Design and Development of Milling Fixture for Accumulator Casing

Owing to the present market demand leading toward a reduction of lead time and human effort devoted to fixture design, it has been found that the experiments and manufacturing were done for the prismatic components with available fixturing technology to meet the manufacturing demands. This paper aimed to design the milling fixture for the non-prismatic component, which has milling operations in four different planes of the accumulator casing component in a single setup with CAD packages. Analysis was done for the assembled fixture to know the behavior of the component against the operating load and cutting forces to optimize the designed milling fixture. The designed milling fixture is optimized by analyzing the assembled milling fixture for load-carrying capacity and cutting force under machining load by the CAE packages. Cost estimation was done for the milling fixture including the spare parts to predict the total cost of the milling fixture. The analysis results show maximum stress 9.98 MPa acting on the fixture and component is against the machining load of 1697 N which is less than the ultimate tensile strength of the component. And maximum design stress of three M20 threads is 66.8 MPa which is greater than the maximum stress acting on the three M20 threads which is 9 MPa. And also there is no interface between the cutting tool and fixture elements. Hence the designed milling fixture for accumulator casing is suitable for continuous production. The total cost of the milling fixture is estimated to be Rs. 137,904.