ISSN (Online) 2581-9429

IJARSCT
International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 6, Issue 1, June 2021

Impact Factor: 4.819

Design of Fixture to Reduce Loading Time on

VMC Machine
Aher Atul1, Bagul Rahul2, Bhamare Anirudha3, Bharambe Varsha4, Mr. Y. S. Khadke5
UG Scholar, Department of Mechanical Engineering1,2,3,4
Faculty, Department of Mechanical Engineering 5
Matoshri College of Engineering and Research Center, Eklahare, Nashik

Abstract: Fixtures play an important role in machining process. They are widely used in mass
production as they help in reducing the loading and unloading time. Small scale industries in India
are looking forward for the affordable and effective fixtures for the process of manufacturing. Many
operations like turning, shaping, drilling requires skills for the workers and any mistake done by the
workers may results in inaccuracy. Fixture helps in these operations by providing the support to the
working piece. The work piece needs to be properly fixed and supported when mechanical operations
are performed over it. This will be advantageous as it will reduce labour efforts and improve
production of the work piece. In this project, we are going to design a fixture for a VMC machine as
per the requirement of the Industry which will help in reducing the loading and unloading time,
operator efforts and improve productivity.

Keywords: Fixtures, Casting, Jig, VMC.

I. INTRODUCTION
Fixture is a holding device for fixing, supporting and positioning the work piece for specific operations. It only
provides a reference surface or device. The word “Fixture” is derived from latin word which means ‘fixed’ or
‘attached’. Jig is a work holding device that holds, supports and locates the workpiece and guides the cutting tool for a
specific operation. Fixture does not provide any help to guide the tool as that of jig. But it is always fixed in a particular
position on the machine. Fixtures are normally designed in order to perform definite operation. The main purpose of the
fixture is to provide a safe mounting point allowing support during process and to provide improved accuracy,
reliability and inter changeability in the finished part. It also allows you to quickly set up and smooth the transition
from parts to it to reduce working hours. It often reduces the complexity of the process, allowing unskilled workers to
perform this process and effectively transfer the skills of toolmakers to unskilled workers. Machining is essentially a
method of removing material or stock to a specified limit or tolerance. In order to control this removal rate, the tool is
equipped with a stops and gauges. Many machining operations can be done by clamping the work directly onto the
surface of the machine without the use of a fixture, requiring only a few parts to be machined. But the number of parts
is large enough to prove the cost of the fixture, usually used for holding and positioning. if fixture is not used during
operation the machine may require two or more operators, and when fixture is used it eliminate one of the operators

1.1 Types of Fixture

Fixtures are mostly used in milling operation but it is also used in other operations such as: turning, boring, welding
and grinding. Fixtures are also made for inspection and assembly works. Moreover fixtures are used for castings and
forgings which are rough and irregular in shape. With the use of locators and proper clamps, handling of those jobs will
be made easy in fixtures than any other standard work holding devices.

Copyright to IJARSCT DOI: 10.48175/568 1006

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 ISSN (Online) 2581-9429
IJARSCT
International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 6, Issue 1, June 2021

Impact Factor: 4.819

Adjustable Fixture

Grinding Fixture

Types of Fixture
FixtureFixtures
Welding Fixture

Assembly Fixture

Inspection Fixture

Milling Fixture

Straddle Milling Fixture

Indexing Fixture

Figure 1: Types of Fixtures

II. LITERATURE SURVEY

1. P.H. Joshi, “Jigs and Fixture” Design Manual (Second Edition) (2003). The author has given detailed process
of designing Jigs and Fixtures, their principles, elements and all the terminologies related to them. [4]
2. Shailesh S. Pachbhai, Laukik P. Raut, “A Review on Design of Fixtures”. International Journal of Engineering
Research and General Science Volume 2, Issue 2, ISSN 2091-2730 (2014). They have explained the general
process of designing a fixture and its function in the research paper. [1]
3. B. Patil, S. Mhatre, “Overview of Fixture Design for Indian Industries”. International Journal of Innovations in
Engineering Research and Technology. Issn: 2394-3696, Volume 7, Issue 5, (2020).The authors has given a
brief overview of fixture in India and its significance. [2]
4. S.Gothwal, R. Tilak. “Different aspects in design and development of flexible fixture”. Int. J. Services and
Operations Management, Vol. 26, No. 3, (2017). They have mentioned the different considerations in design
of fixtures. [5]
5. H Radhwan, M S M Effendi, “Design and Analysis of Jigs and Fixtures for Manufacturing Process”. IOP
Conf. Series: Materials Science and Engineering 551 (2019) 012028 IOP Publishing doi:10.1088/1757-
899X/551/1/012028, (2019). They have concluded the the cost of production can reduce and productivity is
increase which is the parts per hour can be increased.[6]

Copyright to IJARSCT DOI: 10.48175/568 1007

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 ISSN (Online) 2581-9429
IJARSCT
International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 6, Issue 1, June 2021

Impact Factor: 4.819

III. DESIGN OF FIXTURE

3.1 Finalized Design

Figure 2: Finalized design of fixture

Figure 3: Tray Slider Guide(Part of Fixture)

Figure 4: Tray Slider (Part of Fixture)

Copyright to IJARSCT DOI: 10.48175/568 1008

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 ISSN (Online) 2581-9429
IJARSCT
International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 6, Issue 1, June 2021

Impact Factor: 4.819

Figure 5: Tray Slider (Part of Fixture)

The design consists of a sliding trolley and tray in which we will be able to fix more than one workpiece on the
machine. The basic design is shown above. After some modification and changes, the final design will be fixed and
then analysis will be done after that.

3.2 Consideration in Design

For designing fixture, following points are to be considered:
 Type of Operations
 Inspection requirements
 Provision of reliable, rigid, and robust reinforcement to the blank
 Production of jigs and fixtures with minimum number of parts
 Fast and accurate location of the jig or fixture blank
 Rapid mounting and un-mounting of the work-piece from the jigor fixture
 Set up time reduction
 Standard and quality parts must be used
 Reduction of lead time

IV. ANALYSIS AND RESULT

4.1 Arm with only Centre Support

Figure: Stress analysis result (Scenario 1) Figure: Strain analysis result (Scenario 1)

Figure: Displacement analysis result (Scenario 1)

Copyright to IJARSCT DOI: 10.48175/568 1009
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 ISSN (Online) 2581-9429
IJARSCT
International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 6, Issue 1, June 2021

Impact Factor: 4.819

Arm with only Centre Support

Maximum Stress 3.156x10^8 N/m^2

Maximum Strain 9.088x10^-4

Maximum Displacement 0.8756 mm

Table: Arm with only Centre Support FEA Results

4.2 Arm with Centre Support and Toggle Clamp

Arm with Centre Support and Toggle Clamp

Maximum Stress 3.4x10^8 N/m^2

Maximum Strain 9.545x10^-4

Maximum Displacement 1.352 mm

Table: Arm with Centre Support and Toggle Clamp FEA Results

V. RESULT AND DISCUSSION

From the analysis results we can see that the design of fixture is safe to be manufactured. No hazardous risk is
involved while machining. The Stress generated are within limits. The displacement observed is nominal and
acceptable.
After discussing the third scenario with the company’s representative we got the clearance to finalize the design.
The time which we have saved by designing the Fixture is to be calculated. First of all we are clamping 4 parts at a time
and loading it in the machine. Thus the loading and unloading time has been reduced to one fourth of total Ideal time.
Also the miscellaneous time has been reduced to one fourth.
Then while machining there are total five tools to be used. In ATC (Automatic tool change) also it takes 17 Seconds
to change tool every time. That is in single part cycle there are 5 tool changes thus 85 seconds are required for ATC.
Now as we have used the fixture with four parts in it the total ATC time for four parts is equal to 75 seconds. Thus we
have saved 255 seconds in every four parts.
Referring to loading time table on next page we can see we reduced almost 255 seconds in every four parts. Also the
human effort has been reduced, as in earlier method the operator has to do work every 22 minutes. And now by using
fixture operator has to work on machine after every one hour and 15 minutes approximately.
Sr. .no. Specifics Time without Fixture Time With Fixture
1 Loading time taken by operator 43 sec 11 sec
2 Total Program Time 19 min 50 sec 18 min 46 sec
3 Unloading 12 sec 4 sec
4 Miscellaneous (Cleaning & Inspection time) 30 sec 7.5 sec
Total time required 21 min 15 sec 19 min 8.5 sec
Table: Total machining time comparison
We can see from the above table that we almost save two minutes per part by using fixture. Also we can increase the
speed and feed of machine to reduce the cycle time on machining as the fixture is rigid and sturdy to take vibrations.
Main aspect from company’s point of view is that the dedicated operator is not required on machine now. The one
operator can handle two machines at a time. Thus that is direct labor cost reduction. The dependability on operator has
been reduced.

Copyright to IJARSCT DOI: 10.48175/568 1010

www.ijarsct.co.in
 ISSN (Online) 2581-9429
IJARSCT
International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 6, Issue 1, June 2021

Impact Factor: 4.819

Due to fixture the skilled operator is not required. As we have provided the location pins and precise slots for part
loading. The toggle clamp has reduced the clamping effort. In overall aspect we can see that the fixture has played its
role and the company’s representative is positive towards manufacturing this fixture.

VI. CONCLUSION
The fixture we designed for the Industry has reduced the loading and unloading time as required by the industry. It
will lead to reduced labor efforts and make the operator’s job easy. It will fulfill the requirement of production. More
than one job can be machined at a time. This project has prove to be very beneficial for the team as we will get to
experience practical problems faced by industry and also provide the industry with a solution by applying our
knowledge thus, proving a great experience for everyone.

REFERENCES
[1]. “A Review on Design of Fixtures”- Shailesh S. Pachbhai, Laukik P. Raut. International Journal of Engineering
Research and General Science Volume 2, Issue 2, Feb-Mar 2014 ISSN 2091-2730 (2014)
[2]. “Overview of fixture Design for Indian Industries”- Patil Bhaskar Sambhaji, Mhatre Sairaj Sudhakar.
International Journal of Innovations in Engineering Research and Technology. Issn: 2394-3696, Volume 7,
Issue 5.(2020)
[3]. http://www.nitc.ac.in/dept/me/jagadeesha/Tool_Engineering_and_Design
[4]. P.H. Joshi - Jigs and Fixture Design Manual (Second Edition). McGraw-Hill Education (India). (2003)
[5]. “Different aspects in design and development of flexible fixture”. S.Gothwal, R.Tilak. Int. J. Services and
Operations Management, Vol. 26, No. 3,(2017).
[6]. H Radhwan, M S M Effendi, “Design and Analysis of Jigs and Fixtures for Manufacturing Process”. IOP
Conf. Series: Materials Science and Engineering 551 (2019) 012028 IOP Publishing doi:10.1088/1757-
899X/551/1/012028,(2019).
[7]. Xiaobing Dang, Kai He, Feifei Zhang, Ruxu Du, A new flexible sheet metal forming method of incremental
bending, Procedia Manufacturing 15 (2018) 1298–1305

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