ASSIGNMENT 2

FIXTURE DESIGN
GROUP 7

DIP MUKESHBHAI PATEL 8966859

ARCHIT DHARMESHKUMAR DAVE 8980888
REHAL AVNEET SINGH 8976112 GUIDED BY: PROF. NAGA YALIGAR
OVERVIEW
• INTRODUCTION OF FIXTURE
• TALK ABOUT TASK
• FIXTURE DESIGN WITH LABELLED COMPONENTS
• EACH COMPONENT EXPLANATION
• MANUFACUTRING PROCESS
• COST OF FIXTURE
• TIME CALCULATION
• CONCLUSION
INTRODUCTION:
What are the fixtures?

• It is a work-holding device that is used to support and hold the workpiece for the manufacturing
processes.
• It is used to accurately manufacture duplicate parts.
• Reduce the requirement of skilled manufacturing labours.

Why do we use fixtures instead of jigs?

• Fewer components and less complexity

• Cost effective than jigs
• Easy to manufacture
GIVEN TASKS:
NOTES:
MATERIAL: MILD STEEL (AISI 1020)
NO OF PARTS: 1400

B: MAKE A 120-DEGREE CUT

C: MAKE A SLOT
NOTES FOR TOLERANCES:
• Positional tolerance of holes: ± .01"
Hole Diameter: ± .01"
Step depth: ± .002"
Slot Width: ± .002"

• The part will have already been heat treated and surface ground (top and bottom) to within .001" and outer
edges (perimeter) pre-machined to ± .001 length and width

• Also, while fixture design I applied the 20-50% tolerance rule to it where necessary concerning GD&T principles,
Carr-Lane Handbook.
DESIGN CONCEPT WITH LABELLED COMPONENTS:
EXPLODED VIEW:
1. BASE PLATE:

MATERIAL:
ALUMINIUM 7075

WHY?
- Strength
- Lightweight
- Corrosion-resistant
- Machinable

WITH THE HELP OF RECTANGULAR CUT PIECES, I CAN MAKE T SHAPE LOCATOR & “SAVES THE MATERIAL”
2.T - SHAPE LOCATOR:
MATERIAL:
ALUMINIUM 7075

WHY?
- Strength
- Lightweight
- Corrosion-resistant
- Machinable

LOCATION OF LOCATOR:
 3. M4 SCREW: 4. L SHAPE LOCATOR:

WHY WE NEED?
It helps to locate the
first and last part of
the fixture plate.

MATERIAL: STAINLESS STEEL

MATERIAL: ALUMINIUM 7075

LOCATION OF L SHAPE LOCATOR

LOCATION OF 8 SCREWS
5. CLAMP

CLAMP MATERIAL: ALUMINIUM 7075 PRECISION: ±0.005

LOCATION OF CLAMP
6. PNEUMATIC CYLINDER:
• It is the one type of actuator.
• It will be helpful to push and pull clamp in horizontal direction.
• By this mechanism we can achieve automation in clamping, it saves time for clamping instead
of clamp manually.
7. MAIN PART:
ANIMATION:
MANUFATURING AND COST OF FIXUTRE:
Use a CNC machine for excellent precise parts.

Weld small block

(size 0.5*0.5 in)

Thickness: 1 in
L X W = 18 * 2 in

Number of blocks: 5 but we required only

4 locators
Block size: 1.5*1.7*0.5 in

Create
Thickness: 0.5 in
L X W = 18 * 6 in M4 holes
for screw

PART NAME HOURS RATE TOTAL

CLAMP 2 hr 40 $/hr $ 80 MANUFATURING
BASE PLATE 1 hr 40 $/hr $ 40 COST
Thickness: 0.5 in T LOCATOR (4) 1.5 hr 40 $/hr $ 60 $ 200
L X W = 4 * 2 in L LOCATOR (2) ½ hr 40 $/hr $ 20
 TIME CALCULATION:
Reference machine: https://ca.syil.com/x7

Time for per cycle (5 pieces)

PROCESS TIME
120-degree cut 2 Minutes * 5
Slot making 3 Minutes * 5
Tool change (ATC) 1.5 Seconds * 4
Loading & unloading 4 Minutes
Chip cleaning 1 Minutes
TOTAL 30.1 Minutes

For 280 cycles: 30 Minutes * 280 = 8428 / 60 hr = 140.45 hours.

This whole process takes 17 - 18 days to complete if the worker works for 8 hours of shift per day.

The calculations are attached in the rough work for reference.

BILL OF MATERIAL (BOM)
NO PART NAME QUANTITY PRICE
1 Fixture manufacturing cost 1 $ 200
2 Aluminium plate for clamp (2*18 in) 1 $ 65.96
3 L locator plate (2*4 in) 1 $ 25
4 Aluminium plate for base (6*18 in) 1 $ 87.74
5 Pneumatic cylinder 1 $ 82
6 M4 bolt (stainless steel) 8 $ 15
TOTAL $ 462.7

TOTAL COST OF WHOLE PROCESS

= BOM + WORKER WAGES Per piece cost: $1.807
= $ 462.7 + $ 2107
= $ 2569.7
ADDITIONAL INFO:
• CNC machines running costs have from $50 to 350$ in Canada.
• It depends on the operations, quantity, and precision.
• If we assume our CNC machine has an hourly rate of $50/hr.

• our total operating cost: $50*140 hr = $7022.5

• After the calculating cost of the CNC machine operation, we modify one piece for $6.85
 CONCLUSION:
• Our fixture design is easy to understand to everyone.

• It may take a little bit longer time to make a fixture, but it saves time during the manufacturing process

because of automation.

• Its time-saving and cost-effective design because it increases production efficiency and reduces labor

costs.
ROUGH WORK:
DIP PATEL:
REHAL AVNEET SINGH:
ARCHIT DHARMESHKUMAR DAVE