Fixture Design

Introduction to Jigs and Fixtures:

Jig: A device that holds the work and locates the path of the tool.
Fixture: A device fixed to the worktable of a machine and locates the work in an exact position
relative to the cutting tool.

Fixture Design Fundamentals:

• Fixture planning,
• Fixture layout design,
• Fixture element design,
• Tool body design.

Basic fixture concepts:

• Fixture design deals with the establishment of the basic fixture concepts:
• Fixture layout is an conceptual in the form of a configuration of the fixture.
• Fixture element design is concerned with the concrete details of the locators, clamps and supports
• Tool body design produces a structure combining the fixture elements in the desired relationship
with the machine tool.

Fixture planning:
Fixture planning is to conceptualise a basic fixture configuration through analysing all the available
information regarding the material and geometry of the workpiece,operations required, processing
equipment for the operations, and the operator. The following outputs are included in the fixture plan:
• Fixture type and complexity
• Number of workpieces per fixture

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• Orientation of workpiece within fixture
• Locating datum faces
• Clamping surfaces
• Support surfaces,

Fixture layout:
Generation o f fixture layout is to represent the fixture concepts in a physical form. The following
outputs are included in fixture layout:
• Positions of locators
• Positions of clamps
• P ositions of supports
• Type of locators
• Type of clamps
• Type of supports
• Clamping forces and sequence

Fixture design procedure:

In the design of a fixture, a definite sequence of design stages is involved. They can be grouped into three
broad stages of design development.
Stage One deals with information gathering and analysis. These include product analysis such as the
study of design specifications, process planning, examining the processing equipment and considering
operator safety and ease of use. In this stage, all the critical dimensions and feasible datum areas are
examined in detail.
Stage Two involves the consideration of clamping and locating schemes. A clamping scheme is
devised in such a way that it will not interfere with the tools or cutters and are fully compatible with
proposed locating surfaces or areas. The locating scheme, using standard elements such as pins, pads, etc.
is designed to be consistent with clamping and tool-guiding arrangements.
Stage Three is the design of the structure of the fixture body frame. This is usually built around the
work piece as a single element which links all the other elements used for locating, clamping tool-guiding,
etc. into an integral frame work.

Types of Fixtures:
• Plate fixtures: From a plate by adding locators and clamps & Reference surface is parallel to the
mounting surface
• Angle plate fixtures
• Vise jaw fixtures
• Indexing fixtures
• Multipart fixtures

EXTERNAL-MACHINING APPLICATIONS:
Flat-Surface Machining:
1) Milling fixtures 2) Surface-Grinding fixtures
3) Planing fixtures 4) Shaping fixtures
Cylindrical-Surface Machining
1) Lathe fixtures 2) Cylindrical-grinding fixtures
Irregular-Surface Machining
1) Band-sawing fixtures 2) External-broaching fixtures

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NON-MACHINING APPLICATIONS:
Assembly
1) Welding fixtures
2) Mechanical-assembly fixtures (Riveting, stapling, stitching, pinning, etc.)
3) Soldering fixtures
Inspection
1) Mechanical-inspection fixtures 2) Optical-inspection fixtures
3) Electronic-inspection fixtures
Finishing
1) Painting fixtures 2) Plating fixtures
3) Polishing fixtures 4) Lapping fixtures
5) Honing fixtures

1. Milling Fixtures:
It is most common type of fixture in use.
The simplest type of milling fixture is a milling vise mounted on the machine table.
However, as the workpiece size, shape, or complexity becomes more sophisticated so does the fixture

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Design Criteria of Milling Fixture:
• The design should permit as many surfaces of the part to be machined as possible, without
removing the part.
• Whenever possible, the tool should be changed to suit the part. Moving the part to accommodate
one cutter for several operations is not as accurate or efficient as changing cutters.
• Locators must be designed to resist all tool forces and thrusts. Clamps should not be used to resist
tool forces.
• Clearance space or sufficient room must be allowed to provide adequate space to change cutters or
load and unload the part.
• Milling fixtures should be designed and built with a low profile to prevent unnecessary twisting or
springing while in operation.
• The entire workpiece must be located within the fixture’s area. In cases where it is either
impossible or impractical, additional supports or jacks must be provided.
• Chip removal and coolant drainage must be considered when designing the fixture.
• Sufficient space should be permitted to easily remove chips with a brush.
• Set blocks or cutter-setting gages must be provided in the fixture design to aid the operator in
properly setting up the tool in production.

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2. Lathe Fixtures:
• The same basic principles as milling fixtures.
• The only major difference between the two is the relationship between the workpiece and the
cutting tool.
• In milling, the workpiece is stationary and the cutting tool revolves. However, with turning
operations, the workpiece revolves and the cutting tool is stationary.
• This situation creates another condition the tool designer must deal with-centrifugal force.
• The complete fixture must be designed and constructed to resist the effects of the rotational, or
centrifugal, forces present in turning.

Design Criteria for Lathe Fixture:

• Since lathe fixtures are designed to rotate, they should be as lightweight as possible.
• Lathe fixtures must be balanced. While perfect balance is not normally required for slow speed
turning operations, high rotational speeds require the fixture to be well-balanced.
• In most fixtures, balance is achieved by using counterweights positioned opposite the heaviest part
(or area) of the workpiece.
• Projections and sharp corners should be avoided, since these areas will become almost invisible as
the tool rotates and they could cause serious injury.
• Parts to be fixtured should, whenever possible, be gripped by their largest diameter or cross
section.
• The part should be positioned in the fixture so that most of the machine operation can be performed
in the first fixturing.
• Clamps should be positioned on rigid surfaces or areas before and after machining.
• Clamping over an area to be bored to a very thin-wall thickness could cause the part to warp or
deform, thus causing the hole to be bored incorrectly.
• As with other fixtures, some means of cutter setting should be incorporated into the design.
However, since the workholder will be rotating, this setting device should later be removed.
• Whenever possible, standard lathe accessories should be adapted in the design of turning fixtures.
• Lathe faceplates are an ideal method to mount large fixtures. Likewise, a standard lathe chuck, or
collets, can and should be modified for many fixturing applications.

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3. Grinding Fixtures:
It’s family of fixtures rather than a single classification. Major types are
• surface grinding fixtures and
• cylindrical grinding fixtures
Design Criteria of Grinding Fixture:
Surface grinding fixtures:
• Similar in design to milling fixtures, but made to much closer tolerances.
• Whenever practical, use magnetic chucks to hold the workpiece.
• In these cases, the fixture is simply a device to contain the workpiece and prevent any lateral or
transverse movement of the part.
• Provide adequate room or slots to permit the escape of coolant and easy removal of built -up grinding
sludge.
• Provide coolant containment devices or splash guards to keep the fixture from spilling coolant on the
floor around the machine.
• Fixture elements in contact with the magnetic chuck should be made from ferrous materials if they are
to be held on the chuck.
• If they are not to be held to the chuck, then a nonferrous metal should be specified.
• Include provisions for rapid wheel dressing and truing in the design of the fixture, if not built into the
machine.
• All locators must be accurately and positively positioned.

Cylindrical grinding fixtures:

• Are very similar to lathe fixtures.
• Since cylindrical grinding is normally a secondary operation, performed after turning, it is often
desirable to use the same center holes for grinding as turning the part.
• Coolant buildup is seldom a problem with cylindrical grinding; however, sludge removal must always
be considered.
• Cylindrical grinding fixtures should always be perfectly balanced to achieve the desired results.
• When possible, use standard accessories and attachments. These include grinding collets, chucks, and
drive plates with special right angled holders called dogs.
• Incorporate provisions for wheel dressing and truing into the design.

4. Boring Fixtures: Design Criteria

l Boring fixtures are designed to hold the workpiece while the part is bored. These fixtures differ
from boring jogs in that they do not have any provision for guiding or supporting the boring
bar.
l Boring fixtures are normally used for large parts with large holes where the boring bar is rigid
enough to provide additional support. A pilot bushing is not needed.
l Boring fixtures, like milling fixtures, should have some provision for setting the position of the
cutting tool relative to the part. In cases where a boring fixture is to be used on a very large
machine, such as a boring mill or vertical turret lathe, it is also good practice to include
alignment areas on the fixture to ensure proper alignment with the machine.
l Broaching fixtures are designed to simply hold and locate a part relative to either an internal or
external broach. Since there is a great deal of cutting force exerted during broaching, the
complete.
l Fixture must be built more substantially than those for other processes.
l Internal broaching fixtures need only locate and hold the part in proper position relative to the
hole in the broaching machine. Most broaching performed today is of the pull type and tends to

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keep the part firmly seated on the fixture.
l However, clamping devices are necessary to establish the proper relationship and maintain the
position of the part until the broaching pressure pulls the part against the table.
l External, or surface broaching, requires a different approach to fixturing.
l Since this type of broaching is performed on the outside of a part, the fixture must be designed
to resist both pulling and perpendicular thrust that tends to try to push the part away from the
broach.
l In either case, the principle purpose for a broaching fixture is to maintain the proper
relationship between the part and the cutting tool, and to prevent the part from moving.

5. Sawing Fixtures:
Two primary machines commonly used for sawing operations are the vertical bandsaw and the
horizontal bandsaw.
With both types of machines, the main intent is to accurately position and
gold the workpiece so it can be either sawed into pieces or slotted with the saw blade. The following are
a few design characteristics peculiar to these saws and the sawing process in general.
When possible, standard saw accessories and attachments should be used in conjunction with fixturing
elements.
Clamps, locaters, supports, or similar fixture details must be kept clear of the blade path. Since the area
occupied by the saw blade on both types of band saws extends above and below the actual working
area, any overhanging fixture elements could interfere with normal operation of the saw.
Provisions for coolant drainage and chip disposal must be planned into the fixture design.
While most band saws have an internal chip disposal system, a significant amount of chips also will
collect in the fixture unless some means for their elimination is planned.
When practical, table slots should be used to reference the fixture to the saw blade.
Use power feed whenever possible. This may require designing a means to secure the power-feed chain to
the fixture.

6. Welding Fixtures:
l A welding fixture serves the same purpose as a welding jig; but, in addition, it permits the
changing of the position of the work during the actual welding, so as to place the welds in a
plane convenient to the operator at all times.
l This increases welding speed.
l Fixtures are considered to be of a more general character and not so specialized as jigs.
Fixtures may include rollers, clamps, and wedges etc., used for convenience in positioning
of the work.
Welding Fixture Characteristics:-
The actions provided by welding fixtures may be
i. Supporting
ii. Clamping
iii. Grounding and
iv. Imparting movement (usually referred to as travel or traveling) to name but a few.

l Mostly Used Welding Equipment Fixtures - Welding equipment fixtures (some are called welding
manipulators) may provide only stationary support or both support and travel to the welding
equipment.
l The equipment may be no more than a welding head or welding gun - or it may include all of the
equipment in the welding circuit, including the power sources and even the flux-recovery unit.

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l The fixtures for holding the head stationary, range from a simple arm and mounting bracket, to the
very complex installations common in continuous mill welding.

Considerable Point in Fixture Selection (Design Criteria):

In selecting fixtures for mechanized welding, the engineer must evaluate considerations such as:
i. Production volume,
ii. Joint geometry,
iii. Movability of the welding head.

a. Production volume:-
l Elaborate welding equipment or work fixtures cannot be justified unless the part volume is
substantial.
l In this case fixture adaptability, simplicity and cost often are the important factors for the selection
of fixtures. This may mean combining a variety of work supporting or holding devices with a
simple beam-with-carriage fixture.

b. Joint Geometry:-
l Joint geometry plays an important role in the selection of a welding fixture. For example,
o Circular welds are usually made with the welding head stationary and the work
rotating.
o Welds in a straight line usually require a welding equipment fixture that travels the
(welding) head along the joint with a stationary work fixture providing clamping to
maintain part alignment and fit up.

c. Stationary Welding Head:-

l Because a stationary welding head requires work movement, it invariably calls for complex
fixturing. In fact, the work fixturing necessary for stationary head applications can be highly
automated.
l Some fixtures are designed so that the weight of the incoming work activates the positioning,
and clamping devices, and then initiates the welding cycle. As a result, even 1he simple act of
pushing the start button is eliminated.

d. Movable Welding Head:-

In this case, the work remains stationary and the welding head travels along the joint. Head movement
may result from
o Travel of a carriage on a beam or rail
o A traveling boom mounted on a stationary column,
o The travel of the entire manipulator riding on a track in the floor,
o Travel of a tractor riding the workpiece surface.

In this case both the welding equipment and workpiece are traveling but in opposite directions to
keep the weld puddle in the flat position.

Principles Governing Design of Welding Fixtures:

l The fixture should be strong and light but rigid enough to ensure accurate alignment.
l Whenever possible, a fixture should be positioned, enabling all welds to be brought to a convenient
welding position.
l The fixture should permit quick and easy positioning (by one hand, if possible). Thus, balancing of
the fixture may be necessary.

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l Design should be as simple and inexpensive as possible; accuracy and elaboration should be no
greater than required. Only essential dimensions should be controlled in a fixture. Appearance
should be disregarded.
l Welded construction is best, tool room work should be avoided and machining should be kept to a
minimum.
l The use of light alloys for moving parts reduces weight. Air or electric motors should be used for
revolving, and air or hydraulic rams for tilting the fixture assembly.
l A fixture should be built around the work and should locate and clamp components in position so
th at assembly, tacking, and welding may be carried out in one fixture. The fixture should ensure
one way correct' assembly only.
l The fixture should permit freedom of movement in one plane to avoid residual stress. Design
should permit heat dissipation to release, rather than bind, the assembly being welded. Rams or
bumpers may be used to dislodge heat bound parts.
l Joints must be readily accessible for welding. By slots or other means, the fixture should readily
present seams on the reverse side of the object.
l Fixtures should be kept cool enough to handle air, water, fins or insulated handles can be used.
l Clamps must operate quickly. Screws and moving parts should be protected against weld spatter.
l Fusion to a fixture or to clamps can be avoided by the use of slots or copper backing. If possible,
clamps and locating devices should be integral with, and hinged to, the fixture.

7. Inspection fixtures:
l Inspection fixtures are designed to check tolerances at various stages of assembly.
l They are used to hold a part,registering it on the critical datum's.
l It contains only those elements needed to check the specified sizes of forms.
l There are two general types of inspection fixtures:
o Gauging fixtures are used to check a part against a preset standard size.
o Measuring fixture indicates exactly where and by how much a part is out of tolerance.
o

8. Assembly fixtures:
l They are used for assembling a wide range of products.
l This has included handling: injection molded components,
springs, screws, plugs, rivets, tape, stamped metal components,
clips and other components found in the manufacture of the
automobile, furniture and other mass produced products.

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l These fixtures have ranged from simple, manually operated assembly aids up to sophisticated units
with component sensing, gauging and self-diagnostic controls.

9. Lapping fixtures :
l Lapping is a operation, in which two surfaces are rubbed together with an abrasive between them,
by hand movement or by way of a machine.
l This can take two forms. The first type of lapping (traditionally called grinding), typically involves
rubbing a brittle material such as glass against a surface such as iron or glass
l The other form of lapping involves a softer material for the lap, which is "charged" with the
abrasive.
l The lap is then used to cut a harder material the workpiece.)

10. Honing fixtures:

l Tools are available in silicon carbide and aluminum oxide in 60-320 grit sizes, and are suited for
cross-hole deburring and edge radiusing applications

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