Jig Design Research Articles

Use of a 3D-Printed Patient-Specific Surgical Jig and Ready-Made Total Sacral Endoprosthesis for Total Sacrectomy and Reconstruction

Objective In the present study, the authors aimed to optimize the workflow of utilizing a 3D printing technique during surgical treatment for malignant sacral tumors, mainly on preparation of patient-specific surgical jigs and ready-made 3D-printed total sacral endoprosthesis. Methods Three patients with a malignant sacral tumor received total sacrectomy with preoperative design of a patient-specific 3D-printed cutting jig and endoprosthetic reconstruction. Size of ready-made 3D-printed endoprosthesis was determined based on preoperative images, planned surgical margin, and size of the endoprosthesis. A patient-specific cutting jig was designed with a bilateral cutting slot matching the bilateral planes of the implant precisely. The tumor was removed en bloc through a single posterior approach only, being followed by reconstruction with ready-made total sacral endoprosthesis. Results The mean time for preoperative design and manufacture of the surgical jig was 6.3 days. Surgical jigs were successfully used during surgery and facilitated the osteotomy. The mean operation time was 177 minutes (range 150-190 minutes). The mean blood loss was 3733 ml (range 3600-4000 ml). R0 resections were achieved in all the three cases proven by pathology. Evaluation of osteotomy accuracy was conducted by comparing preoperative plans and postoperative CT scans. The mean osteotomy deviation was 2.1 mm (range 0-4 mm), and mean angle deviation of osteotomy was 3.2° (range 0-10°). At a mean follow-up of 18.7 months, no local recurrence was observed. One patient had lung metastasis 15 months after surgery. Two patients were alive with no evidence of the disease. Conclusions The patient-specific surgical jig and ready-made 3D-printed total sacral endoprosthesis can shorten the surgical preparation time preoperatively, facilitating accurate osteotomy and efficient reconstruction intraoperatively. The workflow seems to be feasible and practical.

Conceptual Design of Modular Chassis Jig of Student Competition Car

Chassis jig is needed to ensure that the welded chassis components does not warp or deform during welding process. Through concept screening and concept scoring, multiple design of chassis jigs is narrowed down to next development process. This study aims to design a chassis jig for the fabrication of student car competition chassis. The desired result of this design process is chassis jig with the ability to manufacture a wide variety of student competition car chassis.

Design of Flexible Jig for Leg Manufacturing on Jack-up Plateform

Due to various designs in racks and semicircle tubes, dedicated jigs are used in the manufacturing of most jack-up legs, which decreases the productivity. In this research, a new flexible jig system with jig and support column is designed to meet different production requirements of many jack-up platforms. Firstly, two kinds of adjustment bolts i.e. position bolts and angle bolts are designed for accurate positioning and attitude adjusting. Moreover, considering supporting height differences of the legs, an integrated mode of standard and specific components is adopted in construction of the support columns. By using of the new flexible jig, productivity of many jack-up platforms construction is greatly improved.

Design and Build JIG Design on Friction Stir Welding Using Fillet Connection on AA6061-T6 Material

This research was conducted to test the jig design that can be used in the Friction Stir Welding process on the fillet connection of two aluminum plates. The research method used is the experimental method in the engineering laboratory of the Muhammadiyah University of Sidoarjo. The jig design is a V shape for the aluminum plate base facing up so that the Friction Stir Welding welding is done vertically. The type of aluminum used is AA 6061-T6. The experimental results show that the jig can function well to support Friction Stir Welding at fillet joints using a chisel that has convex shoulders and a small degree of inclination. Jig design with three V plate supports can withstand tool pressure and provide stability during the welding process.Keywords – Jig, Friction Stir Welding, Aluminum

A Study on the Manufacturing of Molybdenum Pins for Electrodes

The molybdenum cup and molybdenum pin, which are the main materials of the molybdenum electrode used for the LCD BLU CCFL electrode, have not been developed in Korea and imported from Japan. In this paper, especially, research on prototype manufacturing and CAE analysis is performed to develop a molybdenum pin. In this research, to develop the manufacturing technology of molybdenum pin used for CCFL electrode of LCD BLU, development of linear processing technology, development of molybdenum wire surface treatment technology, development of wire cutting technology, production of molybdenum pin, design and fabrication of JIG and Fixture for inspection, molybdenum pin prototyping and analysis, and development of 100% molybdenum pin inspection technology. The development of molybdenum pins developed through this research can overcome Japan's technological level, which depends entirely on imports from Japan, and it is thought that the development will have a significant impact on the overall industry using molybdenum pins.

Determination of the influence of clamping on welding distortion applied to PS2 mock-up using finite element simulations

The large number of welds and the achievement of tight tolerances defined for the ITER vacuum vessel (VV), require improvements in the manufacturing strategy to minimize the welding distortion. The influence of clamping on welding distortion has been determined for one of the VV prototypes manufactured by AMW consortium, the ‘poloidal segment two’ (PS2) mock-up. Clamping influence was evaluated, and improvements in clamps for the mock-up were obtained, using finite element simulation of the welding and assembly process, based on detailed thermo-mechanical transient non-linear analysis (welding distortion analysis).The results of simulation are presented along with the experimental measurements. The results and improvements obtained from simulation, presented in this article, and demonstrated during PS2 mock-up manufacture have been used to improve the jig design of the real VV - PS2.

Manufacturing of molybdenum pin(CCFL) for electrode- convergency research on design and manufacturing of JIG and Fixture for molybdenum pin manufacturing and inspection

Manufacturing of molybdenum pin(CCFL) for electrode- convergency research on design and manufacturing of JIG and Fixture for molybdenum pin manufacturing and inspection

Electromagnetic and circuit modelling of a modified design of bulk current injection probe calibration jig

In this study, a wideband rounded-shield calibration fixture or jig used to calibrate in-band injection probe is implemented based on 3D electromagnetic modelling in CST Microwave Studio; the Electromagnetic (EM) model is validated and then used in studying the effect of the jig layout parameters on its bandwidth. The impact of a rounded instead of the typical flat shield is studied too, and showed an improvement of about 15% in the bandwidth at Voltage Standing Wave Ratio (VSWR) level of 3. A new systematic rules procedure for extracting the circuit model of transmission lines based structures is proposed and applied in deriving a circuital model for the jig. The EM and developed circuital models are validated versus vectorial scattering parameters and VSWR. The estimation of the uncertainty shows small values at the band of measurement. The developed prototype meets DO-160 and MIL-STD-461E requirements and shows an improved high frequency performance when compared with reliable products. An application is presented in measuring the insertion loss of bulk current injection probe and in illustrating the effect of the shield slot distance on the probe High Frequency (HF) performance.

Development of a Re-engineered fixture to reduce operation time in a machining process

Manufacturing a part component for an overall assembly requires utmost care and composition. When a component is undergoing its specified operation time becomes a major parameter so as to satisfy the customer. Unloading a loading of a component takes much of a time during a machining process. The specification and detailing as prescribed by the customer should be concentrated on a broader scale. The overall project deals in designing and fabricating a fixture so as to minimize the operation time when employing it in an manufacturing technological process (Erik Karl Henriksen, 1973). The ultimate goal of all manufacturing process is productivity. This productivity can be depicted in terms of a positive and in a negative aspect. The positive focus of a productivity deals with a combination of production process with high quality as specified by the customer. And along with this the minimal time it took to complete a production process integrated with an economical scale of production. Among the integrated factors time plays a major role in each and every machining process. Time and motion studies reveal the hidden errors and unintended actions and the invisible patterns during a machining process. This in turn leads to the downtime of a respective process. Downtime will lead to decreased productivity. The end result of these factors would be losing a valuable customer missing a place in the market and shares and losses. To overcome all the above mentioned negative factors a fixture has been fabricated to avoid failures happened due to time factor. The details for the design of jigs is re-engineered in order to reduce the manufacturing time. As a result it reduces manufacturing time, thereby increasing its efficiency at comparatively lower cost than that of the existing system, by introducing a fourth-axis.

Design and Analysis of Jig and Welding Fixture for Car Panel to Shift the Locate Pin

Design and Analysis of Jig and Welding Fixture for Car Panel to Shift the Locate Pin

Design and Fabrication of Jigs and Fixture for Radial Drilling Machine in Automotive Industry to Improve Productivity

Design and Fabrication of Jigs and Fixture for Radial Drilling Machine in Automotive Industry to Improve Productivity

Mechanical Pre-Compression System of the JT-60SA Central Solenoid

The mechanical loading technology has been developed for the pre-compression of central solenoid for the tokamak device of JT-60 super advanced (JT-60SA) being constructed in Japan. Four central solenoid modules were manufactured one by one, then 4 modules were stacked. The pre-compression were conducted to bind stacked 4 modules by support structure called tie-plate as a final process of the central solenoid manufacturing. The pre-compression jigs were designed by using the finite element analysis taking into account of plastic deformation of the jigs and the tie-plate. The pre-compression was performed using developed jigs. The hydraulic jacks and pumps were separately installed to the each tie-plate to control the pre-compress load individually. Since the pre-compress load changed by insulation creeping after initial loading, additional shims were inserted for the tie-plate with small load. Finally, pre-compress load of all tie-plate became within the target range. These results indicate that the pre-compression has been successfully completed using the developed jigs. In this paper, the design and analysis of the pre-compression jigs and the result of the pre-compression are reported.

낮은 반사손실을 갖는 ASTM D4935 지그 설계

낮은 반사손실을 갖는 ASTM D4935 지그 설계

Establishing a Quality Management System for Production of Certified Customised Titanium Medical Implants through Additive Manufacturing

ABSTRACTVarious cases of medical implants produced through additive manufacturing (AM) in Ti6Al4V have been reported in literature. Not all manufacturing processes used, were qualified. In striving to deliver certified AM medical implants and devices, an ISO 13485:2016 quality management system was implemented in the Centre for Rapid Prototyping and Manufacturing (CRPM) of the Central University of Technology, Free State (CUT) in Bloemfontein, South Africa. This certification is valid for design, development and production of patient-specific custom-made titanium implants, preoperative models, jigs and cutting-guides in nylon through AM, and contract-production of these products. For maintaining this quality management system, the generation of data to validate the individual processes in the AM process-chain is crucial to prove the DMLS product-quality of CRPM’s products. During the past five years, directed research data was produced and published to prove that medical implants produced through DMLS can fully comply with the accepted international standards for material, physical, chemical and mechanical properties of such parts. The paper discusses the quality management system’s establishment; materials research projects executed to generate validation data are mentioned; and examples of customised titanium implants for restoring the quality of life of patients are shown.

Exploring the Effectiveness of a Complex Coating Technique for Use the Smallest Parts of Advanced Powertrain Fuel System

The objective is to develop the complex coating technique with high quality and homogeneity of coating for spherical parts with diameter of 2 ∼ 4 mm and stable mass production shall be secured with consideration of coating material, process and jig design. Silicon oxide-diamond like carbon (SiO-DLC) complex coating chemistry is expected to enhance the high temperature stability as opposed to DLC. Currently, the spherical part is first welded and then assembled with other parts, finally they are coated with DLC. However in this manner, the maximum charging in one coating batch is limited due to the very big size of the whole component which increases cost. Therefore the spherical part is to be coated before welding. Overall, reactive sputtering with high precision fixturing and masking technique resulted in the best overall properties for modern powertrain fuel system. The jig design was optimized with consideration of coating properties (height, width, thickness, inserting distance) and spherical parts were fixed at the jig with magnet plate. Coating material and process were determined with several trials. In conclusion the PVD+PACVD coated parts is developed and coatings with high quality, homogeneity and 30,000 inserting amount are secured. Coated parts are minimum 100 % more durable than non-coated parts.

Angled Abutment Transfer Jig: A Technical Report

To introduce an angled abutment transfer jig that splints abutments securely together to facilitate easy and quick orientation. Transferring angled abutments from cast to patients' mouth could be tasking and time-consuming. Transfer jigs are often used to facilitate orientation of abutments into implant fixtures. However, with the available jigs, abutments could move out of place and thus pose a hassle in repositioning. This technical report introduces an angled abutment transfer jig that consists of two impression copings screwed onto angled abutments which are splinted together with red acrylic resin. Access to abutment screws is feasible through slots created in the impression copings. The introduced jig is rigid and thus ensures very accurate and easy transfer of abutments into implants followed by accurate prosthesis seating. This transfer jig design allows clinicians to transfer the orientation of angled abutments from cast to patients' mouth with optimal speed and precision.

PNEUMATIC SYSTEMS FOR AUTOMATIC SORTING EQUIPMENT

The aim of the research work was focused on a research of manipulators design using suction grippers. The results of the research can be applied in the design of jigs - manipulators for handling thin sheets. The FME analysis was used in the investigation to show the course of elastic deformations and stresses in stressed areas. An experimental observation of the change in the free deflection of the workpiece from the positioning of the suction cups under gravity load by means of a laser 3D scanner was carried out for the FEM deflection detection method.

The Effect of Femoral Cutting Jig Design on Restoration of Femoral Offset in Posterior-Referenced Total Knee Arthroplasty.

Femoral component sizing and rotation in total knee arthroplasty (TKA) affects patellofemoral tracking and tibiofemoral mechanics. Posterior referencing is said to optimize restoration of posterior condylar offset. However, it typically allows the surgeon to select 3° to 5° of external rotation to the posterior condylar axis, inevitably changing the offset of one or both condyles. The axis about which external rotation occurs varies between the jigs of various TKA systems. The location of this axis can result in a medial, central, or lateral reference point for posterior offset restoration. Variations in jig design will result in varying posterior offset changes at the same jig setting, with differential effects on balance between the flexion and extension gaps. Using identical Sawbones in a controlled laboratory setting, 9 TKA instrumentation systems were examined. Two systems referenced medially, 1 referenced laterally, and 6 referenced centrally. The authors measured distal and posterior resections in both 3° and 5° of external rotation to the posterior condylar axis. They calculated changes in both distal and posterior joint lines using resection measurements and implant specifications. Posterior resection thicknesses were greatest with instruments that referenced laterally and least with instruments that referenced medially. With increasing external rotation, instruments that referenced off the lateral femoral condyle introduced the greatest mismatch between the distal and posterior joint lines, as compared with instruments that referenced centrally or medially. Surgeons should be aware that laterally referencing systems can differentially restore distal and posterior joint lines at higher settings of femoral external rotation, potentially introducing incongruity between flexion and extension gaps if the posterior slope of the tibia is maintained. This may be particularly problematic if flexion laxity is increased by posterior cruciate ligament sacrifice. [Orthopedics. 2019; 42(6):316-322.].

Design and Analysis of Jigs and Fixtures for Manufacturing Process

This final year paper report is about the design and analysis of jigs and fixtures for manufacturing process. For this project, it is focus on the perspective of the job handling to produce the part. Currently, they implement the manual handling to assembly each component. Improvement that is trying to do is by replace the manual handling for the process by designing the semi auto jig for this process. The objectives of this project are to investigate the collected data and analyse the design of jig and fixture to ease work handling. The methodology of research procedures covered on this project consists of collect data, brainstorming and interprets data, design concept, and documentation. The design of jig and fixtures is using Unigraphics NX7.5 software. The data that can be studied include the analysis of Finite Element Analysis (FEA) using CATIA software, the analysis of design ergonomic, the time study analysis and cost analysis. At the end of this project, this research will be able to give understanding about jig and fixture, design by using Unigraphics NX7.5 software and finally able to do the analysis for the selected part of product by using FEA and other relevant analysis

Single Minute Exchange of Dies as The Solution on Setup Processes Optimization by Decreasing Changeover Time, A Case Study in Automotive Part Industry

Industrial competition nowadays demanding automotive manufacturers to increase productivity and organise lean production to meet all the targets. The rear axle manufacturer, one of the automotive industry in 2018, experienced production constraints that were unable to meet production targets. The Line Housing F as the object of this research had 9 machines that involved setup time for the changeover process out of 24 machines. The setup process was not being standardized, conducted manually and involved readjustment on the engine jig, which would, causes a long changeover time because the process was repeatedly carried out. This study aimed to optimize setup activities in order to reduce changeover time. The Single Minute Exchange of Dies (SMED) method was one of the applicable tools to reduce change over time, by changing the internal activities into external activities. In the final stage, SMED simplified the jig setting process by changing the jig design on the M16.3 machine and parallelizing the setup and process operations of the machine. The final results improved the 33% overall changeover time, from 58.36 to 39.22 minutes.