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 5
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
6
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
vii
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
