Workholders

Workholders
and
and
Workpiece
Workpiece
Control
Control
Elements of a Machining System
Elements of a Machining System
Cutting Tool
Tool
Holder
Machine
Workpiece
Workholder
Machining System Analysis
Machining System Analysis
Workpiece
Workpiece
A partially finished part or assembly which A partially finished part or assembly which
does not as yet have all the part print does not as yet have all the part print
specifications. The specifications. The workpiece workpiece changes changes
from operation to operation and is that from operation to operation and is that
piece of material upon which work is being piece of material upon which work is being
performed. performed.
Workholder
Workholder
All devices that hold, grip, or chuck a All devices that hold, grip, or chuck a workpiece workpiece
to safely perform a manufacturing operation. to safely perform a manufacturing operation.
Variables in Machining
Variables in Machining
Independent Variables: Independent Variables:
Cutting Tool Material, Cutting Tool Material,
Condition, Geometry Condition, Geometry
Workpiece Workpiece Material, Material,
Condition, Geometry Condition, Geometry
Machine Tool Parameters Machine Tool Parameters
and Characteristics and Characteristics
Cutting / Lubricating Fluids Cutting / Lubricating Fluids
Cutting Speed Cutting Speed
Cutting Feed Rate Cutting Feed Rate
Cutting Depth Cutting Depth
Dependent Variables: Dependent Variables:
Type of Chip Type of Chip
Forces and Energy Forces and Energy
Temperatures Temperatures
Tool Wear and Tool Life Tool Wear and Tool Life
Workpiece Workpiece Finish Finish
Dimensional Accuracy Dimensional Accuracy
Material Removal Rate Material Removal Rate
Type of Type of Workholder Workholder
Function of
Function of
Workholder
Workholder
Position or locate a Position or locate a workpiece workpiece in a definite in a definite
relation to the cutting tool. relation to the cutting tool.
Must withstand holding and cutting forces Must withstand holding and cutting forces
while maintaining precise location. while maintaining precise location.
Provide a safe operating environment. Provide a safe operating environment.
Elements of a
Elements of a
Workholder
Workholder
Locating elements Locating elements position the position the
workpiece workpiece
Tool structure or body Tool structure or body provide base for provide base for
withstanding holding and machining withstanding holding and machining
forces. forces.
Brackets (if Brackets (if req req d d) ) provides means to provides means to
attach attach workholder workholder to machine bed. to machine bed.
Clamping elements Clamping elements provides provides workholder workholder
holding forces. holding forces.
Workholder
Workholder
-
-
Mill Fixture
Mill Fixture
Workpiece
Workpiece
Control
Control
Workpiece Workpiece Control Control - - To insure successful To insure successful
operation of a operation of a workholding workholding device, thus insuring device, thus insuring
that the that the workpiece workpiece is produced within the is produced within the
tolerances specified on the part print, the tolerances specified on the part print, the
workpiece workpiece must be accurately located to must be accurately located to
establish a definite relationship between the establish a definite relationship between the
cutting tool and some points or surfaces of the cutting tool and some points or surfaces of the
workpiece workpiece. This relationship is established by . This relationship is established by
locators in the locators in the workholding workholding device which position device which position
and restrict the and restrict the workpiece workpiece to prevent its moving to prevent its moving
from its pre from its pre- -determined location. determined location.
Workpiece
Workpiece
Control
Control

con
con

t
t
.
.
Geometric Control
Geometric Control
Deals with the placement of locators in order to insure Deals with the placement of locators in order to insure stability stability of the of the
workpiece workpiece. .
RULES: RULES:
Place locators as far apart as possible. Place locators as far apart as possible.
Place locators to insure balance of Place locators to insure balance of workpiece workpiece. .
Place locators such that holding forces will not shift the Place locators such that holding forces will not shift the workpiece workpiece
away from the locators. away from the locators.
Place locators such that tool forces will not shift the Place locators such that tool forces will not shift the workpiece workpiece away away
from the locators. from the locators.
Place locators in such a way that the Place locators in such a way that the workpiece workpiece is easy to load and is easy to load and
unload from the unload from the workholder workholder. .
Place locators such that they contact the Place locators such that they contact the workpiece workpiece on a solid, on a solid,
stable point or surface. stable point or surface.
Dimensional Control
Dimensional Control
That control relating to the maintenance of physical dimensions That control relating to the maintenance of physical dimensions as specified on as specified on
the part print. The the part print. The workpiece workpiece must be produced within tolerances shown must be produced within tolerances shown
for each dimension. Dimensional control is obtained by: for each dimension. Dimensional control is obtained by:
Selecting the proper surfaces for placement of locators. Selecting the proper surfaces for placement of locators.
Correctly positioning those locators on the selected surfaces. Correctly positioning those locators on the selected surfaces.
Rules: Rules:
Place locators so that no process tolerance stacks are present. Place locators so that no process tolerance stacks are present.
Place locators so that Place locators so that workpiece workpiece variation does not interfere with obtaining the variation does not interfere with obtaining the
dimensions within tolerance. dimensions within tolerance.
Place locators so that Place locators so that workpiece workpiece irregularities do not interfere with obtaining irregularities do not interfere with obtaining
the dimensions within tolerance. the dimensions within tolerance.
Dimensional control is best when locators are placed on one of t Dimensional control is best when locators are placed on one of two surfaces wo surfaces
to which the dimensions are shown on the part print. to which the dimensions are shown on the part print.
Dimensional control is best when locators are placed astride the Dimensional control is best when locators are placed astride the centerline to centerline to
which the dimension is shown on the part print. which the dimension is shown on the part print.
When close tolerances are required on parallelism, When close tolerances are required on parallelism, squareness squareness, and , and
concentricity, more than one locator must be placed on one of th concentricity, more than one locator must be placed on one of the surfaces to e surfaces to
which the tolerances apply. which the tolerances apply.
Mechanical Control
Mechanical Control
That control relating to the proper application of forces on the That control relating to the proper application of forces on the workpiece workpiece - - tool forces and tool forces and
holding forces. holding forces.
RULES: TOOL FORCES RULES: TOOL FORCES
Place locators opposite tool forces to control Place locators opposite tool forces to control workpiece workpiece deflection. deflection.
When required, use fixed supports to limit When required, use fixed supports to limit workpiece workpiece deflection caused by tool forces. deflection caused by tool forces.
When quality outweighs economy, adjustable supports may be used When quality outweighs economy, adjustable supports may be used to oppose tool to oppose tool
forces. forces.
Use tool forces to assist in holding the Use tool forces to assist in holding the workpiece workpiece against the locators. against the locators.
RULES: HOLDING FORCES RULES: HOLDING FORCES
Place holding forces directly opposite locators. Place holding forces directly opposite locators.
Use supports when necessary to control deflection caused by hold Use supports when necessary to control deflection caused by holding forces. ing forces.
Holding forces must make up for the loss of the sixth locator by Holding forces must make up for the loss of the sixth locator by using friction. using friction.
Non Non- -rigid rigid workpieces workpieces require several holding forces rather than one large force. require several holding forces rather than one large force.
Workpiece Workpiece marring can be controlled by placing holding forces on non marring can be controlled by placing holding forces on non- -critical critical
surfaces. surfaces.
Holding forces applied by one resultant force are desirable to r Holding forces applied by one resultant force are desirable to reduce the effect of the educe the effect of the
human element. human element.
Tool Design Process
Tool Design Process
Statement and analysis of the problem Statement and analysis of the problem
Analysis of the requirements. Analysis of the requirements.
Development of initial ideas Development of initial ideas
Development of design alternatives Development of design alternatives
Finalization of the design ideas Finalization of the design ideas
Design Development
Design Development
Following is one structured method that can be utilized when des Following is one structured method that can be utilized when designing igning workholders workholders (jigs or fixtures): (jigs or fixtures):
1. 1. Sketch or layout the Sketch or layout the workpiece workpiece in the required number of views (or obtain / create a 3 in the required number of views (or obtain / create a 3- -dimensional dimensional
computer model computer model at full scale) to a proper scale. The at full scale) to a proper scale. The workpiece workpiece should be represented with should be represented with
phantom lines in an identifying color phantom lines in an identifying color usually red. usually red.
NOTE: NOTE: Scales are listed on the tool drawing in the form of a ratio. Scales are listed on the tool drawing in the form of a ratio. Appropriate scales are as Appropriate scales are as
follows: 1:1, 1:2, 1:4, 1:5, 1:8, and 1:10 follows: 1:1, 1:2, 1:4, 1:5, 1:8, and 1:10 reduced reduced and 2:1 and 4:1 and 2:1 and 4:1 enlarged enlarged . .
2. 2. Add reference information to the layout (blue phantom lines). T Add reference information to the layout (blue phantom lines). This includes the following: his includes the following:
Cutting tools utilized in the operations. Cutting tools utilized in the operations.
Gages utilized to fabricate the tool. Gages utilized to fabricate the tool.
Machine travel constraints / machine work envelope. Machine travel constraints / machine work envelope.
Facilities constraints (table heights, room area constraints, et Facilities constraints (table heights, room area constraints, etc.) c.)
3. 3. Develop the locating system for the Develop the locating system for the workpiece workpiece and indicate on the drawing. (Follow and indicate on the drawing. (Followworkpiece workpiece
control rules). control rules).
4. 4. Develop a clamping system and indicate on the drawing. (Follow Develop a clamping system and indicate on the drawing. (Follow workpiece workpiece control rules). control rules).
5. 5. Inspect for clearance or interference problems. Inspect for clearance or interference problems.
6. 6. Add drill bushings if/as required. Add drill bushings if/as required.
7. 7. Add cutter Add cutter- -setting devices if/as required. setting devices if/as required.
8. 8. Inspect for clearance or interference problems. Inspect for clearance or interference problems.
9. 9. Add the tool body. Add the tool body.
10. 10. Indicate the proposed mounting device if/as required. Indicate the proposed mounting device if/as required.
11. 11. Check for the proper relationship between the jig or fixture and Check for the proper relationship between the jig or fixture and the machine tool components the machine tool components
(spindle, cutting tool, machine bed, etc.). (spindle, cutting tool, machine bed, etc.).
12. 12. In cases of Computer Numerical Control (CNC), check the program In cases of Computer Numerical Control (CNC), check the programto insure that the tool will not to insure that the tool will not
interfere with the operation of the machine tool. interfere with the operation of the machine tool.
13. 13. Initiate the final design drawings. Initiate the final design drawings.