DESIGN AND DEVELOPMENT OF VACUUM TABLE

By


Jagadheesh Raju .K
Reg no: 03BME806



Under the guidance of
Mr: R. Ramesh Babu
1.0 PROBLEM DEFINITION

NEED FOR WORKING DEVICES FOR
FRAGILE AND OTHER ENGINEERING
MATERIALS WHICH SAVES HOLDING
& POSITIONING TIME AND PROVIDES
ACCURACY
2.0 PROJECT OBJECTIVE


Design and Develop a work holding device for
holding of fragile and other engineering
materials.
In the metalworking sphere, this inertia includes the premise that secure
and reliable work holding is possible only by mechanical means.
In the past, acceptance of vacuum chucks has been limited by
persistence of traditional practices, as well as by some common misconceptions.
Despite evidence to the contrary, for example, the belief that persist that vacuum
chucks arent sturdy enough to withstand heavy machining operations. Another
prevalent assumption is that vacuum chucks are only suitable for small work
pieces. Reinforcing this view, many of the vacuum chucks in use today do serve
small application.
LITERATURE SURVEY
Ceramic is important material in Aerospace engineering. But it
is difficult to machine by using mechanical &magnetic type work
holders

Holding of fragile & non ferrous material is difficult with help of
normal work holders

All problems can be eliminated by vacuum type work holder
3.0 METHODOLOGY
Factors to be considered for machining.
Design calculation for the factors
considered.
Design of venturiblock, vacuum table and
other accessories.
Manufacturing and assembly.
Testing and validation.

3.1 Factors to be considered for machining

3.1.1 FORCES IN MILLING:-

TANGENTIAL (CUTTING) FORCES

This acts in a direction tangential to the fixed work piece and
represents the resistance to the rotation of the tool


LONGITUDINAL (THRUST-FEED) FORCES

Longitudinal force acts in the direction parallel to the axis of the
work and represents the resistance to the longitudinal feed of the work piece


RADIAL (PASSIVE) FORCES

Radial forces acts in a radial direction from the center line of the
workpiece
3.1.2 MACHINING PARAMETERS

There are three important parameters in milling operation
Cutting speed
Depth of cut
Feed rate


i. CUTTING SPEED:-
Cutting speed refers to the relative surface speed between tool and work


ii. DEPTH OF CUT :-
The depth of cut relates to the depth the tool cutting edges engages the
workpiece


iii. FEED RATE :-
The feed rate is the axial advance of the tool along the work for each
revolution of the work

Based on above graphs, cutting force is maximum among all
forces while machining
DESIGN CALCULATION FOR THE FACTORS CONSIDERED

3.2 Cutting Force

Specific cutting energy: A parameter giving an indication of the

efficiency of the process , independent of cutting speed, defined

as the energy consumed per unit volume o f removed metal

The rate of energy consumed during machining P
m
is
P
m
=F
C
*V

Energy consumed per unit volume of metal removed, specific cutting energy ps is


P
s
=
C
c
w
m
A
F
Z
P
=
If A
C
=1 , then P
S
=F
C

Where P
m
= Power consumed

F
C
= Cutting force

V = Cutting speed

Z
W
= Metal removal rate

A
c
= Undeformed chip cross section area

P
s
= Specific cutting energy
Based on above tabular column refractory alloys has max.
Specific cutting energy value of 9.6 W-s/mm
3

So max cutting force is 9.6 N
Material
Specific energy
W-s/mm
3

Aluminum alloy 0.4 to 1.1
Cast irons 1.6 to 5.5
Copper alloys 1.4 to 3.3
High-temperature alloys 3.3 to 8.5
Magnesium alloys 0.4 to 0.6
Nickel alloys 4.9 to 6.8
Refractory alloys 3.8 to 9.6
Stainless steels 3.0 to 5.2
Steels 2.7 to 9.3
Titanium alloys 3.0 to 4.1
APROXIMATE ENERGY EQUIREMENTS IN CUTTING OPERATION

3.3 Design of venturiblock, vacuum table and other
accessories

Max cutting force during machining is 9.6 N
For machining vacuum force of work of work holder should be more
then cutting force


VACUUM FORCE= VACUUM PRESSURE X AREA OF CONTACT OF
VACUUM WITH JOB


VACUUM PRESSURE CAN BE CREATED WITH FOLLOWING WAYS:
1. VACUUM PUMP
2. VENTURI VACUUM PUMP




VENTURI VACUUM PUMP SELECTED FOR VACUUM TABLE
BASED ON FOLLOWING REASONS & COMPRESSED AIR AVAILABLE
WITH US

In general the following are the advantages of using venturi
vacuum generators:

i. Fast cycling
ii. Temperatures
iii. Corrosive environments
iv. Noise levels
v. Contamination
vi. Ease of mounting
vii. Maintenance
viii. Lower Cost


When Is A Venturi Undesirable?
One of the basic requirement of a venturi vacuum generator is
compressed air. If compressed air is not available, an electric vacuum
pump is the only alternative.
If constant vacuum flow is required, venture may not be the most
efficient device compared to vacuum pumps . Also, if the application
requires a large vacuum flow at high vacuum, a vacuum pump may be
more energy efficient then a venture.

3.3.1 VENTURI BLOCK DESIGN: (using Bernoullis theorem)


VACUUM FORCE =VACUUM PRESSURE *AREA
=VACUUM PRESSURE * AREA BASED ON JOB

Take minimum area as 30*30=900 mm2
=0.0009 m2

Cutting force as per data =9.6 N
=10 N
10 N = vacuum pressure * 0.0009 m2

Vacuum pressure =11111.1 N/m2
= 83.3 mm of Hg
=80 mm of Hg

Factor of safety taken as 5

So required vacuum pressure is 400 mm of Hg

8 . 234
4
2
1
1
= =
D
Q
V
t

2 1
2
2
2 2
1
2
1 1
2 2

A
+ + + = + +
p
gz
V p
gz
V p
0
2 1
= A

p
2 1
gz gz =
2
2
2
4
D
Q
V
t
=
4
1
2
1
1
|
|
.
|

\
|

D
D
4
2
2
D t

) ( 2
2 1
p p
AVAILABLE DATA:
Discharge Q=30 CFM =.0149m
3
/s
Pressure P
1
=80 psi =551428.6 N/m
2

Pressure P
1
=-400mm of hg =-53328.9N/m
2

Diameter D
1
= 9mm =.009m

Calculation:

m/s

;
V
2
= 1124.5 m/s



D2=.004 m


Q=
VACUUM FORCE =VACUUM PRESSURE *AREA

=400 mm of hg * AREA BASED ON JOB
3.3.2 Design Of Vacuum table

VACUUM TABLE HEIGHT= 300 mm
VACUUM TABLE WIDTH = 300 mm
VACUUM TABLE DEPTH = 70 mm
HOLE DIAMETER = 10 mm
GAP BETWEEN TWO HOLES (Pitch) = 15mm
GAP BETWEEN HOLES & Edges x axis) = 25 mm
GAP BETWEEN HOLES & Edges y axis) = 22.5 mm
NO. OF HOLES = 288
WALL THICKNESS = 16mm

TOP & BOTTOM PLATE THIK = 10 mm
Vacuum table rough diagram
S.
N.
Piece
dimensions
Hole
dia Gap
No. of holes
Total
no. of
holes
Radiu
s Area
Total
area(m
m2)
Total
area(m2
)
Force
(N) X Y Xh Yh
1 30 30 10 5 2 2 4 5 78.5 314 0.0003 15.9
2 30 30 10 2.5 2.4 2.4 5.8 5 78.5 452.2 0.00045 22.9
3 30 30 5 5 3 3 9 2.5 19.6 176.6 0.00018 8.9
4 30 30 5 2.5 4 4 16 2.5 19.6 314 0.00031 15.9
5 30 30 4 2.5 4.6 4.6 21.3 2 12.6 267.6 0.00027 13.6
6 30 30 4 2 5 5 25 2 12.6 314 0.00031 15.9
7 30 30 2.5 2.5 6 6 36 1.3 4.9 176.6 0.00018 8.9
8 30 30 2.5 2 6.7 6.7 44.4 1.3 4.9 218.1 0.00022 11
9 30 30 2 2 7.5 7.5 56.3 1 3.1 176.6 0.00018 8.9
10 30 30 2 1.5 8.6 8.6 73.5 1 3.1 230.7 0.00023 11.7
11 30 30 2 1 10 10 100 1 3.1 314 0.00031 15.9
12 30 30 1.5 1 12 12 144 0.8 1.8 254.3 0.00025 12.9
13 30 40 10 5 2 2.7 5.3 5 78.5 418.7 0.00042 21.2
14 30 40 10 2.5 2.4 3.2 7.7 5 78.5 602.9 0.0006 30.5
15 30 40 5 5 3 4 12 2.5 19.6 235.5 0.00024 11.9
16 30 40 5 2.5 4 5.3 21.3 2.5 19.6 418.7 0.00042 21.2
17 30 40 4 2.5 4.6 6.2 28.4 2 12.6 356.7 0.00036 18.1
18 30 40 4 2 5 6.7 33.3 2 12.6 418.7 0.00042 21.2
19 30 40 2.5 2.5 6 8 48 1.3 4.9 235.5 0.00024 11.9
20 30 40 2.5 2 6.7 8.9 59.3 1.3 4.9 290.7 0.00029 14.7
21 30 40 2 2 7.5 10 75 1 3.1 235.5 0.00024 11.9
22 30 40 2 1.5 8.6 11.4 98 1 3.1 307.6 0.00031 15.6
23 30 40 2 1 10 13.3 133.3 1 3.1 418.7 0.00042 21.2
24 30 40 1.5 1 12 16 192 0.8 1.8 339.1 0.00034 17.2
Selection Of Hole Diameter And Number Of Holes
MATERIAL REQUIRED FOR VACUUM TABLE UNIT
SI
.N
O.
ITEM
DESCRIPTION
MAKE/SUP
PLIER MATERIAL UNIT
UNIT
PRIC
E QTY
TATAL
COST
1 VACUUM TABLE SELF MS NO 4100 1 4100
2
VENTURI
VACUUM
GENERATOR SELF MS NO 850 1 850
3 RECIEVER TANK SELF MS NO 1650 1 1650
4 1/2" BALL VALVE
AUDCO
INDIA LTD MS NOS 888 3 2664
5 1/2" HOSE
ABDULKAD
AR & SONS
NYLON
INFORCED MTR 36.5 2 73
6 1/2" CLAMP NA MS NOS 14 4 56
7 1/2" NIPPLE NA MS NOS 14.5 10 145
8 1/2" STRAINER VITA MS NO 1420 1 1420
9 1/2" REGULATOR VITA NA NO 880 1 880
1
0
VACUUM
PRESSURE
GAUGE NA NO 550 2 1100
1
1 1/2" NRV VITA MS NO 1430 1 1430
GRAND TOTAL 14368
FABRICATION ITEM LIST
SI.
NO.
ITEM
DESCRIPTION
MATERIA
L COST
WELDING
& GAS
CUTTING
MACHINE
COST
QT
Y
TATAL
COST
1
VACUUM
TABLE 1500 600 2000 1 4100
2
VENTURI
BLOCK 200 0 500 1 700
3 NOZZLE 50 0 100 1 150
4
CONDENSATE
TANK 650 750 250 1 1650
TOTAL 6600
SI.NO. ITEM DESCRIPTION MAKE/SUPPLIER MATERIAL UNIT
UNIT
PRICE
QTY
TATAL
COST
1 VACUUM TABLE SELF MS NO 1 0
2
VENTURI VACUUM
GENERATOR
SELF MS NO 1 0
3 RECIEVER TANK SELF MS NO 1 0
4 1/2" BALL VALVE AUDCO INDIA LTD MS NOS 888 3 2664
5 1/2" HOSE
ABDULKADAR &
SONS
NYLON
INFORCED
MTR 36.5 2 73
6 1/2" CLAMP NA MS NOS 14 4 56
7 3/4" STRAINER VITA MS NO 1420 1 1420
8 3/4" NRV VITA MS NO 1430 1 1430
EQUIPMENT REQUIRED FOR VACUUM TABLE UNIT
MIN HRS
1 VACUUM TABLE MS 25 0.417 90 200 1 173.33
2 VENTURI BLOCK MS 1 0.00
3 NOZZLE MS 1 0.00
4
CONDENSATE
TANK
MS 1 0.00
173.33
TATAL COST
FABRICATION ITEM LIST
GRAND TOTAL
M/C'ING
TIME SI.NO.
ITEM
DESCRIPTION
MATERIAL
SETUP
COST
MACHINE
COST /HR
QTY
RESULTS AND RECMODATION
CONCLUTION


Trial carried out with vacuum work holder by fixing it on milling
machine table and came to following conclusions.

Job holding and positioning time become very less. (i.e. 3 to
5 sec)

By using vacuum work holder we clamp the 10mm plate
very easily. But it is difficult hold this plate with mechanical
fixture.

Surface of plate (10 mm thickness) fully machined up to
3mm thickness depth without disturbing the initial set up of
plate. But it is not possible with mechanical fixture.

Ceramic material job held with vacuum holder as a trial
and found ceramic piece held perfectly. It is not possible with
magnetic fixture and ceramic piece may got damage if we held
it with mechanical fixture.

Length Breath Area
Vacuum
pressur
e
(mm of
Hg)
Vacuum
pressure
(N/m2) Force
0.265 0.11 0.02915 400 53328.94737
1554.
539
0.265 0.23 0.06095 400 53328.94737
3250.
399
0.005 0.005 0.0000785 400 53328.94737
4.186
322
MAXIMUM FORCE THAT VACUUM TABLE CAN WITH STAND
RECOMMENDATIONS OF FUTURE WORK



Auto vacuum pressure controller unit to control pressure if pressure
drops

Computerized fluid dynamics analysis to increase performance of
vacuum work holder

Refine the vacuum table for more applications

Reference


- Prof. Dr.Omer Anlagan, Mechanics of metal cutting, 2005

- Haci Saglam, Suleyman Yaldiz *, Faruk Unsacar, The effect of tool geometry
and cutting speed on main cutting force and tool tip temperature

- S_eref Aykut a, Eyup Bagci b,*, Aykut Kentli c, Osman Yazcoglu a
Experimental observation of tool wear, cutting forces and chip morphology in face
milling of cobalt based super-alloy with physical vapour deposition coated and
uncoated tool

M.S. Shaw, Metal Cutting