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ABSTRACT
A Machine vice is a production tool. The main aim is to locate, support and hold the work securely so we can perform the required machining operations. Feeler or thickness gauges and set blocks are also used to provide reference of the cutter with the work piece. A bench vice must be easily fastened with the machine and the table. As a result, the work can be done. It can be used for the other operations on most of the standard machining tools like drilling machine. Machinevices are available in different size and shapes ranging from cheap and simple devices to very expensive and complicated devices. Machinevices can also help to simplify the metalworking operations which are performed on the special equipment.
Table of Contents
COVER PAGE i
TITLE PAGE ii
CERTIFICATION iii
DEDICATION iv
DECLARATION v
ACKNOWLEDGMENT vi
CHAPTER ONE 1
INTRODUCTION 1
1.1 BACKGROUND OF THE STUDY 1
1.2 TYPES OF BENCH VICE 4
1.3 COMMON FEATURES 4
1.4 STATEMENT OF THE PROBLEM 4
1.5 OBJECTIVE OF THE STUDY 5
1.6 PURPOSE OF THE PROJECT 5
1.7 Scope of the project 5
CHAPTER TWO 6
LITERATURE REVIEW 6
2.1 WORKING PRINCIPLE 9
2.2 TYPES OF VISES 9
MERITS & DEMERITS OF A MACHINE VICE 14
CHAPTER THREE 15
METHODOLOGY 15
3.1 DESIGN CONSIDERATION 15
3.2 COMPONENTS OF THE MACHINE VICE 17
3.3 FACTORS DETERMINING THE CHOICE OF MATERIALS 18
3.4 SUMMARY 20
CHAPTER FOUR 21
PRESENTATION, TESTING, RESULT AND ANALYSIS 21
4.1 DESIGN PROCESS 21
4.2 RESEARCH PRESENTATION 21
4.3 DESIGN OF VICE SCREW 22
4.3 DESIGN OF COLLAR 23
4.4 DESIGN OF JAW PLATE 23
4.5 DESIGN OF SLIDING JAW 24
4.6 DESIGN OF VISE HANDLE 24
4.7 DESIGN OF HANDLE NUT 25
4.8 DESIGN OF FLAT TAPPING SCREW 25
4.9 DESIGN OF FIXED JAW OF BENCH VISE 25
CHAPTER FIVE 27
CONCLUSION AND RECOMMENDATIONS 27
5.1 CONCLUSIONS 27
5.1 RECOMMENDATION 28
REFERENCES 29
CHAPTER ONE
INTRODUCTION
1.1 BACKGROUND OF THE STUDY
A machine vice is like an extra hand. Its purpose is to hold material steady, allowing you to use both hands to work on the material with other tools.The machine vice is of the screw base bench design. It is a heavyweight, portable vice. It is attached to a table or bench with the mounting screw holes. It has rough jaws for holding material with stationary base. Screw base machine vices are considered most appropriate to hold light materials or in areas where a heavier vice is not available such as laboratories and school workshops.
It consists of a mounting base or body which is secured to the machine table, a stationary jaw against which work piece is located, a movable jaw and screw mechanism consisting of a buttress-threaded spindle and handle. When the spindle is rotated in the clockwise direction using the handle, the jaws move closer thus clamping the workpiece against the stationary jaw. This clamping action holds the part securely while the machining operation takes place. On the other hand, when turned in the anticlockwise direction, the jaws move away thus loosening the grip on the work piece
The stiffness created through the design that pulled the jaw down has the added benefit of pulling the nut and driving the movable jaw up creating a sandwich of vice body, nut and movable jaw. The resulting stiffness and dampening allowed a significantly lighter vice to be offered, allowing for manual lifting and positioning of the vice on a machine table, which contributed to its popularity. The stationary jaw is cast integral with the vice body. It is a good selection when density and absolute minimum deflection is needed.This vice hardware is adaptable for installation in a variety of positions, and on different styles of bench tops.They are ideal for sawing, sanding, plaining,drilling, screwing and soldering.
The machine vice is a threaded transmitter mostly used to hold tight a work piece in order to be successfully realized mechanical processing operations, such as lathing, cutting, drilling, welding etc. Given the large number of products in use, which differ in size, destination and/or by the number of component parts, there is a need to accelerate the design process. Accelerating the design process can be achieved by relying on new design methods and with the help of computer programs. The advantage of using these options when design these product variants is the speed of manufacturing and time to market and the result is reduction of cost production.
Increasing the accuracy and productivity are the two basic aims of mass production. As we know the solution to this is by reducing the manual fatigue and also reducing the set up cost of the machine. In this case the device that fulfils our needs is the use of jigs. Let us take one example. Let us consider that one gets an order of say 1000 products. There need to be drilled three holes on this product. In such a case the designer tries to draw out every single hole with the help of square, straighteners, scribers and center hole. In order to align the axis of the drill with the axis of the hole we generally go for trial and error method. Accuracy is the main problem in such cases. In doing so accuracy increases the work load on the operator. Hence using of jig to position and guide the tool to its right path is preferred rather than using scribers, square, straighteners or center punch etc. Thus, the productivity is increased which is done by eliminating individual marking, positioning and frequent checking. Interchangeability is the chief advantage here. All the parts fit in properly except only the similar components are interchangeable. One does not need to repeatedly unclamp and clamp the object for various purposes like positioning as the locating, guiding and clamping of the tool is done by the jig itself. Bushing is used which is a tool guiding tool. So, it reduces the presence of skilled laborer. Drill jig helps to ream, drill and tap at a much faster speed and with great accuracy as compared to holes done conventionally by hand. The responsibility to maintain the accuracy of the hole is now shifted from the operator and given to the jig. May it be a drill fixture or a drill jig the necessity of a clamping device is inevitable. In case of a drill jig bushings are used. These drill bushings guide the drill bit during the drilling operation. Generally, work piece is held by a fixture and the fixture is arranged in such a way that the loading and unloading of the job is fast. As we all know a fixture is a production tool which is mainly used to hold, locate and support the work piece firmly to the table. Feeler and Set blocks are sometimes used to provide reference of the cutter to the work piece. The main concern is the fastening of the fixture. These fixtures also help in simplifying the network operations which are performed on special equipment.
1.2 TYPES OF BENCH VICE
There aretwo types of bench vice that share acommon anatomy.
- WOODWORKING VICES
Woodworking vices are usually incorporated into the structure of a woodworking bench, often fabricated from the same type of timber as the bench. The top edge of the jaws is usually flush with the bench top and does not protrude beyond the edge of the bench.
- ENGINEER’S VICE
Engineer’s bench vices are also known as metalworking vices and are typically fabricated from iron or steel. These vices are not an integrated part of the workbench, allowing them to be removed and used on any suitable worksurface. They are attached so that the jaws of the vice sit above the level of the work surface, at about elbow height, to give more purpose for working on harder materials and slightly protruding beyond the edge of the bench.
1.3 COMMON FEATURES
For the engineering bench vice, it consists of two jaws, one stationary and one moveable. These are fitted into a frame with a screw apparatus operated by a lever which controls the moveable jaw, allowing the space between the jaws to be expanded or contracted to accommodate different-sized pieces of material.
1.4 STATEMENT OF THE PROBLEM
A problem with known types of vice is that the numerous component parts thereof mean that the clamp is relatively expensive to manufacture. Furthermore, if the clamp is of relatively complex construction it may be similarly complex to operate. In particular, it is inconvenient to have to use both hands in order to clamp an object in the clamp and a one-handed operation would be more desirable. Also, vices tend to be heavy and are normally fixed to a work surface. Research have also shown that the available machine vice are not cost effective, hence these machine tools are not readily available to the engineers, technicians, artisans who are greatly in need of this machine tool for their daily work in the workshop.Most vices in the workshops are too big and are not amenable to small work pieces holding. Besides, because of their sizes, their materials of construction are big and hence cost much.When under pressure, most vice designs deflect creating part alignment problem requiring that lifted work pieces be forced down with hammer. It is therefore an object of the present invention to provide a clamp which alleviates the above-described problems
1.5 OBJECTIVE OF THE STUDY
- To design a machine vice.
- Modify an existing machine vice for small scale workshop production.
- To analyze the design structure of the machine vice.
- To improve the existing design through material and size reduction
- Evaluate the cost of the modified machine vice.
- Alleviate the sufferings of engineers, technicians, artisans who use hand to grip object for cutting, planning, gluing etc.
1.6 PURPOSE OF THE PROJECT
From the research, it is expected that the student would be exposed to and learn how to progress from design to actual fabrication of equipment, using conventional system.
1.7 Scope of the project
In general, to address the work holding needs of a particular machining operation, one needs to consider part size, material, machine speed, feed rate, and the quantity of Parts to be produced. Single part production or low quantity requirements generally make a single vice setup a good choice. The part configuration will point toward either contoured jaws or any number of standard or special jaws. The gripping area for the planned operation must allow for sufficient depth of jaw engagement (bite) to safely allow the planned operation to take place.
Higher quantity lot sizes make multiple vice setups desirable. The workpiece size determines the spacing between the vices as well as the vice size itself. Generally, attempts must be made to produce the maximum amount of parts per cycle. Many additional operations by the same operator can then be done simultaneously. The key to freeing the operator is quick clamping and the highest efficiency of the workpiece loading cycle. This includes prepping the work area for thorough chip flushing and cleaning.
But in particular, with reference to this project, the vice design is guided by the following considerations;
- Suitable clamping forces
- Fast and ease of clamping
- Modest construction
- Low cost
- Resilience