ISSN: 2319-8753
International Journal of Innovative Research in Science,
Engineering and Technology
(An ISO 3297: 2007 Certified Organization)
Vol. 3, Issue 4, April 2014
Development, Fabrication and Analysis of
Fixture
Kiran Valandi1, M.Vijaykumar2, Kishore Kumar S3
Student, Dept of IEM, JSSATE VTU, Bangalore, Karnataka, India 1
Professor, Dept of IEM, JSSATE VTU, Bangalore, Karnataka, India 2
HOD, Application and Turnkey, Starrag India Pvt.ltd, Devanhalli/Bangalore, Karnataka, India3
Abstract: A fixture is designed, built to hold, support and locate every component to ensure that each is drilled or
machined with accuracy and manufactured individually. A fixture can be designed for the particular job using
production tools which make the standard machine tool more versatile to work as specialized machine tools. They are
normally used in small scale production by semi skilled operators. This dissertation work aims at designing a fixture
used for performing machining operations at certain angle (102.5 degree) on the Crank case used in commercial
vehicles. The design is proposed so that the required operations are performed properly with the conventional CNC
machines to obtain required dimension which includes Design & Structural analysis of fixture is carried out using
known and proven methods, i.e., Creo Elements/Direct modelling 17.0 Software.
Keywords: CNC’s, Design, Structural Analysis, Creo Elements
I. INTRODUCTION
Fixtures are the tools used to locate and hold the work piece in position during the manufacturing process. Fixtures are
used to hold the parts firmly which are to be machined, it is used to produce the duplicate parts accurately. In order to
produce parts with required accuracy and dimensions the parts must be firmly and accurately fixed to the fixtures. To
do this, a fixture is designed and built to hold, support and locate the work piece to ensure that each work piece is
machined within the specified limits. Set blocks, feeler or thickness gauges are used in the fixture to refer the work
piece with the cutter tool. A fixture should be securely fastened to the table of the machine upon which the work is to
be done. Though largely used on milling machines, fixtures are also designed to hold the work for various operations
on most of the standard machine tools. Fixtures vary in design based on the use of relatively simple tools to expensive
or complicated devices. Fixture helps to simplify metalworking operations performed on special equipments.
II. LITERATURE REVIEW
Chen Luo, LiMin Zhu,Han Ding, in his paper Two-Sided Quadratic Model for Work piece Fixturing Analysis,
2011proposed that presents a novel model for work piece positioning analysis. Existing fixturing models may
underestimate the positioning error due to neglect of the curvature of one or both contacting bodies.
S. Kashyap W.R. DeVries in their paper Finite element analysis and optimization in fixture, proposed with minimizing
deformation of the work piece due to machining loads about fixturing support positions, especially in thin castings.
Y. Zheng & Y. Rong & Z. Hou in their paper, A finite element analysis for stiffness of fixture units, proposed a
systematic finite element model to predict the fixture unit stiffness by introducing nonlinear contact elements on the
contact surface between fixture components.
M. Y. Dakhole, Prof. P.G. Mehar, Prof. V.N. Mujbaile , in their paper, Design And Analysis Of Dedicated Fixture
With Chain Conveyor, gives a feasible solution on conventional roller chain conveyorised arrangement with dedicated
moving fixture with conveyor for the tractor components like rear axle career, bull gear and shaft of a tractor model.
Copyright to IJIRSET www.ijirset.com 11414
ISSN: 2319-8753
International Journal of Innovative Research in Science,
Engineering and Technology
(An ISO 3297: 2007 Certified Organization)
Vol. 3, Issue 4, April 2014
III. METHODOLOGY
Methodology is a systematic approach for realization of total task. It consists of following details:
• Study of component: The study of component is the most important and the first step for the designer. The
component drawings are carefully scrutinized to extract the maximum possible information. The important information
available is the critical dimensions, locating and clamps areas.
• Geometric model of component: Geometric modeling of component is done using Co- Create considering all the
critical dimensions.
• Step by step design calculations: It is carried out to determine the various design parameters that determine cutting
force induced on the component during milling operation.
• Selection of tooling materials: The material used in the manufacturing of fixture varies depending on the
applications. Proper material selection and proper combination of alloys in varying percentages are required for
finished fixture.
• Solid modeling of tool: 3-D modeling of entire Component is done using Co-Create software. For the better
understanding of 2D drawings and visualization, modeling has been done. The required dimensions are determined by
calculation, which is used during modeling of the tool.
• Analysis: Structural analysis is carried using ANSYS software to determine the total deformation and the stresses
induced in the fixture during operation.
Fig.1 Deformations occurred due to applied loading conditions in ANSYS.
Fig.2 Stresses acting on the fixture due to the applied load.
IV. CONCLUSION
The design of the fixture is simple, the loading and unloading of component is very easy. At a time all the operations
such as milling, boring, drilling, tapping can be done in a single set up which in turn decreases the handling and
Copyright to IJIRSET www.ijirset.com 11415
ISSN: 2319-8753
International Journal of Innovative Research in Science,
Engineering and Technology
(An ISO 3297: 2007 Certified Organization)
Vol. 3, Issue 4, April 2014
machining time. This fixture is designed in such a way that any operations are supposed to be done at certain angle can
be easily performed on this fixture as we can perform the machining action on both the sides. And this fixture is
designed with minimum number of parts. Considering the static forces over the component which is in contact with the
fixture is analysed, it shows the total deformations and the stresses acting on the fixture during the machining process
done on the fixture. Hence these results indicate that the design is well within the safe limits. Hence the design is safe.
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