Design and development of a fixture for Kelly bar mounting

Abstract

The Kelly bar is a bulky, long and heavy device that is used in piling. The Kelly bar surface is not smooth and contains ribs and grooves. The Drilling process makes many damages to the Kelly bar. These damages are required to be repaired in a workshop. Therefore,the gap of this research was the difficulty and the high cost associated with Kelly bar maintenance.The aim was to design a suitable fixture.The Objectives were to study the process and then create a new fixture and implement it in the workshop. In the methodology, the development process of the fixture and testing was explained. The research focused on the design and the development of the Kelly bar mount The. Kelly bar mount was required to do sliding and rotation both. This mount was required to be designed so as to prevent injuries to workers and damage to the environment, with low energy consumption.A Literature review was done.Thus,the main areas of the report were to identify a suitable fixture, to design and produce the mount and then test the mount. Next, a Project plan was developed and a project path was identified. Then a free hand sketch was identified. Then the optimal solution by design tree was shown and the conceptual design was obtaitend. Next, calculations for engineering strength were carried out. The material requirement plans and machine requirement plans were prepared. Afterwards,the model was designed,and carried out. So, the actual model was made. Based on this,the cost of production was analyzed . The investment and the cost saving points were discussed. After which the production was carried out. Next , testing was done.Then it was implemented in the workshop. Finally it was painted. For this research, the cost of production and opportunity cost were calculated. Based on this, a simple payback period as 29 days was calculated. Based on these results, finally,it was concluded that, implementing this fixture reduced the cost of operation massively in the workshop.