Fixture Design and the Number of Setups - Coursework Example

Fixture design Student’s Name College Instructor’s Name Course Name: Table of Contents Introduction 3 Part 1: Fixture design 3 Fixture design 3 Clamps assembly 4 Locators 5 Modular base 6 The number of setups and fixtures 7 Bill of materials 7 Part 2: The machining process 8 Non-traditional machining 8 The need of fixture 9 References 10 Introduction The aim of the paper is to design a modular fixture using standard fixture elements such as clamps, locators, pin, and modular base that will be used for machining operations after designing hundred components of similar nature will be produced. The block of aluminium that will be used in machining has geometry of 72 mm x 35mm x 42mm. The designed modular fixture will have the ability to hold in position the block to be machined and locates the component for machining. Part 1: Fixture design Fixture design In designing a fixture that will have the ability to hold a component for machining we will need, locators of 5/8”-11 thread sizes modular base of the same size, pins and a clamp. The component will need to have the ability to hold the block of aluminium for machining purposes. And have the hole than can host the pin. The following is Solid Works Clamps assembly The design of a clamp that will be used to hold the block into position will have the following appearance in Solid Works. The clamp designed above will have the ability to hold the component that is aluminium block in position during machining process. Three clamps of similar nature will be required during the machining process. This will ensure that the aluminium block is held firm without any movement which may cause faulty in machining. Clamping will also provide stability and allow it to remain in position for the purpose of machining. Locators There is need to have well designed locators which will be used in machining. The locators are designed in such a way that they are able to locate required poles for machining in the case at hand; three types of locators will be required for plane, concentric and radial of pin like nature. The pin like locators is ideal for this case. Concentric locators will help in dividing the aluminium components into necessary parts for machining. While plane locators will help in locating the aluminium components that is being machined. Radial locator will assist in restricting the aluminium components in place that is holding firm to avoid movements. Locators can be purchased from online store of Carrlane a bolt will be used to tighten so that stress is distributed from the component being designed. The pin that is required will be designed using the following calculations. To know which bolt would be most reasonable for this application, certain calculations are needed as shown below: Pin Calculations- The diameter of this pin is necessary and is calculated as follows: Where F = 16,000 N and  = 250 MPa The above were located as Modular base We will design modular base which will help the clamp move without affecting the machining process. The modular base will also be purchased form the same site. The number of setups and fixtures There are two set ups that is fixture drilling and milling. We begin by setting up the designed components in position by using locators for drilling. The aluminium block will be positioned using the clamp and locators for drilling. The figure below shows how the pin will be positioned and clamped. After clamping the components against the locators modular base is fixed to ensure that the component is held in position but the clamp is able to move horizontally. Then the hole is made using M5 drill which is also available in the market. Milling set up The second set up is for milling where the component is cut into the required sizes but in proper dimensions. This will set the cutter axis of the miller perpendicular to the aluminium component surface while cutting the edges on both outside and the end sides of the cutter. The pins will be used to position aluminium component as well as line up it for machining. The clamping and modular base are used to ensure that the aluminium component is held on the machine. Bill of materials Item no. Description Quality Cost Total cost 1 M5-drill 1 $100.00 $100.00 2 Clamp Modular base 3 $25.00 $75.00 3 Locator 3 $10.00 $30.00 4 Clamp 3 $30.00 $120.00 5 Pin 3 $4.00 $12.00 Total £183.05 (Carrlane, 2015) Part 2: The machining process Non-traditional machining If the material is changed from aluminium to titanium traditional method of machining will not be feasible because titanium is a hard metal. This means that non-tradition milling process will be used. The best machining process that will be applicable will depend on the type and nature of processing. There are many non-traditional manufacturing processes which use mechanical, electrical and thermal energy for cutting or machining. The most suitable method for machining titanium, type of metal is electrochemical machining where a metal is removed by reversed electroplating. The aluminium block will be subjected to a machining tool which has cathoditic element and a current will flow to aluminium block eroding the section that is required. This is shown in the figure below This method does not in any way get affected by the hardness of a metal as it can produce any shape of components as designed. This is clearly shown in the systematic figure above. The machining tool will be the ability of electrochemical machining will be put in place using locators and clamps as described in part 1 before processing begins. This process is very expensive but wear and tear of materials will be minimal. The machining rate will be calculated using the following formulas. Min) where, and The need of fixture If the material is changed from aluminium to titanium the component will still be needed because their other areas where hard things are required however. It should be noted that the manufacturing cost will be higher which will require an increase in the component produced for breakeven. The cost of producing hundred units will be evaluated using the revenue that will be generated by hundred units to determine the viability. Otherwise the component metal of titanium is durable and will serve the purpose for a long period. References Carrlane, 2015. Subplate locating keys Madsen, D., 2001, Engineering Drawing and Design, New York, Cengage Learning. Markham, E.R., 2012, Milling Fixtures, South Carolina, Nabu Press. Smid, P, 2010, Control Setup for Milling and Turning: Mastering CNC Control Systems, New York, Industrial Press Inc. Read More