Design of a fixture for wire-cut EDM: A generic approach

Abstract

The increase in the need for high precision parts across various engineering fields demands a rapid pace in terms of manufacturing products, which leaves a little window for lead times related to auxiliary manufacturing requirements like tooling and fixtures. Similar to their application in conventional machining processes, fixtures serve as work-holding devices for non-conventional machining processes as well. This paper tries to bridge the gap between fixtures in traditional and non-conventional machining processes by developing a generic approach for designing a fixture for Wire-Cut EDM based on the methodologies followed for conventional processes. Different phases of the design process have been discussed in detail including the need to manufacture new or modify existing fixtures. Ashby charts method for material screening, and AHP and TOPSIS for material ranking have been included to help select the correct material. Additionally, due consideration is given to manufacturing and assembling the fixture body with the optimal processes to ensure cost savings. The approach can cut down on the lead time required from the conceptualization to the actual assembly of the fixture from a month to about a week depending upon machine availability on the shop-floor.