Work-holding devices

Mass production methods demand a fast and easy method of positioning work for accurate operations on it. Workholding devices are production tools used to accurately manufacture duplicate and interchangeable parts. Jigs and fixtures are specially designed so that large numbers of components can be machined or assembled identically, and to ensure interchangeability of components.

Work-holding devices
Jigs and fixtures, these flexible workholders which form a critical element in manufacturing cells, particularly perticullarly in unmanned cells. Workholding flexibility-programmable clamps using air-plungers part encapsulation with low melting point alloy Designers usually do not calculate the clamping forces or stress distribution in the fixturing elements to determined the loads that will deform the fixtures or the workpiece elastically or plastically.

Work-holding devices
Workholding devices have primary functions; locating and clamping
Locating-orienting and positioning of the part in the machine tool with respect to the cutting tools to achieve the required specification Clamping-holding or maintaining the part in that location during operations

Jigs and fixtures are specially designed and built work holding devices which hold the work during machining or assembly operations

Jigs and fixtures

A Jig determines a location dimension that is produced by machining or fastening
a hole on a plate; dimensions two types: size and location

A jig is a special device that through built in features, determines location dimensions that are produced by machining or fastening operations.

Jigs and fixtures

A fixture is a special device that holds work during machining or assembly. Fixtures hold or grip a work piece in the predetermined manner of firmness and location, to perform on the work piece a manufacturing operation.

Jigs and fixtures

The economical production of engineering components is greatly facilitated by the provision of jigs and fixtures. The use of a jig or fixture makes a fairly simple operation out of one which would otherwise require a lot of skill and time. Both jigs and fixtures position components accurately; and hold components rigid and prevent movement during working in order to impart greater productivity and part accuracy.

Jigs and fixtures

The correct relationship and alignment between the tool and the work piece is maintained. Jigs and fixtures may be:
large (air plane fuselages are built on picture frame fixtures) or very small (as in watch making).

Their use is limited only by job requirements and the imagination of the designer.

Jigs and fixtures

The jigs and fixtures must be accurately made and the material used must be able to withstand wear and the operational (cutting) forces experienced during metal cutting. Jigs and fixtures must be clean, undamaged and free from swarf and grit. Components must not be forced into a jig or fixture.

Jigs and fixtures

Jigs and fixtures are precision tools. They are expensive to produce because they are made to fine limits from materials with good resistance to wear. They must be properly stored or isolated to prevent accidental damage, and they must be numbered for identification for future use.

Design steps
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2. 3.
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6.

Analyze the drawing of the work piece and determine the machining operations required to machine it. Note critical dimensions and tolerances Determine the orientation of the workpiece in the relation to the cutting tools and their movements Perform an analysis to estimate the magnitude and direction of the cutting forces. Study the standard devices available for work holders and for the clamping formation. Can an off the - shelf device be modified? What std elements can be used Form a mental picture of the work piece in position in the work holder in the machine tool with the cutting tools performing the required operations. Make 3-D sketch of the workpiece in the workholding device in its required position to determine the location of all the elements: clamps, locator buttons, bushings, etc.

The basic location principle in locating the workpiece

Basic 3-2-1 principle is used.
Three points will define a base surface, two points in a vertical plane will establish an end reference, and one point in a third plane will positively locate a part. All plane surfaces are perpendicular to each other.
2 points in second plane

3 points on reference plane

1 point on third plane

Work piece

Clamping considerations
Clamping stresses should be kept low. Clamping induces some stresses that tend to cause some distortion of the workpiece, usually elastic if measurable, it may cause some inaccuracy in the final dimensions.

Support for work during machining