Introduction

The various forces acting upon the work piece during a machining operation necessitate a mean of clamping it in position after it has been correctly located. Selection of locating and clamping methods and devices will depend upon the original machining operation and the configuration of the part. The tool designer must have thorough understanding of locating and clamping before design of jig and fixture

Principles of location
One of the principal purposes of a machining fixture is to locate the work piece surfaces for performing a machining operation. This is usually done with respect to a number of factors to be considered such as the reference datum, supporting surfaces, features that are likely to obstruct the tool movement or access direction, etc. Configuration of work piece is determined by combination of flat, circular and irregular surface.

Locating from plane surface

Basic reference for location is a flat plane generally a m/c table. M/cs have 3 standard movements up & down, right &left , in or out. All locating devices are made with regards to the basic reference plane (M/c table). the m/c table acts as a stop and becomes a locating surface It is necessary to reduce the contact area of locating surface. A minimum of three points (locators) must be used to locate the work piece. The locating points should be placed as far as possible to minimize the effect of inaccuracies in the work piece and locators.

Locating from Circular surfaces

It is necessary to locate the axis of the circular work piece. One commonly used method is referred as conical location and employed when locating is done from the hole. V method primarily to locate round work piece with convex circular surfaces. Variation in the work size will cause the axis of round work piece to shift A method of locating from a circular surface so common that it is often overlooked is the use of Chucks.

Locating from irregular surfaces

They may or may not be geometrically true. Examples casting, forgings and weldments. It may be necessary to locate from an irregular surface only during the first operation, as it should produce holes or surfaces that can be used as reference or locating points for subsequent operations. The unevenness of the surface of casting will allow a maximum of three contact points. more than three points will deform work piece when clamping pressure is applied. The mechanical equalizing devices give equal pressure between two locators and are used to replace on of three supporting points on rough surface.

Principles of clamping
Once a work piece is located , it is necessary to press it against the locating surfaces and hold it there against forces acting upon it. this action referred as clamping and mechanisms used for this action are known as CLAMPS. or A device that resists secondary cutting forces during a machining operation. Clamps are used to hold a workpiece against the locators. Choice of clamp is largely determined by the work piece and kind of operation to which it is applied Clamps must fulfill four requirements (a) Work piece must be held rigidly while the cutting tools are in operation (b) The time for loading & unloading must be short. (c) The clamping must be positive to vibration, chatter (d) Clamp must not damage the work piece.

Clamp
Clamps are a versatile part of any tool kit, they can be used to secure a workpiece to a work surface, to secure a straight edge across a work piece for sawing or routing, or to hold a workpiece during gluing. A clamp is a fastening device to hold or secure objects tightly together to prevent movement or separation through the application of inward pressure. A device that resists secondary cutting forces during a machining operation. Clamps are used to hold a work piece against the locators. Temporary : These clamps (or cramps) are used to position components temporarily for various tasks Permanent: Hose clamp, Wire rope clamp

Hose clamp

Locating methods and Devices

An adjustable locator with a metal button or tang that pushes a work piece up against fixed locators on the opposite side. Spring stop buttons exert more force than spring locating pins.

Pin and button locators:

A round pin or button is used to firmly support or hold the work piece in position. The simplest form of pin locators is a short length of steel drill rod pressed into a hole in jig or fixture base. A pin that is used to lock a workpiece into position on an indexing jig. An operator pulls the alignment pin into and out of a hole that lines up with another hole in the workpiece. Lockscrew pins are sometimes used where the pin is subjected to excessive wear and must be frequently replaced. Large pins used in holes for locating are generally referred to as plugs.

 Locating and fixturing pins are removable devices used to locate, align or fix two or more parts together. They can accomplish this manually using a simple pin, or by pneumatic, hydraulic or electrical power in a more complex device A pin that is used to lock a workpiece into position on an indexing jig. An operator pulls the alignment pin into and out of a hole that lines up with another hole in the workpiece.

Rest pads and plates

Rest buttons and rest pads are used to provide a surface to locate or support a component in a jig or fixture. Rest pads and plates are used to support and locate work vertically in manner similar to rest buttons, but used with larger and heavier work pieces. Rest pads do not have shank. Rest plates are essentially rest pads with larger bearing surfaces. rest pads are sometimes grooved to reduce bearing area and still provide support rigidity. Rest buttons and rest pads having flat, radius, and serrated heads By contrast, screw rest buttons and screw rest pads have a relatively small contact area and can be used as a workpiece support or jig foot.

Nest or cavity location

The Nest of jig or fixture should be pocket or cavity into which the workpiece is placed and located .Nests may be milled directly into a base plate to same contour as the work piece. Properly designed nests should locate the work piece without supplementary locating devices although locating pins are occasionally used. Disadvantage of nest location is that work piece is often difficult to lift out of cavity because it is completely surrounded. this can be overcome by providing ejecting device

Locating methods and chip control

Machining metal involves the removal of waste material in the form of chips. the small chips tend to collect in corners and other inaccessible areas and cause error in location. Chip control at locating points is consists of providing relief or opening at areas where chips would tend to accumulate and prevent the work piece from properly contacting the locator.

Types of Clamps
An operation that holds the workpiece against the locators. Clamping resists secondary tool forces. Groups: Strap, Cam, Screw, Latch, Wedge or Key, Toggle and rack and pinion. In a combination, name of the most prominent element is given to the complete clamping device

Strap Clamps: A type of clamp that reaches over the workpiece to hold it in place. Strap clamps are often used when extra toughness is required.

Strap clamp

Strap clamp

Strap Clamp

Cam Clamp: A clamp that uses a gradual curved surface to lock itself in place. Cam clamps may be dislodged by excessive vibration

Cam Clamp

Screw Clamp
Spring Loaded Screw Clamp - Spring Loaded For highvibration applications spring loaded Screw Clamp Terminal Blocks. Although standard screwclamp design is already resistant to vibrations, it is further strengthened against vibrations by provision of compression springs in the terminal block

Hoffman Screw Clamp

Latch Clamp
This type of construction is limited to relatively light work, as it is difficult to secure rigidly. the leaf is pivoted member of a jig that may or may not contain bushings.

Latch clamp

Wedge Clamp
A clamp that uses a wedge to gradually exert pressure on jaws located on each side of the wedge. Wedge clamps push out and down and typically hold a workpiece from the side.

Wedge clamp

Toggle clamps
Toggle clamps depends upon the movement of rigid links for their movement

Toggle clamp

Clamping and Locating Devices