v
TABLE OF CONTENTS
Abstrak i Abstract ii
Dedication iii Acknowledgement iv
Table of Contents v List of Tables iix
List of Figures x List of Abbreviations, Symbols And Nomenclature xiii
CHAPTER 1 : INTRODUCTION 1
1.1 Background
1 1.2
Problem Statement 2
1.3 Objective
3 1.4
Scope of project 3
CHAPTER 2 : LITERATURE REVIEW 5
2.1 Jigs and Fixtures
5 2.2
Material Used in Jigs and Fixtures 7
2.3 Welding
13 2.3.1
Type of welding method 14
2.3.2 Classification of welding
15 2.4
Welding Parameter Used In Welding Fixture 19
2.5 Application of Welding In Manufacturing
19
vi 2.6
Load 23
2.7 Theoretical of weight
24 2.8
Factor of safety F.O.S 25
2.9 Fatigue Life
25 2.10
Heat Transfer 26
2.10.1 Heat conduction 27
2.10.2 Heat convection 28
2.10.3 Radiation 28
2.10.4 Heat flux 29
2.10.5 Steady-state and transient heat transfer 30
2.11 Finite Element Analysis FEA
31
CHAPTER 3 : METHODOLOGY 32
3.1 Project Methodology
32 3.1.1
Flow chart 33
3.2 Phase 1
34 3.2.1 Start
34 3.2.2 Problem Statement
34 3.2.3 Design Planning
35 3.2.3.1 Workpiece
36 3.2.3.1.1 Part A: 40x60x4mm
39 3.2.3.1.2 Part B: 30x50x4mm
42 3.2.3.2 Design concept
45 3.2.3.2.1 Concept 1
46 3.2.3.2.2 Concept 2
48 3.2.3.2.3 Concept 3
50 3.2.4
Concept Scoring 52
3.2.4.1 Concept scoring table 53
3.2.5 Design Selection
54
vii 3.2.5.1 3D model of concept 3
54 3.2.5.2 Material selection
56 3.2.5.3 Heat transfer calculation
57 3.3
Phase 2 60
3.3.1 Simulation in ANSYS
60 3.3.1.1 Pre-processing
62 3.3.1.2 Solution
62 3.3.1.3 Post-processing
62 3.4
Phase 3 63
3.4.1 Expected Result
63 3.4.1.1 Structural Static analysis
63 3.4.1.2 Transient Thermal Analysis
64 3.5
Phase 4 64
CHAPTER 4 : RESULTS AND DISCUSSION 65
4.1 Fixturing device A and B
65 4.1.1
Transient Thermal Analysis 67
4.1.1.1 Transient Thermal Analysis result 74
4.1.1.1.1 Global Temperature graph 74
4.1.1.1.2 Temperature distribution 77
4.1.1.1.3 Total Heat Flux 80
4.1.2 Static Structural Analysis
83 4.1.2.1 Static Structural Analysis result
87 4.1.2.1.1 Equavalent von mises stress
87 4.1.2.1.2 Total deformation
90 4.1.2.1.3 Fatigue Life
93 4.1.2.1.4 Fatigue damage
94 4.1.2.1.5 Factor of safety F.O.S
95 4.2
Fixturing device C 98
viii 4.2.1
Static Structural Analysis for Fixturing device C 99
4.2.1.1 Equavalent von mises stress
99 4.2.1.2
Total deformation 102
4.2.1.3 Fatigue life
105 4.2.1.4
Fatigue damage 106
4.2.1.5 Factor of safety F.O.S
107 4.3
Discussion 110
4.3.1 Material selection for Fixturing device A and B
110 4.3.2
Material selection for Fixturing device C 114
CHAPTER 5 : CONCLUSION AND RECOMMENDATION 117
