Designed a machining fixture for a vertical CNC mill. Fixture mounts to a 4th-axis rotary indexer. The aluminum die cast part is easily distorted so it needed to be held with minimal external force. A steel stud, cast into the part, is held by a collet with slide locators manually moved into position against the part to position it relative to the stud and prevent it from moving during machining. The hole through in the part is then milled to within .002" diameter and .008" position from the stud centerline. The end faces are milled to within .002" of the stud centerline.
Designed and built an automated machine for an assembly line. This 4-station indexing machine will set a specific amount of spring tension in an assembly, clamp the assembly in place, line ream a series of components in the assembly, press a bushing into the reamed hole, unclamp the assembly to allow the components to relax against the bushing, re-clamp the assembly and line ream a second in the assembly.
Designed a honing fixture to hold two parts for simultaneous honing. The parts needed to be located and held concentric within .0005". The same fixture can be used to hone a larger variation of this part, one part at a time, minimizing tooling costs.