Table of ContentsIntroductionSteps in Device DesignDevice DesignConclusionDevices are the production tools that make the standard machine tool more adaptable to work as specialized machine tools. Manufacturing industries have brought many revolutions in manufacturing technology, following which several developments such as CNC lathes, CNC machining centers, robotics, etc. were developed. The fixture should be designed to adopt a cost-effective manufacturing process so that it can be machined easily and in less time. The different methodologies and applications of different authors are reviewed in this article. Say no to plagiarism. Get a tailor-made essay on “Why Violent Video Games Should Not Be Banned”? Get the original essay Index Conditions – Hydraulic Fixing; precision; Universal lighting; ProductivityIntroductionA fixture is a holding or supporting device used in the manufacturing industry during a machining operation. Fixtures are essential parts of mass production because they are required in most automated manufacturing operations. The origin of lighting fixtures dates back to the Swiss watch industry. Designing a lighting fixture is a very complex and demanding process. The hydraulic device provides the manufacturer with flexibility in holding forces and increased precision, reliability and interchangeability of parts. A clamping system that uses high-pressure fluids to power the clamps and hold a workpiece in place is called a HYDRAULIC FASTENER. Stages of luminaire design Appropriate definition of functional requirements forms the basis of luminaire design. The main task of the luminaire is to simplify the loading and unloading process and reduce the rejection rate. Preliminary analysis can take anywhere from a few hours to several days for complex luminaire designs. Luminaire design is a five-step problem-solving process. The steps are discussed in detail - Step 1: Define the requirements To begin with the design of the luminaire, a clear statement of the need for the luminaire should be stated. Requirements should be stated as broadly as possible to understand the issues. The designer should know the basics such as “should the tooling be started from an existing tool or should a completely new tool be designed?” » Step 2: Gather information Collect all relevant data. The main sources of information are part descriptions, process sheets and machine specifications. A thorough study of the design of CNC machines and components must be carried out. Workpiece specifications, operating variables, equipment availability and personnel should be considered at this stage only. Step 3: Develop multiple options This step of the process requires maximum creativity and also some experience. A designer should think about several good tooling alternatives, and not stick to just one path. The designer's goal at this stage should be to add options, not remove or remove them. First, the designer must draw the component and the positioning points before considering drawing the clamping devices. Step 4: Choose the best option The total manufacturing cost of the product will be the sum of the raw material configuration and the tooling cost. This can be expressed in terms of a formula: The designer must be able to decide what the model isthe most suitable among its alternatives. Making these decisions requires considering both the economic and ergonomic aspects of the design.Step 5: Implement the designThe final step in the luminaire design process is to replicate the chosen design approach in reality . Final details are decided, final drawings are made and tooling is built and tested. Tolerances must also be mentioned. The following guidelines should be considered to improve its effectiveness. Important factors to consider when designing a luminaire:a. Study of the part and geometryb. Machine type and capacityc. e. Availability of indexing devices and their precision.df Evaluation of machine performance results.eg Rigidity of the machine tool considered. fh Study of ejection devices, safety devices, etc.g. Required level of precision in the work and the quality to be carried out. The mounting design, whether manual or hydraulic, is the same. The assembly structure must be sufficiently rigid and heavy to avoid deformations and vibrations produced during machining.A. Principles of Location Location refers to establishing a desired relationship between the workpiece and the fixture. The goal of pitches is to squeeze the piece in a way that limits body movement in as many directions as possible. For a rigid part in space, there are six degrees of freedom describing the position and orientation of the part, as shown. They have three linear movements and three rotational movements. Fig. Degrees of freedom of a part Guohua Qin et al., focus on the tightening sequence of the device. J Cecil proposed an innovative approach to clamping design.B. The common positioning principle is as follows: 3-2-1 principle: Three positioning pins are inserted into the base of the fixed body, which stops five degrees of freedom. Two additional pins are inserted into a vertical plane of the fixed body, which restricts three additional degrees of freedom. Another pin in the second vertical face of the fixed body stops the other. The remaining three degrees of freedom can be locked using a clamping device. This method of locating a part in an assembly is called the "3-2-1" principle or "six-point locator" principle.C. Clamping Principle The main objective of clamping is to hold the workpiece rigidly against the locators during machining operations. The basic needs of a tightening system should be · - tightening should be easy, fast and consistent, tightening should not be affected by vibration or high pressure. The workpiece must not be damaged due to the application of clamping pressure. When handling fragile components, the grippers should be provided with fiber pads.D. Types of Clamps Clamps should be selected very carefully depending on the type of material and the loading and unloading procedure. It also depends on the area where the clamp is applied to the workpiece. Some common types of clamps available are listed below: - Strap clamp - Heel clamp - Bridge clamp - Screw clamp - Power clamp - Equalizing clamps - Latch clamp Fixture design To reduce associated design costs During assembly, various tightening methods have been developed over the years. to assist the lighting designer. The design of the device, whether manual or hydraulic, is the same. Any work holding device must perform three basic functions: 1) Position the component accurately. 2) Support the component accurately. 3) Tighten the component precisely. Fordesigning the device, it is necessary to study the details of the components, including the geometry of the parts, the machining process, the design rules and interpretation of the machining setup. The fixture must meet the customer’s needs and budget. In terms of constraints, many factors must be considered, mainly dealing with: the shape and dimensions of the part to be machined, tolerances, the sequence of operations, machining strategies, cutting forces, the number of settings, adjustment times, volume of material to be removed, batch size, production rate, machine morphology, machine capacity, cost, etc. Ultimately, the solution can be characterized by its simplicity, rigidity, precision, reliability and economy. The following steps are involved: • Analytical design of the luminaire. • 3D modeling in one of the modeling software (preferably PRO-E CREO, Solidworks) • Assembly • Analysis using analysis software (preferably ANSYS). If a light fixture is pre-existing. then the locations of the tightening points would be known, and this would reduce the work of finding the centroid of the component and finding the appropriate locating and tightening points. Luminaire material selection criteria - Mechanical properties The material must possess a certain strength and rigidity. The selected materials are examined for their strength and rigidity values ​​- Wear of the materials It must be ensured that the selected materials have resistance to 'sufficient wear and tear.- CorrosionThis is an important engineering design criterion for designs open to the environment for a longer period of time- Manufacturing capacityThe material is well capable of being used for the design, it may be difficult to make. If this selection criterion is neglected, the manufacturing process can be very expensive, making it unprofitable as a commercial product. - Cost is a vital fact to consider while selecting materials for a certain design for most products as they face severe competition in the market. The fixture parts are generally: A. Fixture base plate B. Support cylinder C. Clamp and hydraulics Fixture base plate When designing, the overall length of the base plate should be considered. Using the Roark formula presented for designing the plates, the base of the fixture is designed. Using this formula we can calculate the plate thickness and stress. The deflection at the center is also calculated. Usually the material of the base plate, support cylinder and clamp is the same. Fig. Roark's formula After calculating the stresses in the plate, they should be compared with the allowable stress of the material. And the plate must be of safe design. Once we get the dimensions and material, we create the model in the modeling software. Support CylinderHydraulic cylinders are manufactured according to custom requirements or ready-made cylinders are available according to force specifications. These cylinders are called ZPS (Zero Point System) modules. These ZPS modules must be supported by support cylinders designed using modeling software and then imported into ANSYS for analysis and verification for safe design. The results in ANSYS are compared to the strength of the materials. There are no specific methods for designing the support jacks and therefore designed for the appropriate dimensions based on the module dimensions. The module is attached to the component by means of nipples which are inserted into this module and tightened with hydraulic pressure. From a configuration point of view, the cylinders have six.