and other 4 slots feature at 45° for clamping purpose. Also has 4 holes for lifting of base
plate after machining is carried out or completed.
6.1.1.3 Locating Pin
Figure 27: Locating Pin - GSP05 & GSP07.

The design of the locating pin is intended to be compatible with both the GSP 05 and GSP
07 machines. It is a straightforward pin designed to fit precisely into the counter bore of
the machine's base plate, ensuring accurate alignment of the base plate. The height of the
locating pin is specifically designed to match that of the supporting pin. This ensures
proper alignment and stability when positioning the base plate over the pin.
6.1.2 Design of Elements for Upper Portion of Fixture
The upper portion of the fixture is designed to fulfill the requirement of accommodating,
locating, and clamping workpieces with varying diameters and face widths at a specific
height. Several options were considered to achieve this objective efficiently, including the
use of self-centering chucks, stepped jaws, and stepped V-blocks. These proposed options
offer different methods for quickly and accurately locating, positioning, and clamping the
workpieces, allowing for efficient workflow and reduced setup time.
6.1.2.1 Self-Centering Chuck
Three jaw self-centering is best option to position and clamp workpiece in shortest
possible time. The self-centering chuck with stepped jaw can be used to accommodate
workpiece of different face widths and diameters. Self-centering centering chucks are
known for its versatility, quick operation, accurate and consistent centering and great
ability of clamping forces. Three jaw self-centering chuck also eliminates arduous
centering of workpiece by dial gauges. But have certain limitations too.
38
A self-centering three-jaw chuck may not be appropriate for a heavy cylinder workpiece
for the following reasons:
Figure 28: Self Centering Stepped Jaw Chuck.
→ Torque Requirement: Heavy cylinder workpieces require a lot of torque to rotate,

especially if they are large in diameter and have large face widths or are made of
heavy materials. A self-contained three-jaw chuck may be incapable of providing
the necessary torque to rotate the workpiece, resulting in poor machining accuracy
and potentially dangerous situations.
→ Chuck Size: Due to the size and weight of the workpiece, the chuck size required
for heavy cylinder workpieces is typically large. A self-centering three-jaw chuck
may not be large enough diameter to securely hold the workpiece, resulting in
slippage and poor machining accuracy.
→ Poor Runout: Because self-centering chucks have poor runout accuracy, the
workpiece may not be held concentrically. This can lead to poor machining
accuracy and surface finish.
→ Limited Grip Force: The grip force of self-centering chucks is limited by the
strength of the jaws and the chuck mechanism. This can be a problem when
machining heavy or large workpieces, as the chuck may not be able to hold the
workpiece securely, leading to slippage and poor machining accuracy.
39
Therefore, due to the torque requirements, chuck size, and practical considerations
involved in job shop production, a self-catering 3 jaws chuck may not be the best option
for heavy cylinder workpieces. For such applications, a four-jaw independent chuck or a
hydraulic chuck may be more appropriate.
6.1.2.2 Stepped Jaws
While stepped jaws are suitable for locating the workpiece, the alignment of the workpiece
axis with the machine's base table and the clamping process requires additional steps. For
Figure 29: Stepped Jaws - GSP05 & GSP07.

aligning the workpiece axis, a dial gauge is utilized to ensure precise positioning. As for
clamping, a strap clamp is employed to securely fasten the workpiece in place. These
measures contribute to accurate alignment and effective fixation of the workpiece during
machining operations. The design of stepped jaws takes into account the concept of
overrun, considering specific ranges of face widths. The dimensions of the jaw, including
height and width, are determined based on these considerations. The intention is to create
stepped jaws that can accommodate multiple ranges of workpiece sizes. This design
approach ensures versatility and the ability to handle a variety of workpiece dimensions
effectively.
40
6.1.2.3 V - Block
A V-block is a precision tool that is used to hold cylindrical workpieces in place while
machining, inspecting, or performing other related operations. The V-block is made up of
two angled surfaces that meet at a 120° angle to form a "V" shape. his design enables the
workpiece to align itself and grants convenient accessibility to both sides for machining
purposes.
Figure 30: Stepped V - Block.
The self-centering feature keeps the workpiece securely in place, while the annulus gear
keeps the V-block precisely aligned with the machine axis. Vee blocks are designed with
steps or multiple levels to accommodate a wide range of cylindrical gears with varying
face widths. The steps also provide a larger surface area for the gear to rest on, allowing
the weight of the gear to be distributed evenly across the block and preventing damage to
the gear during the operation.
41
6.1.2.4 Power Screw
Figure 31: Power Screw.
A power screw is a mechanical device used for transmitting rotational motion into linear
motion. It typically consists of a threaded rod or screw and a mating nut or block. When
the screw is rotated, the nut or block moves along the length of the screw, converting the
rotational motion into linear motion.
One type of thread commonly used in power screws is the square thread. Square threads
have a 90-degree thread angle and are designed with a flat crest and root. This results in a
larger contact area between the screw and the nut, which provides a more efficient transfer
of force and reduces the risk of thread damage. Square threads also have a self-locking
feature, which means that the screw will not move unless a force is applied to it.
The power screw designed has left hand thread over one end and right-hand thread over
other hand, so that on rotation of screw in any of the direction either retracts or else opens
the stepped v-blocks from the center. This power screw’s axial movement is restricted by
SKF [14] single row angular contact ball bearings, and that of by bearing supports.
42
6.2 Fixture Layouts
Among the various options discussed for the upper portion of the fixture, only two options
are feasible for implementation: the utilization of stepped blocks and stepped V-blocks.
These options offer practical solutions for accurately locating and clamping the
workpiece’s axis aligned with base plate axis. By employing either stepped blocks or
stepped V-blocks, the fixture can effectively accommodate and secure the workpiece with
precision.
6.2.1 Fixture Layout 01
Upper fixture
Strap Clamp
Workpiece
Heel Screw
Jack Stepped
Jaw
Base
Plate
Supporting
Locating Pin
block
Machine
Base Plate
Figure 32: Fixture Layout 01.
Above figure illustrates the Fixture layout 01. The support blocks are placed and secured
firmly onto the machine's base plate using fastening devices, as depicted in the image. The
locating pin is inserted into the bore of the machine's base plate to precisely align the base
plate of upper portion of the fixture concentrically with the machine's base plate.
Once the supporting blocks and locating pins are properly positioned, they will be securely
fixed in place. The base plate of the upper portion of the fixture is then placed over the
locating pin and supported by the blocks using tenons provided underneath it, ensuring a
precise and stable alignment. The stepped jaws are located on the base plate using T slots
and securely fastened in place using fasteners. To achieve the desired diameter, the
43
stepped jaws can be adjusted by aligning them with the concentric ring's marks on the
base plate, using a copper hammering block to ensure accurate placement.
The stepped jaw allows for the accommodation of various workpieces with different
diameters and face widths. To ensure the workpiece's concentricity with respect to the
upper fixture's base plate, a dial gauge can be employed for precise adjustment. This
allows for accurate alignment and positioning.
After completing the machining process for a workpiece, the operator simply needs to
replace the upper fixture with another base plate that accommodates the next clamped
workpiece. This seamless transition allows for efficient workflow without any
unnecessary adjustments or modifications except troughing out.
6.2.2 Fixture Layout 02
Strap Clamp
Workpiece
Heel Screw
Jack Stepped V-
Block
Base
Plate
Supporting
Locating Pin
block
Machine
Base Plate
Figure 33: Fixture Layout 02.
The overall arrangement of this fixture is comparable to that of layout 02, with the main
distinction being in the upper portion of the fixture. In the upper portion, the fixture
incorporates stepped V-blocks and a power screw that is supported by bearings and a
bearing support. The power screw is designed with a left-hand thread on one end and a
right-hand thread on the other end.
44
The stepped V-blocks are equipped with t-slot extrusions and are assembled within the t-
slots. When the power screw is rotated, the stepped V-blocks can either move away from
the center or move closer to each other. This mechanism allows for self-centering of the
workpiece, eliminating the need for additional centering using a dial gauge. As a result,
valuable setup time is saved, improving efficiency in the process.
3-2-1 Principle:
Fixed Locator
Alternate Locator
Clamping
Figure 34: 3-2-1 Principle for Stepped V blocks.
According to the 3-2-1 principle, a short cylinder is defined as a cylinder with a height
that is one-tenth of its diameter. Consequently, an annulus gear workpiece can be
classified as a short cylinder. Following the principle, the largest surface area of the
workpiece is positioned on the primary datum, the second-largest surface area on the
secondary datum, and the third-largest on the ternary datum. In the case of a short cylinder,
the principle dictates the use of five fixed locators: three on the face of the cylinder and
two on the circumference. These locators serve to restrict the degree of freedom and
ensure proper alignment and stability of the workpiece.
45
In our specific fixture design, a total of 11 locators are necessary. The horizontal steps of
the V-blocks serve as the primary datum for the workpiece, requiring three locators to
position and align the workpiece's face accurately. To achieve self-centering of the
workpiece, two V-blocks are utilized. Each V-block contributes four locators, resulting in
a total of eight locators for locating the circumference of the workpiece. Among these
locators, two are fixed, while the remaining locators are utilized alternately.
Additionally, to prevent rotation of the workpiece during machining, two clamping forces
are applied using the V-blocks and strap clamps. These clamping forces ensure the safety
and stability of the workpiece throughout the machining process.
As a result, achieving workpiece control, geometric control, and mechanical control

requires the utilization of five fixed locators, six alternate locators, and two clamping
mechanisms. These essential components are responsible for accurately positioning,
centering, and securely holding annulus workpieces of different sizes. By incorporating
these locators and clamping features, the fixture ensures precise alignment and steadfast
stability throughout the machining process.
6.3 Fixture Layouts with Machine
Figure 35: Fixture Layout 01 and 02 with Machine.

46
6.4 Material Listing
→ AISI 1010
Table 6: AISI 1010

Material. [11]
→ AISI 1020
Table 7: AISI 1020

Material. [12]
→ AISI 321
Table 8: AISI 321

Material. [9]
→ AISI 1045
Table 9: AISI 1045

Material. [13]
→ AISI 316
Table 10: AISI 316

Material. [10]
47
7. FIXTURE ELEMENTS DRAWING
7.1 Drawing Sheets of Fixture Layout 01

7.1.1 Drawing Sheets of Fixture Components for GSP05
7.1.1.1 Base Plate
Figure 36: Base Plate Drawing Sheet GSP05.
48
Figure 37: Support Drawing Sheet GSP05.
49
Figure 38: Stepped Jaw Drawing Sheet GSP05.
50
Figure 39: Locating Pin Drawing Sheet GSP05.
51
7.1.2 Drawing Sheets of Fixture Components for GSP07
7.1.2.1 Base Plate
Figure 40: Base Plate Drawing Sheet GSP07.
52
Figure 41: Supports Drawing Sheet GSP07.
53
54
55
7.2 Drawing Sheets of Fixture Layout 02
7.2.1 Stepped V – Blocks
Figure 44: Stepped V-Block Drawing Sheet.
56
7.2.2 Power Screw
Figure 45: Power Screw Drawing Sheet.
57
7.2.3 Power Screw & Bearing Supports
Figure 46: Power Screw & Bearing Support Drawing Sheet.
58
8. FIXTURE DESIGN ANALYSIS
This chapter aims to analyze a fixture element, identify the stress concentration in the
elements, and then reduce that concentration by making the necessary modifications to
the element’s design. The Finite Element Method feature of SOLIDWORKS was utilize
to analyze the fixture elements. Once the elements are designed modelled, the maximum
value of stress and point of concentration were analyzed, and thereby by optimizing the
dimensions, stress values or concentration is minimized. Following statical analysis was
carried out: [15] [16]
1. Factor of Safety - In SolidWorks, the factor of safety analysis is performed using the
Simulation module, which allows to simulate and analyze the behavior of models
under different loading conditions. The factor of safety is a measure of how much
stronger a component or structure is compared to the maximum load it is expected
to experience without failure. Red color in 𝑓𝑜𝑠 analysis represents more safer the
part is compared to blue.
2. Von mises Stresses - Von Mises stress is a measure of the combined stress in a
material that takes into account both the normal and shear stresses. The Von Mises
stress is often used in materials science and engineering to predict the yielding or
failure of a material under different loading conditions. Bluer the model to be analyze
indicates lower the stresses generation in model. Hence lesser chance of failure.
3. ESTRN analysis - allows to simulate and analyze the deformation and strain behavior
of your models under different loading conditions.
❖ Loading condition – for assembly of fixture with workpiece, cutting force of 32𝑘𝑁
for GSP05 and 23𝑘𝑁 for GSP07 is acted upon on workpiece.
❖ Other individual elements are loaded with self-weight along workpiece weight
consideration.
59
8.1 Static Analysis of Fixture Layout 01
8.1.1 Static Analysis of Fixture Elements of GSP05
Meshing FOS Analysis
Von Mises Analysis
Deformation Displacement
Figure 47: Supporting Block Static Analysis GSP05.
60
8.1.1.2 Locating Pins
Von Mises Analysis
61
8.1.1.3 Base Plate and Jaw
Von Mises
Analysis
Figure 49 Base Plate and Jaw Static Analysis GSP05.
62
8.1.1.4 Workpiece Clamped on Base Plate
Von Mises
Analysis
Figure 50: Workpiece Clamped on Base Plate GSP05.
63
8.1.2 Static Analysis of Fixture Elements of GSP07
Von Mises Analysis
64
8.1.2.2 Locating Pins
Von Mises Analysis
Figure 52: Locating Pin Static Analysis GSP07.
65
8.1.2.3 Base Plate and Jaw
Von Mises Analysis
Figure 53: Base Plate and Jaw Static Analysis GSP07.
66
8.1.2.4 Workpiece Clamped on Base Plate
Von Mises Analysis
Figure 54: Workpiece Clamped on Base Plate GSP07.
67
8.2 Static Analysis of Fixture Layout 02
8.2.1 Stepped V – Block Jaws
Von Mises Analysis
Figure 55: Stepped V Block Jaw Static Analysis.
68
8.2.2 Workpiece Clamped on Base Plate using Stepped V – Block
Von Mises Analysis
Figure 56: Workpiece Clamped on Base Plate, Static Analysis.
69
9. RESULTS AND DISCUSSION
 The design of the Power Screw, conducted using MITCalc software, has been found
to closely align with the analytical calculations. Therefore, it is expected to perform
its intended function reliably without failure.
 The static structural analysis has been conducted to determine the appropriate
dimensions for the fixture's elements in order to prevent them from failing under
various forces. The stresses generated within the fixture are within safe limits, and
the static analysis model indicates a satisfactory factor of safety for the fixture's
elements. [16]
 Based on the aforementioned results, it can be concluded that all the designed
elements of the fixture are deemed safe under different loading conditions. As a
result, they are expected to function without failure during the machining process.
70
10. CONCLUSIONS
10.1 Conclusion 01
In conclusion, although the self-centering chuck mechanism shows potential for achieving
faster and more efficient alignment between the job's axis and the machine axis in theory,
its implementation in practical applications is hindered by the heavy weight and high
torque requirements. Furthermore, the use of hydraulic systems is not suitable due to the
rotating nature of the worktable, leading to potential issues with fouling of hydraulic
pipelines. While self-centering chucks offer certain benefits, there are significant practical
limitations that need to be addressed before widespread adoption in the manufacturing
industry is possible. Nonetheless, this research provides valuable insights that can guide
future efforts to improve chucking mechanisms and enhance machining efficiency
10.2 Conclusion 02
In conclusion, the incorporation of stepped jaws, supports, and flat head locating pins in
the fixture design has led to a significant enhancement in the efficiency of the workpiece
setup process. This fixture layout allows for accommodating different job sizes, reducing
maximum stock length, and achieving precise alignment with the machine axis. As a
result, the setup time has been reduced by 𝟔𝟕. 𝟐𝟏% compared to the previous fixture
design. However, it is important to emphasize that the concentricity of the workpiece still
needs to be verified using a dial gauge to ensure the quality of the final product. Overall,
this fixture layout provides a practical and effective solution for streamlining the setup
process, improving manufacturing efficiency, and reducing setup time.
 Ranges of workpiece sizes for the machines:
 GSP 05: Diameter 400𝑚𝑚 – 1800𝑚𝑚
Face Width 150𝑚𝑚 – 650𝑚𝑚
 GSP 07: Diameter 250𝑚𝑚 – 1400𝑚𝑚
Face Width 50𝑚𝑚 – 560𝑚𝑚
71
10.3 Conclusion 03
Finally, the implementation of the 120° Vee-Blocks with Steps and the square thread
power screw has significantly reduced the setup time of the workpiece by incorporating a
self-centering mechanism. The integration of a square thread power screw and a standard
single row angular contact ball bearing has resulted in a reliable and durable mechanism
capable of efficiently converting rotational motion of screw into linear motion of the
stepped v-blocks. This design provides an effective solution for optimizing the setup
process, leading to improved productivity with an impressive 𝟖𝟕. 𝟑𝟎% reduction in setup
time compared to the previous fixture. The V-blocks are capable of accommodating
workpiece diameters up to 800𝑚𝑚 and face widths up to 600𝑚𝑚.
In conclusion, two fixture layouts have been designed and proposed to Elecon
Engineering Company with the aim of reducing the setup time for annulus ring gears on
vertical shaper machines. These fixtures have been thoroughly analyzed for safety in
statical analysis and accepted to be effective in reducing setup time and increasing
production time for same the machine. The implementation of these fixture layouts is
expected to have a positive impact on the overall manufacturing process.
72
REFERENCES
[1] B. W. ,. A. S. ,. C. G. ,. N. P. Prof. A. A. Karad, "A Review on Design Consideration and Need of

Fixture in Manufacturing Industries," International Journal of Engineering Research and
General Science , vol. 4, no. 2, p. 5, 2016.
[2] R. M. U. H. JOE CECIL, "An Integrated Methodology for Fixture Design," Journal of Intelligent
Manufacturing , vol. 7, no. 95 - 106, p. 12, 1996.
[3] Y. C. M. T. C. L. CJMT, CJMT Machine Manual, CJMT YKM51250C/7.
[4] P. H. JOSHI, Jigs and Fixture Design Manual, Second Edition, The McGraw-Hill Companies.
[5] C. Blaszczyk, Locating Pins and How They Are Used, MISUMI USA.
[6] P. D.-I. H. Tschätsch, Applied Machining Technology, Springer, 2009.
[7] L. Wenwen , H. Penghao and F. Kuangchao , "Comparison of Current Five-Point Cylindricity

Error Separation Techniques," MDPI , vol. 8, no. 10, p. 20, 2018.
[8] V. B. Bhandari, Design of Machine Elements, Tata McGraw Hill Education Private Limited.
[9] "AISI 321 Stainless Steel," AZOMaterials, [Online]. Available:

https://www.azom.com/article.aspx?ArticleID=967.
[10] "AISI 316 Stainless Steel," AZOMaterials, [Online]. Available:

[11] "AISI 1010 Carbon Steel," AZOMaterials, [Online]. Available:

[12] "AISI 1020 Low Carbon Steel," AZOMaterials, [Online]. Available:

[13] "AISI 1045 Meduim Carbon Steel," AZOMaterials, [Online]. Available:

[14] T. A. S. o. M. E. ASME, Dimensioning and Tolerancing, ASME Y14.5 - 2009.
[15] "Clamping Elements," Hoffmann - Group, [Online]. Available: https://www.hoffmann-

group.com/ID/en/asia/Clamping-technology/Clamping-elements/Heavy-screw-jack/p/374400.
[16] F. A. Saad, "Gear Terminology," Shutterstock.com, [Online]. Available:

https://www.shutterstock.com/image-vector/gear-terminology-internal-gears-657249397.
[17] A. Katz, "Cutting Mechanics of the Gear Shaping Process," Canada, 2017.
73
[18] S. S. Pachbhai and P. R. Laukik, "A Review on Design of Fixtures," International Journal of
Engineering Research and General Science(IJERGS), vol. 2, no. 2, p. 22, 2014.
[19] B. Iain , R. Yiming and C. B. David , "A review and analysis of current computer-aided fixture
design approaches," Robotics and Computer-Integrated Manufacturing, vol. 1, no. 12, p. 12,
2011.
[20] K. S and R. D. W, "Finite element analysis and optimization in fixture design," Springer, vol. 18,
p. 9, 1999.
[21] S. Bearings, "Single row angular contact ball bearing, 7303 BEP," SKF Bearings, [Online].
Available: https://www.skf.com/in/products/rolling-bearings/ball-bearings/angular-contact-
ball-bearings/single-row-angular-contact-ball-bearings/productid-7303%20BEP.
74
PLAGIARISM REPORT
INTRODUCTION
LITERUATRE REVIEW
METHODOLOGY
OBSERVATION
SET – UP PLANNING
FIXTURE PLANNING
75
FIXTURE ELEMENTS DRAWING
FIXTURE DESIGN ANALYSIS
RESULT AND DISCUSSION
CONCLUSION
76

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DESIGN A FIXTURE FOR ANNULUS RING GEARS TO

REDUCE SETUP TIME ON VERTICAL SHAPER MACHINE

Birla Vishvakarma Mahavidyalaya

Er. Jinesh Patel Dr. P. M. George

It is certified that Industrial Project (4ME32) - Report entitled “DESIGN A FIXTURE

[4] There is no falsification by manipulating research materials, equipment or

Krish Vataliya 19ME423

Soham Patel 20ME307

Krish Vataliya 19ME423

Soham Patel 20ME307

TABLE 1: SPECIFICATION OF GSP 05 MACHINE CJMT YKM51250C/7. [3] ......... 22

FIGURE 1: PLANETARY GEAR BOX. ............................................................................ 1

Symbol Definition Units

𝐾𝛾 Correction factor for rack angle ~

𝐾𝑉 Correction factor for cutting speed ~

𝐾𝑣𝑒𝑟 Wear factor ~

𝐾𝑠𝑡 Correction factor for chip compression ~

𝜂𝑚𝑎𝑥 Maximum efficiency 

𝑓𝑜𝑠 Factor of safety ~

𝐹𝐸𝐴 Finite element analysis ~

GSP Gear Shaping Process Machine ~

Ishwarbhai B. Patel founded Elecon Engineering in Goregaon, Mumbai in 1951. The

ELECON Engineering is one of the largest Asian manufacturers of industrial gear

We were provided the opportunity to perform project in the workshop of ELECON

Figure 1: Planetary Gear Box.

1.1 Fixture Significance

1. Consistency: With a fixture in place, the workpiece is held in a consistent position

8. Versatility: The fixture should be designed to accommodate a variety of workpieces

1.2 Shaping Process

Figure 2: Gear Shaping Cutter. [17]

Figure 3: Gear Shaping Process. [17]

1.3 Current Shaping Fixture Arrangement

Figure 4: Fixturing Arrangement.

Figure 5: Elements of Current Fixturing Setup Arrangement.

1. Supports – For different size of workpiece, different supporting block of different

1.4 Time Study of Main Losses

Figure 6: Time Study of GSP-05.

Figure 7: Time Study of GSP-07.

2.1 Literature review

2.1.1 Design Considerations

2.1.2 Methodology Phases

2.1.3 Consideration of tool over run

Main motion length (Over Run) is depended on the tooth

Cutting Length 𝐿 = 100 × 1.2 = 120𝑚𝑚

Over Run Length OL = 20𝑚𝑚 from both sides of faces.

2.1.4 3-2-1 Principle

A locating pin is a mechanical component used in manufacturing and assembly processes

2.1.6 Cutting Force

Power screws are used in various applications, such as in machinery, automotive,

2.1.9 Material Selection

Material selection is an important consideration in fixture design. The material must be

2.1.10 GD&T Standards

Figure 9: Research Gap for Fixture Design.

→ Static analysis of the fixture designed.

→ Reduction in actual setup time to upsurge production time.

3.1 Methodology Flow Chart

• Base Plate Modeling

• Statical Analysis of Fixture

Fixture Design Conclusion and