Development of an Innovative Assembly Fixture for Machining Synchronization of Multi Fuse Parts on Vertical Machining Center and Productivity Enhancement

Abstract

Manufacturing fuse bodies for defence applications demand precision and efficiency, posing challenges due to the complexity of machining operations. This study proposes a novel fixture design to address these challenges on vertical machining center. The study highlights the practical utility of tailored fixture designs in defence manufacturing, offering a replicable framework for productivity enhancement. Two fixture types were modelled using SolidWorks, with the Type-B fixture selected for its superior production capabilities. The study focuses on a specialized Type-B fixture design for fuse body machining, supported by rigorous analysis and testing, distinguishes it and underscores its potential impact on defence manufacturing processes. ANSYS software, stress, strain, and deformation analysis guided the design and simulation process. The novel Type-B fixture reduced entire manufacturing time to 5.41 minutes per part, 33.76% quicker than conventional methods, resulting in a 34.02% increase in production rate (77 parts/shift). This research concludes critical efficiency concerns in defence manufacturing, offering a practical solution to improve productivity while maintaining quality standards. This research highlights the fixture's potential towards significant improvements in productivity and operational efficiency. The detailed comparison of performance of existing manufacturing process with the process using Type-B fixture is presented in this study.