E3S Web of Conferences 430, 01288 (2023) https://doi.org/10.

1051/e3sconf/202343001288
ICMPC 2023

Design, development and modelling of ginning

clutch fixture for productivity improvement
Purushottam Barve1, Yogesh Deshpande2, Yash Palkar3, Nishika Sangode4
1,3-4Yashwantrao Chavan College of Engineering, Nagpur
2Shri Ramdeobaba College of Engineering and Management, Nagpur

Abstract. Fixture is one of the important part of machining processes

which use for enhancing the efficiency of the process. The conventional
ginning clutch fixture is positioned with single fuse body on vertical
machining centre. During machining, more time is consumed for loading
and unloading which resulted high production time and cost. The solution to
an industrial challenge of the design and fabrication of fixture is attempted
in the present work. SolidWorks software is used for 3D modelling of novel
fixture and stress analysis is performed using ANSYS software which
determines the maximum stresses and deformation. Based on the ANSYS
results, fixture is fabricated and use for further testing. The ginning clutch
fixture was tested during production and was found that the efficiency of the
production of ginning clutch was increased by 33%.

Keywords: Fixture, ginning clutch, ANSYS, productivity.

1. Introduction

Ginning is the main tool used in gin industries, and its job is to extract the fibre from
cotton seeds while maintaining the fiber's inherent qualities. For the purpose of preparing raw
or semi finished cotton for the cotton mills, cotton ginning machines are used. By using a
cotton ginning machine, mechanically harvested cotton is transformed into a marketable
good. Ginning clutch is one of the major components of gin. During the manufacturing of
ginning clutch the sequence of process is forging, turning, drilling, milling and slotting.
Milling is one of the machining processes during the manufacturing of the ginning clutch
which is done on the vertical machining centre (VMC). In the manufacturing industry, a
single job (ginning clutch) is machined at the VMC, one at a timewhich requires more loading
and unloading time for a work-part. Researchers analysed the design, development and
fabrication of fixture using modelling and simulation approaches is presented in Table 1.

*Corresponding author: [email protected]

© The Authors, published by EDP Sciences. This is an open access article distributed under the terms of the Creative
Commons Attribution License 4.0 (https://creativecommons.org/licenses/by/4.0/).
E3S Web of Conferences 430, 01288 (2023) https://doi.org/10.1051/e3sconf/202343001288
ICMPC 2023

Table 1 Literature review

Authors Work area Method Highlight

Radhwan et al. Analysis of jigs and Uni-graphics Jig and fixture, designed and
(2019) fixtures NX7.5, analyzed using FEA
FEA and
CATIA

Pachbhai and A review on design CATIA Study of fixtures for enchancing

Raut (2014) of fixture productivity

Mundhe et al. Multipurpose fixture Solid works The more process duration is required
(2018) for VMC forloading and unloading the
material. Thus, fixture use in
enhancing productivity.

Gothwal and Study for CAFD The flexible fixture system is

Tilak-Raj development of intended tofix as many workpieces as
(2017) flexible fixture possible.

Rajmohan et Design and FEA The primary goal of developing the

al. (2015) optimization turning fixture is to reduce cycle
techniques in turning time, setup time, andproduction costs
fixture by replacing the existing fixture in the
VMC machine.

After studying various processes and understanding different types of processes in

depth. It is noticed that cycle time, loading and unloading time, overall machine time,
machining parameters are responsible for improving productivity. Therefore, an attempt has
been made for redesigning the fixture which hols multi work-parts.

2. FIXTURE DESIGN PROCESS:

While designing the fixture, the following 3 major factors should be considered such
as locators, clamps and supports. It can also improve the stability of the fixture-workpiece
system. There is no limitation to thenumber of supporting elements used in fixtures. To took
the main idea of making fixtures by taking a general aspect from the previous setup of
manufacturing operation (milling) which helpus to understand the major of freedom which
has to be restricted.
The design planning of a fixture is based on the data collected of the ginning clutch
manufacturedin the industry and which aim to increase productivity. The data which is
mainly required as a draftingsheet of the ginning clutch which shows all the dimensions with
proper accuracy in Fig 1.

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Fig 1 Ginning clutch

3. Design and experimentation:

The data of the VMC machine on which ginning clutch is manufactured such as bed of
the VMC machine is 550×1000 mm. Tool material was EN8. The design process also
included the analysis such as the clamping position, load distribution and material selection,
etc. The modelling of the fixture is done using SolidWorks designing software. By using all
the data, the following design dimensions of the fixture is presented.
➢ Design of top plate:-
Top plate length = workpiece diameter + clearance between jobs + Clearance on both
side
= (60×4) +(30× 3) +35×2
=240+90+70
= 400 mm
➢ Design of pillars
Height of job= 138mm ,Length of pillars = 140 mm Breath of pillar
=140 mm (use the square plate for the pillar)
➢ Design of the middle plate
Length of plate = diameter of the hole + clearance between holes + clearance on both
sides
= 20×4 + 68×3 + 30×2
= 80+204+60
= 344 mm
While designing fixture there were various restrictions and parameters which were
supposed to be kept in mind for failure less designed. After creating and plotting basic ideas
of fixture which were supposed to hold four components at a time. So after the changes,
baseplate length is 515 mm Which was supposed to hold a pillar of the square dimension of
140 mm and having a thickness of 23mm. The base plate was supposed to hold the various
forces acting on the parts resulting in reason forces on the baseplate. Dimension of the
baseplate is 200x23 mm. Further going on the pillars which make up the overall height of the
component and hold the top plate which directly attached the part to it install. To make a new

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ICMPC 2023

change to its motion for vertical playing while machining forces come into action. So this
pillar plays an important role and has the dimensions of 140 × 140mm. In this work structure,
the degree of freedom is equal to 0. To hold the clutch, upper part of the plate designed having
a length of345x140x40 mm. To keep a safe distance from clutches, have to provide
allowances at each side as wellas from the outer diameters of clutches. SOLIDWORKS
software is used to design fixture. Figure 2 shows the final design based decision. Figure 3
shows various views of the fixture.

Fig 2 Final design of the fixture

Fig. 3 Different views of the ginning clutch fixture by using

ANSYS software

Design analysis: The analysis of the design of the fixture was executed using
SolidWorks software. The first analysis which executed was static loading to find out
how different types of stresses, strain, and displacement forces can act upon the fixture.
Figure 4 is the model information; it is the fixture information that shows us the

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volumetric properties of the fixture. The volumetric properties of the fixture include the
mass, volume and ddensity. The material used during the manufacturing of the fixture is
AISI 1020 Steel, cold rolled. 1020 steel has a tensile strength of 350MPa. 1020’s
modulus of elasticity is 205 GPa and the shear modulus is 80 GPa. It has good

mechanical properties. Such propertiesare highly efficient for the manufacturing of

fixtures. 1020 steel has high strength which can help the fixture to increase its shelf life.
The model information of ginning clutch fixture shown in figure-4 and material
properties shown in Table 2.

Fig. 4 Model information

Table 2 material properties

Loads on fixture: During the simulation of the fixture, the bottom plate of the fixture is
fixed and applied 100N static perpendicular force on the fixture. Figure 5 shows the fixed
plate and the different forces acting upon the X, Y, and Z direction of the fixture. The
simulation result is presented in Fig 5.

Fig. 5 Fixed geometry and force components on the fixture

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ICMPC 2023

Mesh information: Meshing is one of the important factors during the simulation of any
engineering drawing. Mesh is the most significant for correctness, convergence, and rapidity
of the simulation. Table 3 presents the mesh information. After simulation of the fixture using
static loading, stress, strain, and displacement are analysed loading on the fixture. The results
of the fixture after stress, strain, and displacement analysis came out successfully and were
ready for the dynamic analysis. Figure 6 shows the stress analysis of the fixture. Figure 7
showsthe displacement analysis of the fixture. Figure. 8 shows the strain analysis of the
fixture.

Table 3: Mesh Information

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ICMPC 2023

Fig. 6 Stress analysis of the fixture

Fig 7 Displacement analysis (Static loading)

Fig 8 Strain analysis

Dynamic loading: After successful results of the static analysis, moved forward toward
the dynamic analysis of the fixture. For dynamic analysis, free vibration is considered over
the fixture. Fixture is tested, 5 times applying different amplitudes each time. Figure 9 shows
the dynamic loading analysis for the first analysis whose amplitude ranges up to 500 hertz.
Fig 10 shows the dynamic loading analysis over the fixture whose amplitude ranges up to
1000 hertz. Fig 11 shows the dynamic loading analysis over the fixture whose amplitude
ranges up to 1000 hertz but for different nodes. Fig 12 shows the dynamic loading analysis
over the fixture whose amplitude ranges up to 1500 hertz but for different nodes.

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ICMPC 2023

Fig 9 Dynamic loading – amplitude 1

Fig 10 Dynamic loading- – amplitude 2

Fig 11 Dynamic loading – amplitude 3

Fig 14 Dynamic loading – amplitude 4

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➢ Dynamic loading results

Fig 12 Dynamic loading – amplitude 5

After applying dynamic loading which is free vibration for different amplitudes and
frequencies on the fixture it was found that the fixture design was safe and ready to
fabricate. Table 4 shows us the mode list of the dynamic loading for different frequencies.
Table 5 shows the mass participation of the fixture during various frequencies applied to
the fixture in X, Y, and Z, directions.

Table 4 Mode list

Table 5 Mass participation

➢ Fabrication of fixture:

Following design analysis, it is time to create a working model for the fixture and
manufacture various fixture parts. The manufacturing processes for the various parts take
different paths, but the first process for each component was the same, which was gas
cutting. To begin with different parts, the base plate as shown in Fig.16 was followed by
the top plate because it has the most processes attached to it. The components and processes
are discussed further below. This plate had its overall required dimensions after the first
gas cutting process, and it was held on a machine bed for drilling holes on four corners.
After drilling and increasing the hole diameter on the VMC, the plate was ready to use.

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These pillar plates as shown in Fig.17 were brought on a drilling machine after being cut
to the required dimensions and have a total of four side holes, four of which are peck holes
and the remaining two are through holes. Threading is present in the peck holes as well.
This middle plate has also gone through the primary process of gas cutting and comes to its
dimensions after which it was given for another process of drilling which includes making
4-peck holes and has also gone through the processes of internal threading. After threading
the small holes, the plate was held on its length and drilled with the largest drill possible.
After drilling process, increased the hole diameter on VMC, and then the plate was ready
to use as shown in Fig.18

Top plate: This plate goes through several machining processes, the first of which is
cutting the plate and then making the small holes, which are through holes, to hold the plate
with the pillar plates, thus the 4 and through holes. After the pillar holes, the clamping holes
are supposed to be made to hold the clamps, so these holes have additional threading in
them, totalling 8 threaded holes. These eight holes on each side of four large holes are
supposed to keep the clutch in its cavity. Drilling is created and then modified using a
milling process as shown in Fig.19. The fabrication of fixture is presented in Fig.20.

Fig. 16 Base plate of the fixture

Fig. 17 Pillar plate of the fixture

Fig.18 Middle plate of the fixture

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Fig. 19 Top plate of the fixture fabricated model

Fig 20 Fabricated fixture

4. Results and discussion:

Successfully designed and developed fixture for the ginning clutch is manufactured for
productivity enhancement. The basic process applied for the manufacturing of the ginning
clutch fixture was to define the parameters for designing the fixture. Modelling of fixture is
done through SolidWorks software. Using the ANSYS, fixture is analysed for various stress,
strain, and displacement. The results came out to be successful for manufacturing the fixture
as shown in Fig.20 AISI 1020 steel, cold-rolled material is used to manufacture the fixture.
The fixture is tested on the VMC machine which used to manufacture ginning clutch on the
VMC machine. After testing the fixture for manufacturing four ginning clutches at a time. It
is observed that the time required to mill 4 ginning clutch (loading and unloading time) has
been decreased. Hence, manufacturing productivity using novel fixture (holding 4 ginning
clutch parts at a time) has been increased by 33% compared to conventional fixture. Shop
floor industries would be benefited by using muti-part holding novel ginning clutch fixture.

5. Conclusion:
• The ginning clutch fixture was successfully designed, modelled and
simulated by considering various stress, strain loading, and free
vibrations.
• The ginning clutch fixture was successfully fabricated.

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ICMPC 2023

• The ginning clutch fixture was tested during production and found that the
efficiency of the production of ginning clutch was increased by 33%.

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