Professional Documents
Culture Documents
A.Senthil Kumar
Assoc Professor
Dept of Mechanical Engineering
EA-05-26 / 6516 6800
mpeask@nus.edu.sg
Course Outline
• Introduction
• Principles of Location
• Principles of Clamping
• Drill Bush and Jigs
• Milling Fixture
• Turning Fixture
• Indexing and Miscellaneous Fixtures
• Modular Fixtures and CAD of Fixtures
Learning Outcome
• Identify the types of locators and clamps
used for jigs and fixtures
• Specify the location of locators and clamps
• Design a jig or a fixture for a given part
Assessment
• Examination – 50 marks from my section –
two questions
Workpiece
Toolholder
n Flat surfaces have flat bearing area, such as: edges, flanges,
steps, faces, shoulders, and slots.
9 10 8 7
3-2-1, or six-point, locational method
• The next two
locators are
normally placed on
the secondary 12 11
locating surface, 3
restricting an
additional three
degrees of freedom
by arresting the
axial movement
along the +y axis
(#3) and the
rotational
movement about
the z (#11 and #12)
axis.
3-2-1, or six-point, locational method
Pins restricted
n The final locator, is 3pins 5DOF
positioned at the end
of the part. It 2pins 3DOF
restricts the axial 2 1pins 1DOF
movement in one 9DOF
direction along the -x
axis (restricting one
more degree of
freedom). Together,
these six locators
restrict a total of nine
degrees of freedom.
Plane locators locate a workpiece from any surface. The surface may
be flat, curved, or have an irregular contour. In most applications,
plane-locating devices locate a part by its external flat surfaces.
workpiece
locators locators
Forms of location
Concentric locators, locate a workpiece from an internal or external
diameter. The most-common type of concentric location is the use of a
locating pin.
Some workpieces, however, might have a cylindrical projection that
requires a locating hole in the fixture.
workpiece
workpiece Concentric
locators
Concentric
locators
Forms of location
Radial locators restrict the movement of a workpiece around a
concentric locator.
Concentric Radial
locators workpiece locators
Equalizing Support
Equalizing Support
Locating from Internal Surfaces
• Locating a workpiece from an internal diameter is the most-
efficient form of location.
• The primary features used for this form of location are
individual holes or hole patterns.
• Either concentric, radial, or both-concentric-and-radial location
are accomplished when locating an internal diameter.
• The two forms of locators used for internal location are locating
pins and locating plugs.
– The only difference between these locators is their size: locating pins are
used for smaller holes and locating plugs are used for larger holes.
Locating from Internal Surfaces
How many degrees of freedom are restricted in this system?
– With internal features, like holes, it is Carr Lane, Fig 3-20. The MMC sizes for both
external and internal features.
the smallest size within the limits.
2- Tolerance
• Tool tolerance should be between 20 and 50 percent of
the part tolerance.
Question:
If a hole in a part must be located within ±0.010 mm, then the tolerance
of the hole in the jig must be between ……mm ……mm
From10.0±.002
10.0±.010 To 10.0±.005
Part Jig
2- Fool proofing
• A means by which the tool designer ensures that the part will fit
into the tool (only in its correct position).
• The simplest and most cost effective method is positioning a
foolproof pin.
Block
block
Carr Lane, Figure 3-16. The best locating surfaces are often
determined by the way that the part is dimensioned.
5- Using Spring-Loaded Locators
One method to help ensure accurate location is the installation of
spring-loaded buttons or pins in the work holder.
– spring force pushes the workpiece against the fixed locators
until the workpiece is clamped.
– not only ensure repeatable locating but also make clamping
the workpiece easier
Contact Button –
Steel or polymer Flat Face Flat Face with Tang
6- Controlling Chips
• Chips are an inevitable part of any machining operation and
must be controlled so they do not interfere with locating the
workpiece in the work holder.
• Chip control must be addressed in the design of any jig or
fixture.
• Position the locators away from areas with a high
concentration of chips.
• If this is not practical, then relieve the locators to reduce the
effect of chips on the location.
• To minimize the negative effects of chips, use locators that
are easy to clean or protected from the chips.
6- Controlling Chips
• Coolant build-up can also cause problems.
• Solve this problem by drilling holes, or milling slots, in areas of the
work holder where the coolant is most likely to build up.
• With some work holders, coolant-drain areas can also act as a
removal point for accumulated chips.
• When designing a work holder, always try to minimize the chip
problem by removing areas of the tool where chips can build up.
• Omit areas such as inside corners, unrelieved pins, or similar
features from the design.
Test yourself!
• Which locating is appropriate?
Fixed locators:
n Solid locators that establish a fixed position for the part.
Adjustable locators:
n Movable locators,
n Used for rough-cast mainly,
n Used for parts with surface irregularities,
n Used in conjunction with fixed locators to permit variation in part sizes.
Fixed External Locators
Fixed Locators
• Integral locators:
– Machined into the body of the workholder,
– Least preferred type of locators because of:
• Additional material required to allow for the machining of the locator
(wasted material),
• the time which takes to machine the locator,
• The problem of replacing the locator if it wears or becomes damaged.
Fixed Locators
• V-type: X
Locating nests:
Feature a cavity in the workholder
device into which the workpiece is
placed and located,
No supplementary devices such as pins
are normally required.
Fixed Locators
Locating nests part
Disadvantages:
1. Since the workpiece is completely
surrounded, It is difficult to lift out of the nest.
n Solutions 1: the workholder can be turned over and
the part shaken out.
n Solution 2: ejector pins can be used (which will add
time to the processing).
2. The operation performed may produce burrs that tend to lock the part
into the nest.
3. Chip from the operation may lodge in the nest and must be removed.
4. In case of polymer or low-melt alloy, a prototype of the part is required
to make the locators or jig.
Adjustable External Locators
Adjustable Locators
Adjustable locators:
– Movable locators,
– Used for rough-cast mainly,
– Used for parts with surface irregularities,
– Used in conjunction with fixed locators to permit variation in
part sizes.
• Types:
– Threaded,
– Spring pressure,
– Equalizing.
• Adjustable locators as well as adjustable supports are available.
•
Adjustable Locators
Adjustable supports are positioned beneath the workpiece.
Threaded
adjustable
supports
Adjustable Locators
• Spring-type adjustable
supports are used to level the
workpiece.
• Rather than using threads to
elevate the locator a
secondary threaded element
(such as thumbscrew) is used
to lock the position of the
spring support.
1 2 3
Supports Stops