Design and Construction of 2.5kg Weight Bench Vice

Design and Construction of 2.5kg Weight Bench Vice

ABSTRACT

Prototyping or model-making is an important step in finalizing a product design. Traditional Rapid Prototyping (RP) is called layered manufacturing or solid free-form fabrication. It is used to physically model a new product design directly from computer-aided design (CAD) data without special tooling or significant process engineering. This rapid procedure reduces the lead time required to produce a product prototype by eliminating much or all of the process engineering time and tooling requirements. It helps in the conceptualization of a design. Designing a rigid, flexible, cost-effective, and highly durable vise is a need of today’s era. Safety should also be taken into consideration while designing the vise. This paper is related to the designing and manufacturing modified bench vise components on a rapid prototype machining process. We have designed the conventional and modified bench vise in Pro-E CAD software and manufactured it on a Dimension 1200es RPT machine.

CHAPTER ONE

Design and Construction of 2.5kg Weight Bench Vice

INTRODUCTION

A vise (American) or vice (British) is a mechanical device used to secure an object to allow work to be performed. Vices have two parallel jaws, one fixed and the other movable, threaded in and out by a screw and lever.

DESCRIPTION OF A BENCH VICE

A bench vice is like an extra hand. Its purpose is to hold the material steady, allowing you to use both hands to work on it with other tools.

The bench vise is of the Clamp base Bench design. It is a lightweight, portable vise. It is attached to a table or bench with a mounting clamp. It has rough jaws for holding material with a stationary base. Clamp base bench vices are considered most appropriate to hold light materials or in areas where a heavier vice is unavailable, such as laboratories and school workshops.

It consists of a mounting base or body secured to the machine table, a stationary jaw against which the workpiece is located, a movable jaw, and a screw mechanism consisting of a buttress-threaded spindle and handle. When the spindle is rotated in the clockwise direction using the handle, the jaws move closer, thus clamping the workpiece against the stationary jaw. This clamping action holds the part securely while the machining operation takes place. On the other hand, when turned in the anti-clockwise direction, the jaws move away, thus loosening the grip on the workpiece.

The stiffness created through the design that pulled the jaw down has the added benefit of pulling the nut and driving the movable jaw up, creating a sandwich of vice body, nut, and movable jaw. The resulting stiffness and dampening offered a significantly lighter vice, allowing for manual lifting and positioning of the vice on a machine table, contributing to its popularity.

The stationary jaw is cast integral with the vice body. It is a good selection when density and absolute minimum deflection are needed.

This vise hardware is adaptable for installation in various positions and on different styles of bench tops.

They are ideal for sawing, sanding, planing, drilling, screwing, and soldering.

TYPES OF BENCH VICE

Two types of bench vice share a common anatomy.

WOODWORKING VICES

Woodworking vices are usually incorporated into the structure of a woodworking bench, often fabricated from the same type of timber as the bench. The top edge of the jaws is usually flush with the bench top and does not protrude beyond the edge of the bench.

ENGINEER’S VICE

Engineer’s bench vices are metalworking, typically fabricated from iron or steel. These vices are not an integrated part of the workbench, allowing them to move barely and be used on any suitable work surface. They are attached so that the vice’s jaws sit above the work surface level, at about elbow height, to give more purpose for working on harder materials and slightly protruding beyond the edge of the bench.

COMMON FEATURES

The engineering bench vise consists of two jaws, one stationary and one moveable. These are fitted into a frame with a screw apparatus operated by a lever which controls the moveable jaw, allowing the space between the jaws to be expanded or contracted to accommodate different-sized pieces of material.

STATEMENT OF PROBLEM

A problem with known types of vice is that the numerous component parts thereof mean that the clamp is relatively expensive to manufacture. Furthermore, if the clamp is of relatively complex construction, it may be similarly complex to operate. In particular, using both hands to clamp an object in the clamp is inconvenient, and a one-handed operation would be more desirable. Also, vices are heavy and normally fixed to a work surface. Research has also shown that the available bench vice is not cost-effective. Hence, these machine tools are not readily available to the engineers, technicians, and artisans who greatly need them for their daily work in the workshop.

Most vises in the workshops are too big and are not amenable to small workpieces holding. Besides, their sizes make their construction materials big and expensive.

When under pressure, most vise designs deflect, creating part alignment problems requiring that lifted workpieces be forced down with a hammer.

It is, therefore, an object of the present invention to provide a clamp that alleviates the above-described problems.

OBJECTIVES OF THE STUDY

To design a bench vise.

Modify an existing bench vice for small-scale workshop production.

To analyze the design structure of the bench vice.

To improve the existing design through material and size reduction

Evaluate the cost of the modified bench vice.

Alleviate the sufferings of engineers, technicians, and artisans who use their hands to grip objects for cutting, planning, gluing, etc.

PURPOSE OF THE PROJECT

From the research, the student is expected to be exposed to and learn how to progress from design to actual equipment fabrication using a conventional system.

DESIGN AND OPERATION CONSIDERATIONS

To address the work-holding needs of a particular machining operation, one must consider part size, material, machine speed, feed rate, and the number of Parts to be produced. Single-part production or low quantity requirements generally make a single-vice setup a good choice. The part configuration will point toward either contoured jaws or any number of standard or special jaws. The gripping area for the planned operation must allow for sufficient depth of jaw engagement (bite) to allow the planned operation to take place safely.

Higher quantity lot sizes make multiple vise setups desirable. The workpiece size determines the spacing between the vises and the vise size. Generally, attempts must be made to produce the maximum amount of parts per cycle. Many additional operations by the same operator can then be done simultaneously. The key to freeing the operator is quick clamping and the highest efficiency of the workpiece loading cycle. This includes prepping the work area for thorough chip flushing and cleaning.

But in particular, with reference to this project, the vise design is guided by the following considerations;

1. Adequate clamping forces

2. Quick and easy clamping

3. Simple construction

4. Low cost

5. Durability

DESIGN CONCEPTUALIZATION AND EVALUATION

Having established the need to design a bench vice, the first step was deciding on the vise variant. Today’s vices range from simple single-station models to elaborate multiple-station designs. Many refinements of the basic vise concept have been made, particularly in the last 50 years, to improve precise repeatability, increase part density within the work holder, and automate its operation with pneumatics and hydraulics. Their refinement parallels the advancements in machine tool technology, greatly accelerated in the 1960s with the advent of computer numerical control (CNC) machines.

Double stations, multiple stations, self-centering, hydraulic, vertical, and many other versions were developed out of the basic concept of the original single-station, precision machine vise. Today, there are hundreds of vise models in many sizes with many options, including automation, which gives the manufacturer an infinite arsenal of choices.

The size and configuration of the vise are dictated by the workpiece shape and the machine it is used on. The cycle time length, if very short, may make using a power-operated vise desirable to reduce the time of the clamping cycle. The material to be machined and other production factors also impact the final choice of vise types.

This called for the consideration and analysis of the various known vise variants.

Based on the known vise variants, the following essential features of a vise were identified and used as the basis for analysis.

REFERENCES

Pulak M. Pandey, Rapid Prototyping Technologies, Applications and Part deposition planning, Department of Mechanical Engineering, Indian Institute of Technology Delhi. June – 2012.

Jain Pranjal, KutheA. M., Feasibility Study of manufacturing using rapid prototyping: FDM Approach. MESIC 2013.
Gebhardt, A., Rapid Prototyping, Hanser Gardner Publications, 2003.

Hajra S. K., Choudhari Elements of workshop and technology volume 2, Media promoters and publishers pvt. Limited, 2007.
C. J. Luis Perez Analysis Of the surface roughness and dimensional accuracy capability of fused deposition modeling. 14 Nov 2010.

Sanjay Joshi,Zhi Yang, et al. Conventional Machining Methods for Rapid Prototyping and Direct Manufacturing. The Pennsylvania State University, 2012.

Mihaiela Iliescu, Kamran Tabeshfar, et al. Importance of Rapid Prototyping to Product Design, 1454-2358, August 2009.

Dimension BST/SST 1200es 3D Printer user guide.

KantarosAntreas, KaralekasDimitris, Fiber Bragg grating based investigation of residual strains in ABS parts fabricated by fused deposition modeling process.50 (2013) 44–50.