Dr.
Apiwat Muttamara
Introduction
Modern Manufacturing
FMS, CIM
Workholder (Jig & fixture)
What s different between Jig and Fixture
Basic Principle of workholder
Identify the types of locators and support
used fro jigs and fixtures
Hold & support
guide the cutting tool.
references the cutting tool
Jig
COUNTERSINK&BORE
Fixtures
Permanent Jigs and Fixtures
Modular Fixtures
Drill jig and milling fixture.
Assembly
Welding fixtures
Inspection
Mechanical-inspection fixtures
Optical-inspection fixtures
Electronic-inspection fixtures
Go - No go gage
Tool Design
Purpose and function of work holders
Consistently position workpiece relative to
the tool
Hold workpiece in position against tool
forces
Restrict deflection of the workpiece due to
tool and holding forces
A locator is usually a fixed part of a fixture, the
purpose of which is to restrict movement of the
workpiece.
A clamp is a moveable part of a fixture, the
purpose of which is to provide a holding force.
A support is a fixed or moveable part of a fixture,
the purpose of which is to prevent workpiece
deflection under the action of imposed cutting
forces or clamping forces.
Clamp
Locator
Support
Degrees of Freedom
Translational Rotational.
Two objectives when mounting a
part in a fixture for machining:
1. Accurately position the part at the
desired coordinates.
2. Restrict all six degrees of freedom so
that the part cannot move.
First Plane
TIPS
Use the largest surface of the part for the
first ("primary") reference plane.
Position the three support points as far
apart as possible.
If more than three support points are
required to prevent deflection, make the
additional points adjustable.
Second Plane
Third Plane
If more than one support point
is required to prevent
deflection, make the
additional points adjustable.
9 degrees fix
Positioning Locators
BASIC PRINCIPLES OF
LOCATING
To perform properly, workholders must
accurately and consistently
position the workpiece relative to the cutting tool,
part after part. To accomplish this, the locators
must ensure that the workpiece is properly
referenced and the process is
repeatable.
Workpiece should automatically come to
rest against locators despite operators skill
or effort.
Location system must consistently position
all workpieces in relations to the tool despite
the variations in the working environment.
e.g. surface irregularities, wear of locators,
dirt, temperatures difference.
1. Establishing a locating plane
Surface should be machined to insure
accurate location
Choose locating point as far as possible.
2. Part size
Number of locator used to reference a part
normally depends on the part size.
3-2-1 principle determines the minimum number
required
When holding force cannot be applied more than
six locators can be used
Less operator skill is required when placing the
workpiece in the holder
To Increase center line control
3. Stability
Workpiece is unstable when placed on
the locators, the workpiece tends to lift or
rock away from one or more locators.
Place locators far for more stability and
to minimize the effect of wear of locators
and workpiece irregularity.
Top heavy workpiece may led to stability
Poorly placed holding force
Not enough locators
4. Cutting pressures
Try to place locator opposite of the tool
force to avoid deflection of the workpiece.
Where possible, tool-forces should be
such that they force the workpiece into
contact with the locators.
Holding forces should not be in the
opposite direction to the tool forces
6. Fool-proofing
Process of position locators such that part
will only fit in the proper position. Achieved
by foolproofing pin.
Chip removal
Chips and burr on locating surface can
cause wear and disturb proper location.
1. Make locators easy to clean 2. Make
them self cleaning 3. Protect them
Chips can be swept easily
Controlling Chips
Sharp locators
Burr and Chip Relief
Summary:
Clamping Rules of Thumb
Define three reference planes on the
workpiece and fixture.
Provide one opposing clamping force
opposite each plane to restrict movement.
When in doubt, rely on additional
cylinders to take up uncertainty.
Types of workpiece location
C) Radail Location
Radial location
Supplement to the concentric locators to
provide a specified fixed relationship to the
concentric locator.
Combined location
Most workholders use a combination of
locational methods to completely locate a
workpiece.
1. External locators
Devices used to locate the part from
external surface.
Two basic forms of external locators are
fixed or adjustable.
Commercial Locating pins
easily available in market,
Adjustable support
Threaded type adjustable supports
Spring type adjustable support with
locking nut
Internal locators
For locating holes and bored diameters
usually located internal surfaces.
Fixed locators machined to suit specific size
when the size variations are not large
example: base plate
Compensating locators: conical and self
adjusting
Integral locators
Locators which are machined into the
body of the work holder.
Disadvantage extra time for machining
and no replacement for wear or damaged
locators
Assembled locators
Similar to integral locators
Replaceable locators
V locators
Cylinder can come along upward Y (1),
forward X(1) , Backward Z(1) and rotation
along Z ( 2) 5 movement is possible.
Nests
FULL
Partial
Adjustable locators
Application: Workpiece surface is irregular; large
variations is the workpiece (Sand Castings)
Advantage: Cost is reduced as the location is
not critical
Relieved locators
To minimize contact between workpiece
and locators to avoid locator sticking and
jamming in the part.
.
Diamond Pin location
Floating Pin locator
Floating Pin locator
ECCENTRIC LEVELING LUGS
Conical locators
14. Spring pins
Not the locating
device but ensure
that workpiece is in
contact of all locator
Used for small and
compact parts
15. Spring stop buttons
Work same like spring pin but are
designed for large workpiece.
Using Spring-Loaded Locators
Todays Agenda
Type of Locator
Trick of Design
Clamping Principle
Jig Design
Avoiding Redundant Location
Preventing Improper Loading
Determining
Locator Size and
Tolerances
CLAMPING GUIDELINES
Clamping principles
1.Design and use consideration
Simple clamps should be used
Quick loading and unloading should be permitted
Production rate should be considered
2.Cutting pressures
Understanding of cutting forces may eliminate need to
restrain 12 DOF
Drilling Torque and upwards force
Milling operation horizontal force should be directed
towards jaw
3.Part damage
Excessive clamping leads to elastic deformation.
4.Clamping and location
Tool forces tend to move the workpiece away from the
locators
B. CAM
A. Screw
D. Toggle Linkage
C. Wedge
E. Lever
F. Combined screw and wedge
Basic types of clamps
1.Strap clamp
Positioning the Clamps
2.Screw clamp
Direct Pressure screw clamps
Hook Clamp
Indirect Pressure (Magnification
is possible by using leverage
3. Cam clamp
Fast operating clamping devises
Direct tendency to loosen during machining
Indirect efficient and safest
4. Toggle clamp
Fast clamping and release actions
Move completely clear of the workpiece
High ratio of holding force to actuation
force
Limited range of movement
Inability to compensate for different
thickness (suitable to only slight changes
of workpiece thickness)
A possible tightening with a single
turn is as efficient as screwing 10
turns, but so much faster
Automatic toggle clamp:
A.
Definition
Jigs are work holders, which are designed to hold, locate, and support a workpiece
while guiding the cutting tool throughout its cutting cycle.
Drill jigs are drilling, tapping, reaming, countersinking, counter boring, chamfering,
and spot facing.
B.
Design considerations
1.
General, machine and process
General Consideration
Justification of manufacturing cost reduction
Machine Consideration
1. Size, Type, and Capabilities of machine
2. Machine should be capable of handling the part shape, size and accuracy
3. Enough space to mount Workholding device
4. Tool designer must know about table size, T slot size, machine travel axis
Jig Design
Process Consideration
1. Consider all manufacturing steps
2. If the part is not pre-processed first-operating
jigs are used to make hole to serve for location
purpose is subsequent steps.
3. Multiple jigs and fixtures can be used for one
part
4. Chip removal should be considered for each
manufacturing step
a.
Template
1. They do not incorporate clamping device
2. Plate containing hole or bushings to guide a drill
3. Place on parts
b. Plate
Template jig equipped with clamping device
c. Universal or pump
Universal jigs utilize a handle connected to a cam or rack and pinion to move either a busing plate or nest plate. Parts held in the universal jigs have surface adaptable
to fitting against the surfaces of the bushing plate and nest.
Changing bushings it can be used for different components
Leaf
Small and incorporates a hinged leaf that carries
bushings, and through which clamping forces is applied.
Can be a box type
Channel
Permit drilling in more than
one surface
Reduces number of setups
but increase in design and
manufacturing cost of jigs
tumble box
Tumble jigs permit
machining form all six
sides.
Indexing jigs
1. Placed on base and bore
2. Locating stud
3. Hex nut
4. C-Washer
5. Drill bushing
6. Index pin
7. Spring
8. Bushing plate
Used to drill hoes located in pattern.
Location for the holes is generally
taken from the first hole drilled.
54.1
2%
P = Pitch = 1/Number of threads per inch (tpi)
H = Angular Depth = 0.866025 x P
H/8 = Shortening of major dia = 0.108253 x P
H/4 = Shortening of minor dia = 0.216506 x P
d = Actual Depth = 0.541266 x P
r = Radius at the Root = 0.1443 x P
Hn = Basic height of Internal Thread = 0.54127 x P
Hs = Basic height of External Thread = 0.61344 x P
