Design and Optimization of Modular Fixture Using Finite Element Method for Cylindrical Parts

Authors

  • Awais Ahmad Khan Department of Mechanical Engineering, University of Engineering and Technology, Lahore, Pakistan https://orcid.org/0000-0003-1163-5979
  • Naseer Ahmad Department of Mechanical Engineering, University of Engineering and Technology, Lahore, Pakistan https://orcid.org/0000-0001-7773-2830
  • Kamran Saleem Electrical Engineering Department, University of Central Punjab, Lahore, Pakistan
  • Khurram Hameed Mughal Department of Mechanical Engineering, University of Engineering and Technology, Lahore, Pakistan | Mechanical Engineering Department, The University of Lahore, Lahore, Pakistan https://orcid.org/0000-0001-8977-0674
  • Salman Abubakar Bubvi Mechanical Engineering Department, The University of Lahore, Lahore, Pakistan
  • Shaiq Ahmad Department of Mechanical Engineering, University of Engineering and Technology, Lahore, Pakistan

DOI:

https://doi.org/10.23055/ijietap.2025.32.6.10919

Abstract

To ensure the production of high-quality parts, a precise fixture is essential in minimizing the workpiece displacement while maintaining positional accuracy, stability, and avoiding interference with the cutting tool. Workpiece deformation during machining operations can be curtailed by adequate selection, number, and position of locators/clamps. This work integrates advanced finite element method (FEM) simulations to accurately predict and optimize the performance of modular fixtures, improving precision, flexibility, and efficiency of the manufacturing process. An optimized fixture layout design methodology is proposed, enabling attainment of these machining objectives for quality work on solid and thin-walled cylindrical parts. In addition to geometric optimization, clamping forces are refined using the force-moment method, minimizing workpiece deformation and improving hold accuracy. The optimal layout is determined with minimal sample runs and implemented for drilling 14.5 mm diameter holes in Al-T3 pipes used in the HVAC systems of SANPAK Pvt. Ltd. The experimental results obtained after the modular fixture optimization through FEM were found to increase the accuracy of hole (rejection rate drop from 5% to 2%) and reduction in setup time and efficiency of process. A chi-square test confirmed the significance of this improvement (χ² = 20.05, p < 0.00001). The unique study integrates multiple parameters, such as clamping force, deformation, and stability, in a single framework, for a comprehensive and improved solution to the challenges of fixture design for cylindrical parts. This approach enhances the overall effectiveness, adaptability, and cost of modular fixture design and provides manufacturing solutions applicable to diverse industrial components.

Author Biographies

Awais Ahmad Khan, Department of Mechanical Engineering, University of Engineering and Technology, Lahore, Pakistan

Associate Professor at Department of Mechanical Engineering, Main Campus UET Lahore

Naseer Ahmad, Department of Mechanical Engineering, University of Engineering and Technology, Lahore, Pakistan

Dr. Naseer Ahmad, serving as an Assistant Professor at the Department of Mechanical Engineering, University of Engineering and Technology, Lahore, Pakistan; He holds PhD degree in Mechanical engineering (Multidisciplinary system modeling and control) from King Fahd University of Petroleum and Minerals, Saudi Arabia, MSc in Mechatronics and BSc in Mechanical Engineering from the University of Engineering and Technology, Lahore, Pakistan. His field of interest are modeling & simulation, dynamical systems, embedded control, and computational mechanics.

Kamran Saleem, Electrical Engineering Department, University of Central Punjab, Lahore, Pakistan

Dr. M. Kamran Saleem is an Associate Professor and also serves as the Director of the Space Research Center (SRC-UCP) in the Faculty of Engineering at the University of Central Punjab (https://sites.google.com/view/space4all/home).

Khurram Hameed Mughal, Department of Mechanical Engineering, University of Engineering and Technology, Lahore, Pakistan | Mechanical Engineering Department, The University of Lahore, Lahore, Pakistan

An expert of mechanical design engineering and ultra-precision / advanced manufacturing, Mr. Khurram Hameed Mughal earned his Bachelor’s and Master's degrees in Mechanical Engineering from University of Engineering and Technology, Lahore. His PhD is near completion in the same university.

Salman Abubakar Bubvi, Mechanical Engineering Department, The University of Lahore, Lahore, Pakistan

A higher education teaching professional engineer involved in mentoring, teaching, guiding, assessing and enabling students for the past 15 years. Basic Background of Mechanical Engineering with specialization in Management and related field in engineering. Diverse individual with synthesis of knowledge and expertise in various branches such as Thermal Science, Mechanical Design and Engineering Management At University of Lahore involved in various Department initiatives such as Operations Management, planning, organizing, of daily activities. Involved in Lab operations, restructuring, maintenance and performance. Involved in research work in the following fields

  • Total Quality Management
  • Project Management
  • Operations Management
  • Human Resource Management
  • Supply Chain Management
  • Human Factor and Ergonomics.

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Published

2025-12-14

How to Cite

Khan, A. A., Ahmad, N., Saleem, K., Mughal, K. H., Bubvi, S. . A., & Ahmad, S. (2025). Design and Optimization of Modular Fixture Using Finite Element Method for Cylindrical Parts. International Journal of Industrial Engineering: Theory, Applications and Practice, 32(6). https://doi.org/10.23055/ijietap.2025.32.6.10919

Issue

Vol. 32 No. 6 (2025)

Section

Modelling and Simulation

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