DESIGN AND FABRICATION OF STEERING

OPERATED HEAVY DUTY MOVABLE MACHINE VICE

SYNOPSIS

The main purpose of this project is used to DESIGN AND

FABRICATION OF STEERING OPERATED HEAVY DUTY

MACHINE VICE. Holding machine is a mechanical device used to hold

or otherwise exert a force on an object too heavy to deal with by hand. A

common example is the workshop machine vice, which is used to fix the

end of a work piece by a system of ratchets, gears, and screws.

Holding machine vices are used for leveling or positioning heavy

equipment, or for supporting structures. In this project we are doing the

machine vice with rack and pinion mechanism arrangement with steering

wheel.

1
 CHAPTER - I

INTRODUCTION

1.1 GENERAL INTRODUCTION

This device the steering machine vice for workshops and work

piece garages has been developed to later the needs of small and medium

workshop. In most of the garages the work piece are holded by using

machine vice. This needs high man power and skilled labours.

In order to avoid all such disadvantages, this machine vice for

workshops has been designed in such a way that it can be used to hold

the work piece very smoothly without any impact force. The operation is

made be simple that even any person can handled, by turning the steering

wheel.

This is an era of automation where it is broadly defined as

replacement of manual effort by mechanical power in all degrees of

automation. The operation remains an essential part of the system

although with changing demands on physical input as the degree of

mechanization is increases.

2
Degrees of automation are of two types, viz .

Full automation.

Semi automation.

In semi automation a combination of manual effort and

mechanical power is required whereas in full automation human

participation is very negligible.

1.2 NEED FOR AUTOMATION

Automation can be achieved through computers, hydraulics,

pneumatics, robotics, etc., of these sources, pneumatics form an

attractive medium for low cost automation.

To achieve mass production

To reduce manpower

To increase the efficiency of the plant

To reduce the work load

To reduce the production cost

To reduce the production time

To reduce the material handling

To reduce the fatigue of workers

3
 To achieve good product quality

Less Maintenance

CHAPTER - 2

NEED FOR AUTOMATIC SYSTEM

3.1 AUTOMATIC SYSTEM

In the development of the submarine from pre-war classes, many

changes and improvements have occurred. One of the outstanding

differences is the large variety of submarine devices which are now

operated by automatic power. In early classes, there was no automatic

system, and power requirements were met by means of air or electricity.

Along with constantly improving submarine design has gone a constant

extension and diversification of the use of automatic power.

3.2 Comparative advantages of automatic power

Automatic systems possess numerous advantages over other

systems of power operation. They are light in weight; they are simple and

extremely reliable, requiring a minimum of attention and maintenance.

4
Automatic controls are sensitive, and afford precise controllability.

Because of the low inertia of moving parts, they start and stop in

complete obedience to the desires of the operator, and their operation is

positive.

Finally, automatic units are relatively quiet in operation, an

important consideration when detection by the enemy must be prevented.

Therefore, in spite of the presence of the two power sources just

described, automatic power makes its appearance on the submarine

because of the fact that its operational advantages, when weighed against

the disadvantages enumerated for electricity and air in the preceding

paragraphs, fully justify the addition of this third source of power to those

available in the modern submarine.

5
 MACHINE VICE

A Machine vice is a portable device consisting of a screw mechanism

used to hold or lowers the load. There are two types of machine vices-

mechanical and hydraulic. Mechanical machine vices can be either hand

operated or power driven. The hydraulic machine vice consist of cylinder

and piston mechanism Although a machine vice is a simple device used

to hold various types of loads Proper size, strength and stability are

essential requirements for the design of the machine vice from safety

consideration

6
A vice is a mechanical apparatus used to secure an object to allow work

to be performed on it. Vises have two parallel jaws, one fixed and the

other movable, threaded in and out by a screw and lever.

Types

Woodworking

Woodworking vises are attached to a workbench, typically flush with its

work surface. Their jaws are made of wood or metal, the latter usually

faced with wood to avoid marring the work. The movable jaw may

include a retractable dog to hold work against a bench dog.

"Quick-release" vises employ a split nut that allows the screw to engage

or disengage with a half-turn of the handle. When disengaged the

movable jaw may be moved in or out throughout its entire range of

motion, vastly speeding up the process of adjustment. Common thread

types are Acme and buttress.

Engineer's

An engineer's vise, also known as a metalworking vise or fitter's vise, is

used to clamp metal instead of wood. It is typically made of cast steel or

malleable cast iron. Cheaper vises may be made of brittle cast iron. The

7
jaws are often separate and replaceable, usually engraved with serrated

or diamond teeth. Soft jaw covers made of aluminum, lead, or plastic

may be used to protect delicate work.

An engineer's vise is bolted onto the top surface of a workbench, with the

face of the fixed jaws just forward of its front edge. The vise may include

other features such as a small anvil on the back of its body.

Others

Other kinds of vise include:

Hand vises

Machine vises - drill vises (lie flat on a drill press bed). Vises of the same

general form are used also on milling machines and grinding machines.

compound slide vises are more complex machine vises. They allow

speed and precision in the placement of the work.

Cross vises, which can be adjusted using lead screws in the X and Y

axes; these are useful if many holes need to be drilled in the same

workpiece using a drill press. Compare router table.

Off-center vises

Angle vises

8
Sine vises, which use gauge blocks to set up a highly accurate angle

Rotary vises

Diemakers' vises

Pin vises (for holding thin, long cylindrical objects by one end)

Jewellers' vises and by contrast

Leg vises, which are attached to a bench but also supported from the

ground so as to be stable under the very heavy use imposed by a

blacksmith's work.

9
Advantages

An advantage of vice over some other types of vice is that they are self-

locking, which means when the rotational force on the cam is removed, it

will remain motionless where it was left and will not rotate backwards,

regardless of how much load it is supporting. This makes them inherently

safer than hydraulic vices, for example, which will move backwards

under load if the force on the hydraulic actuator is accidentally released.

Mechanical advantage

The mechanical advantage of a cam vice, the ratio of the force the vice

exerts on the load to the input force on the lever, ignoring friction, is

where

is the force the vice exerts on the load

10
 is the rotational force exerted on the handle of the vice

is the length of the vice handle, from the cam axis to where the

force is applied

However, most cam vices have large amounts of friction which increase

the input force necessary, so the actual mechanical advantage is often

only 30% to 50% of this figure.

Applications

A vice threads must support heavy loads. In the most heavy-duty

applications, such as cam vices, a square thread or buttress thread is used,

because it has the lowest friction. In other application such as actuators,

an Acme thread is used, although it has higher friction.

The large area of sliding contact between the cam threads means vice

have high friction and low efficiency as power transmission linkages,

around 30%50%. So they are not often used for continuous transmission

of high power, but more often in intermittent positioning applications.

The Ball cam is a more advanced type of leadcam that uses a

recirculating-ball nut to minimize friction and prolong the life of the cam

threads. The thread profile of such cams is semicircular to properly mate

11
with the bearing balls. The disadvantage to this type of cam is that it is

not self-locking.

Applications

Amachine vicescrew's threads must support heavy loads. In the most

heavy-duty applications, such as machine vices, a square thread or

buttress thread is used, because it has the lowest friction. In other

application such as actuators, an Acme thread is used, although it has

higher friction.

The large area of sliding contact between the screw threads

meansmachine vicescrews have high friction and low efficiency as power

transmission linkages, around 30%50%. So they are not often used for

continuous transmission of high power, but more often in intermittent

positioning applications.

The Ball screw is a more advanced type of leadscrew that uses a

recirculating-ball nut to minimize friction and prolong the life of the

screw threads. The thread profile of such screws is semicircular to

properly mate with the bearing balls. The disadvantage to this type of

screw is that it is not self-lockin

12
 Machine vice operations

It is necessary that the work should be properly and securely held on for

machining operations, a VISE is a effective work holding device.

Vises: Vises are the most common appliances for holding work on table

due to its quick loading and unloading arrangement. There are mainly

three types of vises commonly used,

Plain vise Swivel vise Tool makers universal vise

Plain Vise: the plain vise bolted directly on the table on the T-slots. The

vise may be fastened to the table with the jaws set at right angles to the

table T-slots. Work is camped between the fixed and movable jaws and

for holding work pieces of irregular shape special jaws are used.

Swivel vise: the swivel vise is used to mill angular surface in relation to a

straight surface without removing the work from the vise. In construction

it may be considered a plain vise, which is mounted on a circular base

graduated in degrees. The base is clamped on the table by means of T-

slots.

13
The required machining operations to be performed are:

Facing, chamfering, turning to provide clamping surface to jaws.

External Square threading on the spindle.

Drilling, Boring and internal threading on base plate.

Drilling on the spindle and threading on lever to fit into the spindle

for application of manual load.

C-clamp for clamping the Vice on the table.

Vise Installation

This vise hardware is adaptable for installation in a variety of positions,

and on different styles of bench tops. The key to successful installation is

careful planning and preparation. Installed properly, your vise will give a

lifetime of useful, daily service.

First: Choose vise position and jaw size

This vise can be mounted in a variety of positions, depending on your

working style and bench type. Assuming youre right handed, typical

mounting positions would be either towards the left of the front edge of

your bench, or the right end of your bench. Carvers will probably find the

end position most useful, as will those who will most often clamp wide,

14
flat work like doors and wide panels. If the vise will mostly be used to

hold small parts, or narrow boards on edge for jointing, the benchs front

edge will likely be the best option. Just be sure that the location you

choose doesnt interfere with bench legs or aprons.

Jaw size is determined by a combination of bench top thickness and

width, the mounting style you choose, and your preference.

Jaw Material: Traditional bench (and vise jaw) materials include

European beech and hard maple; where these species are for sale theyre

usually available in 8/4 thickness. Birch and white oak are also good,

tough woods to consider. If youve made your own top, youll have your

own preference.

Jaw Thickness: We recommend that jaws be at least 1-5/8 inches thick,

which allows both secure fastening to the hardware, and room to

accommodate dog holes (either square or 3/4 inch round) in the front jaw.

Jaw Length: For the small vise, recommended jaw length is 12 to 15

inches. The large vise can accommodate jaws up to 18 inches long;

anything longer subjects the vise to excessive racking, which can shorten

its life.

15
Jaw Depth: the starting point for determining jaw depth is throat depth.

Throat depth is the vertical distance from the top edge of the jaw (flush

with the bench top) down to the top of the

CHAPTER - 5

COMPONENTS AND DESCRIPTION

The major components of this project are,

MOVABLE JAW

FIXED JAW

RACK AND PINION

FRAME

STEERING ROD

STEERING WHEEL

16
Steering wheel

A steering wheel (also called a driving wheel or hand wheel) is a type of

steering control in work piece and vessels (ships and boats).

Steering wheels are used in most modern land work piece, including all

mass-production workshops as well as light and heavy trucks. The

steering wheel is the part of the steering system that is manipulated by

the driver; the rest of the steering system responds to such driver inputs.

17
This can be through direct mechanical contact as in recirculating ball or

rack and pinion steering gears, without or with the assistance of hydraulic

power steering, HPS, or as in some modern production cars with the

assistance of computer controlled motors, known as Electric Power

Steering.

As a driver may have his hands on the steering wheel for hours at a time

these are designed with ergonomics in mind. However, the most

important concern is that the driver can effectively convey torque to the

steering system; this is especially important in work piece without power

steering or in the rare event of a loss of steering assist. A typical design

for circular steering wheels is a steel or magnesium rim with a plastic or

rubberized grip molded over and around it. Some drivers purchase vinyl

or textile steering wheel covers to enhance grip or comfort, or simply as

decoration. Another device used to make steering easier is the brodie

knob.

A similar device in aircraft is the yoke. Water vessels not steered from a

stern-mounted tiller are directed with the ship's wheel, which may have

inspired the concept of the steering wheel.

18
Early Formula One cars used steering wheels taken directly from road

cars. They were normally made from wood (necessitating the use of

driving gloves), and in the absence of packaging constraints they tended

to be made as large a diameter as possible, to reduce the effort needed to

turn.

19
The wire spokes were a buffer or absorber between the driver's hands and

the drum of the road. Most were 3 or 4 spokes made of four or five wires

in each spoke, hence the name "Banjo".

Adjustable steering wheels

Usage

The steering wheel should be used with strategic movements of the hand

and wrist in spinning motions. Caution and care should be used to ensure

safety of the extremities. The constant motions used must be performed

with caution. "Proper posture of the hand-arm system while using hand

tools is very important. As a rule the wrist should not be bent, but must

be kept straight to avoid overexertion of such tissues as tendons and

tendon sheaths and compression of nerves and blood vessels."

The act of turning the steering wheel while the work piece is stationary is

called dry steering. It is generally advised to avoid dry steering as it puts

strain on the steering mechanism and causes undue wear of the tires.

20
Rack and pinion

A rack and pinion is a type of linear actuator that comprises a pair of

gears which convert rotational motion into linear motion. A circular gear

called "the pinion" engages teeth on a linear "gear" bar called "the rack";

rotational motion applied to the pinion causes the rack to move, thereby

translating the rotational motion of the pinion into the linear motion of

the rack.

For example, in a rack railway, the rotation of a pinion mounted on a

locomotive or a railcar engages a rack between the rails and forces a train

up a steep slope.

For every pair of conjugate involute profile, there is a basic rack. This

basic rack is the profile of the conjugate gear of infinite pitch radius.(I.e.

a toothed straight edge.)

21
A generating rack is a rack outline used to indicate tooth details and

dimensions for the design of a generating tool, such as a hob or a gear

shaper cutter.

Rack and pinion combinations are often used as part of a simple linear

actuator, where the rotation of a shaft powered by hand or by a motor is

converted to linear motion.

The rack carries the full load of the actuator directly and so the driving

pinion is usually small, so that the gear ratio reduces the torque required.

22
This force, thus torque, may still be substantial and so it is common for

there to be a reduction gear immediately before this by either a gear or

worm gear reduction. Rack gears have a higher ratio, thus require a

greater driving torque, than screw actuators.

A rack and pinion is commonly found in the steering mechanism of cars

or other wheeled, steered work piece. Rack and pinion provides a less

efficient mechanical advantage than other mechanisms such as

recirculating ball, but less backlash and greater feedback, or steering

"feel".

Gears

Gears,toothed wheels or cogs are positive type drives which are used to

transmit motion between two shafts or a shaft and a component having

linear motion, by meshing of two or more gears. They have advantage

over other drives like chains, belts etc. in case of precision machines

where a definite velocity ratio is of importance and also in case where the

driver and the follower are in close proximity; the downside is that gears

23
are more expensive to manufacture and their operating cost is also

relatively high.

Power screws are used to convert rotary motion in to translational

motion

. It is alsocalled translational screw. They find use in machines such as universal

tensile testingmachines, machine tools, automotivemachine vices, vises; aircraft flap

extenders, trench braces,linear actuators, adjustable floor posts, micrometers, and C-

clamps. There are two kindsof power screws, hydraulic and mechanical power

screws.A special case is machine vice which holds or lowers the load by applying a

small force inthe horizontal plane. A screw thread is formed by cutting a continuous

helical groovearound the cylinder. These grooves are cut either left hand or right

hand.The majority of screws are tightened by clockwise rotation, which is termed a

right-hand thread

. Screws with left-hand threads are used in exceptional cases. For

example,anticlockwise forces are applied to the screw (which would work to undo a

right-handthread), a left-hand-threaded screw would be an appropriate choice.Power

screws are typically made from carbon steel, alloy steel, or stainless steel and theyare

usually used with bronze, plastic, or steel mating nuts. Bronze and plastic nuts

arepopular for higher duty applications and they provide low coefficients of friction

forminimizing drive torques.

24
S1. PARTS Qty. Material
No.1 LEAD SCREW 1 MILD STEEL

2 Hold pad 1 Mild steel

3 Steering wheel 1 C.I

4 Stand (Frame) 1 Mild steel

5 Frame 2 Meter Mild steel

6 Mechanical gear arrangement 1 Mild steel

7. Steering rod 1 Mild steel

Table 5.1 List of Materials

25
26
 CHAPTER 6

BLOCK DIAGRAM (Holding)

Arm Power

Steering wheel

Power To Front
Wheel
Machine vice
Rack and Arrangement
pinion

27
 Hold the work
piece

CHAPTER - 8

WORKING PRINCIPLE

The steering will be operated at the time of any hoding the work

piece or machining operation. The arm power is given to steering which

transmits mechanical power. The steering rotates which is coupled with

28
pinion also rotates. The rack and pinion converts rotary to linear motion

in the system which moves the movable jaw in the machine vice and the

work piece gets holded.

This is an era of modern technology where it is broadly defined as

replacement of manual effort by mechanical power in all degrees of

automation.

In order to hold the heavy load of the work piece a mechanical

lock arrangement is also provided.

CHAPTER - 9

29
 CALCULATION

HOLD

Calculation of Linear Speed for a Machine vice

Metric Units

RPM of Input Shaft * HoldingScrew Lead

Linear Speed (mm)

(mm/min) =

Gear Ration

or alternatively

RPM of Input Shaft

Linear Speed

(mm/min) =
Turns of Worm for 1mm Hold

Imperial Units

30
 RPM of Worm Shaft * HoldingScrew

Linear Speed Lead (in)

(in/min) =

Gear Ration

or alternatively

RPM of Worm Shaft

Linear Speed (in/min)

=
Turns of Worm for 1" Hold

31
 CHAPTER - 10

ADVANTAGES AND DISADVANTAGES

ADVANTAGES

It requires simple maintenance areas.

The lengthy work piece can be easily holded.

Checking and cleaning are easy, because of the main parts are

screwed.

Handling is easy.

Manual power not required for holding the work piece.

Repairing is easy.

Replacement of parts is easy.

Maximum length upto 1.5 feet can be reached.

DISADVANTAGES

32
 Initial cost is high.

CHAPTER - 11

APPLICATIONS

It is very much useful for machine Owners and Auto garages. This

automatic machine vice for workshops is used for holding/ braking the

work piece.

Thus, it can be useful for the all types of industries.

CHAPTER - 12

CONCLUSION

This project work has provided us an excellent opportunity and

experience, to use our limited knowledge. We gained a lot of practical

knowledge regarding, planning, purchasing, assembling and machining while

doing this project work. We feel that the project work is a good solution to

33
bridge the gates between institution and industries.

We are proud that we have completed the work with the limited time

successfully. DESIGN AND FABRICATION OF STEERING

OPERATED MACHINE VICE IN WORKSHOPS

is working with satisfactory conditions. We are able to understand the

difficulties in maintaining the tolerances and also quality. We have done to our

ability and skill making maximum use of available facilities.

In conclusion remarks of our project work, let us add a few more lines

about our impression project work.

By using more techniques, they can be modified and developed

according to the applications.

34
 REFERENCES

1. G.B.S Narang, Workshop Engineering, Khanna Publishers, Delhi,

1991, pp.671.

2. William H. Crowse, Workshop Engineering.

3. MECHANISMS IN MODERN ENGINEERING DESIGN Vol. V.

PART I

4. ELEMENTS OF WORKSHOP TECHNOLOGY VOLL II

-S.K. HAJRA CHOUDHRY

- S.K. BOSE

- A.K. HAJRA CHOUDHRY

5. STRENGTH OF MATERIALS I.B. PRASAD

35
Web Site : www.maritime.org

36