Design & fabrication of table frame making Fixture

Chapter No.-1

INTRODUCTION
The fixture is a special tool for holding a work piece in proper position during
manufacturing operation. For supporting and clamping the work piece, device is
provided. Frequent checking, positioning, individual marking and non-uniform quality
in manufacturing process is eliminated by fixture. This increase productivity and reduce
operation time. Fixture is widely used in the industry practical production because of
feature and advantages. To locate and immobilize work pieces for machining,
inspection, assembly and other operations fixtures are used. A fixture consists of a set
of locators and clamps. Locators are used to determine the position and orientation of a
work piece, whereas clamps exert clamping forces so that the work piece is pressed
firmly against locators. Clamping has to be appropriately planned at the stage of
machining fixture design. The design of a fixture is a highly complex and intuitive
process, which require knowledge. Fixture design plays an important role at the setup
planning phase. Proper fixture design is crucial for developing product quality in
different terms of accuracy, surface finish and precision of the machined parts In
existing design the fixture set up is done manually, so the aim of this project is to replace
with hydraulic fixture to save time for loading and unloading of component. Hydraulic
fixture provides the manufacturer for flexibility in holding forces and to optimize
design for machine operation as well as process functionability.

In most of manufacturing processes, the component should be fixed securely

and accurately in front of the machine in order to desire task can be accomplished. This
fixing duty is the main role of fixtures in the industries. The set includes base plates,
supports, locators, clamps and various other accessories. Fixtures are widely used in the
industries for production because of their feature and advantage. Welding is a metal
joining process by heating of the materials to a suitable temperature with or without the
application of pressure, or by the application of pressure alone, with or without the use
of filler metal. Welding is one of the most common processes in the manufacturing
industries. The purpose of a welding fixture is to hold the parts to be welded in the
proper relationship both before and after welding. Welding fixture will maintain the
proper part relationship during welding. The process of fixture designing and

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 Design & fabrication of table frame making Fixture

manufacturing is considered complex process that requires the knowledge of various

areas, such as geometry, tolerances, dimensions, procedures and manufacturing
processes. Good fixture design will, of itself, largely determine the product reliability.

Welding fixtures are typically the most common devices used to align and retain
the various pieces for welding. Fixture design plays an important role at the setup
planning phase. Proper fixture design is crucial for developing product quality in
different terms of accuracy, surface finish and precision of the machined parts in
existing design the fixture set up is done manually. While designing a fixture it is quite
possible, even for an experienced person to overlook some basic aspects of fixture
design. It is not necessary that these kinds of situations arise only due to lesser technical
knowledge. While designing this work, a good number of literatures and titles written
on the subject by renowned authors are referred.

1.1Problem statement

As we decided to solve problem related to table frame making in fabrication

workshop. There is no. of table frame we have to make of same dimension. Problem is
arises that there is lot of time get wasted to hold the table frame angle perpendicular to
each other. Also it workers feel fatigue for doing this to every frame. It having very
low accuracy of geometric tolerance because operator have to set try square every time
of making weld. So we define our problem in following manner

Conventional frame making suffers following problem

1. Time consuming
2. Fatigue to operator
3. Less accuracy
4. Less production
1.2Objective of Project

From the statement of problem our project objective is that we have to create
such a fixture for table frame making such that it eliminates the problem arises for
conventional table frame making process.

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1.3 Scope of Project

Here we implement our fixture for making table of dimension 2.5 feet by 3.5
feet. Our project is made here for model purpose but it can be use for any convenient
dimension also. So our project helpful for those workshop or industries where table
frame, bed frame, flex frame, benches are make.

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Chapter No.-2

LITERATURE REVIEW
Patel et. al [1] Jigs and fixtures are the special production tools which make the
standard machine tool, more versatile to work as specialized machine tools. They are
normally used in large scale production by semi-skilled operators; however they are
also used in small scale production by when interchangeability is important. Various
areas related to design of fixture are already been very well described by various
renowned authors, but there is a need to couple and apply all these research works to
an industrial application. That integrates all these aspects and the evolutionary
functional approach of designed fixture is proved from the fact that a real industrial
component is considered for fixture designing. In addition of the fixture being hydraulic
type, it is also collet type and has expanding customized collet as its main fixturing
element. The fixture shows great time saving in the production.

A viable fixture designed for a workpart experiencing dynamic machining

must ensure: the workpart is restrained for all time, the clamping forces are not too large
or small, deterministic positioning, accessibility, stability of the workpart in the fixture
while under no external forces, and a positive clamping sequence. Considering all
above mentioned facts, the complete locating & clamping is accomplished by using
collet, stopper and V – block. 4 work-stations with 8 cylinders are used for complete
hydraulic fixture assembly. To start with, component is loaded keeping it in horizontal
position into collet side manually. After loading, component is located using stopper,
clamped by activating collet side cylinder and aligned by using V-block cylinders. As
V-block cylinders are bigger than collet side cylinders, the job is pushed from V-block
side and maintains the central axis to be perfectly aligned with respect to the collet axis.
Distinguished feature of fixture design –collet and manufacturing of fixture. In addition
to the hydraulic nature of fixture, another exclusive feature of the fixture is design of
collet. It works in the following manner: When the piston rod is retracted, puller road
and expander along with collet will also move from right to left as a single unit. As
mandrel is fixed with the rest pad, the collet must have to expand which will fix the job
resting over it firmly.

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Fig. 2.1.1 view of Fixture without Component

Fig. 2.1.2 3D view of Fixture with Component

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Shailesh et. al.[2] In machining fixtures, minimizing workpiece deformation

due to clamping and cutting forces is essential to maintain the machining accuracy. The
recent trends in industry are towards adopting the hydraulic techniques, because it save
time generates accuracy and it is having some flexibility. Hydraulic Fixture is major
application in the field of designing, where in several software’s are available for the
purpose of design. Hydraulic lift housing is engine part of an agricultural tractor which
plays an important role in application of lifting trolley of tractor and machining of
hydraulic lift housing is a important task. Loading and unloading of workpiece in
manual clamping is time consuming process, so reducing machining time, set up time
etc is a main aim of process. The job having cylindrical shape, this is a challenging task
for design engineer, hence hydraulic fixture design is incorporated in manufacturing
industry. Except toggle clamp, no other option is available to hold cylindrical object,
hence special type of fixture is design for this case, which can be used for machining
of hydraulic lift housing, Fixture reduces operation time, increases productivity, and
best quality of operation is possible. The project deals with the designing of different
parts of fixture assembly, 3D modeling by using Pro-E WILDFIRE 5.0, finite element
analysis of hydraulic lift housing by using ANSYS software.

Tofiq et. al. Welding and drilling are main processes of making chair frame from
metal material. Commonly, chair frame construction includes many arcs which bring
difficulties for its welding and drilling process. In UNS industrial engineering
integrated practicum there are welding fixtures which use to fixing frame component
position for welding purpose. In order to achieve exact holes position for assembling
purpose, manual drilling processes were conducted after the frame was joined.
Unfortunately, after it was welded the frame material become hard and increase drilling
tools wear rate as well as reduce holes position accuracy. The previous welding fixture
was not equipped with clamping system and cannot accommodate drilling process. To
solve this problem, our idea is to reorder the drilling process so that it can be execute
before welding. Thus, this research aims to propose conceptual design of modular
fixture which can integrate welding and drilling process. We used Generic Product
Development Process to address the design concept. We collected design requirements
from 3 source, jig and fixture theoretical concepts, user requirements, and clamping
part standards. From 2 alternatives fixture tables, we propose the first which equipped
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with mounting slots instead of holes. We test the concept by building a full sized
prototype and test its works by conducting welding and drilling of a student chair frame.
Result from the welding and drilling trials showed that the holes are on precise position
after welding. Based on this result, we conclude that the concept can be a consideration
for application in UNS Industrial Engineering Integrated Practicum.

Fig.2.3 Prototype of Welding Fixture

Vural et. al.s In their study, a welding fixture is designed and welding parameters,
affecting distortions and residual stresses, such as welding speed and reverse distortion
are taken into consideration Weld sequence is effective on distortions. Purpose: of this
paper is to examine the effect of welding fixture used to prevent the distortions during
cooling process utilizing a robot controlled gas metal arc welding method on cooling
rate and distortions of welded structures. Design/methodology/approach: Using a
specially designed welding fixture for a welded steel structure, six different types of

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AISI 1020 steel specimens are tested in three different welding speeds and two different
cooling conditions either at fixture or without using fixture. Findings: designed fixture
is reduced amount of distortions. The preheating effect of previous weld on the next
weld has increased distortions on the other side of part. Increase in distortions is directly
proportional to the increase in welding speed which affects the weld heat input.
Research limitations/implications: the study can be repeated on more complex
structures and fixtures. Practical implications: the study has shown that the fixture
design has an important effect on cooling rate of the welded parts. Originality/value:
most of papers in literature is about fixture design methodology, but this paper is an
example of demonstration for a practically applied welding fixture. First weld seam on
the part creates preheating effect on the next weld seam and increases distortions. After
analysis of six specimens, inversely proportional to weld speed, distortions are
increased by increasing heat input, as expected. Reverse distortions applied to see how
they effect the main distortion arising from the welding process. Although reverse
distortions are applied to part 3 of the specimens, they presented a positive distortion
characteristic because of being preheated while part 2 was being welded. This
characteristical based on decreasing of yield strength by heating. This results can be
used to predict the amount of reverse distortions.

Fig. 2.4 welding fixture setup

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Siddesha et. al. Designing a welding fixture for a component is not an easy
task. The component has to be located properly. Since this component has flat surface
at the bottom it is easy to locate the component on rest pad. The fixture consists of three
locating pins and these pins restrict the movement at the either side of the component.
A circular locating pad is used to locate the circular shaped region of the component.
There are two more locating pads used to locate the component which is also used to
align the bushes with the component. The bushes are fixed properly to the plate with
help of clamping. The clamping punch applies the load on the bushes so that the bushes
cannot be moved. The fixture also consists of one base plate, one rest plate, two
supporting plates and C clamps are used for clamping. In the operation the component
is placed on the fixture, bushes are placed in the required positions on the component,
with help of handling lever the clamping punch descends towards the bushes and restrict
the movement of bushes. Once the bushes are fixed to the component then welding
operation will start. Once the welding is done the clamping punch move upwards with
the help of lever. Fig. shows the different views of the fixture.

Fig.2.5 Isometric view for welding fixture

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Chapter No.-3

DESIGN PROCEDURE
3.1 MATERIAL SELECTION
The proper selection of material for the different part of a machine is the
main objective in the fabrication of machine. For a design engineer it is must that he be
familiar with the effect which the manufacturing process and heat treatment have on
the properties of materials. The choice of material for engineering purpose depends
upon the following factors.

1. Availability of the materials.

2. Suitability of materials for the working condition in service.

3. The cost of materials.

4. Physical and chemical properties of material.

5. Mechanical properties of material.

The mechanical properties of the metals are those, which are associated with the
ability of the material to resist mechanical forces and load. We shall now discuss these
prosperities as follows. Required properties for the selection of material are Strength,
stress, stiffness, elasticity, plasticity, ductility, brittleness, toughness, resilience, creep,
hardness. The science of the metal is a specialized and although it overflows in to realms
of knowledge it tends to shut away from the general reader. The knowledge of material
and their properties is of great significance for a design engineer. The machine elements
should be a material which has properties suitable for the conditions of operations. In
addition to this a design engineer must be familiar with the manufacturing processes
and the heat treatments have on the properties of the materials. In designing the various
part of the machine it is necessary to know how the material will function in service.
For this certain characteristics or mechanical properties mostly used in mechanical
engineering practice are commonly determined from standard tensile tests. In
engineering practice, the machine parts are subjected to various forces which may be
due to either one or more of the following.

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1. Energy transmitted

2. Weight of machine

3. Frictional resistance

4. Inertia of reciprocating parts

5. Change of temperature

6. Lack of balance of moving parts

The selection of the materials depends upon the various types of stresses that
are set up during operation. The material selected should with stand it. Another criterion
for selection of metal depends upon the type of load because a machine part resist load
more easily than a live load and live more easily than a shock load. Selection of the
material depends upon factor of safety which in turn depends upon the following
factors.

1. Reliabilities of properties.

2. Reliability of applied load.

3. The certainly as to exact mode of failure

4. The extent of simplifying assumptions.

5. The extent of localized.

6. The extent of initial stresses set up during manufacturing.

7. The extent loss of life if failure occurs.

8. The extent of loss of property if failure occurs.

9. Materials selected in machine.

The machine is basically made up of mild steel. The reasons for the selection
are Mild steel is readily available in market .It is economical to use and is available in
standard sizes. It has good mechanical properties i.e. it is easily machinable. It has
moderate factor of safety, because factor of safety results in unnecessary wastage of

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material and heavy selection. Low factor of safety results in unnecessary risk of failure.
It has high tensile strength. Low coefficient of thermal expansion. The materials of the
sheets to be cut are taken as aluminium and plastic as they are replacing many metals
in the present scenario because of their distinguished properties and features.

3.2 Steps of fixture design

Successful fixture designs begin with a logical and systematic plan. With a
complete analysis of the fixture's functional requirements, very few design problems
occur. When they do, chances are some design requirements were forgotten or
underestimated. The workpiece, processing, tooling and available machine tools may
affect the extent of planning needed. Preliminary analysis may take from a few hours
up to several days for more complicated fixture designs. Fixture design is a fivestep
problem-solving process. The following is a detailed analysis of each step.

Step 1: Define Requirements

To initiate the fixture-design process, clearly state the problem to be solved or
needs to be met. State these requirements as broadly as possible, but specifically enough
to define the scope of the design project. The designer should ask some basic questions:
Is the new tooling required for first-time production or to improve existing production?
Step 2: Gather/Analyze Information
Collect all relevant data and assemble it for evaluation. The main sources of
information are the part print, process sheets, and machine specifications. Make sure
that part documents and records are current. For example, verify that the shop print is
the current revision, and the processing information is up-to-date. Check with the
design department for pending part revisions. An important part of the evaluation
process is note taking. Complete, accurate notes allow designers to record important
information. With these notes, they should be able to fill in all items on the "Checklist
for Design Considerations." All ideas, thoughts, observations, and any other data about
the part or fixture are then available for later reference. It is always better to have too
many ideas about a particular design than too few. Four categories of design
considerations need to be taken into account at this time: workpiece specifications,
operation variables, availability of equipment, and personnel. These categories, while

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separately covered here, are actually interdependent. Each is an integral part of the
evaluation phase and must be thoroughly thought out before beginning the fixture
design.

Step 3: Develop Several Options

This phase of the fixture-design process requires the most creativity. A typical
workpiece can be located and clamped several different ways. The natural tendency is
to think of one solution, then develop and refine it while blocking out other, perhaps
better solutions. A designer should brainstorm for several good tooling alternatives, not
just choose one path right away. During this phase, the designer's goal should be adding
options, not discarding them. In the interest of economy, alternative designs should be
developed only far enough to make sure they are feasible and to do a cost estimate. The
designer usually starts with at least three options: permanent, modular, and general-
purpose workholding. Each of these options has many clamping and locating options
of its own. The more standard locating and clamping devices that a designer is familiar
with, the more creative he can be. Areas for locating a part include flat exterior surfaces
(machined and unmachined), cylindrical and curved exterior surfaces. The exact
procedure used to construct the preliminary design sketches is not as important as the
items sketched. Generally, the preliminary sketch should start should start with the part
to be fixtured. The required locating and supporting elements, including a base, should
be the next items added. Then sketch the clamping devices. Finally, add the machine
tool and cutting tools. Sketching these items together helps identify any problem areas
in the design of the complete fixture.

3.3 Important Considerations While Designing Jigs and Fixtures.

Designing of jigs and fixtures depends upon so many factors. These factors are
analyzed to get design inputs for jigs and fixtures. The list of such factors is mentioned
below,
1. Study of workpiece and finished component size and geometry.
2. Type and capacity of the machine, its extent of automation.
3. Provision of locating devices in the machine.
4. Available clamping arrangements in the machine.
5. Available indexing devices, their accuracy.

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6. Evaluation of variability in the performance results of the machine.

7. Rigidity and of the machine tool under consideration.
8. Study of ejecting devices, safety devices, etc.
9. Required level of the accuracy in the work and quality to be produced.

3.4 Proposed System

Considering limitation of previous system here we three approaches used which
eliminates problem of conventional table frame making fixture is
1. Use of screw clamping device which reduces time for clamping
2. Use of slider hence can be used for no. of dimensions of frame.
3. Rotating system is provided for back side fabrication work.

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Chapter No.-4

METHODOLOGY
4.1 STEP
Following methodology implemented for completion of our sea saw Project

Step 1:- Identification of problem

This step includes Problem Statement, background for research work and
objectives of current work. It also covers need for dissertation work, problem
statement, definition of methodology to achieve desired objectives.

Step 2:- Literature Review

In this step we study the various researchers & summarised shortly. The papers
from various journals and conferences, which are relevant to the topic of
dissertation are included.

Step 3:- Design of mechanical parts

Here design of system done by selection of proper material and theories of

failure of material.

Step 4:- Brought our material.

In this step we have to buy material required for our projects such as

1. Indexing Plate
2. Nut bolt
3. Shaft
4. Square pipe

Step 5:- Manufacturing processes.

Manufacturing Processes required for this project are

1. Screw clamp
2. C channel Column
3. Frame
4. Indexing mechanism

Step 6:- Running of project.

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For running purpose we can use square pipe frame and load it on fixtyre and
measure the time required for loading.

Fig.4.1 Steps in Methodology of project

4.2 SCHEME OF IMPLEMENTATION / ACTION PLAN

The proposed work concentrates on Design of mechanism for suitable operation
of climbing obstacle. The work regarding this will be divided in the following phases.
Phase I: Information Gathering -Literature Survey.
Phase II: Gap Analysis, Project Formulation.
Phase III: Objective, Problem statement definition.
Phase IV: Design & Capston project Report

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Phase V: Brought out Material

Phase VI: Manufacturing of project.
Phase VII: Test & result discussion

The phase wise scheme of implementation is as follows,

Table 4.2 Phase Wise Scheme of Implementation
Phase Phase Phase Phase Phase Phase Phase
Period
I II III IV V VI VII

July -19

Sept-19

Oct-19

Nov-19

Dec-19

Jan-20

Feb-20

4.3 Clamping
There are different types of clamps which help in clamping of the jib at the
required position. Clamps hold the workpiece firmly. This helps in better engagement
of job during the operation. Various forces develop during the cutting operation. The
clamping should be such that it will sustain these forces during the operation. At the
same time if clamping is so tight that it damages the workpiece then it must be avoided.
The timing required for clamping and unclamping of the device should be as less as
possible. These clamping must also restrict vibrations and chatter during the cutting
operation.

4.3.1. Principles of clamping:

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Various principles are followed during the clamping operation. Some of them
are listed below.
a) The positioning of clamps should be done in such a way that clamping force does
not act on weak and unsupported part of the workpiece. If clamping force acts on weak
part of the jib it bends the job. This will affect the accuracy of the drilling operation.
Finally a straight drilled hole will become angular when the unclamped

b) The workpiece should be hold securely against the forces developed during the
operation. It should also be taken care that the pressure of the clamping system does
not affect the workpiece. For clamping of weak job instead of keeping the surface area
less the surface area can be increased. It will prevent the damage of the workpiece. The
clamps of the workpiece can be fitted with pads eg. Nylon or fiber. This prevents the
damage to the job.

c) It should also be noted that the clamping of the job is not preventing the path of
loading and unloading.

d) Time require for clamping should be as minimum as possible. This can be done using
handles, hand wheels, hand knobs, tommy bars and knurled screws.

e) The points of clamping should be provided with sufficient radius. This radius will
take care of the vibration of the job during the drilling operation. Sphere heel pin might
be used to help in tilting the clamp.

4.3.2 Types of clamps

1. Strap clamp
Strap clamp is rectangular in shape and is easy to operate. It also acts as a
lever. Hence it is used almost everywhere. It is shown in Fig. As the figure suggests the
clamp is tightened by rotating the hexagonal nut on a central screw. The clamp has one
end which presses against the workpiece and the other end presses against the heel pin.
Thus the clamp acts like a simply supported beam. The clamping face of the workpiece
is curved. It is done to prevent the extra pressure on the workpiece during the clamping.
The press face of the clamp is curved. This is to take care of the variations of the surface
of the job. There is also a spherical washer between the hexagonal nut and the clamp
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provides a spherical joint which allows clamp to tilt with respect to screw and nut. In
this way the clamp takes care of the variations of the surface of the job. Usually washer
and spring are provided below the claps of the strap clamp.

Fig.4.3.1Strap clamp

2 Screw clamp
In screw clamp there are provisions for screw threads to clamp a job. It has knurled
collar, head knob, tommy bar or spanner flats. These are provided for rotating and
tightening the screw. Screw clamp is shown in Fig.8. Screw clamp exerts adequate
force. It also resists tendency of loosening set up by vibration. But the disadvantage is
that they are slow and may not be suitable for high production.

`
Fig. 4.3.2 Screw Clamp

3. Toggle clamp
Toggle is also quick action clamps. Toggle clamp is shown in Fig. These can
be withdrawn by considerable distance for loading and unloading of the workpiece.

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These depend upon the movement of rigid links for their movement. These clamps are
used extensively to hold the sheet metal parts in position while they are being welded
or otherwise being fastened. They provide heavy clamping pressure.

Fig. 4.3.3 Toggle Clamp

4.4 Indexing Mechanism

Indexing in reference to motion is moving (or being moved) into a new position
or location quickly and easily but also precisely. When indexing a machine part, its new
location is known to within a few hundredths of a millimeter (thousandths of an inch),
or often even to within a few thousandths of a millimeter (ten-thousandths of an inch),
despite the fact that no elaborate measuring or layout was needed to establish that
location. In reference to multi-edge cutting inserts, indexing is the process of exposing
a new cutting edge for use. Indexing is a necessary kind of motion in many areas of
mechanical engineering and machining. A object that indexes, or can be indexed, is said
to be indexable.
Usually when the word indexing is used, it refers specifically to rotation. That is,
indexing is most often the quick and easy but precise rotation of a machine part through
a certain known number of degrees. For example, Machinery's Handbook, 25th edition,
in its section on milling machine indexing, says, "Positioning a workpiece at a precise
angle or interval of rotation for a machining operation is called indexing."
Indexing is vital in manufacturing, especially mass production, where a well-
defined cycle of motions must be repeated quickly and easily—but precisely—for each
interchangeable part that is made. Without indexing capability, all manufacturing
would have to be done on a craft basis, and interchangeable parts would have very high
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unit cost because of the time and skill needed to produce each unit. In fact, the evolution
of modern technologies depended on the shift in methods from crafts (in which toolpath
is controlled via operator skill) to indexing-capable toolpath control. A prime example
of this theme was the development of the turret lathe, whose turret indexes tool
positions, one after another, to allow successive tools to move into place, take precisely
placed cuts, then make way for the next tool.

Fig.4.4 Indexing Plate

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Chapter No.-5

OUTCOMES OF PROJECT
5.1 ADVANTAGES
1. Save holding time

2. No need of extra worker

3. More accuracy

4. Reduction in operator fatigue and increase in productivity

5.2 LIMITATIONS

1. limitation for making in big size

5.3 APPLICATIONS
1. Bench table

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2. Dinner table

3.Counter table

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Bed

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Flex board

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Chapter No.-6

CONCLUSION
In that way we have to make table frame making fixture. As we decided to
solve problem related to table frame making in fabrication workshop. There is no. of
table frame we have to make of same dimension. Problem is arises that there is lot of
time get wasted to hold the table frame angle perpendicular to each other. Also it
workers feel fatigue for doing this to every frame. It having very low accuracy of
geometric tolerance because operator have to set try square every time of making weld.
Hence our project overcome the all above difficulty by making such portable fixture
tool at low price.

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REFERENCES
1. “Design and manufacturing of 8 cylinder hydraulic fixture for boring yoke on VMC
– 1050”Chetankumar M. Patel, Dr.G.D.Acharya, , ICIAME 2014
2. “Design And Development Of Hydraulic Fixture For Machining Hydraulic Lift
Housing” Shailesh S Pachbhai and Laukik P Raut, , IJMERR.Vol. 3, No. 3, July,
2014
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