1.

Introduction:
Fixture is the work holding or support devices used to securely
locate and support the work. This ensures that all parts produced using
the fixture will aid in repeatability and interchangeability. Fixtures help
to smoothen the operation by reducing the requirement for skilled
labour by simplifying how work pieces are mounted, quick transition
from part to part and increasing conformity across production a run.

2. Purpose of Fixtures:
A fixtures primary purpose is to create secure mounting point for
a work piece, allowing for support during operation, increased
accuracy, precision, reliability and interchangeability in finished parts.
It reduces working time by reducing set up time. It reduces complexity
of the process by allowing unskilled labours to perform effectively.

3. Design:
Fixtures must always be designed with the purpose to reduce cost
of production. They must be designed to facilitate two or more process
or operations. It should also aid in manufacturing of multiple small or
medium sized component.
Clamps are moveable components which allow work pieces to be
easily placed in the machine or remove from the machine. Clamps are
also adjustable in type which facilitate work pieces of different sized
for different operations. Fixtures must be designed such that the
pressure are the motion of the machining operation is directed primarily
against the solid component of the fixtures this reduces the probability
of failure of the fixture.

4. TYPES OF FIXTURES
4.1Milling fixtures:
Milling operations tend to involve large, straight cuts that produce
lots of chips and involve varying force. Locating and supporting areas
must usually be large and very sturdy in order to accommodate milling
operations; strong clamps are also a requirement. Due to the vibration
of the machine, positive stops are preferred over friction for securing
the work piece. For high-volume automated processes, milling fixtures
usually involve hydraulic or pneumatic clamps.

4.2 Drilling fixtures:

Drilling fixtures cover a wider range of different designs and
procedures than milling fixtures. Two common elements of drilling
fixtures are the hole and bushing. Holes are often designed into drilling
fixtures, to allow space for the drill bit itself to continue through the
work piece without damaging the fixture or drill, or to guide the drill
bit to the appropriate point on the work piece.
Bushings are simple bearing sleeves inserted into these holes to
protect them and guide the drill bit. Because drills tend to apply force
in only one direction, support components for drilling fixtures may be
simpler. If the drill is aligned pointing down, the same support
components may compensate for the forces of both the drill and gravity
at once. However, though mono directional, the force applied by drills
tends to be concentrated on a very small area. Drilling fixtures must be
designed carefully to prevent the work piece from bending under the
force of the drill.
5. Locating Methods
5.1Locating from plane surfaces:
The proper location of work piece requires use minimum number
of locating points. Redundant locations is not desired in a jig or fixture
design. For external plain surface, 3-2-1 principle of location is
generally employed. In order to understand 3-2-1 principles of location,
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let us consider a rectangular block with all the plains are perpendicular
to each other. The rectangular blocks has 12 degrees of freedom such
as 6 rotation and 6 axial degrees of freedom. In order to properly locate
the block, all the 12 degrees of freedom need to be restricted with
suitable locating points. Location of the block can be done using 6
locating points; 3 locating points in the primary locating surfaces, 2
locating points in the secondary locating surface and one locating point
in the ternary locating surface. Placing the primary locating surface of
the block on the 3 locating pins restricts 5 degrees of freedom. The 2
locators placed on the secondary locating restricts 3 more degrees of
freedom. The 6th locator positioned on the trinary surface of the block
restricts 1 linear movement. Therefore, 6 locators restricts 9 degrees of
freedom. Remaining 3 degrees of freedom is restricted by clamping the
block.
5.2 Locating from circular surfaces
The basic reference for location is the flat plane of the machinetool table surface. It is necessary to locate the axis of the circular work
piece. One of the come methods of locating from a circular surface is
by using cones, a method commonly referred to as conical location and
usually employed when locating is done from a hole. The same system
may be used when locating on the outside of the circle, except that the
cones are inverted to form cups.
V method is used primarily to locate round work pieces or
workpieces with convex circular surfaces. Smaller included angles hold
a round workpiece more securely but are more susceptible to location
errors case by burrs, chips, dirt, and workpiece inaccuracies. The V
should be directed in such a way that variations in workpiece size will
not affect location on the workpiece.
5.3 Locating from irregular surfaces
Irregular surfaces are neither flat nor circular the degree of
roughness may determine whether a surface would be considered flat,
circular or irregular. V locating method may be used to locate certain
parabolic surfaces and button locators may be used to locate certain
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elliptical surfaces. It is necessary to locate from an irregular surface

only during the first machining operation, as it should produce holes or
surfaces that can used as a reference or locating points for subsequent
operations.
The unevenness of the surface of a casting will allow a maximum
of three contact points. More than three points will allow the casting
teeter. Moreover, if more than three points are used, the workpiece will
reform when clamping pressure is applied. It is therefore necessary to
used adjustable rest pins are equalizer to compensate for the
unevenness of the workpiece surface. One of the simplest type of
adjustable rest pins is a fixture jack the workpiece is positioned on three
non-adjustable locators, and the jack or jacks are adjusted until they
touch the workpiece locators. The constant pressure between the jacks
and the workpiece depends upon the judgment of the operator and is a
disadvantage when a number of jacks are used.
The Basic Principles of Clamping
Once a workpiece is located, it is necessary to press it against the
locating surface and hold it there against the forces acting upon it.
Clamps is largely determined by the workpieces and the kind of
operation to which it is applied.
However, clamps must fulfil four essential requirements:
The workpiece must be held rigidly while the cutting tools are
in operation.
The time required for loading or unloading the tool must be as
short as possible, which means it must be quick-acting.
When subjected to vibration, chatter, or heavy pressure, the
clamping must be positive.
The clamp must not damage the workpiece.
The clamp design should ensure that the clamping forces should be
directed toward the locating surfaces. They should be arranged in such
a manner that the thrust of the cutting tool is away from the clamp.
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Clamping forces should be applied over a heavy part of the workpiece

whenever possible, preferably directly over a rest pad in order to
prevent distortion of the workpiece. Clamping mechanisms should be
designed in such a manner that they cannot be applied in any way
except the correct one.
6. Types of clamps
While the types of clamps are numerous, they can be classified in
three basic groups namely:
Mechanical clamping
Hydraulic clamping
Pneumatic clamping
Commonly used clamps are readily available from tool specialty
companies. They are often referred to as standard clamps and should
be used whenever possible.
6.1Mechanical clamping
6.1.1 Screw Clamping:
Screw clamps are simple clamps where torque developed in a
screw thread is used to hold the workpiece. They have the advantage of
exerting adequate force besides resisting loosening tendencies set up
by vibration. It can be direct or indirect. There are different holding
forces for different screw sizes. However, they are relatively slow and
may not suitable for high production.

Fig 1: Screw clamping

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6.1.2 Strap clamping:

Strap clamps are simplest and most commonly used clamp. All
strap clamps employ the principles of levers. Numerous shapes are
available as standard parts to suits different applications. Strap clamps
can be easily slid onto and off of the workpiece for easy workpiece
removal. Essential parts of a standard strap clamps are clamping bar,
clamping knob, spherical washer, compression spring and pillar pin.

Fig 2: Strap clamping

6.1.3 Swing clamping:
Swing clamps are swinging type of strap clamp. It is a
combination of strap clamp and swinging clamp. It is used in cases
where the forces acting against the workpiece are light and heavy
clamping pressure is not required.

Fig 3: Swing clamping

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6.1.4 Cam clamping:

Cam clamps are used when it is desirable to push the workpiece
against stops or into a nest. Cam clamps provide an effective and rapid
means of clamping but they are not a positive clamping method and
may loosen under vibrating forces. They should not be used where
heavy clamping forces are required. There are two types of cam clamps
namely spiral and eccentric.

Fig 4: Cam-clamp assembly

6.1.5 Latch clamping:
Latch clamp is known for its advantage in the ease and speed of
manipulation. It is limited to light work as it is difficult to secure
rigidly. The types of latch clamps are Simple latch clamp, Cam type
latch, Self -locking clamp, Thumb screw latch.

Fig 5: Simple latch clamp

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6.1.6 Wedge clamping:

A plain wedge clamp consists of a movable inclined plane which
forces the work piece against a fixed stop. These clamps tend to loosen
under vibration. The taper end of the plain wedge ranges from 6 to 18
degree, depending upon the coefficient of friction of the metal. A plain
wedge clamp can be improved by adding levers and links, so that it is
quick-acting and provides lock.

Fig 6: Wedge clamping

6.1.7 Hinged clamping:
Hinged clamp provides rapid clearance for loading and unloading
the workpiece. It has a hinged bolt and hinged strap/plate which when
swung apart gives space to mount the workpiece.

Fig 7: Hinged clamping

6.1.8 Pivoted clamping:
Pivoted clamps are often pivoted at the centre to simplify their
operation. Tightening and loosening is done using knurled head screw.
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7. Hydraulic clamping
Hydraulically clamped fixtures have many advantages over
manually clamped fixtures. In most cases, these benefits reduce costs
for manufacturers allowing them to justify the initial investment for a
hydraulic clamping system.
7.1Advantages of Hydraulic Clamping:
More productivity: More parts will fit within machine envelope
due to the high clamp forces generated with small hydraulic
components.
Consistent clamping forces: Every cycle, your parts are clamped
with the same clamping force, eliminating variables and
improving process stability.
Repeatable clamp location: Every cycle, your parts are clamped
in the same location eliminating the variability in part deflection
from clamping forces.
Eliminates human error: Assurance that every clamp will be
actuated with every cycle, eliminating human error and missed
steps.
Eliminates human error: Assurance that your proven clamping
sequence was followed on every cycle.
Faster: load and unload times and more productivity when cycle
times are operator dependant.
Ergonomic efficiency: Allows operators to be consistently more
productive with less effort.

 Improved part stability: Hydraulic work supports can be used to

support the part and or dampen machining forces without
distorting the work piece. Manual work supports are easily
ignored, distort the part and cause miss-loads.
Flexibility: Sophisticated clamping sequences can be developed
with live hydraulic systems. Clamping can be sequenced
automatically during the machining cycle to provide clearance for
cutting tools, to remove forces for finish cuts of close tolerance
features, retain parts for robotic loading, reduce cycle times and
improve productivity.

8. Pneumatic clamping:

Pneumatic operated clamps differ from hydraulically operated

ones in the size of the cylinder, which is smaller with hydraulics
because of the higher pressures. Pneumatically operated clamps are not
used where heavy clamping pressures are required because extremely
large cylinders would be required. Pneumatically operated clamping
devices are convenient because most manufactures have a supply of
compressed air available. However, the line pressure may be too low
to provide adequate pressure to cylinders for clamping purposes. This
condition can be remedied by the installation of an air-to-hydraulic
booster, which is used to convert low pressure air into higher hydraulic
pressure for operating a hydraulic work cylinder. The booster operates
from regular shop-line pressure without pumps or high pressure valve.

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9. Locating pins:
Pins are used to locate the components and firmly hold the
workpiece in position. Button locators are also similar. Buttons are
generally shorter than pins and used for vertical location. Pins on the
other hand are used for horizontal location. Some of the common pins
used are cylindrical pins and Diamond pins. Diamond pins are relieved
on two sides to allow variations in the centre to centre distance of holes.
The locators must properly position the work piece and then maintain
its location against primary cutting forces throughout the machining
cycle. As it is a locating element it should have high hardness so the
locator is made with single piece of EN353 Case harden &Tempered
with 58 To 62 HRC. Threads are kept soft during hardening process.

Fig 8: Cylindrical and Diamond locating pins

10. Rough Guide:
Rough guide are used to guide component while loading and
unloading of the component. In this fixture two types of rough guides
were used one is conventional type of rough guide and another one is
bottom rough guide which is used to support the bottom side of the
component while loading. Distance between the component and rough
guide is 2mm. Material used for rough guide is C45, polystyrene.

Fig 9: Rough Guide

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11. Rest pad:

Rest pad is made by En-353 material. Component is rest on this
rest pads. Mainly where ever air holes are located air seat check holes
are given to the rest plate to check for proper resting of the component.
This rest pad is fixed to the base structure by using M6 socket head cap
screws. O-rings are placed at the connection of base structure and rest
pad for avoiding leakage of air. It works on pneumatics i.e. if there is
any leakage of air through it, it sends signals to the machine and the
machine stops.

Fig 10: Rest pad

Conclusion:
The above report is an account of various processes associated
with the industry that were imbibed into me by the exposure to such
activities. Specifically I was astonished to know the existence of many
pre and post machining and assembly processes and had a thorough
learning of the same. I profusely thank the industry for giving me the
opportunity to appreciate the processes in the engineering world.
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