Design and Thermal Stress Analysis of Welding Fixture of a Brake Pedal

Abstract

Fixtures, the component or assembly that holds a part undergoing machining, must be designed to fit the shape of that part and the type of machining being done. The parts to be welded are placed in proper position in fixture and tightened. Welding fixture holds and supports the work piece, prevents distortion in work piece during welding process and withstands high welding stresses. Design of welding fixture involves several parts which broadly include body, locating elements, clamping element and positioning elements. Welding fixture may be modular or permanent fixture, modular fixture is just like permanent fixture with some key changes like it has specially designed tooling plate, block with standard grid pattern and modular elements with great flexibility to arrange them with high accuracy. Brake pedal assembly is to be welded on fixture using MIG welding process. The relative arrangement of different elements on base plate of fixture is vital part of design. The welding fixture will serve in reducing production time, maintain consistent quality, maximize efficiency, and reduce operator error and makes possible mass production of similar parts in very less time.