Multi-operation ECM fixture
A single fixture that holds gas turbine blades through three electrochemical machining operations at the same time.
Three fixtures became one, saving $80,000 on new fixturing.
- Role
- Manufacturing engineering co-op
- Tools
- SOLIDWORKS, CNC router, Bridgeport, welding
- Scope
- Fixture and 17 shop tools
One new machine, three operations
A newly purchased ECM machine had to be qualified for three unique operations, and it needed a fixture that could run all three at the same time.
Reuse the nesting, redesign the frame
An older fixture was no longer in use, so instead of starting over I modified its nesting and guide components to suit the three operations.
The base and frame I redesigned from scratch, built purely from angle iron and small bar stock so they could be welded rather than machined. The design was verified to be structurally sound enough for ECM operations.
Welded without losing alignment
I kept the fixture within ±.01 of the nesting components by giving the frame both alignment pins and bolt holes. The entire fixture could be assembled before it was welded, so it stayed aligned through the process.
The welds were spot welds rather than full beads, done in batches so the fixture had time to cool and settle between them and any distortion could be accounted for.
17 tools for the same floor
I designed and drafted the fixture and saw it through fabrication. On the same floor, I designed and made 17 production tools: 11 3D printed, and 6 made on the CNC router, the Bridgeport and by hand.
