1. FIXTURE DESIGN AND DEVELOPMENT FOR ALIGNMENT &
WELDING TO PIPES
Batch no. VII
Guided By
NAME OF THE STUDENTS
Prof K S Sundar
 Pradeep Behera,
Regn no. – 112082038 SOME/SASTRA University
 Pralay Shankar Mohanty
Regn no. – 112082039
 Sibani Shankar Mishra
Regn no. – 112082050

2. # As per our shop visit we have found that the pipes are welding by utilizing
so many time in alignment & welding with more man power & effort .So we
have planned to prepare a fixture which can be help full for reducing the
man effort as well as man power with time ..
# This savings will be a good impact for company & to reduce fatigue for
labor & time
Index –of First Review
About the project
To whom and how this fixturet will be helpful
Drawings
Cost effectiveness
Advantages
Project Fabrication plan

3. requirement of alignment
1-allignment is the main & basic need for joining of two materials .
2-The pipes which are being to joint with each other by butt welding are
machined for edge preparation .After edge preparation the both pipes
kept in aligned position in such a manner that the three axis should be
match with each other.
3-The joining of two pipes is more essential for boiler industry .The
seamless steel pipes which has the crucial role for boiler parts such as
header ,steam lines , elbow joint ,bend joint etc are procured /prepared
from small length for transportation & machine facility point of view
,some times formed bend pipes also .These are required to form long
pipes by joining with one another .

4. After alignment of pipes
End prepared pipes
After welding

5. OBJECTIVES OF THE FIXTURE
* To reduce the cycle time.
* To reduce additional man power.
* To reduce manufacturing cost.
* To increase productivity.
* To reduce effort of man power
* To avoid fatigue
* To improve quality of the product.
* To create safe working environment.
* To reduce human effort.

6. DESCRIPTION OF THE FIXTURE
The main parts of the fixture are-
1. Rollers
2. Shaft
3. Bearing & Housing
4. lead screw & half nut
5. Column
6. Base Plate
7. Hand Wheel
8. Adjustable v blocks
9.Stand Wheels

7. FIXTURE FOR ALIGNING & WELDING THE END PREPARED PIPES

8. COST BENEFITS
Old Method
New Method
1.Man power:1 welder and 2 Helper,1
1.Man power:1 welder and
fitter,1 crane operator
fitter,1 crane operator
2.Alignment time for one joint :
2.Alignment time for one joint :
1 hour
15min (15/60 Hrs)
3.Cost for 1 no joint:
3.Cost for 1 no joint:
Rs.150x1x5(man hr) =Rs.750
Rs.150x1x (15/60*3)(man hr)
=Rs.112.5
4- total 10 joint is possible in three
shift
4- total 10 joint is possible in
three shift
5- Yearly joint cost : 10 x 300 x 750 =
22,50,000 INR
5- Yearly joint cost : 10 x 300 x
112.5 = 3,37,500 INR
Total savings per annum : 19,12,500 INR

9. SIDE VIEW OF ALIGNMENT FIXTURE
75 75
150 200
18
30

10. FRONT VIEW OF FIXTURE
19
00
18
21 00 21
013 0
13
0 0
29
0
17
10 5
HAND
WHEEL 0
20
25 30
0 90
30
30
BALL
WHEEL
25
00

11. FREQUENTLY USED SEAMLESS STEEL PIPES
Adjustable v blocks
PIPE OD X THICK SPECIFICATION
370 X 35 SA213TP304H
360 X 30 SA335P91
560 X 70 SA335P22
270 X 50 SA335P12
550 X 65 SA335P11
560 X 60 SA312TP316
320 X 90 SA335P92
660 X 80 SA335P5
711.2X45 SA335P9
660.4X75 SA192 •The adjustable v blocks are used to
457.2X95 SA312TP321 support & keep the circular section such
457 X 80 SA335P92
457 X 60 as pipes to a required height .
SA335P23
406.4X55
368 X 60 •This is also used to align the pipes in
324 X 50
219.2X32
vertical axis
720 X 65

12. WEIGHT OF THE USED
PIPES
WT=VOLUME X DENSITY =3.142/4 X(D1^2- D2^2) X L
DESCRIPTION OD THK ID LENGTH VOLUME DENSITY WT IN KG * Since the weight of pipe (660x80 )
370 X 35 370 35 300 2000 73679.9 8 589.44 is maximum ie. 2.333 ton ,the design
360 X 30 360 30 300 2000 62211.6 8 497.69 will be made by considering this
560 X 70 560 70 420 2000 215541.2 8 1724.33 weight
270 X 50 270 50 170 2000 69124 8 552.99
550 X 65 550 65 420 2000 198103.1 8 1584.82 * The fixture has to be withstand the
560 X 60 560 60 440 2000 188520 8 1508.16 load of 2500 kg vertical load along
320 X 90 320 90 140 2000 130078.8 8 1040.63
with its own weight .
660 X 80 660 80 500 2000 291577.6 8 2332.62
711.2X45
711.2 45 621.2 2000 188388.036 8 1507.10 * The 03 layer of plate has to be a
660.4X75 660.4 75 510.4 2000 275899.02 8 2207.19 capacity to bear the static load &
457.2X95
457.2 95 267.2 2000 216226.156 8 1729.81
dynamic load by avoiding from any
457 X 80 457 80 297 2000 189525.44 8 1516.20
bending moment .
457 X 60 457 60 337 2000 149684.88 8 1197.48
406.4X55
406.4 55 296.4 2000 121450.868 8 971.61
*The two adjustable V- block has to
368 X 60 368 60 248 2000 116128.32 8 929.03
be with stand the above load . ie 1.25
324 X 50 324 50 224 2000 86090.8 8 688.73
ton on each block
219.2X32
219.2 32 155.2 2000 37643.6736 8 301.15
720 X 65 720 65 590 2000 267541.3 8 2140.33

13. PLATE MATLS : PLAIN CARBON
STEELAISI-SAE1020 HANDLE (OD x length):25X100
WT=0.39X4=1.56 KG
UPPER PLATE SIZE :
1800X1000X42 MM HANDLE STUB : 65X50
WT1 =volume x density WT=0.43 KG
=1.8x1x42x7.86 =594.2 kg
BEARING (CYLINDERICAL ROLLER TYPE)
MIDLE PLATE SIZE UPPER PLATE : (4 NOS)
:1900X1600X42 BEARING SIZE: SKF NU2211
WT2 =volume x density (d=55,D=100,B=25,,static force=4650 kgf,
=1.8x1.6x42x7.86=951 kg dynamic force=5400 ,N=8000 rpm ) -----
PSGDB-pg4.21
LOWER PLATE SIZE SHAFT : 55x1054 .
:2500X1650X50 Wt=19.66 kg
WT3 =volume x density
=2.5x1.65x50x7.86= 1621 KG MIDDLE PLATE : (4 NOS)
BEARING SIZE: SKF NU2212
LEAD SCREW : 800 X50X3 pitch (d=60,D=110,B=28,,static force=6200 kgf,
SQUARE THREAD dynamic force=7100 ,N=6000 rpm ) -----
WT=13 KG PSGDB-pg4.21
LEAD SCREW NUT :40 ( 02 NOS) SHAFT :60x1660
WT= 0 . 50 KG Wt=36.84 kg
SHAFT : 50X1700 X4 NOS STRAP /SCREW SUPPORT PLATE : 120X100X60
WT=10.79 X4 = 43.16 KG ( 04 NOS)
Wt=.12x.1x60x7.86x4=22.64 kg

14. DESIGN OF V-BLOCK
Angle of v-block=90 degree
Weight of v block
Wt of V-plates=2(volume x density)=2(4.96m^3 x 7.86)=78kg
Wt of lower plate=530 x 70 x .210 x 7.86=61.24kg
Wt of base plate=300 x 20 x.250 x7.86=13.75kg
Wt of screw area=3.142/4 x(80)^2 x 350=13.5kg
Wt of collar =350 x(75^2-45^2)=31.1kg
Wt of nut=0.5kg
Wt of handle=.39kg x 4=1.56kg
Supporting strap=(.5 x 75 x120 x 10 x 7.86)x 4 =2.4kg
Total wt of one V-blocks=78+61.24+13.75+13.5+31.1+.5+1.56+2.4=202.05kg
ie.203kg
V-BLOCK WT=203kg
METAL : Mild Steel Plate
Screw nut : Chromium
Wt of two v-blocks=203 x2=406kg
Pipe wt=2500kg
Load on first surface plate=2500+406=2906kg

15. V BLOCK DESIGN
The adjustable V block has to carry a load of 2.5 ton of pipes metal
Max height to be lift (vertical) =175 mm
W=2.5 ton=2500x10=25000N since 1 kgf=10 N appx
H1=175 mm,(asume Screw matls comp strength=100 mpa,tensile
strength=200 mpa,
Nut is phosphorus bronze having elastic limit=100 mpa in tension ,&
90 mpa compn),80mpa shear
Ie. σet= σec=200N/MM^2,FOS=2)
Since screw is under compression ,
W= ∏/4dc^2xσec/FOS
25500=Maj dia c^2x200/2 Min dia(dc) Pitch(p)
Nominal
dia(d1) ∏/4d
bolt(d)
Majdianut(D
)
Depth of
thread bolt
Depth of
thread nut
Core
area(Ac)
So dc =18 mm 36.5
36 36 Standard dia=30 mm {Pg-6263.25
30 6 3 book} 707 per avl it
(as
has take as 80 mm)
Torque required to rotate the screw in nut
D=(d0+dc)/2=(36+30)/2=33 mm
Tan alpha =p / ∏ d=6/(∏x33)=0.579
Asume µ =Tan θ =.014
Torque =pxd/2 =w [tan α+tan θi)/(1-tan α x tan θ)] x d/2
=25500[.0579+.14/(1-.0579x.14)]x33/2=83946 Nmm
Tensile stress due to axial load=σc=W/A=w/ (∏/4 d^2)=25500/(3.142 /

16. Max principal stress due to tensile & compressive
Thickness of nut collar
σc max=1/2 [σc+ √ {σc^2+ (4τ^2)]=.5[36+ √
W= ∏d1t1 τ
(36^2+4x15.8^2)=42 N/mm^2 25500=3.142x50xt1x80/2
Since design vale ie 100mpa is much higher than this value T1=8 mm
design is safe Thickness of nut collar=8mm
Max =1/2 [σc+ √ (4τ^2)=.5x √(36^2+4x15.8^2)]=24 N/mm^2
Since this value is less than asume value (100 mpa) design safe
Design of nut
Height of nut=nxp=no of threadxpitch
T=thickness of screw =p/2=6/2=3 mm
Asume load is UDL &
Bearing preassure =Pb=18 N/mm^2
Pb =w/{ ∏/4(d1^2-d2^2)}xn
18=25500/[3.142/4(36^2-30^2)xn
No of thread (n)=5
Take n=10 nos
Height of nut =h=nx6=10x6=60 mm
Shear stress on screw =w/(∏ndt)=25500/(∏x10x30x3)=9 N/mm^2
Shear stress on nut= w/(∏nd1t)=25500/ (∏x10x36x3)=8 N/mm^2
Since develop stress is less than asume stress ,design is safe
Collar design
Considering crushing of collar
Od of nut
W= ∏/4(D^2-d^2) σt σt= σt asume / Fos
25500= ∏/4(D1^2-36^2) 100/2
D1=50 mm
Od of nut=50 mm
W= ∏/4(D2^2-d^2) σc
25500=3.142[D^2- 50^2}x90/2
D=60 mm ie outer dia of collar

17. Plate design
Due to impact load low -carbon steel with case hardening is preferred
First plate size=(1800 x 1000 x 42)mm^3
Area=1800 x 1 =1.8 m^2
Force=mass x acceleration due to gravity = 2906 x9.81 =28507.86
ie.28508N=28058KN
Stress=force/area=28508/1.8=15837.7 ie.15838N/m^2
For rolling action:
Shaft design
The shaft is subjected to bending moment only
M/I= σb/y
M=bending moment
I=moment of inertia
σb=bending stress
y=distance
Since total 28.5KN ie.29KN on both shaft
Load on shaft=28.5KN + plate wt=28.5+(594.2 x9.81)=34.337 ie.34.4KN
Load on each bearing=34.4/4=8.584 ie.8.6KN
Wt of four bearings=4 x (3.142(R^2-r^2)x thk=4x3.8kg=15.2kg

18. First plate design
Assuming concentrating load(ie. Creating maximum stress),
t1=k √ [(a x b x f)/(σt(a^2+b^2)]
a=length of plate
b=breadth of plate
k=coefficient=3.45
P=load
σt =design stress
=697N/mm^2 (for C45 steel)
So t1=3.45[(1800x1000x28508)/(697x(1800^2+1000^2)]^(1/2)=14.4mm
1stPlate thickness assumed as =20mm
First shaft row design
Load on each shaft=34.4/2=17.2kN
Length=1800+(30x2)+(20x2)=1900mm
Considering shaft as an simple supported beam with UDL on it,
M=WL^2/8
=17.28x1000x1.9^2/8=7761Nm^2=791kgfm
Max bending moment= (3.141/32)xsigmabxd^3=7761
=>(3.141/32)x.114d^3=7761
=>d=90mm (DDB-PG 7.20 ,R20 SERIES)

19. Bearing design
Force fall on bearing=34.4kn+shaft force=34.4 KN+(2x97.06x9.81)=36.3 KN
Shaft wt=( OD90 & L 1900) =97.06KG
There will be 04 no's of bearing are required at this stage
Force fall on each bearing =36300/4=9076 N=9076/9.81=925 KGF
From data book the standard size of bearing is =SKF6318
qty-=04 nos
[d=90,D=190,B=43,r=4,static force=9800KGF,Dynamic force =11200 KGF]
Second plate design
Weight falling on 2nd plate =34.4kn+shaftwt above the plate+4 bearing
wt=34400/9.81+(2x97.06)+(4x7.42)=3731 kg
Force falling on 2nd plate=3731x9.81=36596N=36.6KN
So 2nd plate has to be a capacity to withstand 36.6KN Force
Plate size =1800x1600
Thickness of plate (t2)=k3√[abf/{σt(a^2+b^2)}] k3=3.45 pg253
3.45 √[1800x1600x36600/{697(1800^2+1600^2)}]=17.7 ie 25 mm (std
size )
T2=thick of 2nd plate=25 mm
Second plate shaft design
There will be 02 nos of shaft
Load on each shaft=(36.6KN+plate force) /2={36600+(680x9.81)}/2=21632N

20. Required shaft length=1700 mm
M=WL^2/8=21700x1.7^2/8=7840 NM^2
Since max bending moment (M)=∏/32xσbxd^3 σb=920kgf, DDB-7.24
SO d2=96 MM ie. 100 mm
Bearing size
From DDB PG-4.14,
BEARING size-SKF100BC03
{d=100,D=215,B=47,r=4,static capacity=13200kgf,dynamic capacity=13700kgf }
Bottom plate /3rd plate design
Load falls on this plate =(21.7KNX2)+(shaft wtx2)+bearing wt
=(21700x2)+(2x105x9.81)+(4x10.5x9.81)=45.9 KN ie.46 KN force
Plate size=2500X1680
Thickness of plate (t3)=K3 √ [(a x b x f)/(σt(a^2+b^2)]
=3.45 √ [(2500x1680x4600)/[697(2500^2+1680^2]=25mm
Thickness of 3rd plate (t3)=30mm
Wt of matls upto this plate =46kn/9.81 +3rd plate wt
=4690+972=5.7ton
Lead screw design to provide to & fro motion to 1st plate
W=∏/4xdc^2xσt
28500= ∏/4xdc^2x100 since σt=100N/MM^2
.dc=20 mm
Standard size of scre thread=25 mm Pg-626 D book
Nominal Maj dia Majdianut Min Pitch(p) Depth of Depth of Core
dia(d1) bolt(d) (D) dia(dc) thread thread area(Ac)
bolt nut
28 28 28.5 25 3 1.5 1.75 491

21. Length of the stud =600 mm
Other end there is a supporting rod of 18 mm dia which has to
fit with bush in the supporting strap having length =600 mm
2nd plate Rack & pinion design
Length of rack=1500 mm
Module =3
Press angle=20degree
No of teeth in pinion=12
Centre distance =ZM/2+H=51.8 mm
Pitch dia=d=zm=36
Addendum for pinion=M(1+X)=4.8
Addendum forrack=3
Bearing size=SKF6309 (with housing)
[d=45,D=100,B=25,stat force=3000.Dyn=4150)
Qty=2 nos
Shaft=45 mm having length 1500mm
Rotating wheel design
Wheel dia=170 mm, having 04 support with hub
Hub dia for 1st plate=90 id & 110 od
Hub dia for 2nd plate= 100 id & 120 od
Stand & bottom wheel design
There are 04 nos of ball wheel rqd having 360 deg movement in
their own axis .