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30107
DESIGN MANUAL
ERRATA
(Henriksen:
DESIGN MANUAL
Erik K. Henri ksen, M. Sc.
Fellow of the
ASME
Academy
of Technical Sciences
INDUSTRIAL PRESS
INC.,
in
Publication Data
902-
I.
Title.
621.9'92
TJ1187.H46
ISBN 0-831 1-1098-8
ACCESSION
73-8810
--)(
7 (55
No.
CLASS No
n
JIG
Copyright
1973
oct
m
.
*V
book
New
or parts thereof
may
Contents
VI
vii
Preface
Introduction
19
25
Locating Principles
32
42
68
Chip Problems
82
Centralizers
87
Clamping Elements
105
Equalizers
136
Supporting Elements
147
13
Cutter Guides
151
14
Drill
Bushings
154
170
16
185
17
194
18
Design Studies
Design Studies
II
20
Design Studies
III
21
281
22
Economics
295
Appendix
Appendix
II
219
Drill Jigs
244
Milling Fixtures
Measuring Angles
in
Radians
III
Appendix IV
Index
298
Appendix
259
The
299
302
304
307
The Use
of Metric Units
units.
the conversions are performed varies with the nature and purpose
of the data quoted.
Where accurate conversion of dimensions is made, it is based on 1 inch = 25,4
EXACT.
mm
Several tables for the conversion of inches and millimeters, feet and meters,
and pounds
and newtons are presented in Appendix IV. Precise inch dimensions, written with
three or
four decimal places, are converted, as a rule, to the nearest 1/100 or 1/J000 mm.
The
purpose is to present the result of the conversion in a manner representative of the
equivalent level of workshop accuracy.
In other cases, Lc, when dimensions include
fractions of an
converted to 13
inch,
mm. There
where a
For example,
1/2
inch usually
is
approximation would be
meaningless, and where it is more realistic to present the result of the conversion
in a
round number of millimeters. When, for example, a fixture is made with an overall
fairly close
length
16
25.4
406.4
mm
but would
make
it
mm.
an even 400
as
Likewise, an American
in length,
while a European
manufacturer may have an equivalent eyebolt that is 150 mm, not 152.4 mm, long.
Where an American screw thread is converted, it is to the nearest metric screw thread.
No attempt is made to convert American standard fits and tolerances. Parts with metric
dimensions should be designed with the ISO Limits and Fits; a collection of data for this
system is found in Machinery's Handbook, 19th ed pages 1529 through 1538.
In some cases, such as in dimensioned drawings and their accompanying
calculations,
no conversion is attempted. To write two different sets of dimensions into the drawings
Many of
in English
and
is
unnecessary since
metric units.
In
In
all
in
such cases, separate equations are given for use with English and with metric
end
made
System (SI) which is rapidly becoming the recognized standard throughout the world,
Thus the reader will find that the newton (N) and the kilonewton (kN) are the metric
units used for force while the gram (g) and the kilogram (kg) are used for weight (mass).
Preface
The book
is
is
is
a technician in industry or a
college student.
list
and
applicable equally to all types of fixtures, and also calculation methods for the stress
variety
of
The
use
a
components.
deformation analysis of the fixture body and its major
demonstrated by numerical examples.
The author has avoided presenting a confusion of detailed drawings of complicated
drill plate
fixtures. Instead, there are 1 5 actual cases included, ranging from the simplest
For each
operations.
other
and
for
milling
to some complex and quite advanced fixtures
of calculation methods
is
there
is
requirements and one or more typical examples. In addition, the book includes the
design principles for fixtures of the most important non-machining operations, such as
welding and assembly.
A number
drawing
style
which two
in
the
book
The
heavier lines indicate the contours of surfaces that are surrounded by air.
With the dominant position of the metric system outside of the United States and the
approaching introduction of this system within this country, metric units are used
they
Conventional
are
"Measuring Angles
Dimensioning
illustrations
in
System to
vii
CHAPTER
Introduction
Definition, Purpose, and Advantages
fixture
is
a special tool
in the
provided with devices for supporting and clampIn addition, it may also contain
The
to the Swiss
more sophisticated
example of
Fig.
in their
a fixture
clamping devices.
on an N/C lathe
is
An
shown
in
pump body
N/C
housing
lathe.
reserved for skilled mechanics. Jigs and fixtures expand the capacity of standard machine tools to per-
form
1-1.
special operations,
and
in
many
cases, they
make possible to use plain or simplified, and therefore less expensive, machinery instead of costly
it
It
work support.
standard machines.
and simple machine tools into high production equipment and convert standard machines into the equivalent of specialized equipment.
4.
inter-
changeability of the parts, a jig or fixture contributes to a considerable reduction in the cost of assembly, maintenance, and the subsequent supply of
spare parts.
In effect, jigs and fixtures reduce costs and improve the potential of standard machines and the
quality of the parts produced.
1
INTRODUCTION
Jigs
skill.
The
skills
Ch.
of
SURFACE MACHINING
permanently
by
made continuously
available
One important
way as to make
operator.
goal
is
to the unskilled
Straight- Line
Motion
to design a fixture
Single- Point Cutter
in such a
it foolproof, and thereby
contribute to added safety for the operator as well
as for the work.
Lathe Fixtures
Slotting Fixtures
Boring, Broaching,
Honing, Lapping, Milling, Planing,
Profiling, Reaming, Sawing, Shaping, Slotting, Spotfacing, Tapping, and Turning, A systematic master
classification of machining fixtures according to the
characteristics of the operation is shown in Table 1-1.
Outside of the machine shop, fixtures may be
Drilling, Grinding,
applied
to
advantage for:
Assembling, Bending,
characterized as manual
classified as
shown
in
work
Table
fixtures
and
may
Applications outside
shown by
Design and
Feed
Line Feed
Broaching Fixtures
Grinding
Surface-Grinding Fixtures
Sawing Fixtures
HOLE MACHINING
Single-Point Cutter
Boring Jigs
Drill Jigs
Tapping
Jigs
Reaming Jigs
Honing and Lapping
Jigs
universal fixture
is
constructed
then reassembled to
tion.
be
1-2.
Multiple-Point Cutter
of
this
Work
Purpose
Fixtures
Type
area will be
Economy
Preparatory Operations
Layout Fixtures
Metallurgical Operations
Joining Operations
Welding Fixtures
Annealing Fixtures
Quite often,
allow
drill jigs
Fixtures
Riveting Fixtures
Wire-Stitching Fixtures
are built to
Crimping Fixtures
Assembly Fixtures
frequently,
fixture
may
be designed with
Quality Control
Inspection Fixtures
Measuring Fixtures
Pressure-Testing Fixtures
Ch.
INTRODUCTION
sideration,
the
is
number of
parts to be produced.
Typical Examples
be reused.
generally not the case, however, with ordinary jigs and fixtures of special design. Disassembly and reuse of components is ordinarily not ecois
when
the production
is
There are undoubtedly not two identical fixtures in the whole world. The design of these tools
serve.
is,
and different costs. The dewhich must always be taken into con-
short-run
This
ciding factor,
creative imagination
and these rules can be learned, mastered, and practiced by average persons.
As evidenced by the structure of this book, that
erned by
shown schematically
rules,
lies in
the
means
the
sional control. In the milling fixture (Fig. I-2a),
initially
is
work
cutter
and
between
relative position
vast variety
system can be evaluated for its good and bad propaperties, and accordingly assigned to its optimum
plication area.
systematized to an even
is
governed by a logical, step-bystep procedure that is time tested and leads to a useful end result. It is a cookbook recipe. As such, it
supports the beginner, it guides the experienced
higher degree.
practitioner,
It
and
is
it
may even be
of assistance to
the expert.
Any mechanical
documentation of
design
its
is
incomplete without
is,
and deformations
sioning
is
is
more
likely to go un-
noticed.
Fig. 1-2.
The
fixture;
(Bottom)
A drill jig.
(Top)
milling
INTRODUCTION
work depends on the accuracy and rigidity of the
machine tool. In the drill jig (Fig. l-2b), the tool (a
twist drill)
the
drill
is
is
Vpf
fin,
*,'.
^-miiiinc curaa
LjH*J
^^tMy~gnk
I
in the jig.
gag
positively positioned
is
Ch.
{jag]
V
{P
|g|gg[^gg
a relatively
not.
is
The
The
tors
power for a
lifting job,
in
equipment.
Once the
ture
is
is
positioned on the
the
adjustable support 9
is
provided against
a small pro-
lifted
The
it
fixture
body J
casting; although
it
is
is
completed.
jection
fixture
is
and that
a large
cially available.
number of
is
needed
commer-
CHAPTER
design, and
documenta-
They
may
be some
These rules
Rough machining
1.
The
Initial
Design Concept
is,
ing,
even
presumably
in the designer's
of the
phase.
first
if
are:
is
followed by grinding,
done before
if
finish
machin-
required.
roughing operation should be done as early as posThis last rule has, however, one important
sible.
modification concerning the clamping or spanning
manufacturing
"most severe roughing" operation should be performed with maximum possible feed and depth of
initial
veloped
at
operations plan, listing among other things, the sequence of operations, calling for fixtures at the appropriate places within the plan and providing the
It is
an absolute
necessity to have the sequence finalized prior to fixture design. Whether the surfaces are rough (cast or
makes
a radical dif-
In the
ference in locating and clamping the part.
design of a drill jig it makes a difference whether
is
machined internally
first,
and external-
fundamental rule
is
must
have ready access to the surface or surfaces to be machined. The requirement is obvious, but is sometimes forgotten at the start, and a great deal of redesigning may be required when the error is discovered.
of the part.
it
the
requires
In such
in-
may
stances,
it
surface
first,
rule
first, and the outer surfaces machined afterwards, then there would be broken edges or burrs on
one side of each hole and slot. Conversely, if the
milled
The
5.
lows:
chining.
mentary
lists
of such
lists
of items to be considered.
Examples
accumulates
information as far as it concerns the design assignment. Four areas of information must be taken into account; the part material
and
Ch. 2
appear
trivial,
to avoid his
Material Class
i.2
Sintermetal product
square
1.3
Forging
rectangular
triangular
circular
1.4
Weldment
1.5
Stamping
trapezoidal
1.6
polygonal
1.7
Extruded product
Other material class
other shape
4.5
Spherical
4.6
Material Type
2.1
3.
Flat
Casting
1.8
2.
4.4
1.1
Metallic, ferrous
2.2
Metallic, nonfeirous
2.3
Nonmetallic, synthetic
2.4
Nonmetallic, natural
conical
Material Properties
4.7
3.1
Machinability
3.2
Hardness
3.3
Strength
3.4
Modulus of elasticity
3.5
Ductility
3.6
Brittleness
3.7
Weight
listed
thin walled
thin walls with heavier parts (blocks, lumps)
4.8
4.9
Bracket
4.10
Tube
circular
total weight
polygonal
weight distribution
thick walled
thin walled
Magnetic properties
3.9
Electric resistivity
3.10
Specific heat
3.1 1
Thermal conductivity
4.11
5.
Special
4.1
Solid
4.2
Cylindrical
4.3
and combined
shapes
5.1
4.
shapes
thick walled
3.8
pyramid
truncated pyramid
shapes:
Individual
holes
splines
bosses
localized cavities
blocks
undercuts
ribs
special surface
slots
5.2
screw threads
Number of components
5.3
Dimensions
5.4
Locations
and point
requirements
listed
above
Ch. 2
Fixture Design
Table 2-1 (Co/it). Part Description Details for Preplanning of
5.5
5.6
linear
5.7
angular
5.8
listed
above
Fixture Design
Table 2-2. Classification of Operations for Preplanning of
/.
Machining
Stitch
2.8
Stable
2.9
Press-fit
2.10
Shrink-fit
2,11
Swage- fit
2.12
Magneform-fit
1.1
Bore
1.2
Broach
1.3
Drill
1.4
Mill
1.5
Plane
1 .6
Ream
1.7
Rout
1.8
Shape
O-ring
1.9
Slot
gasket
1.10
1.13
Tap
Thread
Turn
Grind
1.14
Hone
1.11
1.12
2,13
Stake
2.14
Tab-bend
Assemble with a
2.15
Other
1.15
Lap
3.1
Linear dimensions
1.16
Polish
3.2
Angular relations
1.17
Brush
3.3
Concentricity
1.18
ECM
3.4
Planarity
1.19
EDM(electrical discharge)
3.5
1.20
diem
3.6
Other inspections
1.21
Manual operations
Other
1.22
mill
4.
Assembling
2.1
Heat-treating
4.2
4.3
Surface coatings
Bond
with adhesives
diffusion
2.2
painting (masks)
Braze
Solder
2.4
Weld
With conventional
2.6
plating
bond
2.3
2.5
4.4
Foundry operations
Number
fasteners
aspects of operations
bolt
5.1
Single operations
screw
5.2
5.3
Rivet
explanatory,
Blueprints and Specifications
An
sea)
flow-sealer
2.16
3,
2.
2.7
Table 2-2
is
self-
able, but
is
must do
his
if
own
operations planning.
As
the spe-
Ch. 2
/.
Material
1.1
Milling
machine
Plastic
2.4
plain
universal
vertical, etc.
1.2
plating tanks
Drill press
painting booths
drying and baking ovens,
sensitive
power feed
2.5
Boring machine
borer
horizontal, etc.
1.4
etc.
Foundry equipment
sand preparation equipment
molding machines
core making machines
mold and core drying and baking ovens
vertical
jig
forming equipment
2.2
2.3
Lathe
engine lathe
face plate lathe
Joining Equipment
copying lathe
turret lathe
3.1
Bonding equipment
bonding press
3.2
Welder
autoclave, etc.
resistance
shaper
slotting
1.6
arc welder
machine
broaching machine,
Gear cutting machine
electron
etc.
3.3
Riveter
3.4
Stapling machine
pedestal, etc.
gear shaper
gear grinder, etc.
1.7
Stitching
3.6
abrasive belt
3.7
3,8
surface, etc.
1.9
1.10
Honing machine
N/C machine tool
milling machine
4.
Inspection Equipment
4.1
press
Optical
lathe
comparator
collimator
mill
4.2
ECM
EDM,
(dial indicators)
air gages
Polisher
wire brush
felt or cloth
mechanical
etc.
laser
chem
1.12
furnace, etc.
drill
1.11
machine
3.5
Grinder
universal
1.8
beam
laser, etc.
wheel, etc.
electric
meters
Heat-treating equipment
furnace
Ch. 2
about the cutter
life
details.
Table 2-3 brings the designer closer to many
A table of this kind is to be used In conjunction
with
with lists of the plant's own machine tools
size, ac{table
capacities
dimensional
their
tables of
range, etc.)
cessories, horsepower, speed and feed
the accumulathis should essentially conclude
and
tion of information
ture
itself.
fix-
One more
be expected.
to
human
limita-
has
assist in
within the developing fixture concept. To
whole
the
within
subjects
individual
pinpointing the
fixture structure,
complicated
quite
sometimes
and
basic
Table 2-5 has been prepared, with a list of the
of
result
the
As
design considerations in the fixture.
defixture
preliminary
the
process
this development
emerges; preliminary because it has not yet
sign
test,
Criteria
Table 2-4. Manipulation and Operator
Lifting,
Adjustment of cutter
2.2
Speed considerations
/.
Operator considerations
J.
weight
1.2
equipment
Loading and unloading of part
1.3
Clamping of part
hoisting
3.1
Fatigue
3.2
Operational safety
(accident-proof concept)
Miscellaneous
4.
2.
Safety of work
Locating part correctly in fixture (fool-proof
2.1
4.2
concept)
1.
1.4
1.5
1.3
1.6
1.7
4.
for re-
locating parts
4.1
4.2
4.3
Stability
elastic
2.2
2.3
2.4
Other
of
part
and
avoidance
5.1
Rotating ("indexing")
5.2
Sliding
5.3
Tilting
7.
Chips
damping of part
3,1
Speed
3.2
3.3
3.4
of
deformation
Concentric to an axis
Vertical and horizontal from established surfaces
2.1
3.
in fixture for
Support of part
Ease of motions
Safety in manipulations
5.
2.
Fixture Design
elements
1.2
in
3.5
4.1
7.1
7.2
Chip disposal
10
its
Economics.
may
some
trivial,
some
serious.
to establish a check
Part Details
Check
cost.
considerations will
22,
Ch. 2
list
Operation
Classification
Some
uses:
1,
It is
designer
will
Equipment
Operator
Selection
Criteria
Phase
Select
Select
Pertinent
Select
Pertinent
Items
Items
Pertinent
Items
Initial
Select
Pertinent
Items
Design Concepts
Discorded
Ideas
Phase
Preliminary
Fixture Design
Cost Analysis
and Evaluation
"
ma y
Fixture Design
Pri
Alternate 1
Fixture Design
Alternate 2
Fixture Design
r~*~-i
j
Fig. 2-1.
Pha
II
Ch. 2
on an assignment,
will
it
in a
For a fixture intended to become a station
sure that it
transfer line, it is important to make
incorporated into the transfer mechanism.
2.9
constant guide.
is
by
should be applied systematically, point
completed.
phase
is
design
a
point, whenever
2.
It
3.
3.1
Check
1.
List
slots in the
Also check T-slots relative to holes or
revisions.
1.2
1.3
all
Make
check
part outlines
shown on
ance
location relative
fixture drawings,
The
fixture
must be
fully
11
The Shop
2.1
3,2
work
station
is
equipped
air
2.3
supply,
fixture.
hoist
For heavy items (fixture as well as part), a
It is advisable to check
should be available.
whether
it
is
If lifting
equipment
is
ing, such as a
2.5
is
recommended that
shop department provide other means of lift-
the
Once the
it
is
fixture
is
ter line
work station.
The same consideration applies with respect to
the loading of the part into the fixture. Specificprojecting out of
ally, watch out for long parts
The
line,
the fixture,
when
is
On
should be cor-
gravity
important to
of
completion
after
fixture,
the
that
sure
make
into such
its design, is also properly incorporated
equipment.
it is
when
installed, or
when
operated, must
line.
jig,
one fixture or
to the
rectly located and oriented with respect
For a
hole
part of a production
installed,
all
lines.
chine.
the fixture,
2.8
center
is,
machine spindle
the distance from center line of
is a critical
to machine column or machine frame,
dimension. With fixture in place, the spindle cen-
parts to the
2.7
from
forklift,
sure
shop layout around the work station to make
delivery of
that it permits transportation and
2.6
purpose,
2.4
to
with
check to be sure that the fixture is balanced
Make sure that breakage of tool,
part in place.
hazard to the
part, or fixture does not present a
machine tool
along
the
otherwise interfere with the transportation of
table.
2.2
end of the
3.4
a drill
a usual and safe practice not to hold
(6-mm)
by hand for holes larger than 1 /4-in.
rails,
diameter. In such cases, be sure that stops,
It is
jig
nests, or
on
the drill
is
moved from
spindle to spindle,
make
12
For
drill jigs
drill
heads,
4.6
in stock.
it is
5.
3.7
if
5.2
drill press,
needed.
to general
5.3
5.4
Check
proper places.
maintenance of cutters,
when
justed
The
6,
The Part
6.1
Can the
is
Check
is drilling
with multiple-spindle
drill
drills
6.2
Look
all
all
A
if
slender drill
the jig
be
the
drill
is
moved
drill.
position,
If
drill
the jig
drill
is
heavy,
breakage
drill
forgings;
travel
enter the
to correct position
and
on
tion,
spindle.
may
for flash
on one
to facilitate production, or
check
stop on the
mismatched
bushing even
by the
of
it will
will
drill
elasticity
of
in line of flash.
Check
their correct
for
locating points
Look
bush-
drill jigs,
must be high enough to allow the jig to be unloaded and reloaded while the drill is
running.
of
castings),
ing
In the case
drills
travel.
by
Clamps may
or brass facings.
of cutter
require
distorted
being op-
4.5
may
case in point
supporting elements.
for interference
particularly
locating and
chined surfaces
faced
tacted by a clamp
4.3
4.2
all
carbide, etc.)
With respect
it
bushings)
Check
Cutters
4.1
drill
5.1
3.6
4.
possible extent.
to
Ch. 2
bushings
in
relative position
6.3
Some
draft,
one
all
ensure correct
of all holes.
surfaces
part drawing
as parallel to
each
Ch. 2
7.
7.1
9.
Clamping
heavy.
good
definition of,
9.1
of such items
and compatibility with, and
the surfaces to be machined;
sioned directly
7.2
surface(s).
Wherever
to assist in
7.5
Space locating points as widely as possible, particularly on rough surfaces use three locating
points. If a fourth (or more) point is needed for
stability, make it adjustable or a jack type.
acts to
or
where
if
it is
cases,
8.3
withstand
all
loads.
sure that clamps cannot be loosened accidentally by centrifugal forces, shock, vibration,
or surfaces,
and chatter,
to
be
buried
in
and should be
chips,
Make
Locating
9.3
9.4
subject
to
wear,
locating pin, to
have a conical
match
even
applied.
all
open or
any part of the
position,
locating
if
All forces
easy catch.
any
If locating
Provide
In
machine.
9.5
elements are
easily
cleanable.
8.5
table.
8.4
twist, or otherwise
All
8.2
tilt,
on the machine
in
the fixture.
unacceptable,
accuracy required
Preferably,
or
ing forces should not act to distort the part
8.1
not rely on
Do
the part.
&
tilt
result in
lift, tip,
Centralizing devices, such as V-blocks for cylinders, are insensitive to diameter variation with
The stacy ng of
in position;
7.6
for
for sta-
bility
7.3
13
connected to the start or feed lever on the machine tool. Hydraulic clamp, supplied with oil
14
the
machine
good
9.9
or requires hard
10.5
Wherever possible, pre-position part for easy loading during machining cycle on the previous part.
Fixtures may be built with duplicate space for
parts so that one space is unloaded and reloaded,
while the part in the other space is being machined.
Or: the finished part may be removed by one
tie
them
to the fixture
by
10.7
hand engages
11. Drill
11.1
11.2
make
details
as:
room
11.3
Heavy
parts should be located end for end; one end
is
supported while the other end is being located.
Small details
in
Make them
drilled
pins,
to
be located
in
previously
them into
drilling operation
position.
Many
Straight bushings (i.e., without flange) are preferred because of their simplicity and low cost;
re-
Flanges on bushings should protrude above accumulation of chips and cutting fluid. Wherever
on the
operation by providing
cutter.
1.4
11.5
as short
parts
Check each
drilling
may
Bushings
The
be significant.
part.
plenty of
by the other
'
Lo-
inserted
is
is
ticular,
Use toggle clamps for quick action. Use compressed air or hydraulics for quick action and/or
large clamping forces.
Many
part
necessity of a bushing.
respect to loading
new
new
10.3
operator's side
by a
10.2
on
10.1
star-shaped
operations.
10.6
if possible,
10.
than
clamping operation.
Evaluate the various aspects of the clamping opwhether it is a quick and easy operation,
eration,
operate
is
to
handles.
comfortable
less
of air
or hydrauljcally operated clamping mechanisms,
activated by the N/C program.
9.8
10.4
tool,
9.7
Ch. 2
are
wear. Accurate
Ch. 2
.6
1 1
Check
Slip bushings
may be omitted
13.2
by using a stepped drill for drilling and counterboring in one operation. Let the large diameter
enter the bushing before cutting starts. A hinged
13.3
slip
It is
marked with
drill size
The
drill jig
should be
of diameter tolerances,
required.
3.4
bearing
13.5
jigs
sizes larger
than
12.3
may
13.8
Precision
14.
when jig
For holes
14.1
For holes
all
is
be clearly
visible to the
14.2
may be
This motion
may be
may be
is
part.
blocks.
14.3
accurately, be locked against loosening when engaged, and unlocked and withdrawn preferably
by one movement.
fluid
in-
dexing fixture.
14.4
may be
removal.
Lift
surfaces of locators
Fixtures in General
13.1
cast
Index pins
is to provide indexing for the jig.
must move in and out easily, engage quickly and
IS,
produced from
facilitated
12.8
fixture should
op-
positioned.
12.7
cut-
a rotary table.
in
design low.
mounted on
12.6
with
The Chips
this
jig,
erator
12.5
vise
Keep the
2.4
hall-
13.7
purpose; larger
an eccentric cut
must be made
Small jigs
mounted
may
Only small
sion
size
this avoids
13.6
drill jig for
have
with a handle.
12.2
drill jigs)
fingertips,
sequence rule:
bore; reason:
lest
Flanges should be large and fluted (preferable to knurled) for easy gripping, with room
place.
the
call for
means
drill jigs
12.1
may
for
bushings.
11.8
weight,
slip
15
Look
for
conditions
small in area
16
14.5
from chips.
16.7
is
If necessary,
16.8
provide shielding.
Ch. 2
fluid.
14,6
Be reluctant
to
of Pan
17. Inspection
use
compressed air; while highly effective on crumbling and powdery chips, it contaminates the
shop atmosphere with abrasive dust.
17.1
14.7
17.2
14.8
from entangling
fit
17.3
ter.
this
fluid
and measuring
of burrs.
An
If necessary,
device.
purpose.
15.2
device.
Fluid
The cutting
surfaces,
surfaces.
15.1
is
or be fastened by screws
from the top, avoiding chip pockets in bearing
15. Cutting
It is
18.
15.3
15.4
Cutting fluid
may
and
Storage of Fixtures
movable
fixture parts.
18.2
and
16. Safety
efficient,
parts.
bushings,
16.1
Make
a general
review of
all
but also:
handles, stops, supports,
clamps, feet and numerous other parts, including
the complete so-called "universal fixture."
Check
manipulations and
Make
16.3
manufactured parts for use of stock sizes of maFinally, check availability of all such
Check
fixture
visibility at all
times
terials.
items,
1
8.3
8.4
facilities for manufacturing capability with respect to this fixture, including its prescribed tolerances.
suspension;
if
necessary,
drill
purpose,
Check
most
8.5
trivial
hazards:
16.6
Make
In case
part
be
pressure
of
all
and
movable
specificaall
wearing parts, and for easy removal and replacement of parts subject to wear or accidental damage. Be certain that replacements can be made
without interference with other fixture elements.
Check
with a press
18.6
end" of
parts
fit.
Ch. 2
18.7
18.9
safety,
When
toolmaking.
Provision for
holes (for
necessary
identification
hose
marks,
in-
items.
18.11 Check design drawings for correct sections, projections, and views, and a clear description of all
functions, for complete dimensioning, complete
and com-
as widely as possible.
18.14
When
final
may
require
number,
18.12 During this
the
purpose.
all
for
18.10 Provide
under
this
following details:
18.8
17
ture design.
CHAPTER
moments and
bending
and
Steps
in
is
sequence
locating,
drawn
elements.
"body"
and
it is
one oprecom-
mended
it
cannot be
of
two directions
in
Now
and cutting forces) are not taken into consideration with respect to their magnitude,
but only
as to their direction, so as to ensure that
the part is
located in a position of static stability.
sures,
18
points (two
three motion
lifted off.
in the vertical
in
these
particles,
many,
six degrees of
in
consisting of several, or
The
motion
against the
end (see Fig. 3-1 c); this eliminates the sixth degree of
freedom and the block is now fully located. The
redundant, but
improve the
stability, as
Locating Principles.
explained in Chapter 4,
Ch. 3
19
apply
above,
six
is
metal,
it
elastic
may
may
deformation or "spring-
if
it
is
of
two or
should be hollow,
it
clamps so
transmitted through
its
reaction
point.
Providing Support
all
of the part.
to
absorb
all
acting loads.
On
must not
Fig. 3-1
single locating
the bottom
surface.
20
Cutter Guidance
cutter.
all
drawn "floating
remaining design
or fixture body that carries
the individual elements and has enough strength
all
to
is
draw a
jig
The
fixture
body must
must
in
number of
accommodate the
also fulfill a
other conditions-it
first
long range of steels are standardized and idenby the prefix SAE (Society of Automotive
tified
step
Standard Steels
Ch. 3
Engineers) or AISI (American Iron and Steel Institute), followed by a four-digit number.
The last
two
The
classes are:
part,
on the machine
Types of Steel
Class
table;
lOxx
have locating elements for aligning it with the machine spindle, and have an adequate number of lugs
plain
llxx
13xx
for
holddown
it
bolts.
The following
fixtures:
Steel,
Steel, specified
by the
SAE and A IS
classifica-
carbon
manganese
steels
steels
2xxx
3 xxx
4 xxx
5xxx
molybdenum steels
chromium steels
6xxx
chromium-vanadium
7xxx
8xxx
9xxx
tungsten steels
nickel steels
nickel-chromium
steels
steels
nickel-chromium-molybdenum
steels
silicon-manganese steels
Tool
The
steel
large class of
carbon
steels,
Cast iron
1
i.e., Machinery's Handbook
Data for materials that are not covered by standards,
are available from the manufacturers.
Not Specified
Much
It is
(New York:
1985-1978.
car-
steel material
any standard.
Steel,
and up, while not usually regarded as carburizing types, are sometimes used in this manner
for large sections or where a greater core hardness
Machinery's
1971.)
is
required.
Handbook
is numbered 1030,
1033, 1034, 1035, 1036, 1038, 1039, 1040,
Ch. 3
they
still
21
have better dimensional stability after heat treatment because they contain less residual stresses.
The cost is higher, however, and alloy steels are only
selected where a carbon steel cannot be used.
Tool Steels
toughness.
They
smooth,
are important,
it
stability
is
relief
stress anneal or normalize the part for stress
required.
medium;
in the interior
is less
than
listed in
Table
mass effect is so dominating that even the surface cannot attain the theoretical full hardness
of 62-64 Rockwell C.
seldom used
lower machinability, they are not used to any significant extent in fixture construction. However, some
fixture components are now commercially available
for purin stainless steel. Stainless steel is also used
poses where its lack of magnetic properties is of
magnetic
value, such as for separating elements in
chucks and for backing bars in welding fixtures.
Alloy steels, in general, have greater toughness
than carbon
of comparable strength.
is
oil
is
in fixtures.
They harden
in
Type of
Chemical
Steel
Components
C
Mr.
Wl
W2
01
02
06 SAE 52100
0.95-1.10
Si
0.50
0,25
Mo
Cr
1.30-1.60
0.50
V
1
Also,
two ways:
desir-
steels
it is
52100 which
number of
3-1
large
is a
able to keep distortion at a minimum and this
of
type
the
of
selection
the
in
major consideration
all fixture requirePractically
used.
to
be
steel
tool
ments can be met with the selection of tool steels
22
limit
undefined.
W]
Ch. 3
43xx class.
bon content
grades
is
steel of
tool
steel
dening steel
pered
300
02
nealed and
is
is
is
of
oil
hardening tool
steel,
vise
made
hardening are
grinding
made
or 06.
Chuck and
steel
or
to
dimensions are
percent.
Tool
at
02
sure that
mum
all
Diameter
(mm)
(inches)
Minimum
Machining
Allowance
on Diameter
(inches)
(mm)
13 or
1/16
over 1/2
13 to 32
1/8
32 to 63
1/4
63 to 127
3/8
10
127 and
1/2
13
to
over
less
1/2
to 2 1/2
over 2 1/2
to 5
5 and over
or 1144 carbon
Surfaces that are exposed to light wear only,
can be case hardened by cyanizing and do not need
steel.
1/4
11/4
tion.
over
06
The
tool steel
is
oil
hardening
used.
Collets and
are
Minimum
Machining
Allowance
on Diameter
1/2 or less
or 06.
somewhat higher
tensile
it
work hardened. It also produces a smoother surface when machined, however, since it contains
is
may warp
it
it is asymmetrically machined.
For
hot rolled material is preferred for parts
that are to be finished by grinding, or machined on
one side only.
if
this reason,
steel,
Larger
drill
bushings are
made of 8620
bushings are
made of low
oil har-
is, high carbon steel wire commonmusic or piano wire, heat treated to
the proper mechanical properties.
ly
known
Dowel
as
pins are
made
expanding arbors are particularly critbecause they require hard gripping surfaces combined with resilience.
They are made from alloy
steels with low carbon content, such as 2312, 2320,
ical
Very
large
41xx
made of 1 060 or 065
a tool steel.
made of
it is
various
preferred to
ground
available.
group.
made of water
har-
psi (1
Ch. 3
The
carbon
carbon
steel
steel
made of 1020
material
tips
made
of a free-machining
low carbon
steel
and case
at least
60 Rockwell C.
some
for parallels, raiser blocks, fixture bases, and in
vibration
where
particularly
bodies;
fixture
for
cases,
damping capacity and absence of
Castings in the
first
a cast product of a
mm
on 2 1/2 m),
erance of 0.010 inch on 8 feet (0.25
jum) surface
to
1.0
micro-inch
(0.6
and 25 to 40
from
range
1/4 inch
thicknesses
Standard
finish.
up to 16
to 6 inches (6 to 150 mm). Thicknesses
inches (400 mm) are available from stock; above 16
inches by special order. The material weighs 0.101
3
pound per cubic inch (2.8 g/cm ), and its tensile
psi
(165
N/mm 2
Magnesium tooling
plate
is
strength
is
24,000
).
a rolling mill
product.
Zn, and
made
Mn. It is thermally stress relieved at 700F (37 1C) and
machined on both sides to a thickness tolerance of
0.010 inch (0.25 mm) and a typical flatness toleron
ance of 0.010 inch in any 6 feet (0.25
Standard thicknesses range from 1/4 inch
1.8 m).
of
It is
AZ31B
alloy containing
I,
weighs
to 6 inches (6 to 150 mm). The material
3
per
cm
) and
inch
(1.78
g
0.0642 pound per cubic
2
strength
35,000
psi
um
combustible
is
is
ignite easily
in the
and burn
magnesium
violently.
to
Very
large
ductile (nodular)
N/mm 2
tensile
made
of
2
65,000 psi (450 N/mm ) tensile strength, and type
SP80 Meehanite Ductliron with 80,000 to 100,000
2
tural
tions
is
172 N/mm ) tensile strength. Larger fixture bases, and fixture bodies in general, are made
with
of gray cast iron in classes 30, 35, and G3500
(138
tooling plate
mm
Castings
portance.
Aluminum
23
beyond the
Sintered Carbides
is
sists
tional tools.
is
har-
Plastics
Plastic tooling is
made by
24
widely in physical properties. The physical propof the end product depend also on the mixing
erties
will
therefore, are representative only; the fixture designer is advised to obtain specific data from the
form of
Cast
1
5,000
strength
12,000 to 35,000
psi (83 to
of
cast
03
strength
N/mm 2 );
the
of
com-
psi (83 to
241
N/mm 2
).
These
X 10 6
to 0.8
pressive strength;
yield,
10
B=> 10 X
E has the
2
(52 N/mm
and
psi
to 150 psi (0 to
Potting
ings
X 10 6
N/mm 2
.0
compounds used
with metallic
fillers
psi (70
(690 to 5520
N/mm ), and a linear shrinkage of 0.001 Jo 0.004
inch per inch (0.025 to 0.10 mm/mm), which is
in
compressive
plastic
epoxy
drill jigs
resins.
are high-
Epoxy
resins
psi
where
light
weight
is
is
growing rapidly. For this application, epoxies are superior to most other plastics and they are
now used almost exclusively for laminates. Epoxy
laminates have an elastic limit of about 15,000 psi
2
(103 N/mm ), and a modulus of elasticity ranging
from 1.5 X 10* to 3.5 X 10 6 psi (10,300 to 24,100
uct
terial is
The shrinkage
).
is negligible and they are
dimensionally stable after curing.
Rigid polyurethane foam is used as a core material
stress.
N/mm 2
N/mm 2 ) at
bored holes
in
10
Cast
temperature-resistant
2,000 to
pressive
is
Ch. 3
A
is
made of wood
is
oil,
1.3
chips and
and
lignite.
(52
flat
plywood and
N/mm 2 ),
X
10
psi
and
the
(9000
modulus of
N/mm 2 ).
is
7600
elasticity
psi
is
It is available in
1/4 to 2 inches (6 to
50 mm).
shells.
It has its optimum
strength/weight ratio in the density range of 6 to 1
CHAPTER
Locating Principles
define a part from two parallel and offset flat
To
Because of the
tol-
punched centers
can only be located from its surfaces and this is done
by providing them with the necessary number of
restraints. To restrain the part on a surface against
only one direction of motion, as was shown in Fig.
termed defining the part and implies the addition of a subsequent clamping action to maintain
faces.
3-1,
is
The
on one
restrained on
part
is
two
surfaces,
on three
it is
when
It
is
either
hang or
tilt
When
surfaces,
it
on the two
(Fig. 4-2),
surfaces.
It
will
more concentric
cylindrical sur-
on two
offset
them on three
points.
restrained
it is
surfaces.
it is
restrained
?-
is a
gen-
example of defining and locating from flat surfaces. The block is single defined as long as it only
rests on the horizontal base of the fixture (position
eral
a),
from two
Nesting
part
may
the part
it
Fig. 4-1
flat
surfaces.
is
is
fully defined
and
In Fig. 4-3a,
single nested, in
it is
b and c
fully nested.
Full
25
LOCATING PRINCIPLES
26
Ch.
sition.
tions to be performed.
as possible
Any
clearance,
An
misalignment.
no matter how
in po-
small, will
will
al-
gen-
interference
the class of
clearance
of these
shown
fit,
fit
moved
into position.
There-
must be
actually selected
fits.
in
many
If the fixture
it
can be seen
is
in position C.
the part
is
now
is
be discussed in detail in Chapter 6, in the section on Circular Locators, and in Chapter 9, Cenwill
tralizes.
If
the fixture
set
is
on a corner with
fully nested
is
also centered.
is
The example
in Fig. 4-1
is
an illustration of the
Fig, 3-1,
It
same principle
is
points back to
as
is
shown
equivalent to the
is
in
first
equivalent to
is
equivalent
locating
points
somewhat
is
different
to
points.
full nesting.
a position
On
it
and
all
To
underline this
termed "stops."
Other equivalences, however, are possible. A set
of two points is equivalent to one strip; a plane is
equivalent to two parallel strips, or to one strip and
a point (see Figs. 4-5, and 4-4a, b and c). A locating
point is not a mathematical point, it is often a small
flat surface (a pad).
The locating elements should
LOCATING PRINCIPLES
Ch.
27
Error Possibilities
feasible
Fig. 4-5.
strips,
is
only
com-
with
patible
fixture surfaces
duction parts.
provides the
the
geometry
errors.
element.
The
effects of curvature
may
The
3-2-1
With
3-2-1 Principle
The
minimum
re-
quirements for locating elements. The locators, together with the clamps (represented by arrows C in
Fig. 3-1) which hold the part in place, provide equilibrium of all forces, but do not necessarily also
guarantee stability during machining. Usually, sta-
it is
now be
Even with
curved.
and may
may
still
new
it
will
surface will
distortion-free clamping,
be insufficiently supported
bility
The
;7l~)
/ >
rT7\>
>
rrr) >///;>/,
r;
the clamps.
slip in
4-2-1 Principle
By
sTTV
/ > s J
>T7 s
rTT/ /
s / ^
7=T7-
if
rock.
This
is
itself
on
a locator,
will
Fig. 4-6.
The
effects
surfaces.
is
is
LOCATING PRINCIPLES
28
mitted by
Ch. 4
the
it
is
surfaces
will
usually
be
located
by
Fig, 4-9.
rn
it,
as
end
strip
shown
in
on the base
When moved
to position
c,
now
shown previously
in Fig. 4-4a,
and
it is
way
as
also centered
removed.
ji
*
p
The
Fig, 4-7.
ing system
is
on
locating.
Some
examples are shown in Fig. 4-7, where the large arrow indicates a clamping force, and the resulting
dimensional error in the locating is indicated by a
double arrow. Perhaps the most dangerous case is
that of Fig, 4-7d, because the error occurs at a place
that
is
Nesting
is
no guarantee
shown in
shown is per-
the
example of
Fig. 4-8.
The
offset
Fig. 4-9.
flat surfaces.
can
locating
The
is
it
as
design,
Fig. 4-8.
be accom-
matching cy-
lindrical
on
nesting.
29
LOCATING PRINCIPLES
Ch. 4
ici
N$h
I
i
Z\
i
i
Incomplete
Fig. 4-10.
locating
means
by*
of a
simple
cylindrical locator.
For
fixture.
this
in Fig. 4-11.
shown
in Fig. 4-1 2.
Two
factors
common
to
all
motion of that point in a tanThese will be termed "radial loUsually, and preferably, the direction of
cators."
the actual contact pressure should be perpendicular
Fig. 4-11.
gential direction.
and
c,
c;
it
may
it
systems,
such
illustrated
in
Any
Fig.
termed
may
offset
is
sketch
vary as
from
its
a,
As indicated
by means of an
other.
widely used.
is
a cylinder
nesting,
part
Locating by
4-13,
Complete locating of
in
in
2{D F
-D P
j
radians
-
" 360
DF -
p
degrees
much
as the clearance
nominal position
as
and may be
much
as one-half
30
LOCATING PRINCIPLES
Ch.
J3&
-F=Fr"
Fig. 4-13.
m&
Fig, 4-12.
Examples of dual
cylindrical location.
n.
as
is
shown
points.
ness
dirt
is
T
cos~a
force
component
T produces
cating plane
lift
occurs
a locating error
perpendicular,
wnen
E=T when
but
the lo-
larger error
is
inclined
They belong
tralizing devices to
be discussed in Chapter
Fig. 4-14.
The
LOCATING PRINCIPLES
Ch. 4
Fig.
plane.
31
CHAPTER
One
Un machined
Surfaces
is
to
produce parts
It is the ma-
It is
obvious that
all
it
to
surfaces,
drastically
is
all
machined
exaggerated example of a
shown
in Fig. 5-1
Machining allowances
are, in
way, related to
is
chining allowance.
Fig. 5-1,
outer surfaces.
chined with
The cylinder
a gross error in
to the right
was ma-
outer surfaces.
tem
32
lines
maximum
tolerance on
Where
mama-
For an order -of-magnitude estimate, it may be asthat machining allowances increase with the
overall size of the raw part. For gray iron castings
made in green sand molds in sizes from 20 to 100
inches (500 to 2500 mm), average machining allowances vary from 3/16 to 7/16 inch (5 to 10 mm),
sumed
Ch. 5
they are
located in the
little
Shrinkage Rate
Material {cant.)
cope, a
33
and
steel castings
Bronze
1.6
Zinc
1.6
Aluminum
3/32 to 5/32
per foot
small castings of
simple design
large castings or
iron castings.
Percent
Linear
com-
1/12 to 1/8
per foot
plicated shapes
in.
ss0.8tol.3
in.
ss0.7 to
Aluminum
up to 1.8
Al-Si alloys
alloys for
1.5 to 1.7
automotive pistons
3/32 to 5/32
Magnesium
in.
swO.Sto
per foot
1.3
On
0.05 %/l7inch
W=
where:
1,65 VH-"
mm
weight in
kilograms.
mm)
allowance for
because of scale pits and other localized surface deall
fects
is
show
will,
I-beam-type
on the
Castings
the
A casting is by no means a mathematical reproduction of the pattern; not even of the mold cavity.
maximum
deflection
L and
length
height
expand
them shrink during the
All of
subsequent cooling period; the resulting total shrinkage depends on type and composition of the metal,
the pouring temperature, and the cooling rate.
Slight variations in the composition may occur from
charge to charge and can affect the shrinkage. Uneven shrinkage often results from differences in wall
thickness and
may
cause warping.
shown
in the
following:
'
Greater warpage
steel castings,
open up
1/8
in.
per foot
Percent
ftsl
Brass
3/16
in.
per foot
may
at the top,
may be
desired for
some
functional
low.
duction
=52
SWlJ
most
considerations can
al-
0.7
Cast steel
3200
Shrinkage Rate
Linear
ma *
ances sometimes
Material
is:
during solidification.
Common
An
gray iron casting with one thick and one thin flange
and decarburization.
Some
man
Any
conscientious pro-
34
Ch. 5
Description
Tolerance
Tolerance
Range,
Range,
Material
Tolerance
of
mm
inch
0.08
up
large castings
to 0.4
mm)
10
.15%
min
0.010
0.010
0.25
is
more
and mold
add
0.010
0.25
mm)
Die castings
on dimensions within
aluminum and
+
magnesium
15% to .25%
zinc-base alloys
1%
to
0.08
.25%
0.06
.3%
min. 0.005
0.13
.1%
.005%
tin-base alloys
greater.
first
min. 0.0025
base alloys
for the
tolerance.
min. 0.003
add
passage.
Tor
add
mold
The
gate
is
100%
mm)
in
Tolerance
mold
inch (0,20
On dimensions
mm)
perpendicu-
is
a slightly
is
the "draft,"
of draft is usually selected and applied by the foundry (the pattern maker), but the fixture designer
(mm/mm)
castings,
mm)
range
may
ing degrees to
the
mm)
which
plane
is
(4.6
terns,
the following:
is
Description
gate
cavity
50%
The
size, is
likely to
on dimensions perpen-
A more
mm) T1R
Concentricity of a cored
0.25
.5%
min
hole
The values
base alloys
mm)
Core location
core
inches (75
inch (0,30
small castings
overall casting
and malleable:
maximum
dimension
is
usually not
mold
pattern
is
shown on
required
when
lifted
Ch. 5
Average draft values
35
are:
minor
Amount of Draft
Casting Method
examples are a mismatch at the parting line between cope (upper mold) and drag (lower mold),
flash or fins at the same parting lines and along
edges of cored cavities, remnants of the gates, displacement of cores resulting in uneven wall thickness and machining allowance, and displacement of
cal
100
internal surfaces
Jo
from pattern:
lifted
ribs,
and the
like.
4*2i/y>
external surfaces
Forging?
lW>
internal surfaces
Handmade hammer
Minimum
draft as
in a
it
values are:
Casting
Method
Value
machining
However, hammer and press forged
parts from ferrous and nonferrous metals are used in
moderate quantities in various industries such as the
weapon and aerospace industries, and these forgings
may need fixtures because of intricate and accurate
machining requirements. The most common forged
raw parts are impression die forgings which, again,
may be drop forgings (closed die forgings) and up-
be manufactured
fixture.
set forgings.
1000
external surfaces,
flat
ribs
ribs
and webs,
500
1
100
1
flat
200
listed in
Po_
small holes
For mold
lifted
from pattern:
u " t0
20
in eastings is pro-
patterns, 10 percent
patterns,
and
may
the following
be applied to
Hammer and press forgings are seldom fully freehand forged, but are made with the use of flat and
simple open-face dies.
For such forgings, tolerances can be estimated from nominal dimensions
and weight.
For elongated shapes of length L (inches or mm)
and any transverse dimension (width, height, diameter, etc.)
tolerances are:
10 percent
when hand
molded.
The uniformity and accuracy of castings (gray
iron, malleable iron, and modular or ductile iron) is
higher from permanent molds, and molds with metallic cores and inserts, than from sand molds; higher
from machine molding than from hand molding;
higher from dry-sand molds than from green-sand
molds; and significantly higher when the castings
are made in shell molds.
all
three classes.
on length
TL =[0.05 + 0,003(1+
TL
on
a transverse
TD =
TD
=+
[1.3
+ 0.003
(L
10/>)]
10 D)]
inch
mm
dimension[0.02
[0.5
0.028 (D
0.028 (0
/,)]
+ ^jL)]
inch
mm
36
For
of weight
a part
Ch. 5
is:
T = 0.05 l/w
inch
T=\.6s\fw
or
mm
significant factor
how
the
other dimensions.
Die cavity dimensions depend on the initial accuracy to which the die was sunk and polished, and
amount of subsequent
wear.
Initial
dimensions
Carbon
Aluminum
Refractory
Stainless Steel
Low
Series
Series
Super
Alloy
400
300
Alloys
Metals*
Titanium
2014
7075
0.004
0.007
Magnesium
Wear Factor
Area
in
Parting Plane,
(i,005
0.004
0.006
0.007
0.009
I.MI08
0.012
Square Inches
0-10
1/32
1/32
3/32
1/16
1/16
1/16
3/32
1/16
11-30
3/32
1/8
1/32
31-50
3/32
3/32
1/8
1/8
5/32
1/16
51-100
101-500
1/8
1/8
3/16
3/32
3/16
5/32
3/16
3/16
5/32
1/4
1/4
50M000
3/16
1/4
1/4
5/16
1/4
5/16
5/16
3/8
3/8
16
1/32
1/8
3/16
1/4
Forging Weight
After Trimming,
Pounds
to 5
1/64
1/32
1/32
3/64
1/16
5,1-25
3/32
1/32
25.1-50
3/64
1/16
1/8
3/64
50.1-100
1/16
3/32
3/32
5/32
1/16
1/8
3/16
3/32
1/8
5/32
1/4
1/8
5/32
3/16
3/16
5/16
1/4
3/8
5/32
3/16
100.1-200
200.1-500
500,1-1000
1000,1 and over
1/64
Forging Weight
Flash Extension, Max., inch
After Trimming,
Pounds
to 10
1/32
1/32
1/16
1/8
10.1-25
1/16
3/32
3/16
1/16
,25.1-50
3/32
1/8
1/4
3/32
50.1-100
100.1-200
1/8
3/16
5/16
1/8
3/16
1/4
3/8
3/16
200.1-500
1/4
5/16
1/2
1/4
500.1-1000
5/16
3/8
5/8
5/16
3/8
1/2
3/4
3/8
W=
Tungsten
0.006
37
Ch. 5
Super
Series
Carbon
Scries
Metals?
Titanium
Alloys
Magnesium
300
400
Alloy
Aluminum
Refractory
Stainless Steel
Steel
2014
7075
0.004
0,007
Wear Factor
Area
in
0.005
0,004
0.006
0.007
0.008
0.012
0,009
Parting Plane,
Square
Oto
6,500 to
20,000 to
mm
6,500
20,000
32,500
65,000
32,500io
65,000 to 323,000
323,000 to 645,000
645,000 and over
Thickness Tolerance,
0.006
mm
0.8
1.5
1.5
2.4
0.8
1.5
1.5
2.4
2.4
0.8
2,4
2,4
1.5
2.4
10
10
0.8
Forging Weight
Mismatch Tolerance,
After Trimming,
mm
kg, approx.
to
2.3
0.4
0.8
1.5
0.4
2.4 to
11.3
0.8
1.2
2.4
0.8
11.4 to
22.7
1.2
1.5
1.2
22.8 to
45.4
1.5
2.4
1.5
45.5 to
90.7
2.4
2.4
90.8 to 226.8
226.9 to 453.6
453,7 and over
10
Forging Weight
Flash Extension, Max.,
After Trimming,
mm
kg, approx.
to
4.5
0.8
1.5
0.8
4.6 to
11.3
1.5
2.4
1.5
11.4 to
22.7
2.4
2.4
22.8 to
45.4
45.5 to
90.7
10
13
10
16
10
13
19
10
90.8 to 226.8
226.9 to 453.6
453.7 and over
W = Tungsten
to
wear consider-
life.
tolerances, are:
sions, the
sions
it
is
center-to-center distances.
(mm/mm)
38
maximum
the
which
flash extension,
may
is
protrude
The fixture designer must be prepared to encounsome minor defects which are considered acceptable and passed by inspection such as scale pits,
shallow depressions caused by scale accumulation;
mistrimmed edges, where the flash protrudes unevenly around the forging; small fins and rags, driven
into the metal surface; cold shuts, produced by mater
terial
folded against
conditioning
Straightness tolerances mean the limitation imposed on deviations of surfaces and centerlines from
ground away.
are those
and
(mm/
pits,
life
die
is
is
The same
Ch. 5
may
be expected when
if
in use.
mm) of length
for flat shapes 0.008 inch per inch
(mm/mm)
Weldments
The values
are for
medium
stiffness materials
and
on external surfaces
values
materials, and
high-stiffness materials.
to 3 degrees for
up to 10 degrees for
Overall
from
be
down
medium-stiffness materials,
low-stiffness
may
common
All
dimensions, such as flange thicknesses. Mismatch tolerances are the same. Cavities require a
axial
many
no
draft.
known
in a fixture will
methods
entailing closer
particularly
to 15 percent of thicknesses,
Finer
tol-
The
Resistance welds
than fusion welds. Least distortion is
found in flash- butt welding, where length tolerances
can be held to 0.02 inch (0,5 mm). When the dies
are not self-centering, a maximum offset equal to
the sum of the tolerances on the part diameters or
distort less
thicknesses
may
be expected.
forgings,
Torch-cut parts
will
may
"commercial."
Calculated tolerances are rounded
off to two decimal places, then converted to nearest
higher 1/32 inch (1 mm) and entered on drawings.
be
Ch. 5
large parts
With
position.
rates,
Mill
edges
may
be beveled as
much
39
Press Products
as 5 degrees.
Products
Some
basic
Thickness
toler-
shapes.
pliers' catalogs, a
shown
on out-
few
illustrative
mm)
in the following:
for thicknesses
tours of
Tolerance, inch
Material
punched
flat parts
mm)
may
as long as the
same tool
is
The same may be expected for small stamped and drawn parts.
Shapes formed by bending may show different
springback. Drawn parts will have thickness variaused without reconditioning.
tion and,
Hot Rolled
I -inch
(earing)
0.009
diameter
or side
2-inch diameter
1/64
or side
4-inch diameter
+1/16,-0
entrance edge.
or side
uniformity.
Cold finished
Carbon
Square
Round
Square
0.002
-0.004
-0.003
-O.005
-0.003
-0.005
-O.004
-0.006
Round
1-ineh diameter
Alloy
or side
2-tnch diameter
or side
-0.005
-0.006
-0.005
-0.007
or side
Rolled
Round
Cold Finished
Round
Square
0.002
0,0025
0.016
0.004
0.005
0.020
0.012
Square
1-inch diameter
0.006
or side
4-inch diameter
or side
+ 0.031
-0.016
Aluminum hollow
shapes, extruded
wall thickness
:15% of nominal
dimen-
on a
hollow section
fix-
sur-
Blueprint tolerances,
sions
1.5-2.5% of nominal
With respect to tubes and pipes, the fixture deknow that they not only have diam-
signer should
ture.
faces
or side
2-inch diameter
rod,
round or square:
overall
4 -inch diameter
Aluminum
Machined Parts
if
from
stress re-
40
and the fixture designer may well encounter the assignment of designing fixtures for these materials.
/////
y //////
t
1
0.002
Ch. 5
material and
filler,
Fig. 5-2.
tilted,
due to the
Ground
surfaces
0.005
Nominally square edges and corners could be out-ofangle from incorrect clamping. Sawed surfaces, even
when machine sawed, are neither straight, flat, nor
dimensionally correct. All machined edges will have
a burr on the side of tool exit.
(mm /mm)
distortion.
Phenolic with wood-flour
filler,
and urea
Cellulose acetate
0.006
to
0.010
0.002 to 0.010
filler,
0.002 to 0.006
Polystyrene
0.001 to 0.003
may
may become
may go out-of-round, and
may curve or twist. The dis-
(mm/mm)
mm)
(mm/mm)
Perpendicular to parting
plane
Warpage, perpendicular
to nominal surface
or straight parts
flat
terms and may well vary from piece to piece. Control of distortion requires careful stress relief of
parts prior to hardening, and depends also
on the
T=
formula:
or
r=0.03
experience of the heat treater and his skillful application of time-honored tricks of the trade.
More
Somewhat
re-
Vimm
liable
is
As
pieces,
Plastic Parts,
Parts
made
(1
Molded
in various sizes
from
plastics (thermo-
are
manufactured
in
not
necessarily identical with high dimensional accuracy,
because of shrinkage, uniform or nonuniform, and
sometimes dimensional changes during aging. While
cellent surface
is
dimensions for
finished
purposes
such as
may
drilling
hole location
many
applications, other
require
is critical,
up to
a total
molded
to 2 degrees
maximum
holes,
on smaller
material.
is
fiber reinforcement
tity
of resin used
is
is
man
shop
The
41
Ch. 5
percent
be
elastically distorted.
Thickness
loosely
Tolerance Ranges,
Kinds of Tolerances
and Material
is
woven matting
is
used.
When
properly ap-
mm)
with matting.
15,
Class
to 6, for
inch
double up
discs
down
Diameter tolerances:
extruded Nylon rod
to 5
0.3 to 0.8
cylinders
Plastics, Prefabricated Shapes
down
(25
material, shape,
dimension.
on OD
Nylon and Teflon, on
down to 0.5
down to 2.5
15, down to 5
0.9,
acrylic resin,
OD
wall thicknesses
5,
cent
down
OD
CHAPTER
Locators and stops present a number of requirements other than merely the proper locating of the
part.
The most important of these are: (a) resist-
and
(e) pro-
must be
locating elements.
At
Sighting
discussed,
is
method is that the part has an accepton which it can rest in a stable pothe jig. Once this is accomplished, the part
for raw parts such as castand forgings, where no great accuracy is required between the part contour and the
surfaces to be machined.
Such parts involve large
tolerances on the part contour, and for this reason,
each marking is made with multiple lines to make
ings,
welded
sure
that
With
this
parts,
operator.
42
Fig. 6-1.
Locating by sighting to
lines.
An example
on
sighting,
of
a different
is a drill jig,
technique,
shown
still
in Fig. 6-2.
based
The
drill
is
lined
Ch. 6
Fig. 6-2.
may be round or
holes or slots.
position
43
elongated
to
its final
Nesting
The next
to nest
its
it
along
its
extreme ends.
one
flat
or fairly
flat surface, is
An example
shown
is
in Fig. 6-3a.
The semicircular notches provide space for the operator's fingers for inserting and removing the part.
The groove at the contour allows for the burr.
The minimum clearance between nest and part is
determined by the part tolerance and, obviously,
permits some displacement. The nesting of irregular
shapes
is,
manufactured
It
Fig. 6-3.
when the
any substantial
load,
on
its
and
con-
cave side.
Dust and chip fragments which, when accumuprevent proper seating and cause misalignment of the part are difficult to clean out of nesting
lated,
allowance
is
therefore required.
Dirt space
Three-dimensional Nesting
was made.
method
shown as
is
cylindrical.
As
will
in
which
is
is
44
Fig. 6-4.
cloth.
They
pair
required.
if
and easy to
The curing temperature is 300
re-
Ch. 6
gram shows
The
/.
dia-
continuous surfaces as well as individual pads. Some aspects of the use of large locating surfaces have already been discussed. Large
bearing areas provide excellent support for the part
and permit a great deal of freedom in the placement
of clamping forces without danger of elastic distortion (deflection, springing) of the part; also, as the
bearing pressures are low the rate of wear is reduced.
On the other hand, large locating areas require a high
degree of accuracy in the part as well as in the fixture, for accuracy is lost if the fixture distorts as a
result of poor stress relief. Dirt space, however, is
only available along the perimeter, thus large surfaces are apt to accumulate dirt and chip fragments.
It
large
is
without
loss
of their advantages.
is
As shown
in Fig.
are Kirksite,
(454C); various lead-lin-antimony alloys with a melting range from 460 to 500F (238 to 260C); and
Cerrobend, an alloy containing bismuth and melting at 158F (70C), that is, below the boiling point
of water.
The
cast surface
is
ground,
if
to
necessary,
facilitate the drainage of coolant as well as the machining of the fixture; particularly the finish grinding.
In this
way
made
to accom-
Integra! Locators
For parts of simple geometry and with flat machined surfaces of sufficiently close tolerances with
respect to flatness and dimensions, the simplest locating solution is to provide mating locating surfaces
integral
to a cast fixture,
is
The
The reduction of
by means
of grooves.
principle, as applied
The ma-
fgp|
Fig. 6-5.
and there
is,
therefore,
maximum
no obligation for
stare-
45
Ch. 6
Separate Locators
and
hard working surface, and to protect them against
chip and dirt accumulation.
Locators have been made from bronze, presumably because of
its
shown a
ting wear strips of synthetic sapphire have
wear resistance several thousand times that of steel.
However, these material selections are exotic and
highly unusual.
from
locators
steel,
steel,
Wear on Locators
Wear
complicated process and has been extenMost wear research is for the purpose
is
sively studied.
ditions
Fig. 6-7.
from a
in their use,
on
from
the con-
ideal,
and
replaceable
when worn.
It is
it is
possible to
make
strips
is
a care-
but more expensive method, is to remove the worn pads by machining and install new
pieces made from hardened steel, secured by means
pair.
operation
It
is
applied.
would be
desirable
if
N/mm 2 ),
inch (0.17
1
value
is
extracted
is
shown
in Fig. 6-8.
safer,
H.
Particular
vol. 10,
1926.
46
Ch. 6
*10"
1
thumb
t
1
DL.Z
0,8
By
rule-of-
it
/
1
1
Buttons
0.6
The
0.4
*KK
tuLU
a a.
UjUl
three
not be used because they lack sufficient bearing surface area and would rapidly wear down.
Buttons are round and have either a flat head or a.
0.2
*^
32
crowned
JO
Courtesy ofH.
The
J.
30
10
UNIT PRESSURE
SO
(spherical) head, as
made
are
Fig, 6-8.
of steel; usually
grade tool
well C,
considerations.
Example -The
therefore,
fective diameter
0.92
is:
1.25
mm)
maximum
are
for side
is:
buttons.
4 X
1.1
X 25 =
78.9, or approximately 80
can be expected. The fixif the locator pressure significantly exceeds the limit quoted, but he
life
lem.
When
obligated to
to keep
them
is
difficult
material
it is
justified.
The
more wear-resistant
wear resistance of
ratio of
the four materials case-hardened carbon steel, hardened tool steel, cast tungsten carbide (Stellite type),
fit
body
is
bore (reamed,
For this purpose the
in a cylindrical
on
a flat surface,
it
sinking.
While the shanks on commercial buttons are supwith standardized tolerances, resulting in an
plied
oversize ranging
is
mm) within
interfer-
An
analysis
LN
3 to force-fit class
FN
2.
The
Ch. 6
Fig. 6-9.
class
FN
fit
Locating buttons.
is in
47
later.
well produce a
y~
fit, if it is al-
'
\
1
i
L
I
I
1
of the fixture,
fit
and
machined surface on
and economical.
It is also
is
ac-
proposed
(in
wrench, as shown
in
Fig. 6-1Q.
not recommended.
is
Courtesy of E. Thaulow
6-10 (Left). Locating button with screw thread and a
hexagonal section.
Fig. 6-1 1 (Right). A hollow locating button.
!n general, this
Fig.
the standardized
Hollow buttons
screws,
by separate
cheaper to
install.
little
interferences,
F. D. Jones,
E.
Thaulow,
Maskinarbejde
vol. II.
(Copenhagen:
G.E.C.
48
Ch. 6
>, as
For
buttons,
flat
from 1/3
to 4/3
H can
be selected:
V7!=,
B=
3/4
1/2
(D-l/8)
(>+#)
With metric
units, use:
B = 3/4(D-3)
For crowned buttons,
H can be selected:
from 1/3
DtoD,
and
Fig. 6-1 2.
R =
3/2
Z)
a.
3/4
ZJ
b.
fl
-3/41?
base,
c,
button,
Pins
stop, e
A button
d.
and
f.
side stop.
fixture
in
a side stop
flat
locating
A
on
pin
its
is
a cylindrical
side.
It
height of a pin
not
side stop
is
little
primitive.
dimension. Buttons
can be substituted for pins, but pins cannot be sub-
is
a critical
are used to
make
a nest
to
shown
its
in Fig. 6- 12c.
Pins
on shallow parts
large
Pads
shown
in
is
Round
to use a button
will
A number of
is
mate the surface on the part. For high preground after installation of the
Pads are usually flat components made from simiand heat treated to similar hardness levels
lar steels
as buttons.
They
are
ground
flat
and
parallel,
some-
installed
body.
They
on machined surfaces
in
the fixture
Ch. 6
Pads located
down
in the interior
Fig. 6-13.
of a cast or
49
edges as
welded fixture are not chamfered on their
tool.
machine
the
to
they are not easily accessible
thereand,
pads
fixed
like
look
should
Loose pads
corners and edges
fore, they are also left with their
noted first, that
intact. In all fairness, it should be
useful in scrapbe
may
pad
sharp edges on a locating
that the
second,
and
part,
mating
the
ing dirt off
chamfering of a pad, particularly one of an irregular
50
outline,
is
eft.
it
requires considerable handwork, while the chamfering of a button is a rapid and inexpensive screw ma-
chine operation.
Pads are fastened by means of screws with wellcountersunk heads, and their position is secured by
means of dowel pins (also other means, as required),
since screws are fasteners only and are not capable
of precision locating anything. The correct use of
(Lower case
letters refer to
Fig.
Courtesy of E. Thaulaw
Fig.
The holes
and reamed to size after the pieces are fixed in position by means of the screws. If the one part, such
as a locator pad,
reamed to
is
size
maybe
solution.
is
used oc-
casionally,
is to leave one section of the part unhardened and to place the dowel pins in that sec-
tion (b).
In
many
cases,
it is
when
number
other locating
a position (f).
If
can be a press fit in each part. This serves the purpose of most fixture applications; in cases where occasional disassembly
is anticipated, it is common
practice to give the dowel pin a press fit in one part
and
ment between
only
(k,
1).
is
sembly (apart from the possibility of infrequent replacement of a component) the fit of the dowel pin
shown
The standard
("Taper"
(1:48),
other hand,
in holes are
(Fig. 6-14).
screw thread.
Dowel
In principle, two dowel pins are required for locating a component and they are placed as far apart
are
6-15 {Right).
the particular
diagram.)
ened,
design
in Fig, 6-1 5. 4
is
it
The nut
is
When
is
head.
When flat pads used as base locators are
fastened by the means described, the countersunk
screw heads offer places for the accumulation of
Unbroken pad
E.
are
difficult
to
clean away.
II.
if
the pads
G.E.C. Gad's
Ch, 6
are fastened
undeniably
it
Dowel
is
presented in
51
at
L2
Circular Locators
=M*
States.
form of
and
pins, mandrels,
and hollow
clear-
affected
A German
in
ming
is
shown
L2
=0,02D
=G.12D
13
ss 1/3
L3
d
1.7
0.97
Li
When jamming
occurs,
it
in Fig. 6-16.
The outer
cylinder (the
in inches)
in
mm)
A^
The
friction
and the
tilt,
it
V^-
additional pressure
/k
1
Fig. 6-17.
The
significant
dimension of a jam-free
circular locator.
The mode of action of a circular locator is modiwhen it is combined with a flat locating surface,
plane perpendicular to its axis. The flat surface
fled
a
Fig. 6-16,
Jamming.
but
it
is
52
is
jam-free, even
CD
agonal
is
if it
is
greater than
L lt and the
AC
di-
inside
the part.
Any
a solution
An
When
it is
shown
This
shown
in Fig. 6-20.
Three
flats
C
clearance of on each land.
This
is
is
a radial
in
AA
for alignment,
If
is
cylindrical locator
ance.
Fig. 6-18.
Ch. 6
made
the part.
it
it still
centers
it
points the
way
to other solutions.
a
Fig. 6-19.
0.8536 CW-C)
Fig. 6-20.
minimize jamming.
53
Ch. 6
radii to
making the
effective
total
E and F
clearance
C
is
1.4142
2
for
vertical
motion:
f+
1.4142^ = 1.2071 C
c up until A
,
To jam,
first
move
on A 7
Fig.
6-21
sig-
nificant diameters.
is
length
critical
2
the
the figure) so that
of
L 2 = 0.8536 flW
The triangular shape has reduced the critical length
percent but has,
for jamming by approximately 15
at the
can be improved in
taneously.
WVV\^\wv\^w\\\\\\\\\^
Fig. 6-21.
significant diameter.
that part
shown
and help
in
54
Ch. 6
Radial Locators
radial locating,
this
purpose.
keys and keyseats, dual cylinder locating, and indexing fixtures. Any radial locator has a certain tolerance and therefore involves the possibility of an
angular error.
{see
is:
T
ir radians
Fig. 6-24.
and removed
ture
in operation.
is
all
in-
keyseat.
T may
as a radial locator.
assembly and are not exposed to wear. Where keyseats and keys are used as fixture elements, they are
if
Since
The key
small radii
made with
a flat
6-23.
The
distance.
The
interplay between
these
diamond pin.
Assume first, a rather special case where the center distances match so closely that their tolerances
can be ignored. The locating accuracy then depends
entirely on hole clearances which can be minimized
by the use of expanding locators. The expanding locator is shown in Fig. 6-25 where A is the bushing,
the
its
keyseat
in
is
key and
its
Fig. 6-25.
clearance.
Ch. 6
the full length of the bushing. The method of splitting, however, in every case, accomplishes the same
object, that of making the bushing capable of ex-
when
pansion so that
fit the tapered hole in the bushing,
the bushing will expand.
is
is
screwed down,
1%
all
Conse-
2T
The
case
is
= -j-
radians
oversimplified
tolerances but
the result
by taking
It is
two
cases (with
an angular error
the stud.
holes,
all
T to L +
L
IT is
turned to
more
be nested in
It
In
55
It is
make
elon-
them
into a
each locator for any permissible dimensional condition, and radial locating must be accomplished with
prescribed angular accuracy.
To illustrate the problem, consider a part with two
holes of diameter D and center distance L T. As-
sume zero
tolerance on
all
it
is
to
D 27
to
make
Fig. 6-26.
it
pos-
The general
Fig. 6-27.
56
Ch.
in the
physically possible
is
fit
to
of the part.
pin
is
It fits
Fig, 6-28)
with lengths.
D with a
clearance C,
so that
D=A
Fig. 6-28.
+ C
Assume
first
points at
figure).
ment
that
its
the
increases with
the width
All this
is
now
(d-C\=
2\
2J
"
curacy ranges,
press
A becomes
ameter) and
W+T=
C
is
is
W=
small;
fit,
A and
press
fit
the use of
it is
from the viewpoints of desired locating accuracy and a sufficiently easy sliding fit. T is the
selected
total longitudinal
tolerance;
on center distances
it
includes tolerances
width
maximum
permissible
and
1/3/4.
thread.
at
y/2CD
as a
T = y/2 CD
ure) so that
1/8 of
A proposed
_c^cd
2
is
mm)
(1%
pin.
lower
of the segment:
diamond
in
width
sible
The geometry of
clear-
ance C. It also follows that for a given hole clearance C (and corresponding angular error) the permis-
Fig. 6-29.
pins.
Ch. 6
57
pensive.
lines,
diamond pin
in
on
are
holes can be used for locating the part in several fixtures, one at a time-and even for reconditioning
operations at
The
is
If a part, as designed,
some
principle
is
later time.
For ex-
ample, two holes are drilled and reamed in the panrail of the cylinder block to closer positional tolerances than required for functional purposes. These
holes serve to locate the block for all operations
machine engine blocks. Smaller automotive components mounted on movable fixtures (also called
Fig, 6-30.
in
combination with a
flat
locating surface.
be designed
6-3
are
is
enters
also
first
when
it
^#^S^^^N
Fig. 6-31.
Dual cylindrical locating arranged for prepositioning and successive entering (one at a time).
58
"transfer" fixtures
chined
or "pallet"
fixtures)
ma-
are
on locating
is
Ch. 6
for a straight-line
are
is by far
most common.
A primitive and inexpensive, but not very accurate,
the
on the
This
locating.
essentially, a case
is,
When
be indexed to
with the pin.
of dual cylinder
withdrawn, the part can
next position and again locked
the pin
the-
is
for
far
more demanding
things, accuracy in
these
by arrows)
previous operation.
are
machined
in
automatically tightened
mount of
to
a predetermined
a-
and have proper locating and clamping deand holding the part.
The fundamental component in most indexing
strength,
fixtures is the indexing table. It performs the following functions: It receives and holds the part by
means of locators and clamps. It rotates around an
axis with a minimum of play and error. It carries
the weight of the part and the load from the machining forces and transmits these forces to the fixture base.
torque.
Finally,
it
sition to position in a
natural wear
in the
a part to a
new
predetermined
position.
Very often,
its
moving
parts.
An example
Indexing Fixtures
on
is
also used
design
made
for
its
upkeep
is
ex-
Ch. 6
cellent.
is
not
index bolt
steel
M of rectangular section
and beveled
at
inner end
its
T of
body of the
S so that
is
care-
fixture,
enters the
it
Clearance
is
care of.
stud
is
keeps
the index bolt and a stiff coiled spring at
the bolt firmly in position. The pin U is obviously
bushing at E, the
steel lo-
method of taking up
wear by the angular lock-bolt M, and the spring N.
cating ring
/.
the automatic
it
ring, as
device,
is
It
In this
ring properly as
spring.
in this, as in
even
The
is
it
most wear
ceives
closes in
it
made independent of
the operator.
typical
and
in position.
is
lock
and has
bearing
it
securely
the fixture
all
around on
ving portion
down
operation.
firmly by
resistant
less
When
to
accuracy.
is
it
and
is
surfaces.
has lost
it
its
flat
worn,
new; as
it
wears, however,
flat bolt,
it
as long
forms recesses
loses accuracy.
Only very
heavy parts
in
collar at
in a
sense, be considered
same applies
They
are
all
work
60
except where they
may
Ch. 6
bolt
may even be
which permits
It
angle
is
zero.
the angle
is
on the
in-
dexing bolt.
to
self-locking.
If
is
made
is
larger
is
no
moment
ball
Such devices
in the
is
applied to
form of spring
drill jig
shown
in Fig. 6-35
The
tion.)
to other
locating plate
ball
The
work.
which runs
bearing
in a
jig consists
A mounted on
bushing that
a hardened steel
hardened spindle,
of
a
is
also hardened.
is
an index plate
A
At
in
drill jig
is
while the
ried in a
the
work
is
the indexing
A. When the
is
done by
same radius
rests
on
a single,
treadle
is
released,
it
lever E.
The
N while
locating plate
as the drill to
Stability
Some
Problems
Small or
on indexing
Heavy parts of
hang,
bearing.
lever.
The work
indexing
foot treadle.
The
An
Fig, 6-35.
following example.
Ch. 6
It is
necessary to
the casting
shown
drill
quite a
number of
holes in
on
different sides
and at various angles to one another. For this reason, an indexing jig is employed. This illustration
lustrate
more
harm
if
means,
tain
force
if
61
They fail
are ineffective
They
2.
lift
They exert
3.
significant forces
upon the
a
part,
deformation
break
(if
it!).
possibilities (compatibility
The various
and the
supports and
is,
a redundant intermediate
statically
indeterminate.
forms of
in-
compatibility is unacceptable, and redundant supports are therefore made adjustable. The various
Fig, 6-36.
large
trunnion-mounted indexing
jig.
Adjustable Locators
port against all the forces acting upon the part when
Any additional
it is being clamped and machined.
elements that may be required for this purpose are
termed "supports."
of the locators can be described
as the elimination of the six degrees of freedom.
In mechanical language, this means that the locators
Any such
its
equivalent.
later in Figs.
It
is
by inspection
If it
so that
does, however,
it
it
62
(m\-
Ch. 6
m
D
Fig.6-38.
ly tightened
when
the work,
the intention
release
is
is
preferable, as
it is
less
screw type
\m
Fig. 6-37.
statically indeter-
shown
The head is hexagonal and the top of the screw is rounded (crowned)
so that it offers a regular bearing area even when the
screw axis is slightly out of alignment due to clearance
in the
is
in Fig. 6-39.
screw thread.
The bearing
area in
all
exceeds the fixture tolerances and appears to be permanent, it is necessary to readjust the fixture. This
is a toolroom operation and is followed by an inspection similar to the inspection of a new fixture.
The operator should not reset locators or other vital
In
and
ed head.
tools.
much
shown
locating
is
may
be placed on either side. By using a squarehead screw, adjustment is very easily accomplished,
but unless the operator is familiar with the inten-
verti-
wedge
principle,
The action of
wedge
is
mechan-
The wedge is, therefore, a suitable device for adjustments in a narrow space.
direction of action.
An example
of
is
E. Thauiow,
Maskinarbejde
Gad's Forlag, 1930) vol. II.
(Copenhagen;
G.E.C.
Ch. 6
Fig. 6-40.
wedge
it
63
is
shoulder screws that are inserted through two elongated slots milted in the wedge; these screws are
tightened after the stop has been brought up to po-
One disadvantage
sition.
that
ter 12, in
a similar type.
The "sliding point"
which
sible
split
wedge and
by
lock screw.
is
plication, therefore,
design
work
is
to
shown
is
in Fig. 6-4
be located;
fits a
side.
it
Its
principal ap-
when
hole in the
jig
The
adjusted.
wall and
is
pro-
tapered as shown, to
back under the pressure of the
work or the tool operating upon the work. This
sliding point design is frequently used, but it is not
as efficient as the one illustrated in Fig. 6-42. In
prevent
its
this design
flat, slightly
sliding
consists of a split
it,
as
forced in by a set-screw C, for the purpose of binding the sliding point in place. Evidently, when the
and
adjustment,
locked hard.
Adjustment for wear as well as for locator displacement from other causes such as overload, carelessness, neglect, misuse, and accidental damage, is
also required on precision locators to be used on
parts with close tolerances.
Fig. 6-41.
Adjustable locators of
64
Table 6-1
Ch. 6
Shoe or Binder
Sliding Point
Dimensions, in Inches
Screw
A
B
%
to 3
7,6
% to 3
%
%
2 % to 3
%
%
2 % to 3
7
/is
A
B
32
Dimensions, in Millimeters
10
13
57 to 75
57 to 75
19
16
57
to
57 to 75
75
10
13
16
10
Screw
1.6
2.4
fine
this
in Fig.
6-43.
fixture
when
It is
it
is
surfaces.
adjusting screws
will
be described
it
mounted on
machined
This
is
is
later.
manner similar
When
to ad-
adjusting
In this
way
The
is
made.
tightened.
fixture
is
Ch. 6
65
s
3"
&
66
Ch. 6
&
E
"
a=
.y
s
o
2x;
Ch. 6
serves to clamp
by forcing
it
This is accomplished by
wedge pin assembly, consisting oi
a wedge pin E, a wedge-pin seat F, and a wedge-pin
The four wedge pins fit closely
seat container G.
These
in the holes below the adjusting screws D.
the face of the nosepiece.
the action of the
room
allow sufficient
An
nosepiece B.
eccentric hole
is
67
a clearance
When
the fixture
locating ring
is
mounted
This
(0.005 to 0.008
mm).
pin that
is
This pin
is
pressed
D until
is
made much
to the
done, as before, by
is
it is
groove to collect
dirt,
wedge-pin seat:
and, G wedge-pin seat container.
This assembly will cause the fixture body C to be
held firmly against the nosepiece B as described for
on
F and
it
serves to
loose
vide
fit
it
in
The wedge-pin
seat
with
is
a very
to pro-
the fixture
a floating collar
clamps themselves.
will
will
have both
a radial
It
manner on an engine
having
lathe,
cross-sliding saddle.
on a turret lathe
The cutting tool is
or
nose,
is
so
small importance.
little
overhang that
Although
its
weight
it is
is
of
on
pass.
These
A bronze
or steel bushing /
is
which corresponds
is
threaded with
to that
on
in Fig.
6-44
is
very satisfactory.
CHAPTER
fixturing
is
comprised of
loading,
moving the
part.
involves
trolled
by the
means
for
fixture designer
who
should provide
Apart
from
these
considerations,
there
is
no
when the
those shown in Figs.
in
three consecutive
it is
it is
Next, the
stop.
Well-balanced parts require lifting and lowering only; an unbalanced part, having
its center of gravity at some distance from its mid-
and
examples is that
each locating step is not interfered by, and does
not interfere with, any other locating step. One
result,
crane, or conveyor.
and lowering.
Space must then be provided inside the fixture
for the part, fingers, a hand, possibly two hands
(and knuckles!), or two hands and arms.
For
heavy parts there must also be clearance from the
machine tool to allow the operator to lean over
the fixture, or to admit the load cable from the
hoist or crane. Although these factors may appear
trivial, they are quite serious and it is a common experience that space always looks larger on a drawing
than in reality.
lifting
pressures
are
applied.
basic
proach.
Assume
to the base.
points
(or
It
the part
is tilted
then contacts
one corner),
while
first
levels
it is
lowered
off,
contacts the
possible.
and, correct
in
may
misplacements or misalignments that the part cannot be properly located. Other causes of insufficient
lost,
scribed
68
tolerances,
jamming, and
friction.
These
Ch,7
termed
fixture.
69
important examples
Symmetry Considerations
AA
denoted^,
are
denoted
part;
is,
and Z.
Y,
X.,
that
completely symmetrical
part
in a fixture in
From an
initial
four dif-
position
it
can
CC
and
shown.
is
Two
action
tive
is
e.
no correc-
If
may be assumed
to
position.
is no
between the four positions, and any machined configuration applied to the part will produce the same
discernible difference
how
be analyzed.
part
case, regardless of
now
will
is
for
position
machined
the
entering
The
The
fixture.
is
surfaces
is
180 degrees
rotated
Notice that the final configuration of the part will not change when it is machined
around the
axis.
A A and CC
is
the result of
symmetry on the
planes.
shown
In the position
initial
its
When
position.
in Fig. 7-2 d,
X
is
axis
from
and
drilled
two surfaces
the
are
relationship
ROTATED
UROUND Y
$Z-_ AX
|S
The
ROTATED
AROUND
ROTATED
AROUND X
Fig, 7-
-\f
the
part
machined pads
An
180
position
Again,
readily
wrong side.
7-2 e has been rotated from its
part in Fig.
initial
~~
it is
are again
on the wrong
side.
their cor-
permissible,
position.
even
The
which consist
entirely
70
~T
SURFACE
Ch. 7
L K >OP SIDE
\|
EU
i?
___
'
II!
Cl/TTER NO. 2
TOP VIEW
SHowim
TOPJIDE SURFACE
CUTTER
NO.
4I
n.
TT
j.
TT
+i TT
TT
bFBOWOTEWEW
.SHOWING
FRONT
SIDE
SURFACE
COTTER NO.
ill
tl
'
i
""
*;
v
ir
^D|
t
1
CU7IIRN0.2
BL
J3.
TJ
littTJ
<M"Q"
MEW OF
FRONT SIDE
INCORRECT--/
TT
TT
-j
T3
WfW Of
FRONT SIDE
SURFACE
SURFACE
Fig. 7-2.
|j
TOP VIEW
SHOWING
TOP SIDE SURFACE
JfL
TJ
ni
lis
TT
TT
ji^aj~ i-
INCORRECT-
Ch. 7
71
nonsymmetry BB plane (satisfied for the end surface, the two pad surfaces, and the hole), and
that they maintain symmetry with respect to one
sents
AA
for
(satisfied
two pad
plane
or the
surfaces),
CC
changes
symmetry
radically
its
fixture, with
tion,
which
When
is
rectly machined, as
shown
(see
Fig.
7-3
c.
is
shown
in Fig. 7-3 b.
X, the part
in the
is still
However,
if
the part
e),
cor-
the hole
is
is
around
drilled in the
which consist of
straight
line generatrices perpendicular to one of the nonsymmetry planes, either the A A plane (satisfied for
the pads), or the BB plane (satisfied for the pads
CC
asymmetries found in part configurations, a systematic classification and the formulation of some
widely applicable rules can be provided. With such
rules and
some
is
able
quickly
Foolproofing is required
one asymmetry. A completely symmetrical part
needs no foolproofing; No matter how it is inserted into the fixture, it presents to the eye, and
to the cutting tool, identically the same configuration and, no matter where the machining cuts are
Foolproofing
is
will
on one end,
within a
formed
as a bracket
If
the arm
is
cated,
downwardly open
cavity, as
shown
in Fig,
is
therefore
must
literally
examples
carried
Fool proofing
Despite the
by
be
a part
When
movable part, they cannot detect an incorrect loading until after the part has been introduced, and
additional time
is
and reload.
in most cases the foolproofing requires simple
means and is done at little additional cost. It very
often happens that the major body of the part,
including its natural locating surfaces, contains one
or several degrees of symmetry, and the asymmetries
are confined to small areas at isolated
locations.
72
Ch. 7
A, TOP SIDE
SURFACE
-a FRONT SIDE
SURFACE
~
I
f-^v-o
~t
TOP VIE
CUTTER HO. I
_
i
_EL
TTT
c-r-
TOP
-1
WW
SHOWING
CUTTER NO 2
oT^
L --^-^
Bt
-u
WVf Of
cmunNo.2
Y
I
-TTJ^1(1
'
CUTTER NO. I
'
'
n^
(II
tMH
t
I
4J
"<feB
"Q~
CUTTER NO.!
-VA
n.
ML
L J
cr
^incorrect
A part with
fa
ir-INCORRECT
W W Oif
FRONT SIX SURFACE
CUTTER NO. 2
Fig. 7-3.
-ft
NO.
CUTTER
%LJ
*
'
Ch. 7
73
HI
XZE
P
m
TZL
kIU^\(^
scctiova-a
Fig. 7-5
Foolproofing
located
fixture,
two
forming a fork.
at a time,
all
they
do
select
is
possible orientations, each of which is closely defined by the actual locators. From the viewpoint of
simplification,
course, desirable
if
foolproofing, or participate in
when
is
is,
of
do the
This happens
one of the two;
made
it.
to serve as
3=1
XZE
a locator
it
accomplished by
ft
a cavity in
some
shape.
proofing
ribs, etc.;
pressions,
slots,
holes,
recesses, de-
perforations,
or
74
Asymmetries
in the
form of
Ch. 7
part
foolproof.
may
signer
not,
find
it
it
LOCATING
PI
may
possible
to
make an
SLIP BUSHING
WORKPIECE
existing
orientation,
jections or cavities
D,
tion.
where
An
analogous example
is
shown
in
this
category
is
Fig. 7-9.
Foolproofing by means of
locator.
a step
on the cylindrical
Ch.7
75
only
if
The
the part
part
between
is
shown
its
boss centered
Fig. 7-11.
Fig. 7-10.
drill jig.
the
with radial locating and tangential asymmetries are shown in Figs. 7-11 and 7-12. In each
case the part is centered on its axis, clamped with a
knob K, and
radially located
Foolproofing
is
a pin
X,
block
is
is
prohibited.
in a slot.
lA
flat A.
would be the poorest
to
by
Parts
possible, as
it
permits a small
in
its
lugs,
correct position.
blocks
all
other
the
bracket.
Fig. 7-12.
Foolproofing by means of a
clamp.
slot in
the hinged
76
With
vertical loading
usually a
is
Ch. 7
little
more
lifting
is
It
the part,
Once
make
this is
understood, the
is
enough
on the
grip
part.
is
fixture,
when
the
to be removed.
Burred Parts
As explained
burrs, the
in
is lifted
out.
tion, particularly
Fig. 7-13.
shown
axis.
Drill
jigs
for
adjacent to the
the burr,
jig
the correct
is
The
now
plug.
is
Removal Problems
in
Fig. 7-14.
is
It
is
a bushing with
it
located on a
drill, and is
machined with upper and lower flat surfaces which
provide clearance for the major burr on the upper
hole in the part, and the minor burr on the lower
hole.
The
operations.
relief
of residual stresses.
is
drill.
An example
is
shown
in Fig. 7-15.
The
Ch. 7
operation
is
77
a cylinder.
operation
work
machined
the
is
is
on the
is
it
provides
being formed
inside of the<part.
Ejectors
the fixture designer's care and forenot always possible to ensure free and
easy removal of the machined part and a mechanical
ejector then becomes a necessity. A warped and
binding part is not the only Justification for the
use of an ejector; in fact, the ejector should enjoy
much wider publicity in the literature and much
Despite
sight,
it
all
Fig. 7-1 S.
clearance.
is
As an example,
lift it
it
a part,
it
in
fixture.
is
easily
done with
some
ejectors.
For
maximum
ejector
air.
Ejector Details
\T7Ttfk
Ejectors are inexpensive since there
l-'ig.
bun
clearances.
close tolerances;
is
is
no need for
by turning
78
single ejector.
explained in Chapter
6.
parts,
surfaces
their
against dirt
bearing
When
Ch. 7
multiple ejector.
ejection
is
in the
own
weight.
must be protected
In most cases
chips by the part itself;
shown in Fig. 7-17 has two pins A, fastened to a flange on knob B. The return spring C
is centrally located and acts on the flange.
The
arresting shoulders D are parts of the pins, which also
provide the inner bearing surfaces E, while the
outer bearing surface F is in a bore in the knob.
Other arrangements are also possible. Each pin could
ejector
Fig.
Fig. 7-19
have
7-18 (Top).
(Bottom).
lever-operated
multiple
ejector.
Ch.7
The
ring
on the
least
returned by means of
is
springs D,
on
ring;
three
large
Two
pins.
springs are
theoretically
part
is
when
the part
is
is
forced
by means of
down
lifted into
Fig. 7-20.
An example
a
handle B,
window
is
in
shown
in Fig. 7-21.
which
in turn,
screw.
When
may
a
screw ejector
is
used for
lifting a
it
must
it
stays
when
is
diameter.
Ejectors
can
also
be
Examples of spring-actuated
part,
flush
loaded. In diagram b
heavy
79
ejectors.
ejector
pins
C.
slotted to receive
The
and guide
Two
knob
2. The
3.
on one
on individual small parts
instead of
large part
by a
with normal
operator effort.
An
system
is
light that
Fig. 7-21.
screw-operated ejector.
80
Ch. 7
m
^^
Fig. 7-22.
When
the drilling operation is completed, the operaopens the clamps so that the part is free, then
lifts the jig and lowers or forces it down over the
tor
jig.
To
facilitate
handling
conveniently accessible
machine
tool.
This is frequently accomplished
through the use of dual fixtures set on opposite
ends of a machine tool tabic, or with one or several
in Fig. 7-23.
Z=P-^ \^J
The
fixture has
movable
many
different shapes,
receiver,
which
is
moved
the fixture
station,
necessary, locking
it
firmly
when
it is
supporting
in that position.
it
back
and,
Fig. 7-23,
Ch. 7
through
81
drill jig
bracket B.
A somewhat
is
shown
in Fjg, 7-26.
For small
parts, the
problem
is
C.
drill jig
with
swinging receiver.
clamped on by means
swung back and locked
in position, and drilling is done through the bushThe fixture shown in Fig.
ings in the receiver.
The receiver R carries a
7-25 is also a drill jig.
the open position, the part
is
is
clamps C.
is
drilling
is
MINI
to
done
Fig. 7-26.
but
3
^-^
the
stronger
magnetic
down
chuck,
to
its
when
own
The receiver,
face in position for grinding.
position.
loading
its
empty, is returned to
also a time-saving device in that
of a
1"%. 7-25.
drill jig
new batch of
previous batch.
it
sur-
now
It
is
CHAPTER
Chip Problems
Types of Chips
Machining cast iron, bronze, and other brittle
materials produces crumbling chips and a great deal
of dust. Steel and other ductile materials produce
several types of chips.
at high velocity, as
chips
may occupy up
volume.
two
lips
wound
chips; tightly
chips.
short, or crumbling,
82
face mill
is
drill
bushings.
Long
produce
Burr Formation
Burrs are always associated with -the machining
of ductile materials. Truly brittle materials do not
produce burrs, but form crumbled and broken edges.
This is a problem of another kind which certainly
enters into the sequencing of operations, but hardly
into the fixture design itself.
resistance
CHIP PROBLEMS
Ch. 8
burr
is
83
automatically
provided for
generous
must be provided
size
if
the part
if
is
not, a hole of
On
is
later.
Chip Removal
Fig. 8-1.
point
No
C on
dimensions of the
more
ductile
and
is
roughness configuration.
The
is
in the fixture
are normally of
few minor yet important points must be conby the fixture designer. The means for
coolant supply and coolant return must be adequate.
This requires a check on the pump capacity, pipe
and nozzle dimensions, and the size and extension of
the collecting grooves and channels in the machine
sidered
tool
table
and
substructure -including
and
filters.
strainers,
of a stream of coolant discharged to horizontal surfaces is not adequately controlled by the direction
of the nozzle; it will splash and spray by the impact,
spread over larger areas and overflow the edges in
an unpredictable manner. This calls for troughs and
pans to collect the liquid and baffle plates to protect
the machine surroundings, including the operator,
to maintain
visibility
air jet is a
double-
edged sword and is endlessly discussed in the literature without a final answer; it is highly efficient in
HL
moving chips
air
blast
for
shown
in Fig. 8-3.
locator plate
K
F(g. 8-2. a.
iv
xi
with two
milling cutter;
airjets
c.
single-
twist
drill.
mechanical
jig
with a fixed
A and
cleans the jig plate and the locator plate before the
part
is
CHIP PROBLEMS
84
Ch.8
The
cylinder
is
To
are drilled.
the jig
reversed.
is
deflector
drill
upper flange
cross section.
is
Relief
The
and Protection
greatest problem,
ture designer at
all
Fig. 8-3.
air blast
types of plastics.
Helpful also
is
the
Fig, 8-4,
The
part
is
a cylinder
i.e.,
is
fix-
caused by
When
another
flat
be
surrounded
by a
relief space.
Incidentally,
accommodate
Any
horizontal locating surface satisfies the conif it is elevated sufficiently over the
dition above
fixture
base.
in
Fig.
6-5,)
in
installed in
the locator.
Pins and buttons can be
bored holes with a chamfer or a straight
recess, as in
Fig. 8-4.
drill jig.
CHIP PROBLEMS
Ch. 8
^ I I
I IX!i
85
In
recess
as
locator
surface
dirt,
it is cheaper to provide
and pins can be
Buttons
the relief in the locator.)
machined with a flat recess as in d, and e. The
latter design has the advantage that it does not reduce the bearing area between the shank and the
hole. The same applies to the designs in f and g,-
ing operation
where
on the
fixture;
is
and button.
turn a
in
h and
i.
The
make
The
locating
Fig. 8-7.
Fig. 8-5.
made
is
and as in Fig.
8-6.
is
an inclined locating
surface.
part. With the clamping pressure applied, as indicated by the arrow, the part is not only located and
clamped sideways, but is also forced down on the
base.
The angle of
inclination
is
from 7 to 10
degrees.
without
arrangement can be used for other types of locators
(nesting blocks, V-blocks, etc.). It requires fairly
close tolerances
on
The
is
to case.
Fig. 8-8.
DIRT
GOOD
JO
An example
Fig. 8-6.
relief
space.
is
shown
in Fig. 8-9.
In this case, as
CHIP PROBLEMS
86
Ch. 8
Modern technology
excellent, although
^^
C
Fig. 8-9.
is
pin)
shielded by
is
tion.
Seals
are
Many
fixture
shielding device at
moving
means of
Shielding
when
fixture with
in Fig. 8-1 1,
bearing surface.
shown
fixture
provided
The
wel! protected.
no
cost,
itself.
supports.
To
Fig, 8-10.
(a),
and a
seal (b).
and
seal applied to
an indexing
fixture.
CHAPTER
Centralizers
Definitions
al-
surfaces.
Single centering
is
else.
1,1
are
termed "cen-
Single centering
locates the middle
layout markings.
The
punched
are
now
exactly located
and axes.
Advantages
In the introductory discussion to locating,
it
has
been stated that one purpose of a fixture is to approximately substitute for the scribed lines and
punched centers provided in the initial layout of a
rough part prior to machining. It was also explained that the part locates within the fixture from
one or several of its surfaces. With tolerances, sometimes quite wide on a rough part, there is no guarantee that the physical middle planes, axes, and centers of the rough part will coincide with the corresponding planes, axes, and centers of the fixture.
The fixture can only guarantee the correct location
Centralizers are
They
single or
multiple components.
fixed
clamps.
shown schematically
in Fig, 9-2.
Double center-
ing
is
common
three-jaw, self-centering
chuck
collet
is
87
CENTRALiZERS
88
Fig. 9-1
machine tool
Single, double,
is
vise
a single-centering device.
and
Ch. 9
full centering.
is,
therefore,
more
closely defined
and more
Ch. 9
CENTRALIZERS
////,, /s
/
/
/
-II
l"! -i
/77777T?
Fig. 9-2.
Classifications
(automatic or scissor-type)
3.
Self-centering
chucks of
commercial
types.
2.
centralizer
The term "angular block" is the common designation for block-type locators with converging or diverging locating surfaces.
They are used in three
CENTRALIZERS
90
the
forms,
V-bloek,
locator.
flat surfaces.
In the
An
the part.
inverted configuration
is
used occasion-
where the
ally
is
The
locating surface of
as a spherical cap or
is formed
and can be convex or concave.
all
Ch. 9
fixture bases or fixture bodies, when they are provided with special jaws or jaw inserts and locators to
Machine tool vises are also comfit specific parts.
mercially
available, general-purpose
not fixtures.
work
holders,
in themselves, centrali-
inserts
general-purpose
its
hand.
The
it
to the assignment in
one or
two
sets of contracting or
external
two
motion
part.
The
equali-
zers carry the clamping points and enable the individual points to adjust themselves back and forth
to
accommodate
local irregularities.
They do not
position
by the
part.
made
spindle axis.
centralizers
as fixtures.
Fig. 9-3.
The
Ch,9
CENTRALIZERS
that they operate satisfactorily only over a small diameter range; inside and outside of that range they
grip only with the edge.
The
(6 to 150
is
mm),
recommended thickness
13/64 inch (2 to 5 mm).
the
arise
varies
if
so,
Any
may
size,
less,
itself,
>,
provided with a
body
wall of the
or through
jig,
jig.
It is also used for adjusting the
V-block and, in some cases, for clamping the work.
V-blocks are usually made of machine steel, but
when
iron.
Little is gained,
is
in case
is
9-5.
I'ig,
For
cially
An
adjustable
mm
cylindrical
in Fig. 9-4.
there
in
place by
much empty
so
is
When
and
the purpose
in
shown
in Fig. 9-5.
Here,
is
the adjust-
The block is held in place by a collarhead screw C, which passes through the elongated
m).
no
is
dirt.
is
a relief
groove
is
used, as
it
often
is,
flats
of the V-block.
adjustment.
parts,
type
V-block
centralizer.
finish
this
is
error (a wobble)
slip
tongue
regard-
is located.
A misalignment
reproduced to true size if the
part is centered on the outside, but is reproduced
with a magnification if the part is centered on the
inside and on a small diameter- the magnification of
the error increases with the diameter ratio.
For a given clamping pressure, the transmitted
torque and the maximum permissible size of cut is
greater when the part is clamped on the outside;
also, with outside clamping the part is less likely to
less
hole.
be con-
reproduced to true
91
semicircle,
to
Much mathematics
reduce
stress
concentration.
and to justify an optimum value for the included angle, but no convincing calculation has yet
appeared in the literature. Some extreme limits can
to find
be easily established.
V-block with
30-degree
a
is
near the
in the height at
degrees
rj-r
Hi
j
V-block.
surface
one.
diameter variations.
rid-fcd
cylindrical
by means of a
V-block with
receive the part freely and
tical
TP-r-n
is
very stable;
it
prac-
is
part
is
not
120 degrees
resting place.
its
limit
and not
dearly an upper
is
one.
a desirable
Industry has solved the problem by accepting, aluniversally, the value of 90 degrees for the
most
included angle.
made with
comand V-
in
this angle,
down
is
to
It
Ch.9
CENTRALIZERS
92
rightly so.
academic only,
is
many
cases
diameter varia-
as
keyseats, and similar configurations are usually designed with a generous depth tolerance that can ab-
drical parts
and
is
it
The point of
starts rolling.
move 45
degrees to
and
is
is
inexpensive.
More
serious, perhaps,
variations
is
dimensioned
are
per-
is,
sym-
move
This effect
is
symmetry with
a diameter variation.
many
so obvious that
but exaggerated
f),
sources
criticism
is
call
it
correct
prob-
lem
is
and
b).
In a, the V-block
is
used as
When A
centering de-
is
the variation
= yAV2 =
In b, the V-block
is
0.707A
is
il is
is
clearly
Fig. 9-6.
The
many
easily recognizable
is
The plane
in
which
stability
it
it
it
pro-
is
the bisector
is
stated, the
V-block with
Long
parts
The
is
This system
is
Ch.9
CENTRALIZERS
93
B3^Kj1
e
fig. 9-7.
parts with
rounded (partly
circular) ends.
typical
three-point
This
support.
one end and rounded forks at the other. It is actwo V-blocks, one adjustable
and the other stationary. The adjustable V-block A
is clamped against the work by a star-wheel and
screw, and it travels between finished ways, thus
providing an accurate as weli as a rapid method of
clamping. These V-blocks have inserted steel plates
B and C. The latter, which is in the stationary Vblock, carries a drill bushing for drilling the lower
fork, and an upper shoulder on this plate provides a
support for the upper fork; thus there are two bushings in alignment for drilling the two ends. The in-
little
example
is
at
serted plate
was accurate,
parts.
is
One reason
is
that
its
is
Conical Locators
ment,
The
drill jig
double V-elamping
jig
is
The
conical locator
is
well
known
in the
machine
To
Ch.9
CENTRALIZE RS
94
center
set
and
drill
The
actually lo-
is
tapers in and
on
The
mandrel
The
work.
(0.5
is a
mm
devices
A common
characteristic of these
is
lathe
is
per m),
by
The
friction.
From
a fixture.
this brief
resume
it
some degree of
axial locating
The
It
conical
can pro-
cision.
flat
is
impractical except
A good
solution
to
is
mount
ing devices.
cal of
workable
within
in Fig. 9-1
is
typi-
some additional
for gripping
without distorting
The work A
Fig. 9-8,
The
on the
locating
and
single centering
it.
been partially machined, Jn order to obtain concentricity of the various surfaces, it is necessary to
locate the
error.
is
in the hub.
sliding V-block.
In order
Ch. 9
CENTRALIZERS
95
Any
circular edges.
is
really circular.
This
be
If
inspected
Fig. 9-10.
b and
c.
Locating
is
possible,
fect contact
pin
the
work
restrains the
is
to
movement.
small
As the outside of
way
it
at their
it
equalizes
all
machine or
work very
up tightly,
tool steel,
The
stud
stud
turned conically
is
is
made from
cases, serve
the work.
they are only used for locating the work and would
require additional means for clamping.
Clamping with
Moving Cone
it is
also possible,
on the edge
Drill
ings.
are
is
that the
The
Locating good.
d.
the
known
locating and
9-15.
In
all
used, the hole in the bushing ought to be counterbored or recessed for a certain distance of its length.
some instances the screw bushing must be movi.e., when the piece of work to be
made is located by some finished surfaces, and a
In
able sideways,
cylindrical part
is
ing principle
cating
immaterial.
The piece of work, being a
would naturally be liable to variations be-
is
casting,
CENTRALIZERS
96
Ch.9
.2?
shown
is
cates
casting.
It is
fitted
flange
hole
on one
C which
is
side.
large
CENTRALIZERS
Ch. 9
The
97
list is
a complete
list
There
pedia.
would require
is still
room
kinematics encyclo-
fundamental
Threaded
a guide, a
and
few
Make
2.
3.
drill
As
it
simple
conical locator.
threaded
drill
used
bushing
dicular to radii
as an
For
4.
sliding
adjustment of the
When
jig bushing.
the bushing
E on
5.
the work;
having
however, to use
It is
Should
b.
in linkages
if
not feasible,
this
not be
let
the
operate through
such as a screw
handwheel
feasible,
seldom necessary,
arms
of equal length;
Make arms
a.
mechanism with a
all mechanisms
Watch for rigidity of
and for
For
6.
a.
backlash in
all
all
individual
members,
contact.
To
follow.
Fig. 9-16.
floating
drill
bushing
used as an outside
conical locator.
fixtures,
wedges
Actuated by
Opposed
(turnbuckle principle)
springs
Linkage systems
Rotating arms and cams
Linkage systems
Symmetrically moving
pairs of levers
Point or strip locators
surfaces
found advantageous, timeand economical in drilling parts having a similar shape, but whose overall dimensions differ.
One of the simplest forms of a self -centralizing detralizing features will be
saving,
This jig is
is shown in Fig. 9-17.
an example of the type with sliding wedges actuated
by opposing springs. It can also be characterized as
a jig with a split V-block and contains a rectangular
pads E.
Pantograph systems
as
Scissor-type linkages
Pantograph systems
When
the
arm
piece
X, holding
it
is
will press
slot
CENTRALIZERS
98
SO
Ch. 9
O X C
MIL.
/^sAvlvu
c
Fig. 9-17.
such
appreciable
piece
is
Each
screws.
slide
a jig,
the jig
rangement.
The projections
holes K.
The
slide in slots
jig
body
which extend
movement
slots or the
ited
is
lim-
work-
of the
jig.
body.
Arm B
O
is
is
swung
into
its verti-
relation to bushing D.
in
in
The second
feature
is
opening has a large operating range so that this fixture can be successfully employed in drilling parts
having considerable variation in width or length. As
with the jig previously described, a swinging arm B
pivoted
is
.
on
a pin
C, which
is
pressed into
jig
body
bushing D is carried in the arm, and located on each side of this bushing are the identical
Also,
the slides.
closing.
easily
facilities
may
drill
fall
through.
J which contact
the sides of the workpiece, are rounded and hardened, and can be serrated to provide a better grip.
The lower ends of the levers are reduced to half
their total thickness so that they overlap, and the
left-hand lever
into the
tail
is
slotted to
levers
fit
over pin
When
pressed
the lower
center of pin
lines
of the
jig
is
body and
drill
CENTRALIZERS
Ch.9
Fig. 9-1 8.
der on rod
to the rod.
then rotated
work
is
in
the
opposite direction
until the
Arm B
is
99
then returned
and clamped by
tightening nut G.
work by pads E.
is
tions in width.
and
In this
jig, a
swinging arm
is
is
again
right
and
is
pivoted
on
pin G.
is
a sliding fit in
Rotation of the
plug is prevented by key N. The lower threaded end
of the plug is screwed through handwheel K which
The
is carried in a horizontal slot in the jig body.
upper head of the plug, on which the workpiece X
rests,
CENTRALIZERS
100
Ch. 9
of the jig body. In operation, arm
and a work piece is placed on top of plug
is
raised,
H, located against
downward against
/
H is drawn
M and pads
Fig. 9-19,
A cam -operated
centraliier.
is a slotted bracket B.
swinging arm C, pivoted about a pin pressed into
the uprights of bracket B, carries drill bushing D.
shank of
Fig. 9-20.
body A
this
arm
is
that carries a
is
on bracket
secured
CENTRALI2ERS
Ch. 9
to the front of the
P. Thus,
when
the handwheel
is
is
101
localized detail
is
ly.
This
is
To
determined by
is
Arm C
is
for a V-block
handled
=T+
in the
is
on the
ensure contact
the workpiece
fl
*,
= 2(0-*i)
in place.
for a V-prism
in the pitch
2(<j>
b2 )
CENTRALIZERS
102
is the pressure angle; the angles b\ and b 2 depend on the gear data and the tolerances (backlash).
All angles are in degrees. Using symbols in Machin<t>
ery 's
Handbook,
Ch. 9
Maximum B = 0.050
For centralizing
Diametral pitch
"i
Number of
N = Pl
teeth
a circular
Chordal thickness
2 cos
2 cos
*e
Backlash (circular)
=D
R =
D=j
Pitch diameter
and by
where
sin b\
=D
s\nb 2
-h -
90
DQ
chuck must be
at
determined by
DQ = D cos b 2 +
n
= I)
CDS
t.
b-,
j,
2R
(\
/l
sin(0
sin
s\
j\
+6r^M
2 )\
,
= Dcosb 2 + s
= 180
N
b,
*a
=*!+( X57.3)
b2
Cones and
tan 1/2(90
b2
used as they are not compatible with the helix (exwhen very short), but pins formed as cylindri-
cept
and held
form a
and holding helical gears
Figure 9-22 shows four such
in position so as to
...
Minimum B
0.030
,
,
Average
Maximum B
0.040
=
The
is
an-
0.050
In connection with the metric system, gear dimensions are based on the module which is denoted
m, and is always expressed in mm. Modules are
l=
The
re-
2SA(J_\
Vinch/
=2d()
Courtesy of Heald Machine Div. Cincinnati Milacron Inc.
,
Fig. 9-22.
mm,
are:
now
expressed
drical
a.
Cylin-
spaces; b.
The complete
grinding fixture.
CENTRALIZERS
Ch. 9
is
'
insert
shown
103
Example- A spur
tor shall
V-block loca-
in Fig.
2 inches
Without backlash
ft
61
-2"72 =
vis
2(20' -115')
3730'
With backlash
B=
0.040
bi=^p:
0.0067 inch
rrrvrX
57.3
=1
15
58
= ri4'02"
Courtesy of E, Thaulow
Fig. 9-23.
2 (20
114'02")
373l'56"
gear chuck.)
a.
piece in place.
and helical gears. Kadi pinion is mounted on an eccentric pivot and the work is clamped ar.d centered
relative to its pitch circle
when
all
taneously rotated.
E,
Thaulow,
Maskinarbejde
vol. II.
(Copenhagen:
G.E.C.
Using symbols
in
Machinery's Handbook,
is
characterized
known
as the
19th
by the
helix
"tooth" angle,
which
is
chordal thickness
width
s,
shown
in Fig,
CENTRALIZERS
104
9-21.
normal
<j>,
chordal
thickness
and
The normal
Pn
0,
Pn
,
,
tan
tan
ffl.
- _
= 23 O 35
__
0.36397
cos 33 33
0.83340
it
33
5
12 inches
0.030
n
g = 0.005 inch
J=
cos
oe
j:
0.005
^ = cos3333' =
cos a
006inCh
90
0,006
,3=1
^ = 60 + 2^T2 X57
,
.,
'
=s
sn
0.43673
tan
P Pn
Bf =
backlash.
cos
f=
tan
<2335'33"
130'52")
~= tan 256'25" X
3052
cos 3333'
256"25"
0.39052
y=2119'55"
s
12sinl30'52"
0.3172inch
tan
Dimensions
J?
-_-
and
tan
Da
cos a
Example- A
sn
by substituting
s.
helical gear
0.3
2cos21
19'55'
o
12cosl 30'52"
0.2643 inch
0.1419inch
2X0.1419(1 +sin2119'55")
72 cos 3333'
0.2643
R =
D =
12.3828 inches
must be designed.
60
cosct
'
tan 20
P = 6cos3333' =
"
B t The
<p f
r
as
backlash
minimum
the
are selected
normal tooth
the
n
and the backlash B.
pres-
Ch.9
10
CHAPTER
Clamping Elements
The Mechanics of Wedges
Classifications
part
and
is
it
also the
is
name
Its
its
is
technical importance
lies in
the fact
because clamping
and releasing the part absorbs a portion, perhaps the
of clamping
is
just as significant,
fore,
There-
is
supported by
on the two
shown
as
a surface in the
friction
P and
<,
fiP,
the forces
and
it
re-
fast
operation.
Fi
To
sin
+ n cos -z
standardized."
to invent
cussion
is
with
F 2 =-2i sin^+2M^cos>
The
.to details.
screws,
become
zero,
which
it
may
gives
a
sin^r
+
a
fX
cos -r
tan^ = P
105
CLAMPING ELEMENTS
106
Ch. 10
Coefficient of Friction
jU t
Clamping
Release
0.19 to 0.20
0.19 to 0.20
Hardened steel
Machine steel
0.17 to 0.19
0.20
Cast iron
0.15 to 0.17
0.17 to 0.19
Aluminum
alloy
0.17 to 0.18
0.18 to 0.20
Laminated
plastic
0.12 to 0,16
0.15 to 0.18
Coefficient of Friction
Good Condition
Pi
0.03 to
(i.06
ji 2
Neglected
0.10 to 0.1 S
sin;
limits
have
347').
a short
close
When
Wedges
that
Example - Assume
iron part with
sin
Fig. 10-1.
F?
0.
for release.
F =
The
fi
0,
2i>(sin3 1/2
0.422/"
unit pressure) and the operating conditions. Everything in a machine shop carries an oil film (unless it
sumed
for
other hand,
if
is
significantly higher.
exposed
to vibration,
On
the
the surfaces
may work
friction.
Recommended
values of
(i
in
in this case,s2
is,
F 2 =2P(-sin3
1/2
= 0.237F
The force
is,
in this case,
approxi-
for wedges,
Table 10-1.
1/3
ju
= tan
3 1/2 as 0.06
down
to
is
CLAMPING ELEMENTS
Ch. 10
The formulas
107
as written are valid for coarse threads.
When
screw
is
clamping force P on the work, or on a strap, is developed by application of torque T to the head of
the screw or to the nut (see Fig. 10-2).
In addition,
surprising result.
ference,
but
is
a greater dif-
is
series of
ing
to this point.
Manual Forces
apply
pressure
their
directly,
or
Nevertheless,
little
relations
thread.
value; the
mum
use of the wedge formulas with the helix angle and
the thread angle taken into account. Detailed analysis
of the system
is
available
machine elements.
cation
is
possible,
and
0.2
DP
(H
0.15)
11
are
T= 0.164 DP
(ju=0.12)
T =0.139 DP
0i
0.10)
(li
0.08)
T=0,U$DP
maximum
value
is
minimum
value
is
0.45 times
the mean.
Data for two operations are needed in manual fixto pull (or push) a lever with one hand,
and to turn a knob. The lever can be a wrench, a
ture design:
one hand
is
From evaluation of
a mean value for
90 to 110 pounds
where he (unknowingly)
cal
T=
Test results
CLAMPING ELEMENTS
108
Ch. 10
Hand Knob
Screw Thread
NC
maximum
1/4
5/16
The turning of a knob is clearly a one-hand operaThe torque that can be exerted depends on the
shape and dimensions of the knob; the maximum
3/8
torque
3/4
- 20
- 18
- 16
11
300
400
700
900
1300
- 10
1200
1/25/8-
tion.
Wrench
13
2200
2500
3000
6800
7800
7500
mm
a.
JS1 cs
tion
loss,
according to the
6.
on the
(Mi
> Mi
reflects the
It
fric-
effort required of
the operator.
the
force
cam contour
/i 3
R on
is
Tomco,
Inc., Racine,
Wisconsin.
Fig, 10-3.
The mechanics of
cam of
arbitrary contour.
CLAMPING ELEMENTS
Ch. 10
moment,
is no friction;
and P; the reaction R
does not enter into the equilibrium equation which is
Assume, for
that there
now F
as
109
HiH
exists
When F
maintained.
removed,
is
is
re-
+n 2 r 7
-(FS)
where (FS)
The pressure P
(FS)
a safety factor
quired, defined by
F L=Pe
F
For
FQ
mended
is
subsides. This
taken as
is
For ft,
1.5 to 2.
it is
Frictions are
is unusable and unrealistic.
always present. Their effect is to drastically increase
F for a given or required P and to provide the pos-
recom-
(column
situation
~F' e
With
clamping phase
is
=FL
ri
H+
1.03M 3 r 2
center), the
in case of overload.
This
danger increases as the cam and its pivots and bearSafety against snap-through is obtained
ings wear.
and the
by proper selection of the location of
contour, or expressed as
= FL
interest; the
P(e+li
l.03u 2 r2
+HtP H + n 2 R
Pe
+ HiH +
Recommended
values for
(3
EG,
2j3
are
is
as
measured on the
in angular measure.
from 30 to 45 degrees.
ing values:
is
clamped
it is
now
in a
de-
In English Units
the handle.
these;
and
l* 2
becomes
~e+(i
F'
H+
is
0.25 inch
0.84 inch, e
0.081 inch
0,18,ju 2
The
self-locking.
0,
= P and
0.05, required
0.081
the
cam
gives
__
+ (0,18X0.84) + (1.03X0.05X0.25)
F=
F
P = 600 pounds
5
"^
(FS)
(0.
29 A pounds
0.84)
(0.05
=_ 2.02
0.25)
0.081
which makes R
600
1.03fJ 2 i-a
is when F' =
5 inches, r 2
P
As long
H=
/i!
R. By
terms in the equation it
and so do the
efficiency
=
0.081
e +
iX t
H+
Miff
ti 2 r 2
Vl r 2
=0
0.081
(0.18
0.84)
X 100 = 33.0%
CLAMPING ELEMENTS
110
The
In SI (Metric) Units
curve
= 125mm
r%
6mm
= 2mm
ff= 21mm
Hi
0.18,
ju 2
0.05, required
determined by
tan a
21)
+ (1.03
is
X 0.05 X 6)
2nr
0.3
wedge
While
is
equivalent to a
gree.
It is
make
not difficult to
the
130N
(0.18X21) + (O.Q5X6)
^
FS =
point on a
%
angle.
and decreases with increasing r. For fixture clamping cams the variation of the angle a over the useful
length of the cam is small, usually only around 1 de-
I25F= 16260
F=
dr
rdd
P = 2670N
125
~2 + (0.18X
The angle a
2670N
Ch. 10
cam
is
self-locking
no low or high
spiral.
For practical applications it is convenient to measure 8 from a fixed point A with radius vector t
Q4
efficiency
{0.18
X 21)+
(1.03
0.05
X 100
6)
+ S
32.8 percent
At an
arbitrary point
D we
have
SPIRAL CAMS
sin
H=
cos
for an
Archimedes
spi-
is
a
Of
(38-mm)
f=2/3r
radius,
The
when
to be self-locking for
Eccentric
shall
and,
/J
0.
spiral
cam.
operating range
is
The
the "throw."
rise
1/2-inch
intended
Cams
cam
circular eccentric
(see Fig.
Fig. 10-4.
is
0-5
) is
char-
and the fixed eccentricity E. This cam has low and high points A
and B. The point of contact D, is defined by r and
8 as before, height H and eccentricity e have, likewise, the same meaning. For calculating // and e it
is convenient first to find angle \j/, which is done by
sin
jg
sin
(180-0) R
sin
$ =
sin 6
CLAMPING ELEMENTS
Ch. 10
in
111
is
shown
in Fig. 10-6.
\/N E
v\
r\
v//)-//^V] *>?//////>/.
Fig. 10-5.
An
The mechanics of
auxiliary angle
is
needed temporarily;
is
it
found by
9O
^=
= 0-^-90
+ (l8O-0) +
Fig. 10-6.
180
gree
80 degrees,
cam
is
degree and
zero at
80 de-
Oto
17,
to 23,
10
to 30,
12
to 37,
14
to 44,
16
to 53,
18
Oto 64,
20
20.08
Operating
Self- Locking
It
eccentric
cam.
Then
to 85,
163 to 180
157 to 180
150 to 180
143 to 180
136 to 180
127 to 180
1
16 to 1 80
95 to 180
Oto 180
has here
determined by
sin
Since tan
that the
tf>
cam
position, or,
always
For
is
^
be self-locking in
this
it is
if it is
follows
it
bility to
self-locking,
(1
2R
=
h
or -7T
is
4/
0.
20.8.
cam
The
is
self-locking for
center.
0.0996
is
sym-
maximum
e.
2R
The
elastic flexi-
is listed
tric
Mathematically
CLAMPING ELEMENTS
112
this
finity for
any
in-
finite value
or conversely, that a
Ch. 10
F.
-6P
S~
zrp-ffi
Fig. 10-7.
The action of the toggle clamp, a. A toggle clamp of the push-pull type
b. The force system in the toggle clamp at the moment of clamping.
in the
Ch.
CLAMPING ELEMENTS
means simply
Fcan
still
finite)
moments about
FL
is
If it
is
dimension.
Example- A
A =
is
elastically de-
maximum
on
their ratio.
12 inches,
B, only
B =
0.
12
= 2X
-=
R =
2 inches and
1/4 inch.
Then
1 5,
sal
0.15
X?X
1/4
X (3/8+
1)
16
In SI (Metric) Units
F and P
A and
clamp has:
toggle
3/4 inch,
FX
through.
Toggle clamps are not designed with the same rigidity as solid cams, and their inherent flexibility drastically changes the force conditions during the clampAfter contact has been established
ing operation.
(a short distance before
ratio of
In English Units
+fiP(A +R)
A~=2nPR{j+l)
Assume fi
center or
its
all di-
2 tiPR
dead center,
at
mensions
is,
ing
=F A +^PR
paradoxical statements
point
the center of
clamping pres-
The
113
Example- A
A =
Assume
toggle
clamp
mm, B = 50
= 0. 1 5, Then
19
fx
has:
mm
L = 300 mm,
D = 6 mm.
and
is
regulated by
in
FX
initial
for
moving the
is large;
calculated as follows:
-=
is
Maximum
any transverse reactions from F. The actuis transmitted to the pressure link by a
force F so far unknown, and a friction force.
consider the forces on the pressure link. Tak-
120.8
on
bearings, and
19
50
SO
link
= 2X 0.15XFX 6X
300
ss
121
beams and
The
includes the five different force arrangein Fig. 10-8, a through e. The angle
ments shown
to ignore
strap
ating force
direct
First,
ing
moments about
pin gives
F B + lP(,B~R)=pPR
is
shown
in
f.
In the design
F B = nP(2R -B)
l
well come out negative. This is not disturbmeans simply that the friction force is significant in the transmission of the actuating force. Now,
consider the forces on the operating lever. Taking
Fj
ing;
may
Case (a)
F~ L
it
M = RLi
I.
=P(L 2 -,) = F-
{L 2
-LO
CLAMPING ELEMENTS
114
Ch. 10
I
T
pT
2I
WA
Y77\
y~i
R1
t:
wx
'
t^ztz^zi
T.
f
Fig. 10-8.
support reaction: R,
R 1t R 2
Case (b)
Applied force;
F,
Flt F7
clamping pressure:
Case (d)
*'
M=F
Case (c)
Fx+F
strap
L L2
V
L2
L2
M = FLi =PL
Case (e)
l
(Li
L 2 )L 2
P;
CLAMPING ELEMENTS
Ch. 10
Table 10-4.
use ff)
115
for
M = FL =PL 3
(Time
17
is
Clamping Devices
Time,
Minutes
cam actuation
more
and (f); me-
common
is
and
(f).
In case (a) the force ratio (the mechanical advantage) is less than 1 only cams (d), (e), and (f) have
the possibility of a mechanical advantage greater
0.22
Screw jack
0.16
0,16
Spoke nut
0.12
0.16
0.11
Hand wheel
Backup screw (on
0.10
a strap)
than
It is
usually desired to
and
(e),
should be as close to
as possible.
hand knob
0.09
fixed jack
Hand-operated cam
0.09
C-washer
0.06
Sliding strap
0.07
/2-inch diameter,
less
0.09
and up
0.05
Economics
part,
commonly
M ost
in c
omm on:
They
1,
are
They
When
moved
and
Example An operation
2.00 or a cam
$50.00
SI 2.00
S38.00
clear of the
^r^X^jp-X
Ott
working area.
$10.00= $2.16
savings mjaperarirtgjime again^Tiabricating (or purchasing) cost. Time-study data are valuable for this
comparativeTstinTates
if available; if not
can be based on average empirical values for the"
pur pose,
operaTionsT"
XTisToTsuch values
With operations
vantages of the
Time
"
_
2.
17.6
18 working days
16
8X^=
1728 parts
Clamping Screws
CLAMPING ELEMENTS
116
Ch. 10
=#>
C
I>
Spherical washers
when clamping on
Acorn nuts are used to
damage and dirt. The
1
1/2 times standard height to reduce the load on the thread.
The acorn nut can be modified as shown in Fig,
10-9.
The purpose of
this design is to
Hook
Fig. 10-10.
the
new
shown at
to make and
permit lifting
lost.
bolt
through
and
is
pushed up
until the
When
the
is
It is
"hook"
very cheap
easily applied.
The bolt A, passes
hole in the jig (having a good sliding fit in
this hole)
the illustration.
left in
great
pressure
is
is
hook or head B,
then tightened.
down upon
jig,
at right), for
When work
is
the bolt
is
is
better suited to
its
pur-
the bolt
Fig. 10-9.
body and
it
Machine
strength
steel of
is
N/mm 2
60,000
psi
satisfactory in cases
tensile
made from
strength
steel.
They
are
now
widely preferred because of their strength and relithe fact that they require less space than
older types of fasteners, and because they are safer
in operation; the wrench cannot slip when it is propability,
good
shown
in Fig. 10-10,
Fig.
bolts.
An
application
is
shown
in
10-12.
CLAMPING ELEMENTS
Ch. 10
mended
117
as a last resort,
it
may
be ac-
Fig. 10-12.
the 4-prong
man
If
knob
anatomy of
the hu-
hand.
screws are to be firmly tightened without the
method of using a pin through
is
mm)
The
more, and
in diameter, or
tightening.
Fig. 10-14.
method;
b.
An
inexpensive
light-duty operations;
c,
a.
method
The
general
suitable for
A clamping method
recommended
Jack Screws
The o rdinary
jack screw
is
frequently employed
deviceTamhbwn,
use of manually operated screws, however,
does not completely eliminate the possibility of overloading the clamp. Full safety against overload can
as
that
work
Oft
the
same
shown in Fig.
The method shown in diagram a is simple
and self-explanatory. The method shown in diagram
substitute for the use of clamps are
10-14.
time.
in
vertically at the
diagram c
is
ma-
same
not recom-
principle
The
is
on
Fig. 10-15.
CLAMPING ELEMENTS
118
being connected to the jig by pin B.
At A, a
Ch. 10
set-
^^
long square nut is threaded on the eyeThese nuts must be of a particular length, and
made
and
at C, a
The
eye-bolts are
and the
jig,
The
is
set-
work, thereby providing a means of double adjustment. This is a very convenient clamping device
which works
and can be
satisfactorily
easily
swung
permanent mounting
commercially
in fixtures are
available.
Fig. 10-17.
This insures an
trally
the
if
should vary
The clamp
left.
at
at a in Fig,
lar
Straps
when
The simplest form of clamping device
A number
of different forms of
straps are
shown
the most
common
in Figs.
0-1 6a.
It is
purposes,
it
shown
diagram
in
of
all
the strap.
that
shown
in diagram
most
The clamp
practically the same
10- 16b
is
commonly used
is
added improvements.
recessed at the
b, to a
on
It
depth
the
two
3*
The hole
strap to be pulled
move
making
it
back
enough
far
and
easier to insert
re-
some cases,
it is necessary to extend the elongated hole, as shown
in Fig. 10-1 6c, so that it becomes a slot (going all
the piece to be held
in
the
jig.
In
prin-
r~rr
To
of having the
clamp bear on only two points, it is sometimes necessary to have it bear on three points, in
which case it may be designed similarly to the strap
strap or
shown
on
all
1 0-1 6d.
In order to get equal pressure
three points, a special screw, with a half-
in Fig.
spherical head
fits
strap.
ft
Fig. 10-16.
it
would be
required pressure
strap
is
Strap clamps.
on
The
D, located cen-
to advantage.
When
The head
same shape
is
in the
made
may be used
^
CLAMPING ELEMENTS
Ch. 10
At
and
in Fig. 10-16,
jig
When
or screws with
hand knobs
it is
in various
quickly,
pi
unneces-
thumb-screws
are frequently
used,
center and
single-
and double-end
-<E3
straps,
spring to keep
it
=5=u]
and a
area,
when released.
made with cam actuation in-
common
can
tyne of fixture
r equires
The
it
slide
when
this are
10-20a
is
the screw.
released.
Shown
in Fig. 10-20,
can
slide
it
Two
lengthwise
In Fig,
10-20b
is
strap, or clamp,
is
eom-
The
strap
is
to
a drill jig.
~i
SS
D"
mo nly
is
shown
a strap that
is
T his
ways of doing
in Fig.
clamp with
\)
-lb-
tft
especially
cations,
119
sJNha
Fig. 10-20.
removal.
The
strap
shown
in
diagram
b,
is
clamped
CLAMPING ELEMENTS
120
fect of
the fixture.
rJ n
!,i
The
is
^Nhl
is
Zl
'C
basic,
shown
H
p
Ch. 10
a bell-crank lever.
combination of
HSI
d Ri
;
S&.
jF-
^^^
dog"
in effect, also a
combinations
is
systematic clas-
i(o)
()i
i
18
^^^
SI
Si
by means of swinging bolts, a principle that has numerous applications. The strap shown in diagram c,
is clamped by means of bolts with C-washers under
the nuts and large bolt holes. When the nuts are released, the C-washers are easily
shown
may
be
lost.
In the present
by the use of
swinging C-washers. The C-washer is pivoted around
a shoulder screw; when the nut is released, the Ccase this condition can be improved
screws
are
standardized and
PjIflD
commercially
available.
Angular Clamps
In
most
Fig. 10-22,
modifi-
dogs.'
CLAMPING ELEMENTS
Ch. 10
sification,
will
type
the one
is
may
10-22,
shown
in
The
be used.
diagram
a.
The
basic
base block
is
position.
jaw
which
is
fulcrumed on
downward
casting
is
is
a cross-pin.
threaded.
By
turning
at the
and forcing
it
down on
is
adjustable, the
same
grip-
sizes.
a fix-
mounted on
121
down
stops,
ferent type
is
shown
of fixtures.
in all classes
diagram
dif-
Care should be
pivoted above point A.
in
is
b.
is
shown
forced
at c.
Plun-
down against
the
"down-and-in" pressure
Slides
washers
are equalized
and E.
is
by
A
a
strap
C and
This fixture
is
ball-and-socket
work
Lever
is
tapped to
zation
on
is
a circular locator.
is
already centered
to flat work.
the
10-24, clamp
MM IT
I
ig.
Fig. 10-24.
PIN
CLAMPING ELEMENTS
122
give the
work.
and wedge simultaneously produces horizontal and vertical clamping. It is simple, strong, efficient, and fast, and has
many applications. Figure 10-25 shows a fixture
\"\g.
10-26b.
a strap
wedge
Ch. 10
shown
in Fig.
An example
Plungers A and
Fig. 10-27.
knob D.
In this
way
it is
is
shown
in
with hand-
action.
Fig. 10-27.
strap,
the
in
Fig. 10-28.
workpiece.
Steel bracket
is
used as
Courtesy of E. Thaulow
Fig. 10-26.
wedge
action.
E.
is
II.
Ch. 10
CLAMPING ELEMENTS
clamp D, with
a small
set-screw
is
located a
by
little
is
The
Swinging Leaves
123
C down,
leaf
of the
quarter-turn screw.
jig,
and holding
The thumb-screw
as indicated.
To swing
is
rapid
frequently used.
is
fl
4
gag
-1
i
!
i
i!
ii
OJ
_^
^fci
"
[OJ
Fig. 10-3 1.
leaf
The lower
fig. 10-29.
The general
Fig. 10-30.
head
will
clamp.
It
when
it
will
The
of the
jig.
is
thumb-screws is made accordon the leaf and the size and design
size of these
commonly
used.
bolt,
shown
in Fig. 10-32 is
from being
worn out too soon by the constant withdrawal and
This kind of
expensive, but
is
leaf,
when
fitted
binding but also for guiding purposes, making a convenient seat for the bushings.
Fig. 10-32.
An
clamp.
CLAMPING ELEMENTS
124
diameter of the bolt.
eye-
is
is
Fig.
jigs
10-33.
It
a great deal
work and expense, and they are used almost exclusively when one or more guide bushings are held
of
at
Ch. 10
at B.
on
latch D. In cases
pivot
where the
is
kind
this
jig,
latch
is
when
ally
it
jig,
requiring no
When
the leaf
is
lock
is
required.
is
is
in the leaf.
r-F
1
tee
rl
if
k=.-
Fig. 10-33.
Fig. 10-35.
hinged
in place
shown
by
jig
a
may
cover
in Fig. 10-34.
_o)
jig is
shown
the part
is
is
signifi-
Should some
required.
IE
-h
S:
where the
leaf
arrangement, using
L_i_
swinging bolt,
is
clamp-
typical
shown
in Fig.
10-36,
_
two
"offll
M==t
LB
S-
'>-"--
7T
F(g. 10-34.
Fig. 10-36.
CLAMPING ELEMENTS
Ch. 10
two
points.
125
is a
cheap and
reliable,
milled
The
slot
on both
in
sides of
knob A
its
slides
work
is
has a
on over
knob. Stud
If
l'ig,
this flat
and
movement
They
are, therefore,
on the
part.
There are
tric
is little
principal difference
between
mechanism
^=3
Fig, 10-37.
is
fairly elastic,
In addition, a toggle
and
this feature
when
closing.
of the
shown.
principle
In diagram
In Fig. 10-39
it
at
applica-
a,
is
two
Figure
enables
center
forced
is
connected to
down when
the eccen-
tric shaft is
clamp C to bear on the work. This clamping arrangement has a very rapid action with good results. The
throw of the eccentric shaft may vary from 1/16
inch ( 1 .5 mm) to about 1/4 inch (6 mm), depending
upon the diameter of the shaft and the accuracy of
the work.
In cases where it is required that the
clamp bear in the center, an arrangement such as
the
to
would
60-degree thread.
that in diagram b
shaft
are
may
be used.
connected to
it
at
each end.
As the eccentricity
CLAMPING ELEMENTS
126
Ch. 10
mechanical advantage with little change in body position. At any position of the handle it must, however,
have a finger clearance of at least 5/8 inch (16 mm).
Figure 10-40a shows a cam specially intended for
A cam
Fig. 10-40.
great a
throw
b.
a.
For
For locking a
leaf
clamp.
lever should, in
shafts.
is
work
in the center.
down
evenly
when
lever
is
will get
If
required to be distributed equally at different points on the work, a yoke may be used in comstress
is
When
it is
poses, guides,
which
it
in
required position,
the
strap.
rigid
strap.
The
bars
may
slots at
also be round,
and the
slots at
more
rigid
all
the
as
the
eccentric
rods described
above.
There are a great variety of eccentric clamping devices frequently used and commercially
available
in several different models. For convenient and efficient
be located so that
its
position of
maximum
would
mm)
give an
extreme throw
of, say,
1/4 inch (6
mm) radius
is
center
work,
thereby
in
one
two
sliding
pieces, or
sliding
V-blocks or some kind of jaws. The cam lever is attached to the jig body, the leaf, or the jaw by a pin
through hole A
Hook B engages the stud or pin C,
which is fastened in the opposite jaw, or part, to be
.
clamped
The
to the part in
which
cam levers is so
show moie than the
but those examples which are shown
great that
principles,
embody
designs.
it
is
impossible to
all
the different
CLAMPING ELEMENTS
Ch. 10
a quick-
is
shown
is
The
in Fig. 10-41.
actual support
member
.4
has a
loaded, spring
flat.
When
the fixture
A up
keeps plunger
127
B
is
against the
work; by actuating cam C, the binder is pulled outward, and the tapered flat engages and locks the
tapered shank on A.
The double taper on both
plunger and binder makes it impossible to press the
plunger down,
away from
the work.
Fig, 10-42.
work.
C, and
when
groove
is
the strap
is
loose, the
cam
rests in this
groove (see sectional view). About 30 degrees movement of handle A is required to cause cam E to ride
on top of the
strap, as
shown by the
sectional view
at the left.
The head of screw B has six grooves (lower righthand corner), which are engaged by set-screw D to
prevent it from turning.
To adjust the lever or
tighten the strap
to a
new
when
which
also serves to
inter-
of the
jig.
It is
advisable to
is,
by
its
make
will
shown
not
stop for
fall into
the
secured
that the
The quick-ac ting jig clamp, Fig. 10-42, has a hanA, threaded to fit screw B, and a cam lobe E that
engages strap C. As handle A is turned, cam E ap-
dle
cam
one end.
is
is
shown
by a cam-
The workpiece
A movement
a positive
in Fig. 10-43,
dle
turned
The clamp
is
is
provided with
It
will be
handle having
noted
a ball
This causes a
cam
moving
to enter a notch
it
away from
loaded from the fixture. The ciamp is held in contact with the cam by a spring-loaded support finger
of handle
up and down on
When
which
a 5/8-1
screw, a tolerance
slides
tooth provides
a positive
dowel-pin.
CLAMPING ELEMENTS
128
Ch. 10
Spri/lf
Fig, 10-43.
on the
part, holding
it
is
slot
is
milled
D (which
is
locked
in
The bayonet
in place
by
the part
is
check-nut), slides in
it.
fast in
In operation,
while
amount of
float to
SECTION X-X
Fig. 10-45.
Fig. 10-44.
multiple
toggle
CLAMPING ELEMENTS
Ch. 10
129
is guided by blocks C,
The spring hanpinned to the shank of the stud, and the
their action
operating handle
dle B,
tated
is
which
is
is
beveled to
fit
rack D,
By turning
the
work
straps
The
is
may
location
of
drilled
hold-down
bolt
holes
tated
pumps was
when
bushing plates
of the same shape as the casting were used as jigs.
often inaccurate
flat
fit
the
drill jig
To overcome
latch
become
will
be rotated
'.
head castings
this difficulty,
in this operation.
will
other.
counterclockwise,
work
at four points
by means of
Relatively
bushing plate
made by
are a loose
fit
shown elsewhere
lizes;
Fig. 10-46.
machine tool
when
vise.
is
the
CLAMPING ELEMENTS
130
The cheapest kind of
built
is
Fig.
Made of
0-47.
cold-rolled steel
jaws.
vise
and
in
case-
They can be
The same
is
Hydraulically op-
re-
shown
Ch. 10
vise,
stock,
which
is
(0.03 mm).
conventional
chuck may be adapted to hold small workpieces that might otherwise be distorted if clamped
drill
directly in a vise.
'M
Magnetic Chucks
Magnetic chucks are available
1
1
in
3
two main
--
types,
usually of rectan-
mounting on a
The body
of the chuck can be trunnion mounted for precision
gular shape and as a face plate (for
Fig. 10-47.
Accuracy
is
improved
if
by dowel
ture base.
It
pins.
The
fixed jaw
the fix-
is
and
small part.
Almost
all
many
of the
vise
the
machined to an angle
slots.
by the addition of a
Insert
angular cuts.
reference pin
drill jig
I.
G.E.C. Gad's
CLAMPING ELEMENTS
Ch. 10
chuck body by
per,
brass,
plastic) of a
(3
mm).
strips
aluminum, or
The
131
moved
or all individual poles have one polarity, and the surrounding face of the chuck has the opposite polarity.
Either permanent magnets or electromagnets are
as general-purpose
used.
work
holders,
it
occasionally
may
esti-
the circuit
which prevents the part from sliding along the surface. The shearing holding force is essentially a friction force and is significantly weaker than the ten-
circuit
sile
is closed.
In electromagnetic chucks thepermanently closed within the chuck; when
the current is switched on, the magnets are energized,
and the magnetic flux passes through the workpiece
clamping the work to the chuck. Chucks with permanent magnets have mechanical devices for opening and closing the magnetic circuit inside the chuck;
the magnets may rotate or slide in and out of their
closing position, or they are connected at their lower
is
holding power. The tensile holding force depends on the strength of the magnets, the position
of the part relative to the poles, the size of the contacting surface, and the material, configuration, and
surface quality of the workpiece.
The overall strength of the chuck is expressed by
Specifically, the
its energy consumption in watts.
strength of the individual magnet depends on the
Work Dimensions,
Work
Position
Relative to Poles
Width X Height
Holding Force
Clamped on
In English Units
in.
flat
surface
psi
Across at least
three poles
1%
114 x
in.
in.
1% x %
'/
50
l /,
50
l'/a
146
x 1%
l'/j
surface
psi
straddling
/a
150
psi
flat
X
125
edge
Parallel to poles,
1%
150
l'/s
'/.
133
1
l'/i
45
17
IV,
17
1% x %
36
39
two
poles
i% xi
in.
edge
/,
1%
l'/S
1%
75
100
38 X 25
38 X 13
0.86
0.34
38 X 38
25 X 38
13 X 38
1,03
1.01
0.92
0.81
38 X 6
50
psi
75
mm
Hat surface
38 X 38
N/mm 5
,03
38 X 6
0.12
Across at least
mm
three poles
edge
flat
surface
Parallel to poles,
straddling
poles
two
edge
N/mm
mm
38 X 38
38 X 25
38 X 13
N/mm 5
0.34
0.31
0.27
mm
38 x 38
N/mm'
0.34
25 X
38
(1.52
13 X 38
0.69
6 X
38
0.25
6 X
38
0.52
CLAMPING ELEMENTS
132
number of ampere-turns
material property
carbon
steel
common
is
in its coil.
The
significant
devices.
Low
block."
creases with increasing content of carbon and alloying elements (Cr, Ni. Mo, etc.). The clamping force
for cast iron is about 60 percent that of steel. The
best position for the part
ing at least three poles.
is
it
Ch. 10
A
It
is
is
occasionally called
they are
commonly used
in fixtures.
delivers
it
to the
flux
It collects
work, thereby
ing force.
work and
also as
such
way
best value.
locator although
is
is
locally increased
required.
shown
is
field
in Fig. 10-50.
clamping
is
highly
sig-
chuck
has
clamping
is relatively weak.
It is widely used for
and can be used for light milling and turnis fast and convenient.
Magnetic chucks are
---
grinding,
ing.
It
relatively
inexpensive.
f * '1
Fig. 10-50,
field shaper
~~*
lw<
cylindrical parts.
It
and
ments
netic spacers,
and function
by
air
as pole extensions.
come
nition of a locator.
for
Field
a V-block
Electrostatic
Chucks
work on the
between surfaces with
charges. The chuck body consists
opposite electrical
semiconductor.
from
trically
Fig. 10-49.
E,
It
is
make
it
power supply while the workpicce "is elecconnected with the chuck frame which is
1.
CLAMPING ELEMENTS
Ch. 10
SIDE RAIL
PLASTIC
HESIN
COATING
133
after adhesive
must have a matching solvent, so that it can be removed, and the removal is also a time-consuming
process. On the other hand, the adhesive must not
be soluble in cutting fluids. Considering all this, adhesive clamping is selected only when no other acceptable method can be found, and is limited to
ELEMENT
INSULATOR
CONTACT
ma-
chining operations.
VOLTS AC
POWER
SUPPLT
Courtesy of Electroforce,
Fig, 10-51.
Vacuum Clamping
Inc., Fairfield,
An electrostatic
Conn.
chuck.
The amperage of the curby the power supply is very low, just
enough to make up for any leakage that may occur
in the dielectric film. These features eliminate any
The two surfaces are insulated
electrical hazard.
hard resin coating on the chuck
other
each
by
a
from
surface supplemented by a film of a liquid dielectric
to prevent air from entering the interface. The same
permanently grounded.
rent delivered
is
surface.
The
theoretical
is
made
to
maximum
moisture.
um
Law
the attractive
is
is
30
to give
with
it is
sufficient
them
clamping
Vacuum
is
fixtures are
of a rubber hose
in a
groove.
Vacuum chucks
Sonar
resin, varnish,
number of new
The
is
number of drawbacks.
deceivFig, 10-52.
CLAMPING ELEMENTS
134
would
leave
can
parts
is screwed on a
The nest is mounted
three-position index plate by means of which
on
one
at a time.
example
Low-melting alloys can be used for clamping parts
of awkward shapes, large overall dimensions, and
is
The use
fixture
nesting purposes
The
An
Ch. 10
is
A shown
frame
on
typical
in Fig.
10-54.
The
part
is
to be
machined on the four flanges B. The fixture consists of a base C, two boxes D, two removable Vblocks E, and two screw jacks G. The boxes have
Bend,
sistance of a foundry.
making
a set
the pattern;
it is coated with a parting agent, and located in a split mold or flask similarly coated with
the parting agent. The metal is poured, and after
block
is
the part
is
finally installed
fixture,
similar technique
is
An example
is
a valve
Fig. 10-54.
Direct clamping
by means of
cast metal.
is
the
casting
process.
molds for
as
by means of the screw jacks and arbors restThe slots around the legs are
sealed with clay, the metal is poured and when it
has solidified the part is clamped. V-blocksnd arbors are removed, and the loaded fixture is moved
to the milling machine and clamped on the table
with clamps acting directly on the cast-metal blocks.
After machining, the fixture is set in a tray, hot
water is poured over the metal blocks, the metal
leveled
ing in V-blocks E.
melts
away
easily
and
is
for reuse.
an
air- foil
which,
in itself,
G.E.C. Gad's
is
The blade
is
chine
and
low-melting alloy
is
cast
onto and
CLAMPING ELEMENTS
Ch. 10
around the blade, thereby providing
a set of suitable
clamping surfaces.
In the aircraft industry,
honeycomb
in the ex-
135
jig
All
When
num-
result.
When clamping
subjected.
double or triple
ployed to advantage in decreasing the number of
turns necessary to release the piece. Jig lids should
the
with
jig, it is
which they
or locating the
will
be
work
in
clamping pressure
it
will
11
CHAPTER
Equalizers
Definitions
is,
the broadest
in
between two or
When an
on
mechanisms equalizers
locators.
equalizer
is applied to
nism, the force to be distributed
force;
when
is
applied to locators
it
it is,
more
difficult
most
in
cases,
a reaction
izers
to
are, as a rule,
the
the
constitute an equalizer.
to a certain pressure,
it
Fig.
is
10-14b
is
two
increased, as
Strap
C in
in Fig.
is
Fig.
In the
is
in
rod D
B has
Many
drical part is
shown
The
an equalizer.
Fig.
in
toggle-action drill
izer), the
similar effect
tightened
is
shown
jig
is
10-23a
fixture
not equal-
in Figs. 10- 1
trast,
sure
obtained by
is
When screw E
a gripping dog.
in Fig.
is
found
in the
10-45, where
it
is
b.
The
Floating Principle
Representative Examples
An
Although some equalizers
is
10-16d.
it is
136
is
typical equalizer
is
shown
shown
in Fig.
in Fig. 10-36;
shows that
in
all
of
with
at least
some
the workpiece.
member
is
is
reached. In
represented by
The
is
often re-
redundancy. The required movability in the sysis obtained either by forming the equalizer as
beam that can swivel around an axis, or by using
stiff member-such as a rod -that floats between
tem
a
a
two
137
EQUALIZERS
Ch. 11
Although the
springs.
details
Basically,
equalizers
a great
purposes:
number of
When
When
for
Classification of Applications
is
applied to
to supporting points on which it rests, the construction must be such that it will not, by any possibility,
cause distortion. If springs are used under support-
1.
2.
3
4.
springs
the piece out of its true position. Also, when supports are placed against finished surfaces they should
be so arranged that they will not injure them. In
different heights
locating a piece of
To clamp simultaneously on
5.
a horizontal
and a
vertical surface
spread the clamping forces (and their matching locator reactions) evenly over a wide area
to avoid distortion of a thin-walled and elastic
To
6.
8.
a part
(multiple clamping).
The
that the design assumptions are fulfilled. This requires attention to several factors which, under adverse conditions, can restrict the movability of the
equalizer. As applied to clamping or holding methods, the greatest care must he exercised in order to
make sure that the floating action is not constrained
in
equalizer
a tilted position
may occupy
and
it is
neces-
workpiece
To center
To clamp
7.
and evaluate their possible effect. Significant friction forces occur on rough surfaces and also
where forces are transmitted through surfaces that
provide means of equalizing variations in the alignment of the thread. Locking devices for floating
locating point,
out of
its
is
correct position.
is
is,
their size,
The
is
basic and
EQUALIZERS
138
at the center
straight
It
can be
strap, or
Ch. 11
a
it
Fig, 11-1.
yoke which
the
is
fits
work
and B
to be clamped,
is
the
which
it
height.
Pin D takes the full clamping strain, and
should therefore be designed to be strong enough.
this place.
It
should always be
Fig.
A
Fig.
1-1.
The
formed
fixture
is
as a plate, as
drill
jig
1-2,
a piale
type equalizer.
of clamping which will so adjust itself to the inequalities of the casting that an equal pressure will
be obtained so that there will be no tendency for
the
work
shown
rocker-type
in Fig, 11-2.
provided with
a floating
to
heavy latch
is pivoted on a pin
end to allow for the
passage of a thumbscrew N which is used to clamp
it in position. A special screw
is threaded into the
latch, and is ball-ended at />so that it has a spherical
bearing against the floating clamp Q. The screw S
keeps it in position, but clearance is provided to
allow for the floating movement around the body
of the screw. Three pins R are set 120 degrees apart,
L, and
equalizer
in
is
tilt,
three-point bearing
is assured.
In order to assist in
supporting the work under the pressure of the drill,
of piston B.
A stud C is also provided to give the
correct location to the wrist-pin bosses.
rough
state,
it is
is
an angle of
in the jig
will
and
H by
it
drill.
It
139
EQUALIZERS
Ch. 11
enough to permit
fixtures.
rest pins
its
become
The
Floating Screw
The second
equalizers
is
Type Equalizer
screw and
nut are mounted without lengthwise fixation between two clamps or other force-transmitting components. When actuated, the screw and its nut exert
its
ponents.
typical example,
shown
in Fig.
1-4,
is
movement
through auxiliary
plungers H.
fixture that
shows
all
by tightening one
nut.
given a down-and-in
Fig. 11-3.
equalizer.
10-26.
B. Plunger
I-ig.
to rest
11-4.
on and insure
full
EQUALIZERS
140
Fig.
1-5.
They
are used in a
variety of forms
return plunger D.
clamp
Ch. 11
In Fig.
on the plunger
stop C, by
11-7
g>
the pull-through
means of plungers
D and E.
Figure
1-8
The work
is
Fig. 11-7.
floating screw
Multiple Clamping
in
mount
number of
is
simply
on a
Each fixture is equipped with its
own clamping devices and is unloaded and loaded
common
base.
separately.
the
When
the fixture
machined
step to improve
parts are
first
common
in
is
fully loaded,
all
The obvious
simple setup is to combine
one operation.
this
its
Fig.
1-6.
small double
141
EQUALIZERS
Ch. 11
Fig.
1-8.
nonuniform
parts.
SWINGING BAA
BIN ft NO !Cflt*
is
to one.
Fig.
1-9.
string-milling fixture.
(string milling)
is
to hold
all
the parts
fixture
is
shown
in Fig.
11-9,
The
entire package of
parts
is
Bulging of a Package
Bulging or buckling of a package of parallel pieces
as a result of accidental irregularities and
thickness variations. However, buckling may occur
may occur
even
if
surfaces.
In that case
it is
fully located
is
>
142
EQUALIZERS
Ch. 11
table.
consist of
piece C, which
is
bers
are
are arranged so
is
-J~~TT-Y
V7
pull the
<i
ll
f
h
Fig. 11-10. Bulging
of parts
in a
package.
not exceed
Fig.
11-11.
The spacers
are
mounted
in
is
to be clamped.
formed
in full
In the present
as half V-blocks,
parts.
5.
The
shown
which
V-blocks,
when E
is
remove
device
In
most
cases, operations
In the design shown, the two pieces B were originone, the holes being drilled first and the piece
cut in two, afterward. Because of the way parts B
ally
can be milled
one member
in
B,
and
a differently
shaped work seat in the opposite member. If required, it is also possible to have two or more sets of
pieces 5 for different types of workplaces, which
can be used with the same retainer piece C and the
same base A.
A device such as that described can be made without any recesses for workpieces and used for holding
a number of strips of material in a line pattern for
surface grinding or milling their edges, machining
first one edge and then the other. Other variations
in the design are also possible.
pieces
143
EQUALIZERS
Ch. 11
ponent, a screw,
An
clamps are bored to receive the washers, and are returned to normal position by the spring plungers N.
to be unloaded easily
The rocker
principle finds
multiple clamping.
'//mmm>sA
'>;/>/;/;/)//>
a larger
/Z
f
r^O^Ts
Fig.
1-14.
equalizers.
Fig. 11-13.
vise
EQUALIZERS
144
Multiple Clamping with Rollers
this
Ch. 11
condition changes as soon as the device is actuAs each roller is forced downward, it attempts
ated.
made with
cylin-
Examples
also in
some
practical aspects.
is
Rollers
Hardened
steel rollers
shown
in
is
2/3 F;
but
the V.
true equalizers.
with some
less
cost
P,
The
results
There
1/3
is
F and P =
2
(2
Friction, however,
fric-
it
always present; on a
roller the frictional component and the actuation
forces act on the same radius, while on a rocker the
redundancy at each
contact point on a horizontal center line. However,
A
is
tion.
7^}////////*
p2
r2
'p,
Fig. 11-15.
equalizers.
is
is
into account in
cient of friction
0.1
(hardened
rollers
and some
lubrication).
Hydraulic Equalizers
it
is
clamping points.
and single
the multiple clamping of identical parts
parts of irregular contour.
hydraulic fixtures
is
general discussion of
matic Fixtures. A
quiring an outside hydraulic power source
will
be
given below.
vise
shown
145
EQUALIZERS
Ch. 11
in
Fig.
is
leakage.
jaw
system
applied by closing the vise. The hydraulic
that the
preferably is installed in the moving jaw so
of the fixed jaw is not compromised. The
vise is
system is completely self-contained and the
actually converted to a universal fixture.
A similar hydraulic system comprising the oil resE, can
ervoir D and the desired number of pistons
rigidity
be
One of
is
oil is
provided
is
in its place to
plungers.
displaced from the reservoir lifting the
with the
the plungers have established contact
be removed.
the plungers retract, and the part can
be
system is versatile; clamping plungers can
The
as they
arranged in any pattern and direction as long
oil
F1
i
'fV
n Mii'ic
-HuLiLii
\
rt
Fig.
1 1-1 6.
vise
accommodate
part is clamped.
part, pressure builds up and the
disappears,
pressure
the
released,
When the screw is
sealed by
oil pressure.
When
reservoirs are
of fixtures, however, a
sliding fit
an actuating screw with a piston that has a
piston
and
screw
in the end of the reservoir. The
actuated,
are
they
as
pump;
constitute a primitive
is
lever castings
oil
is
jaw
screw thread
The
undamped, and
numbers or company
as are produced by raised part
set-up shown, six
the
In
work.
names cast on the
the reservoirs.
fit
all
fitting into
to
/.
in
is
operation,
In preparing the hydraulic vise jaw for
within
oil
to
3/4 inch
with
filled
are
reservoirs
the
modification
exerted on
machined
Plate K,
of the castings,
146
EQUALIZERS
communicate with the pump piston through the resHigh oil pressures can be produced by these
simple means. The fixture base with the reservoir
must be designed as a pressure vessel and dimenervoir.
limit
of
leakage.
Ch. 11
it is
recom-
mended
pistons shall
be guided
length of at least
in
The
fit
be an intermediate between sliding and running; a class RC2 fit is suitable; mating surfaces
shall be machined to 32 A A roughness and then
lapped to a true cylindrical shape; a bell mouth
shall
Plastic Fillings
is
eliminated by substituting
medium
in the past
and are
still
usable,
it
periods of time,
PLastiflexdl proprietary to Hastings Plastics, Inc.,
1704
is
CHAPTER
12
Supporting Elements
Definition and Classification of Intermediate
Supports
Intermediate supports are those elements in excess
comis basically required for geometrically
the
of
definition
determinate
plete and statically
of what
They
are
locators, as
the part
and freeze
located.
This solution
solid
is
after
has
locking
is
positive
friction
only.
On
cept in such unusual cases as clamping with a castable metal, see Fig. 10-54), but it illustrates the
principal mechanism of intermediate supports.
Commercial Components
Many
individual
components
Several
port devices are commercially available.
comas
available
plungers
are
types of spring-loaded
fixture
the
on
mounting
for
ready
(jacks)
plete units
Since they contain movable parts and are
base.
Method of Operation
or seals
in the
manner shown
shields,
in Fig. 8-10.
6-41
The two
and
adjustable locators
shown
in Figs.
supports.
is
the
and
cheapest one to make, is rather slow to operate,
access
convenient
is
there
where
used
be
can only
the fixture.
for the operator's hand-in a side wall of
The plunger
type,
much more
versatile, is therefore
used extensively.
147
148
SUPPORTING ELEMENTS
Type Supports
Plunger
Ch. 12
jig
is
Figure
support.
2-1 a
It is
it
is
One
objec-
will
Fig. 12-1.
of the milled
with
siderable time
The
support.
also
slow,
will shift as
ened,
it
will
it is
remain
is
tightened, although
when
tight-
in position.
flat
dirt, so that
is lost,
of a
as
it
is
in Figs.
flat,
sents a further
bronze bushing
is
Fig. 12-3.
Courtesy of E, Thauhw
Improved plunger type intermediate supports.
shown
in Fig. 6-40.
The design
Fig. 12-2.
ing
and cap.
E.
II.
G.E.C. Gad's
SUPPORTING ELEMENTS
Ch. 12
clamped separately
149
in
the rim.
work A
plete in
is
one
considered necessary to provide additional supporting points besides the jaw surfaces. A set of special
Fig. 12-4.
wedge-operated,
support.
wedge
is
Intermediate supports can be combined with equaAn equalizer can carry two or more interlizers.
mediate supports, or an intermediate support can
Equalizers and "the floating
principle" are used mainly where a plurality of intermediate supports are applied to a thin plate or
carry
an equalizer.
small vise.
Each
and adjust
its
Fig, 12-5.
Intermediate
ring.
supports
mounted
in
floating
150
SUPPORTING ELEMENTS
is
Ch. 12
clamped by collar-head
screws.
Each bracket on which the ring rests is
provided with a shelf// which is offset slightly from
center to allow the necessary width for the screws.
In using the device, screws L and
are loosened, and
the
work
placed in the jaws, which are then tightened, while the ring floats sufficiently to allow for
is
variations.
It
will
pins, being
ring itself
work
securely, thus
L-J
Fig. 12-6.
floating
thin wall.
ened.
of the mechanism
shown
wall of a workpiece.
a thin
narrow flange
x) and clamp
flange.
itself
CHAPTER
13
Cutter Guides
correctly located within the fixture, then the cutter
is also correctly positioned relative to the work.
milling,
work
is
On
in
Chapter 14.
needed for positioning the cutter for cylindrical turnTurning cuts taken with cutters
ing operations.
m&& '0\
3,
M
r-tii
ir3 Hi
151
CUTTER GUIDES
152
mounted on
a turret
Ch. 13
may
tions
FIXTURE BODY
LOCATOR a stop
FEELER
MITH
-,
dressers.
are
TONGUE STRIP
Fig.
3-2.
the
positioned against a
feeler gage, or a gage block, placed on the reference
surface.
In this
way
is
against accidental
The
come
It is
in Fig. 13-1.
ters
is
shown
is
a pres-
The operation
13-5),
per-
is
e1
Qj
guide
a press fit
is
mounted by
is
(T)
in
1
I
FEELER
FEEL
"
UhrM-
<
11
"J
Fig.
Figure 13-4
part
The
in
The
20 degrees
apart. Each lug is milled on two sides, and the gang
of cutters consists of one slitting cutler and two
shown
fixture.
in Figs.
An example
The operation
is
tH^-
is
the straddle
shown
chain-dotted
DIRECT CN OF FEED
cylindrical locator
Fig.
3-3.
Ch. 13
CUTTER GUIDES
153
dicated).
A dummy
Fig.
provided
13-4,
with
three
shown
in
cutter guides
formed on a
cutters.
ma-
on
shown in
is
is
plate of the
dummy
ters
of the
plate
dummy
is
With the dimensions shown, the mean thickness of a lug is 0.4965 inch (12.61 mm), leaving a
total clearance of approximately 1/16 inch (approx.
1.5 mm) between cutters and gaging lug. The thick-
tion.
mm), and
is
therefore, be offset
of the plate.
on the
Fig. 13-6,
lug must,
Courtesy of k\ Tkaulow
mm)
to
II.
G.E.C. Gad's
14
CHAPTER
Drill
Bushings
and
Definitions, Action,
Classifications
They
positioning, guiding,
The
twist drill
precision work.
is
a tool that
Its
is
tool.
An
less).
angle of
bite.
local variations in
may
drill
is
it
starts to
sensitive to
metal.
The
result
is
drill,
are over-
located that
and
sizes, as
bushings.
USA
fixture
Drill
items.
in
drill jigs.
ommended, because
it
with a different
used
is
By
bushings.
basic
conventional and
special
Conventional
bushings.
on individual dimensions.
Standard bushings satisfy the majority, but not
bushings, depending
all,
In
some cases
the
bushing.
presented.
made
Many
and apply
also to
nonstandard bushings.
Standard Bushings
it
154
Illustrations,
USA
DRILL BUSHINGS
Ch. 14
the
six
comprise
press-fit
shown
in Fig, J4-1
in Fig.
14-2.
and
They
Press-fit
at this
Inside Diameter:
The
'
155
is
specified by
Type Bushing:
The type of bushing
is
by
specified
letters:
Renewable
Renewable
ing bushings,
for Slip
for Fixed
HL
P
for
for use
renewable bushings.
made
in
Head Liner
for
Head
Body Diameter:
The body diameter
is
Press Fit
specified in multiples of
Body Length:
The effective
or
body length
8/16=
is
specified
in
8.
jig.
.5000-
Hxample-
Decimal
2.
Letter
made
3.
Number
4.
Fractional
Type Bushing:
1. S - Slip Renewable
2. F - Fixed Renewable
L - Headless Liner
HL - Head Liner
operation.
All standardized outside diameters are in multiples
all
standardized or uniform
jig
plate
in
c.
d.
Body
Length:
Tolerance
'Eric Oberg and t'.D. Jones, Machinery's
Inc.,
1971) 19th
inch = 48/64 = 48 J
thicknesses of
bushings
portion of these
16
to
facilitate insertion or
S-48-
Handbook (New
ed., pp.
1884-1894.
otherwise
inch.
inch
= 16/16= 16
DRILL BUSHINGS
156
Ch. 14
The included
of the counterbore
is
angle at the
bottom
degrees.
and
largest bushings
is
HEAD TYPE
HEADLESS TYPE
drill
bearing length.
literature
Size of
Above
Hole
Above
to
Maximum,
inches
Minimum, inches
Above
1V4 inches
1
1/2 to 2 times the length of the chamfer.
Bearing length for the drill within the bushing
ideally should be a function of the drill diameter.
to
wear,
is
is
ins.,
incl.
when
WS
the
in.,
incl,
Above 3/4
is
1/4 to 3/4
it
to 1/4 in.,
inel.
to
of drill bushings.
ofASME
A, shall be as follows:
Nominal
drill
Courtesy
Fig, 14-1, Standardized types
fa Fig.
L.NER BUSHING
LINER BUSHING
RENEWABLE WEARING
BUSHING IN HEAD TYPE
is
If
are
allowance
jig
plate holes.
The grinding
An
to
When renewable
analysis of the
is:
jig
each
drill size)
drill
drills
down
to 0.8
for
large
drills
about 2 inches
in
diameter.
metal
is
all
fit.
Fit Bushings
fit
installa-
1/2-inch to
DRILL BUSHINGS
Ch. 14
157
c
7
c
1
B
ST"
2.
fr
^~~
JL
l
-A-
-BCourtesy oj
Fig. 14-2.
The
six basic
types of
drill
bushings.
ASME
DRILL BUSHINGS
158
Ch. 14
Example -When
jig plates
OD, and
3/4-inch length
is
fit,
is
man-
drill size,
bushings
bolt.
The
mounting
hole; drilled pressure plates are placed both on the
free end of the bushing and on the far side of the
jig plate; a bolt is inserted, a nut is screwed on, and
bushing
as the
is
nut
first
its
is
When
the bushing
is
too small to
diameter.
jig plate is
Head type
installed
because
surface of the
and
drill
particularly
ly
recommended for
The hole
by means of
never with
are
installation in relative-
would
for adequate
fit
must be finished
twist
drill.
twist drill
cannot be
for the
own
physical diameter.
Example -A 3/4-inch chucking reamer can be expected to measure 0.7505 inch when in good condition and to produce a hole very close to 0.7510
inch
in
diameteT.
stroke.
the
must be taken
if
two bush-
between them
In such cases,
It is
recommended
faces
are systematically
on the high
side.
be
carefully
cleaned and
lubricated.
is
of facilitating later
An
renewable bushing.
mended procedure.
Distortion of a bushing as a result of excessive
lower portion
due to an "ironing" effect on
the metal in the jig plate whereby small irregularities
in the surface are squeezed down and the effective
interference is reduced accordingly. Thus, a point
in the surface at the top has been in contact with
and "ironed" by the full length of the bushing, while
points further down suffer less and less "ironing"
effect due to the shorter length of bushing to which
interference
is
is
must
White lead
inating
interference
will
for elim-
bond a
fit.
An
steel
adhesive
bushing
in a
is
now
available that
clearance hole in a
Drill
Bushing Co.
DRILL BUSHINGS
Ch. 14
the bushing
is
installed,
is
left to
it
recommended
Maximum
of heat.
application
25
is
OF and
temperature
Head type
press-fit
bushing from
the
by the
plate
application
which
is
being pushed
is
clamped on the
drill,
the
down
to a certain depth, as
which
in a location
even possible to go to
clearance with
0. 003-inch
is
the stop-collar,
to be drilled
it is
common
is
to
be used only
lining
is
made
hole bored
in the
in
jig,
the jig
to go
If
jig,
ill
and
the work
finished seat, or
is
not
make
bushing having
The length A,
in Fig, 14-4b.
is
As the bushing
necessary to
is
driven into
metal
a
the work.
practice to
shown
is
When removable
it
in Fig. 14-4a
a long head, as
Installation of
to allow
shown
located against
is
boss,
then
by means of
in thickness
a boss, as shown.
159
surrounded
the
bushing
all
the
if
the jig
way
up.
liner
by hand.
bushings."
They
Fig. 14-3.
made
to
fit
the
now
larger-sized hole.
reamer bushing.
In order to
into
place.
turn,
in
which closely
bushing, as
body,
fits
shown
When no removable
lining
14-3b in which
bushing
itself
bushings
is
the
be
jig
becomes the
the
bushing or
required,
drill
Fig. 14-4.
fit
project, as
shown
The
in Fig. 14-3c, to
in
in
DRILL BUSHINGS
160
that
is
shown in
is
also
it
Fig. 14-2.
they
common
Their
must
be
safe,
effective,
simple,
foolproof,
shown
in Fig.
called a "dog,"
bushing and
end
is
14-5a.
is
press
bent
resting against
is
that
fit
at the
jig.
sometimes
is
a possibility for
same plane.
Making such dogs involves some extra expense, but
the
tail
they
The
holes.
with
way out of
the
tail
Large bushings
a semicircular groove
in the
Although
the bushing
does
it
it
it
is
jig plate, as
shown
fit
in Fig.
facilitate the
arrangement shown in
Fig.
]4-5b
is
commonly
used
will
have to be
trifle
larger in diameter.
This
Ch. 14
The
tail is
located in the
jig
illustrates
r=^
-i
as preventing
a
Fig. 14-5.
Fig. 14-6,
it
from turning.
DRILL BUSHINGS
Ch. 14
is
in
and
Fig. 14-7
161
push-out by
the recess.
is
to
device for
-g-h
4.
Courtesy
Fig. 14-7.
ofASME
it
r o-
>
3K
'
W
H+-
a separate
is
Courtesy of ASME
OOlSR-
For heavy-duty
pi
r O.DI5
"\ m,
\
*-D-
ft
means of
lock-
and
Clamps provide a larger
bearing surface against the jig plate and are secured
by standard socket-head cap screws. The bending
moment on the screw is also peatly reduced. Clamps
torque
<
WM
H
1
mm<
from rotation.
Courtesy
Fig. 14-8. Standardized locking clamp.
ofASME
projected
ers
mounted
liners,
is
that
is,
head type
not countersunk.
lin-
Typical
*-F-
\L_
t"
Jl
Courtesy
Fig. 14-10. Standardized lock screw.
ofASME
DRILL BUSHINGS
162
Ch. 14
LOCK SCREW
RECOMMENDED
PROVIDES BETTER
SECURITY THAN LOCK
SCREW IN HEAVIER
DUTY APPLICATIONS
DIAMETER SAME AS
FOR LIGHT
DRILLING APPLICATIONS
SMALL HEAD
DIAMETER PER.
MITS CLOSE
BUSHING PLACE-
MENT
FLAT CLAMP
FOR LOCKING
PROVIDES MAXIMUM
SECURITY AGAINST
VIBRATION AND
STANDARD
TORQUE
JIG PLATE
FLAT CLAMP
FOR LOCKING
PROVIDES MAXIMUM
SECURITY AGAINST
VIBRATION AND
STANDARD
TORQUE
MOUNTED
LINERS
SLIP
RENEWABLE BUSHINGS
/"^Tn^
fea
~"M
RECOMMENDED
FDR LIGHT
DRILLING
OPERATIONS
J/tSll
O^^
MS
U
|J\
mr
SMALL HEAD
\\
/>-,rV==n
*&
WLM
_E3
OK
J|J \
PLACEMENT
PROJECTED MOUNTED
(HEAD LINERS ONLY)
SLIP
for bushings.
not standardized.
liner is standard;
standard
slip
is
it is
pressed in place by
means of an
locking tabs
as
shown
in Fig.
14-13.
The con-
Proprietary
to
the
American
Drill
Bushing Company.
DRILL BUSHINGS
Ch. 14
163
Fig. 14-12.
Nonstandard Bushings
of the
The
holes
Kjg. 14-14,
jig.
minimum
theoretical
is
in
place.
The center
if
is
distance
reduced, and
The
Examples of nonstandard bushings: long bushings and a bushing with an external thread.
wall
thickness
is
series.
shown
recessed, as
in
Fig.
14- 14a.
The distance
H of
need
to
small a hole
accommodate
to
body has to be
large
enough
If a
slip
longer than the lining bushing, as illustrated in Fig. 14- 14c, it will be advantageous to make the
projecting portion of the bushing about 1/32 inch
bushing
is
amount of
surface which
it
must be ground,
first
tool
which
are long
enough to prevent
its
running
out.
If
large
compared
is
very
as indicated in Fig.
the bushings
may
In
necessary to
jig,
it.
Courtesy of American
I'lg.
Drill
Bushing Co.
DRILL BUSHINGS
164
Ch. 14
<^P
guiding the cutting too! alone, but frequently combine the functions of locating and clamping of the
work
as well.
9-
and
5,
9-
6.
j3l
Drills with
Attached Bushings
When machining
or
relatively
two
bushings becomes
slip
Considerable time
^XT
is
and
feed.
Jk
Slip
permitted by
location.
made
accuracy
the required
,_oi.Ay
the hole
in
auSHii
IN
J 10,
BORE
as large as
room
A technique
that
14-16.
the
drill
is
with multiple-spindle
drill
Z-shaped bracket
of
shown
in
Fig.
drill
and reaming
is
drill
is
tools.
Some
heads
the bushing
is
machine
drill
mounting
bushing con-
spindle.
The
tip) that
is a long and
screwed into the nose
of the power tool; it carries a flange with two projecting locking lugs matching the prongs on the jig
bushings.
In essence the tip is a slip bushing
mounted on
ports the
pushed
drill,
The
drill jig is
made of
all
the
power
way
bushing
drill
tool;
into
is
when
in
the liner
is
The
drill is
it
up and operate
it.
work.
are capable
drill jig,
tool.
type of equipment
shown
bushings in the
with
drills
is
The operation of
in Fig.
jig
14- 1 7a.
They
this
The
are secured
DRILL BUSHINGS
Ch. 14
165
TURN 30 COUNTERCLOCKWISE
a
Courtesy of American Drill Bushing Co.
Fig.
14-17.
(a)
in a line,
strips
locking
drill
drill
with thin-walled
followed by counterboring,
countersinking, or spot facing to a diameter significantly larger than the hole diameter; perhaps followed by reaming. The diameter of the liner is
slightly larger than the diameter of the counterboroperation
drilling
ing tool.
The
drill
it
is
differs
from
made.
spindle. <b) Pair of locking strips for drilling of holes, closely spaced in line.
is
drill jig.
drill
Bearing length
L, Wall thickness
=T=
1/2 (B-A)
G=
1/2 (E-B).
and Flange width on head =
The basic dimension is the hole diameter A.
According to an old rule-of- thumb, the bearing
length can be taken as
is
bushing
fits
in the
=s
2A
not long enough to cause excessive friction. However, it is larger than is needed for large drills, while
small drills, from 1/4-inch (6-mm) diameter on
Millimeter Dimensions
Inch Dimensions
= \Ta +
for
tools
0.8
0.4 inch
sharp
with
n/T+
more
edges,
5y/~A
such as
0.4 inch
drills;
= 4>/~A+
10
10
mm
and
mm
as boring bars,
T=
0.2 \/~A
Body diameter
Courtesy of Technological Institute, Copenhagen
Examples of very wide bushings.
Fig. 14-18.
r = v7+lram
0.04 inch
will
B=A + IT, or
B = A + 2T + 1/32
then be:
B = A + 2T,
B
or
=A + 2T+0.8 mm
DRILL BUSHINGS
166
depending on whether or not the bushing
bored (Fig. 14- 14a.)
counter-
is
Ch. 14
ixamp/e- Calculate dimensions of 3/4-inch diameter drill bushings of the types shown in Figs. 14-4b
and
4- 14a,
B 0,1125 VT inches
vT = 0.8660;
VT = 0.9086; VT = 0.9306
A =
D = VT mm
0.750 inch;
F;=
0.6
VT inches
F=7vTmm
shown
in
For
Fig. 14-]
4a
5/
6 inches
Fig. 14-4b.
Corner Radius:
Inch Dimensions
D=
25
0. 11
V 0.750 = 0.
022
^ 3/32
inch
E=
B+F-
forU<
1/8 inch
Total Length
For
= B + F- 1/16 inch
for>
Fig.
14-4b
1/2 inch
L + D= 1.2660+0.1022= 1.3682*=
where
3/8 inches
is
inch dimensions.
Wail Thickness:
seat, take:
T = 0.2Vo.750 + 0.04
B<C<3B
for
0.67B<C<3B
for 3/8
0.6B<C<2B
<B<^
for
3/4 inch
Body Diameter:
For
Fig.
14-4b
5 = 0.750+ 2X 0.2132=
1
for C corresponds approximately to the values in the ANSI Standard. Calculated diameters are converted to multiples of 1/64
0.2132 inch
12/64=
1.1764 *=
12/64
3/16 inches
For
inch and calculated lengths are converted to multiples of 1/16 inch. Other calculated dimensions are
The
following
Tolerance
based
fits
limits
(from
on ANSI
ANSI
Standard
B4. 1-1967),
H7-n6
F7-m6
for fixed
renewable bushing
in liner
Height of Head:
For
Fig. 14-
F=
0.6
F7 and m6
1,
p.
are
16 and
found
in
ANSI
1,2077
Length of Seat:
p. 19.
to
1525.
industrial
Press Inc.,
Vo.750
0.6
York:
14a
Diameter of Head;
Em
1.2077
7/32 inches
F7-h6
are
recommended:
1.2077
',?
Handbook (New
X 1.2077
0.7246
<C<; 2 X
1.2077
<C< 2.4154
3/4 inch
< C<
2 3/8 inches
DRILL BUSHINGS
Ch. 14
Millimeter Dimensions
For
E=B +F
5=
forB<
Q.67B<C<3B
0.6B < C -g IB
for 10
10
mm
mm <S<
for B > 9 mm
19
30.8
= 31
19
14.63
=s
15
mm
+ 15-
31
1.5
44.5
mm
Length of Seat:
0.6
3KC<62
19mm<C< 62 mm
H7-n6
(press fit)
F7-m6
F7-h6
The tolerance
mm
mm
0.8
Diameter of Head:
seat, take:
B<C<ZB
for liner in
Fig, 14-14a
F=7V
millimeter dimensions.
11
4i
is
19+
Height of Head:
For
where
167
limits are
found
in reference
books,
good grade of
low tem-
rJjramp/e-Calculate the dimensions of 19-mm-diameter drill bushings of the types shown in Figs.
ing cold
14-4band
A=
14- 14a.
mm;V~A =4.36;VrA =
19
2.67;
\f\ =
2.09
= 5\AT9 +
10
19
answer
all
practical
purposes, provided
the
= 31.8^32 mm
Corner Radius:
3
Bearing Length:
D =V
hardness of 63 2 Rockwell
C.
They are also made of carbon steel of at least
0.6 percent carbon content. They can also be made
of machine steel with a lower carbon content, which
will
work
= 2.67^3 mm
series.
Total Length
made
level,
in a
higher quality
L+D = 32 + 3 = 35 mm
Wall Thickness:
T = s/~[9 +
=4.36+
5.36
*= 5.5
mm
to
The
Body Diameter:
For
Fig, 14-4b
B=
19+
11
=30 mm
made
to
the same
quality
level
from a sintered
is
machin-
1532
to 1537.
C.
may be
DRILL BUSHINGS
168
made
when
come
Ch. 14
is
within the
itself.
to support the
large, as
tool,
::
piiiiu
Special Bushings
Many
steel
jigs are
and cast
iron.
laminated
plastics, plastic
laminated.
is
made, or potted
formed by cores
as the jig
is
is
made
bushing
Fig. 14-19.
are
those
plates in thicknesses
is,
jigs
from about
fit
is
REINFORCEMENT
STRIP
Fig, 14-19.
LOCK RING
CLINCH -L0K
BUSHING
INSTALLATION TOOL
(THREADED FOR
The lower half of the bushing is cylinand precision ground for locating the bushing
in the mounting hole.
The upper half is larger in
diameter and has longitudinal serrations (see Fig.
ADAPTING TO
installation.
RIVET GUN)
drical
14-19).
The step in diameter prevents axial displacement, and the serrations cut into the jig material
Template bushings
TEMPLATE
BUSHING
Template bushings.
DRILL BUSHINGS
Ch. 14
169
0.003 inch (0.03 to 0.08 mm) oversize, and countersunk 90 degrees. The bushing is placed in the hole,
and an aluminum locking ring is crimped around it
and into the groove. The crimping is done with a
special adapter arbor in an arbor press, or with a
rivet gun. Bushings of this type can be removed by
cutting the locking ring, and then can be reused.
Circuit board bushings are small bushings for drills
of
/4-inch (6-mm)-diameter,
down
to
#80 (0.35mm)
With standardized
machines
currently
on
the
market (see
Fig. 14-21).
15
CHAPTER
At
devices
and
intermediate
Using
in their
The
to the part.
and clamping
supports,
these
if
drawing
are
made
is
part outline
is
shown.
also
Fig, 15-1.
must be
phantom
requirements as well.
difference
stands, is a
made
two
the
in
shown
styles
The Use
Components
mm).
step
which case
it is
or
drill jig,
"pump"
jig.
It
is
Chapter 21
cable to box-type
the
cially
available
The
drill jigs, is
jig
box,
an
the use of a
example
commer-
of
which,
170
by
many
8 inches (300 by
In
450
final
continues.
Drill Jigs
drill
to 12
The
They are
15-2.
make-or-buy decision
is based on a cost estimate.
If commercial components do not fit, however, the design procedure
In
a jig plate.
up
available in sizes
of Existing
in Fig.
lies in
the
choices:
plate
jig,
an open
jig,
or a closed
jig.
all
making
projecting bosses of
varying lengths, or to form the plate with bends and
a
flat
offsets so that
it
Ch.
Fig. 15-2.
surface.
The
Two
styles
first possibility is
usually
recommended,
open
jig is
the solution.
If there are
holes in more
jig is
two cases
needed. The
is
described
171
detail in
A
is
is
as
in the
Fixture Clamping
that
is
not
the fixture.
bolts
must
is
gripping position.
Alignment
Alignment is obtained in principle by means of a
key in the fixture and an alignment slot in the ma-
Fig. 15-3.
172
machine table
is
cast-steel
edge
of
tongue
its
as
fit
small
as
possible.
is
is
fit in
hole
drilled to pro-
mm)
for the
it
most subject to
friction
and wear.
clearance of
clamp
are
they will
shown in
take when
located and
cam
parts of the
sleeve
table.
The
downward by simply
movement causes the
it is
stopped
should be backed off slightly to clear the top surface of the fixture lug and allow the sleeve to pass
When the
-by hand
in the lug.
fixture
T-slot.
is
now
nel or a
complete box
up from the
forming a chan-
built
phantom
the
drawing
shows where
Again,
material
is
needed.
principal consideration, apart
from
At
rigidity
is
and
clearance.
may be
unavailable.
following places:
Clearance
Around the
is
required at the
part
of the
machine.
No
If possible,
Windows
in
may
and
little
steel
fixture
built-up type, a
fixture
fixture
It
table.
The
so that
standard, square-
base.
Ch. 15
The cam-sleeve
is
prevented
Typical Examples
As an introduction,
how
it
will
be interesting to see
Ch. 15
15-4,
obvious
same assignment.
plied to the
shown
in Fig.
It is
173
cast channel is
is
fully
integral,
pends for
its
fasteners.
rigidity
on the
screw joint
is
size
and number of
by means of
dowel pins, as shown. The three types
differ also with respect to "clean contours." The
built-up fixture, if made from fully machined or
cold-finished components, presents well defined
inner and outer contours with clean inner corners.
The welded fixture has projecting weld beads in the
inside corners and on the outer sides. The cast
fixture has rounded fillets in the inner corners and
additionally and permanently secured
tightly fitting
zT=l
draft.
in the
C
,
ruitLJ
t\
if.
rc
7^-r
ti
ig. 1
EU>ED
CAST
(LM.T-W
5-4.
bqz
shown
15-5a,
A X
are representative.
is
made
B, as shown.
scale
The
built-up
A and
I
1
The
It is
jig,
de-
B, because the
J.:::)
components
are
smaller circles).
hold
the
pieces
since
forces that
screw holes
screws, they
174
far
apart
possible;
as
therefore,
the
grooves
in
closely
is
would
sufficient,
pins are
mounted with
and holes
sliding
theoretically,
over
fit
the
made with
of
Thicknesses
pins.
the
those
the
in
bearing
fixture
cast
surfaces
in
the
at
in
is
into
fitted
Ch. 15
provide
to
sufficient
The two
joints.
straps
random
at
An
fixtures,
should
in
the area of
is
sometimes
exception occurs
when
ground, an operation
practiced on jigs and
jig
components
located
cleaning.
somewhat
is
in
dowel pins
position, and
that they go
rod.
is
of fundamental im-
60 to 64 Rockwell C, the
core hardness 50 to 54 Rockwell C.
The shear
strength ranges from 150,000 to 210,000 pounds
per square inch (1035 to 1450 N per square millimeter). Diameter tolerance is plus and minus 0.0001
inch (0.003 mm) with a surface roughness of 4 to 6
hardness
surface
is
provide
a secure press
fit,
avail-
work
in
worn or
acci-
As
bearing
length,
i.e.,
the
ream
to
it
penetrate.
It
the
is
length
member
which
the
pin
of the assembly,
the
pin
must
to be drilled.
is
is
hole.
The
bottom of the
Assembly Screws
Assembly screws
head
cap
is
steel.
the screw
diameter):
in steel
in
pin.
hexagonal socket
of a high-strength
in
the
usually
However,
to
are
made
screws
no heavy load
are usually
which
drilled
in cast iron
applied
to
depth
dowel
dies
made
magnesium
aluminum
in fiber
and
Vi
XD
XD
2%XD
2
plastic
2Vi
3
XD
X D and up
Ch.
steel plate.
On
of thinner plates.
are selected as
(see
later),
175
if
they
the other
bearing
A and B
to
The
15-5c
avoid
modulus of
therefore,
of
The part
has no weak
base
the
requires
is
monolithic and,
Again, the machining
fully
areas.
clearance
full
way
the
all
made from
wails
would be
solid,
which
excellent
is
structural
viewpoint, but
sacrifices
base
chip
Should
for
cleaning.
from
access to the
this
point
be
essential, either
provided, as
Forming
windows
in
the
casting
of
possible,
No
used, with
for
is
perfectly
When
usually
OD
provide
and
stiffness,
they
sufficient
preferably
is
areas
limits.
additional rigidity
is
needed,
it
is
necessary
Gusset plates are not practical in built-up fixtures. A number of different joint
patterns are shown in the composite structure in
Fig. 15-6.
different
example
is
The channel is
Standard commercial rolled sections offer but little
opportunity for use in built-up fixture construction
because of their rounded fillets and thin wall
thicknesses. Therefore, where channels and angles
are needed in a built-up jig, they will have to be
flange.
thus
cores,
evaluation or
made
because
factors,
Built-Up Fixtures
made
heat
treated,
thereby
separate hardened
eliminating
components such
the
need
for
as drill bush-
About
the
thicknesses
joints.
only
two
rules
regarding
material
and strength of
Fig. 15-6.
joint patterns.
176
of
side
Ch. 15
base
the
welded together.
Modified approaches to related
problems are shown in Figs. 5-9 and 15-10.
1
IT
TtT
mi
i
I
m
n
rr
Fig.
15-10.
modification of the
made
jig
shown
in Fig. 15-9,
Cast Fixtures
Fig.
15-7.
plate flange.
more or
also,
less
work space
in the
form of
perpendicular
example
Fig. 15-8.
bracket type
drill jig
made of flame-cut
r ID
plate.
offers
the
TORCI
^4
Kt
*
Fig. 15-9.
Fig. 15-11.
The design
to
made from
a one-piece pattern.
fixture
Fig.
in
5-5c.
Another example
with
left,
groove
a circular
The
is
the
design to the
in
shall
be given
here.
2b and
15-1
flange
in
Fig. 15-13.
is
c.
If the
is compensated for
by increasing the thickness in the
design
b,
is
to provide a flat
accomplished by design
c.
177
Two
The
design
design
to
the
to
right
the
requires
left
made without
is
jig.
core; the
a core.
accumulations
na
Ch. 15
A
the
in the
two
it
T's,
shown
in
Fig.
15-14.
contains a
It
and the
casting
made without
cores. If
it
is
now
desired
feet
and
is
lost,
required.
>
a-
Fig. 15-14,
The condition
equivalent
Fig. 15-12.
Telated case
is
can
be
formed
without
core
box
and
to the right
is,
for
all
"free
metal
flow"
is
essentially
metal thickness
in walls. If
below such
a limit,
the
178
For average
Ch. 15
size
castings
3/8 to
/2 inch
to
( 1
mm)
For smaller
castings
mm)
down
castings
The
to
/8 inch (3
more
serves
web
the
as
T-beam, or an angle,
beam
t
cases,
wall
either an I-beam, a
as indicated in Fig.
0.2
and
beam,
in a
5-15. With
can be taken as
f
\/H
= v /7i
inches
for
specifically related
many
mm)
= 0A6y/H
inches
or
0.8
mm
y/H
safer
to
use
entirely
The reason
sufficient
web
'
Fig. 15-17.
panels,
a.
empirical
of
well-balanced
the
satisfies
extreme
thickness.
dimensions,
static
which usually
cases.
retically,
uniform thicknesses;
an upper limit
theo-
means
between
in practice, it
thickness
ratio
this
Fig. 15-15.
the
to
adjoining sections.
also
r>
type;
is
2 to
1,
many
In
of panels
series
indicated in Fig.
members
(ribs,
f=l/4+
1/15
within
forms a
Examples are
I5-17.The length L between cross
a
frame.
y/T
inches
or
may
be taken
= 6+-jy/L mm
as a
lower
limit; in case of a
is
casting with
uniform
is
imperative for
it is of lesser
importance for external corners. The corner radius
r, can be related to wall thickness t, as follows:
cracking;
r
r
= 0.5 t
= 0A8
to 1,0
t
to 0.2
discrepancy
in
is
will
well-proportioned castings)
it
be
is
These
are
minimum
values.
However,
radii
in
>
-w
porosities.
Fig.
S.
web beams.
Ch. 15
179
stresses set
casting
weak lug
design.
(Right)
strong
for a .precision
lug design.
and paint
Figs. 15-18
Welded Fixtures
Welded fixtures are, with few exceptions, made
from low-carbon, hot-rolled steel assembled by
electric-arc welding. This construction principle puts
few
restraints
down nor
virtually
no
up; metal of
15-19.
Fig.
A weak
(Left)
bracket design,
(Right)
Bends
in thin walls
externally
neither
15-20.
heavy sections.
should
Full penetration
is,
there-
between
^
15-20. Large radii of curvature required in thin-wall
Fig.
castings.
As
a general rule,
small
as
possible,
partly
as
of a
is
The
strongest,
cast iron
and
this
When
Fig. 15-21
machined they
the
stresses
distorts
in
(warps)
the
until
in fixtures.
are
I
Weld Details
collection
fixtures
is
shown
in
Fig.
180
Ch. 15
nuxt
n=f\
Wr
A
a
Thickness,
or
>4
Fillet
Rod
Size
Size
mm
in.
mm
in.
Diagram
1/4-3/8
7/16- 1/2
6-9.5
11 -13
14-25
3/8
1/16 up
26 up
1/2
Diagrams
1/4-3/8
7/16- 1
1
1/16 up
6-9.5
11 -25
26 up
welded U-shapc.
Fig. 15-24.
welded bracket.
mm
in.
6-9.5
V4 3/8
9/16-1
11
13
5/32
3/16
4
5
b.
9.5
13
and
c, d,
3/16
3/16
5
5
1/4
5/32
3/8
9.5
3/16
3/16
13
1/2
Fig. 15-25.
e.
Components
Fig.
5-22. Typical
sions.
is
required,
sections.
Where extra
use heavier
The
fillets.
5000 pounds
Relative
details
weld
are
dimensions.
shown
in
Figs.
per
is
mm 2
).
(TlTETU
15-23
?"'^
'
a.
7/16-1/2
Diagram
Fig. 15-23.
is
shown
in Fig.
5-25.
made
Fig. 15-26.
Welded pads.
Ch. 15
181
gussets;
are inexpensive in
shown
easily eliminated
Fig.
deficiency
is
shown in
shown in Fig.
as
1P=T
u u
1
cn
rp
Fig. 15-27.
are cut or
Fig. 15-30.
The use of
pt
^~
2
Fig. 15-28.
Welded hinges.
15-31.
On
diagonal strap, as
welded
a considerable
T-slot.
amount of
Welded design
from
Curved
differs
limitation:
design,
increase.
the
more
Welded
bending
should
shapes
involves
same
is
the
design in one
cast
be
Round
Design Rules
important
cutting; the
serious
cost
artistic
Appearance,
fashion, not of
economy
?>////?//>,
and efficiency.
Fig. 15-31
182
15-32.
Fig.
(left)
with
large
diagonal strap.
in a great variety
of dimensions,
thicknesses,
and
Z-beam, have relatively small wall-thicknesses and
are seldom used, except in special cases, such as foT
structural
shapes,
the
channel
shown
in
and
the
drill jig
shown
shown
in Fig. 15-34.
drill jig
plates
shown
and
fiats,
many box-type
The same
is
Fig.
flat
jigs, is
steel,
structure.
hardness
During
drill jig
will
2imi_j L5
There
fixtures.
tool
or
normalizing,
the
resulting
Rockwell C,
good wear-resistance and still
be approximately 35
be machinable.
fixtures
should
surface
areas
A welded
legs.
be
for
designed
to
machining.
In
have
this
Fig. 15-33.
with angle
made of low-grade
annealing
sufficient to provide
built
feet.
little
design.
operations and
He must
visualize
all
as
machining
do not
it
also
may seem,
T-slot base.
is
may
welded
Welded
is
minimum
15-35, which
5-34.
from
in Fig.
I-
Ch. 15
medium wall
The material
are
To
fixtures should
steels
Fig.
15-35.
welded
drill jig
made of
platus and
flats.
Ch. 15
Comparison and Conclusions
183
mm)
this could
Some
down
for fixtures
little
welding.
same manner
when
or
time
delivery
as
the
welded fixture.
natural
of part;
medium
the
is
be
can
It
any desired
area
may
It
components may
its
The
however,
critical.
is
size.
It
may be
may
On
if
needed.
is
When
casting
larger
it
may
supply of
is
now become
fixture has
the
The welded
may
fixture can be
made
lighter in weight
less
time and
money
It
to
make
for
it
complete
it.
It
is
il
bined construction
may
fixture
is
more
easily
machined out
would
often fall into this category. The material is machine
steel or light metal tooling plate. If hardened
additional
is,
after
thickall,
jig plates
is made of
upper limit for fixtures made
of machine steel is approximately 2 by 3 by 6
inches (50 X 75 X 150 mm). The limit is not an
absolute one, but increases with increased capacity
and efficiency of the machining facilities available.
A simple example of a solid fixture is shown in
tool steel,
15-36;
Fig.
practical
are
body
weldment requires
accomplished.
Solid Fixtures
A com-
that
Solid fixtures
true.
and
a fixture is
takes
The design of
be economically superior
number of
is
countersinking,
The jig
The bushing
is
drill
split in
the
a slip bushing to
allow
E,
l'orlag,
1930)
vol, II.
G.E.C. Gad's
184
Ch. 15
Plastic Fixtures
A
1
different
5-3 7.
type of
The part
is
"solid"
drill
drill jig.
jig
is
shown
body
is
shown
in Fig.
solid fixture
jigs,
directly
They
plastic
repaired,
and
if
less
expensive.
fixtures
are
They
makes
15-37.
drill
jig
The low
cost
'Ibid.
are, therefore,
about
Chapters 3 and
plastic
14.
fixtures
are
presented
in
16
CHAPTER
Economical Design
clearly recognized as
Design
is
relatively
made from
a set of drawings.
with
is
T -slots,
side.
size.
part.
It
is
as seen
is
of rota-
lines
and much
loss of
details,
for
work
holders.
AH
fixtures required
ensure blueprints of
shop and
its
is
maximum
dirt.
from
The part outline
is
General drafting practice, as used for product dedrawings, is followed with respect to pro-
sign
rection
is
allowance
is
ma-
in a revision
in the
modifications of the
surprises.
contrast.
first
general-purpose
to
blueprint
It lists
the
number
each operation,
shown or
a fixture
clearly indicated.
is
The same
is
is
done when
185
186
Tricks of the Trade
Ch. 16
from
a hole center to a
are available
final drawings.
To improve
dimension
lines;
lines
The
addi-
is
negligible
is
some
In
from sketches
welded or assembled.
layout and assembly drawings it may some-
liberately
In this
drawn with
slight
distortion,
i.e,,
maximum
The
Work
done
is
is
straight edges,
and
more
adjusted to
faster as
it is
Lettering
is
easily
new system,
has
a disadvant-
on
it
is
is
now
Modern manufacturing
by the use of jig borers,
jig grinders, and N/C (Afumerically Controlled) machine tools, require each dimension to be defined as
the distance between the particular point or surface and a common datum or reference line, point,
or plane.
Fundamentally, two perpendicular reference lines are required for dimensions in one plane.
Three reference planes are required for complete
definition of all dimensions on a three-dimensional
or the "coordinate system,"
practices,
part.
are
also
front
drawing.
values,
supplemented, and
of the drawing.
the
it
co-
is
all
drafting machine
linear
trifle
will
critical
others that
scale,
obscured part
drawing gains
show
all
aircraft
in
as exemplified
geometry.
Typical
critical
work
two perpendi-
can be
moved
shown
when
toward the left and toward the column of the machine (away from the operator), which again corresponds to an apparent or relative movement of the
spindle to the right (the x axis direction), and
For
toward the operator (the y axis direction).
convenience in the operations and as a safety measure to avoid errors, the dimensions shown on the
Ch. 16
187
*effective"spindle
movement away
from column
EFFECTIVE SPINDLE
ACTUAL TABLE
MOVEMENT TOWARD
MOVEMENT
TOWARD LEFT
RIGHT
ACTUAL TABLE
MOVEMENT TOWARD
COLUMN
Fig. 16-1.
Movements and
moving
in
movement.
part drawing should also go from left to right and
from top to bottom, and the two reference tines in
the plan view should originate
from a point
at,
or
near, the
somewhat
differently.
Le., the
sioned as
shown
N/C machines.
on
jig
compon-
borers, not
on
188
Ch. 16
^#S
V
3.526
3.600
Fig. 16-2.
-#-e
Dimensioning from two reference
is
shown
in Fig. 16-2.
In the
coordinates.
lines.
In this case
it is
shown
the corresponding points in the drawing. The arrangement of the dimension lines shows dearly
This method
lines are
assumed to
be.
Direct
lines
is
simplifies
makes
tion, are
in the
With
it
is
much
if
it
also
numbers.
each
Ch. 16
The
2.
189
system
is
ciples:
1.
The procedure
system.
Appendix
II at
is
explained
in full detail in
components and
inserts,
etc.).
Example Two
hole
first
is
The accuracy of
machined part
is less
than the
ture by
known
as the "degeneration
fix-
part
of accuracy."
To
it is
crucial question
there-
what tolerances
is
shall
literature
is
They range
common
sense, practical
judgment,
logical
sometimes
trivial
nature.
An
tolerances,
but
initially selected
not
tolerance that
with those
possibility of using
it is
is
risk.
therefore
The
If
and
a total
with the
a part
inches could, so
far,
maximum
jig,
diameter of 1.4375
.004
1.4415 inches.
is
maximum diameter.
A part of this small
size requires a
minimum nomi-
gives a
minimum
which
.4375 + .0005 =
applied a manufacturing
nest diameter of
If
the nest
is
at its
maximum
of
The pro-
cedure
close
move
part to
elementary,
left.
location
dimensions.
is
ensure
The
critical
the part.
most
Fixture Tolerances
inter-
1.439
it
a part of
relationships are
shown
in Fig,
is
These
selection
in accord-
The
cost
is
The
resulting
maximum
maximum
In the search
As
a part
of
maximum
the
wide tolerances.
the part
is
clearance
is
within
the
to
The
found to be
recommended
inches.
16-4,
minimum diameter
is
shifted through
shifted
190
DRILL
(= 11
Ch. 16
,191
DRILL)
1
1
1
1
.005
1
1
1.4375
1.4 365
Fig. 16-3.
A part
Let a be the
wear
in the
itial
the
bushing, first assumed to be without tolerThen, to satisfy the part tolerances, we have
drill
ance.
a -.00125
> .498
and a
.49925
.00125
< .502
drill
satisfied
'
center distance as
4Qt) c btct,
in-
is
requirement
comfortably
.0005
.0025
MINIMUM
MAXIMUM
CLEARANCE
CLEARANCE
MINIMUM
MAXIMUM
NEST
NEST
MAXIMUM
PART
,00125
Fig. 16-4,
is
shown
in Fig. 16-3.
satisfied.
Ch, 16
It
is
tolerance. This
ension as
is
'qqqj- inches,
margin of safety.
Toolroom Tolerances
mm)
mean width of
the
The
tained consistently.
mm)
jig
.749-2 X
.120
.509 inch
on the
sions, are,
tmg
._,
feeler gage
block,
"
inch,
.
on the
1
When
is
with
extreme alignments
must be within
Inch
careful
set-
,.
inch.
this
mm) by
jn^
.1205
5Q07 inch, and on the shoulder
jq5
-5093
'
the
is
less
inch (0.013
0.003
setting block
ances of
191
-.1195
minimum
gage, maximum +.1202
shoulder,
feeler
+ .0007
alignment
maximum -.1205
minimum
+ .1198
.0007
limis.
Example:
the crank
arm boss
is
is
Plus
positioned
surface.
When
Inch
cutter space,
minimum
-"a
+ .748
maximum
maximum
feeler gage, maximum
- .5093
- 1 20 2
alignment
setting block,
1
shoulder,
center boss.
is
-.1205
Inch
maximum + .750
minimum -.1195
minimum - .5087
minimum - .1 198
which
is still
.002
+ .002
permissible.
Cal louts
t.m
Additional instruction for the machining of the
Machining operations
is provided by callouts.
that are obvious are not called out, but callouts are
part
used where
LOCATOR
I
ig.
and milling
cutters.
The
cutters are
mounted on
is
maintained
at
is
-
The space
750
inch.
With
mean
cutter
.748
space of ,749 inch and
mean
is
re-
scribed
an arbor.
thickness of the
may be
needed.
because
they
prefer
to
192
Ch. 16
DRILL
DRILL AT ASSEMBLY
DRILL .50 DIA 1.25 DEEP
I-
C'S'K (countersink)
ANNEAL
SAW
TORCH CUT (or FLAME CUT)
WELD
BRAZE
DIA TO FIT INSIDE BUSHING
FIT AT ASSEMBLY
SLIDING FIT IN PART NO. ABC
BORE
.001
COUNTERBORE
CO BORE
C*BORE
COUNTERSINK
CO SINK
C'SINK
NO.
.250
MORSE TAPER
(.60235
PER FOOT)
REAM
REAM
1.250
flat taper)
ROUND WITHIN
.010
ON R
EQUAL SPACES
BOTH SIDES (used
4
LINE
REFERENCE LINE
DIA
1
DEEP
NC THREAD
NCTHD
DRILL & TAP 1/2-13
235
DATUM
DIA
TAP
TAP 1/2-20, 1 DEEP
TAP 1/2-13 UNC-2B,
1/2-13
1/2-13
taper)
TIR
(diameter)
(radius)
TRUER
UNC, 2 HOLES 180 APART
R SPHER (spherical
BEND R 1/4
radius)
TYP (typical)
REF (reference)
HONE
LAP
LAP OUTSIDE
SCRAPE
(or
INSIDE)
AFTER GRINDING
BSC
SYM
4
(basic)
(symmetrical)
(center line)
DEG (degrees)
GA (gage, indicating plate
#12 GA = 105 inch)
thickness,
for
example
KNURL
96
CHAMFER
1/8 X 45 CHAMFER
BREAK EDGES
ROUND EDGES
DEBURR
CASE HARDEN
CASE HDN
4>
(diameter)
mm (millimeter)
cm (centimeter)
m (meter)
A
callout
may be
"WELD" foUowed
is
recommended.
Ch. 16
machining operations made by the workshop personnel. However, industrial callouts are widely used
and the tool designer should be familiar with their
Common
application.
some
and
typical
callouts
are
D
Fig. 16-6.
193
16-6.
F
A. Spot
drill,
center
drill;
B.
face;
17
CHAPTER
USA
USA
Standards
Standardization
(including
are
ings.
Standardized components offer significant advantages to the user. "Design" is reduced to selection of
a component of suitable size from a table, and actual
current edition
is
parts required
reduced.
eliminated.
is
When
The quantity of
is
drill
High-
bushings,
hardened and ground to close tolerances) are available in today's market at prices from less than a
dollar; this is less than the cost of pulling a vellum
from the file and having a blueprint made!
N.U.F.C.M.
bushing and fixture component industry
is today a multimillion dollar industry
USA
and
steadily expanding.
In
components.
made
As standards
available to
its
are
adopted,
members
for
194
It
in Figs. 14-1
is
Jig
in
Chapter
14.
Proposed Standards
The next level of standardization is a set of proposed standards prepared by the N.I.J.F.C.M. for
to the American National
Standards
(ANSI); a package of individual standard
proposals, covering most of the components needed
for clamping and locating. With the unified recommendation of the industry concerned, it may be ex-
submittal
Institute
literature.
USA
will
Standards
in
Manufacturers' Standards
Component
tivity
marketing
193
Bush-
fixture
Jig
three
Bushings.
ize
in the
specifications are
now found on
It
is
is
levels.
the
in
drill
components
identical
The
fixture
mentioned separately)
termined by the function of the particular component, and no consideration of taste or style is involved.
For these reasons, fixture components offer a wide
design time
of
drill
The
facturers" level.
Much
is
at the
manu-
Ch. 17
standardization
is
own
As
it
now
number system.
serial
manufacturer has
stands, each
his
Drafting templates arc also available for most commercial components. When used systematically, they
can save much time in all phases of the design, from
Components
this
ized freely.
available,
it
is
is
Any
is
it
in
any
it
is
20 to 3/4-
195
Range;
forth for
Thread from
1/4-
0,
for
table.
with
steel
from 3/8-16 to
1-8,
length from
to 2 1/2 inches.
with
misalignment,
1/4-20 lo
is
1/4-12.
symbols on
7/8-9.
5/8-11.
fixture
through
adapted
T-slot nuts
ii.)
have
on both ends.
secure
fit
at installation
is
obtained
use of a
down
(j)
are
to the
machine tool
table.
They
are
until
they
fit in
T-slot)
from 1/2 to
1/8 inches.
196
|M
H** *! MM W
l>
(*
Ch. 17
M H-
--
h-
STUD
li|i|i|il
FIT
i|
|i|i
^FIT
SPHERICAL
:THD.
\H0LEDIA
-]
^
END
\
Ui
r 1/8
rA
\threao size
7
J
SIZE
^^
-
r-
^E
-
aTHRFAO St2E
~\
<
g
^cj
Fig. 17-1.
ttCoupling nut;
illustrations courtesy
g.
a.
^-a:
c. + Jig
jL_D J
latch bolt; d. f Swing bolt;
e,
tT-bolt;
ftNorthwestern Tools,
Inc.;
Morton
Machine Works.
Spherical washers (1) act as a ball-and-socket to
are
1/2 inches.
stranded-steel cable in
Ch. 17
197
TABLE
SLOT
' THREAD
SIZE
'I
3
B
j-VI.
TAPEB
INCH
PEKFOOT
fr
+=^k
\-
Ql
Fig. 17-1 (Cant.).
*Bolts,
screws,
and associated
SHOUlDf I SCTiEW
parts,
l.
i.
j.
t+T-slot nut;
k. t
Interchangeable sine
C-washer.
illustrations courtesy
'American
Drill
Inc.;
Morton
Range;
Thread
Machine Works.
ing.
removal to speed
Washer is held
in
Range: Radius
1/4-20 to 3/8-16.
198
Ch. 17
-B
F
-#
of
q
^
c/
THREAD SIZE
+ .000
-.001
-r~~~*
'
'
i
'^^^^
V,
THREAD SIZE
THREAD SIZE
QSffilB^
*Bolts, screws, and associated parts, p. Slotted shoulder screw; q. f Socket shoulder screw;
of
s.
t.
r.
tHand
Drill
Ch. 17
199
-A
THREAD SIZE
THREAD SIZE
THREAD SIZE
ATHREAD SIZE
aa
Bolts, screws,
.
American
tip
peening.
Relieved
inches.
Drill
200
Ch. 17
--
TB
1
cc
^O
HD-*
I
I
dd
H04-
ee
I
'
_|
_L
*-A
THREAD SIZF
KNURL
SPHER. DIAM.
99
ff
II
and associated parts, bb. T4-and5-prong hand knobs; cc. ttStar hand knob; dd. t Knurled
'Speed ball handle; ff. ttPlastic ball knob; gg. Finger handle.
*Bolts, screws,
knob;
Illustrations courtesy
ee,
^American
Machine Works.
Drill
Bushing Co.;
^Northwestern
Tools, Inc.:
^Morton
3 degrees in
for
Ch. 17
Fig. 17-1
(Com,).
*Bolts, screws,
Illustrations courtesy
and associated
parts, hh.
'
tHand wheels
American
Drill
Bushing Co.;
between the
to 3 1/2 inches.
torque,
In this
and
jig plates.
when
Range:
1
Thread from
to 2 1/4 inches.
and jig-plates.
Screw-shoulder locks and
unlocks the plate by rotating the screw one-half
turn. Range: Thread from 10-32 to 1/2-13, length
leaf jigs
ductile iron
They
are
made from
high-strength
a bar
vertical
ii,
Morton
201
Machine handle.
Machine Works.
prongs for
maximum
leverage.
unmachined blanks or as
finished knobs, with choice of tapped or reamed
mounting hole. Range: Hole, blank, tapped from
3/8-16 to 1-8, reamed from 3/8 inch.
Four- and five-pronged hand knobs (bb) are cast
from gray iron, tumbled smooth, and cadmium plated. Faces of reamed or tapped knobs are machined
square with hole. Four-pronged knobs- Range: Hole,
blank, tapped from 10-32 to 5/8-11, reamed from
3/16 to 5/8 inch, diameter A from 7/8 to 2 1/2
inches. Five-pronged knobs- Range: Hole, blank,
tapped from 5/8-11 to 3/4-10, reamed from 5/8 to
3/4 inch, diameter 4, 3 inches.
Star hand knobs (cc) are available in choice of
aluminum or cadmium plated cast iron. Knobs can
be obtained as unmachined blanks or as finished
knobs with tapped hole.
Hole, blank,
Range:
tapped from 1/4-20 to 5/8-11, diameter A from
1
1/8 to 3
as
inches.
Range:
holes.
diameter
Knobs
are
B from
width
A from 4 3/4
to 8 inches.
Plastic
ball
levers.
202
Ch. 17
Steel
diameter
Range:
B from
to
7/8 inches.
Steel
knobs-
inches.
Handwheels fhh)
are
made from
cast iron
and can
spokes.
ease of operation.
with
a press
handles are
fit,
made with
a press
fit.
Solid handles-
from 1/4 to
shank thread from i/4-20 to 1/2-13,
length B from 1 23/32 to 5 inches. Revolving handles-Range:
Shank diameter A for press fit from
5/16 to 1/2 inch, length B from 2 5/8 to 5 1/8
Range: Shank diameter^ for press
1/2
fit
inch,
inches
Quick-acting Screw
through
Single
efficient
Components (See
Fig.
17- 2
d.)
locking
levers
(a)
Courtesy ofJergeiis
Fig, 17-2,
lever; b.
ing workpicces or
large
lever; d.
Double locking
Quick lock knob.
lever;
a.
Inc.
Single locking
c.
Quick
lock
to 3 inches.
Fig.
17-3 a through
m.|
They
Ch. 17
-j
CHOICE OF
TIGHTENING DEVICE
SPHERICAL WASHERS
*J**
^3^1 (J-H-hB
-C|rtjrt
^^^
-*i-
CLAMP STRAP
203
^-p
FINGER GRIPS
CLAMP REST
JAM NUTS
KNOB SCREW
ASSEMBLY
SPHERICAL
WASHERS
TAPPED END
CLAMP STRAP
SPRING
(D
Fig. 17-3.
also
offer
are
STUD
parts
REST PLATE
JAM NUT
standardized
oxide
Single
finish.
Hand knobs
end straps
(b,
c,
d)
are
cadmium
plated.
The
straps are
them in position when released. Spherical washcompensate for irregularities between strap and
Double end straps
part and ensure rigid holding.
ing
ers
204
L^
e s ^F
^ a
Ch. 17
? *fc
f
HAND KNOB
JAM NUT
SPECIAL T-BOLT
OPTIONAL
FLANGE NUT
FOR USE IN LIEU
OF SPEED HANDLE
WHERE ACCESS
IS
JAM NUTS
LIMITED
WORKPIECE
T-BOLT
INSERT
FIXTURE
PLATE
c~
ALTERNATE
STOP PIN
LOCATIONS
+ .000
Xj
J-7T
(SOCKET HEAD
CAP SCREWS
REQUIRED FOR
MOUNTINGSCREWS NOT
+ .000
-.001
FURNISHED)
(e,
f)
shown
holding
in the
maximum clamping
b) the as-
round pieces in
With open hex nuts
arrangements.
sembly provides
illustrations or
(a,
nut
(c,
e)
The hand
Ch. 17
THREAD
1?
205
I
i
,000.
.001
1
F-"
FOR # 10
SOCKET HEAD
1/4H
CAP SCREW
Courtesy of American Drill Bushing Co.
i.
with
knob (d, f) provides quick clamping and release without need of a wrench. With a double end strap, the
assembly can clamp two parts in one operation, and
less
left or right
G from
7/8 to 2 inches.
to 3/4-10,
1/2 to
steel
protects fix-
3/4 inches.
is
jam
and
nut,
is
space requirements.
swing by installing
stop pin
tail
in a
lug.
dowel
Range:
Hookclamp
head cap screw and stud and hex nut, are ideal for
use where space is extremely limited. The hook is
spring loaded for quick release and easily swings
away from the workpiece. The body is an alloy
steel investment casting with precision ground diameter designed for reamed hole mounting Range:
Thread on cap screw from 5/16-18 to 1/2-13, on
stud from 5/16-18 to 5/8-11, capacity from7/8 to
1
11/16 inches.
Hinge clamp assemblies (m) allow
work
area.
on the part or be used for locking a swingA hinged mounted pad bolts to the fixture.
A hand knob swivel screw provides quick
clamping and release, protects work surface and
compensates for minor surface irregularities. Range:
Thread from 5/16-1 8 to 3/8-16, capacity //max from
1
1/4 to 2 5/8 inches, throat A from 2 to 3 1/2
directly
ing leaf.
inches.
to 5 1/8 inches.
While
all
strap
j)
are
made both
for
mounting with a
clamps can be swung
Cam Clamp
Assemblies (See
Fig.
17-4 a through
e.)
for
much
Long
travel
cam clamps
(a)
have
knob
is
pushed
work to
close,
206
Ch. 17
rB
JAM NUTS
SINGLE CAM
SPRING
REST PLATE
JAM NUT
STUD
Fig. 17-4.
b.
e.
c.
Center
and retraction.
*Illustrations courtesy
of the following companies:
Inc.
Cam- actuated
strap
Ch. 17
Nuts on stud
ment
cam,
in
in
single
i,
from
from 1 3/8 to
2 5/8 inches; capacity can be changed by changing
Center
1/2 to
end -Range:
travel
to 5/8-11, travel
fixture dimensions.
Individual
Range:
207
through
d,
Fig. 17-5 a
and
fixtures.
jigs
(c).
BORING POSITIONER
Fig. 17-S.
"Chuck jaws;
'illustrations courtesy
d, t Chuck
a.
jaw boring
clamp
straps; b.
**Aluminum and
positioner.
'American
Drill
Inc.:
**Monroe
208
Ch. 17
serts are
profile.
to 6 inches.
Fixed Locating
through k.)
Use
in pairs
(See
17-7
Fig.
to
support
clamp
Components
plain
strap.
Rest buttons
(a
through
f)
all
blocks
step
permit use of
mixed
sizes.
prevent
dirt.
it
ground to
Round
Courtesy of American Drill Bushing Co.
Fig. 17-6. Clamping setup with step blocks and plain and
step-clamp straps.
shown
compon-
temporary
ents on universal
jigs.
fixtures,
and as
straps- Range:
fit
chuck into a
The materials used permit easy
machining.
Steel inserts are preferred for most
normal applications; they stand up well for mediumturning fixture.
production
some
highly
finished
2 1/2 inches.
To
assist in
The boring
positioner
It is
With this position of the boring posijaws are drawn tightly against the edge
of the positioner to eliminate backlash, and the inis
obtained.
tioner, the
heat-treated
steel,
on principal dimensions.
size
rest
made from
buttons
(a, b, c)
head are made with head thickness (dimenground to final height or manufac-
sion B) precision
by means of a
screw thread on the shank of the button (c) and
These buttons
a tapped hole in the fixture base.
are hexagonal and are made with oversize height for
less
accurate mounting
method
is
finish grinding.
Hollow
rest
The
counterbored for the screw head and precision ground to final height. This type of button
is available in heights up to 2 1/4 inches and is, tobutton
resting
flat or spherical
with
on blocks and clamps are precision machined for perfect fit between half blocks put together and between straps and half blocks. They
Serrations
from
is
f)
Slip-fit rest
with
lock screws.
separate
buttons
mounted
with buttons
The threaded
slip- fit
from 1/8 to
Rest pads
inch.
(j)
Ch. 17
209
+.0000
-.0005'
[ GROUND
RADIUS
LEAD
+.010
SCREW SIZE-
NOT FURNISHED!
+.014
^17
A
THREAD SIZE
CENTER OF
LOCK SCREW
1/81
'1
+.0000
-.0002
+.0000
-.0002
-A
B
+.010
+ .010
+ .014
+ .014
Fig. 17-7.
button for
c.
a.
Threaded hexagonal
slip-fit installation
button;
d.
Hollow rest
f. Threaded hexagonal
rest
slip-fit installation.
They are
available in double
mounted
end
design.
workpiece.
ings
at points
between
moved
When
can
quick twist of
the hand knob locks the jack by the expanding
action of two hardened steel shoes. A lock stop,
mounted on the side of the jig by one screw, prevents
be
Fig.
17-8
fixture.
Range:
inches, travel
from 3/4 to
1/2 inches.
when
lifted to
contact with
base.
210
Ch. 17
ll
t-
-]
1/16
-.343 RADIUS
After contact
is
Range:
inches.
support
final
with
precise
adjustment
is
They provide
adjustment.
positive
Position after
dowel
pin and two dowel holes are provided for this purpose. Discs are supplied in soft steel or carburized
and heat
treated.
ness (height)
from
Range:
Diameter
inch, thick-
Fig.
i.
Threaded
is
slip-fit rest
and a full-length pin are used together; the full-length pin "catches" the part first,
pins; a pilot pin
diamond) with a
wide tolerance in the other direction (the minor
Pin diameters (full round and diamond) are
axis).
direction (the major axis in the
Ch. 17
3H
211
mi
WORK
PIECE
gG
LOCK STOP AND
SCREW FURNISHED
CAVITY FOR
JACK PAD OR
ACTUATOR
EXPANSION
ACTUATOR
SHOES
LOCK STOP
+ .000
r B+.001
3**
1
-D-f-EHF
Courtesy of American Drill Bushing Co,
Fig. 17-8.
offered in an
"B" range;
"A"
the
a.
fit
Jack lock;
"B" range
is
range.
(e,
b.
d.
nut
(f).
with
fix-
ture parts relative to each other, which requires mating liners <d) in the second fixture part.
Standard
212
17>64_J
.005
EDA0K
in H
R
RELIEVED
ROUND
+.0000
-.0002
PIL0T
DIAMETER
F~
h L + .Q0OO
Ch. 17
f 1/3
OF A OR I
-.0005
60 CENTER-
BOTH ENDS
SPHERICAL
RADIUS
A>
1/4 OF
-H r 1/3 OF A OR
RELIEVED
+.0000
-.0002
G-H
SPHERICAL
RADIUS
PILOT
r+
0000
*.OOO0
.0002
1/B
DIAMETER
-.0002-1
1
ROUND
ROUND
LOT
-.0003
Je
"
_*
t.0005
{^
-.0000
AMETER
ORB
M/30FAORB
^-ed~~M
"
\
|
Fig.
7-9.
11
r +.0000
0005
J;
zr
0000
0002
D->-
ROUND
RELIEVED
(Left)
a.
Round and
Round and
relieved
(Right) relieved (diamond type) bullet -nose pins; d. Liner for bullet-nose pin;
e.
pins;
Round and
(diamond type) locating pins for slip-fit installation with lock screw recess; f. Threaded round and
(diamond type) locating pins with straight shank for slip-fit installation; g. Stepped round and relieved
(diamond type) locating pins for press-fit installation; h. Knurled round locating pin.
relieved
relieved
available in diameters
lower
in
7/8 or
limit, to
inch.
(j),
mounted
in a press- fit
diamond pin,
one direction and a
Ch. 17
0000
000?
RO[[ 'IN
SIOI
213
WIDTH-
jj.0O2
3/16 X 3/1
FURNISHED^
DIA.
1
1
0003
{c
-J
c
S*.0005
T~
GROUND LEAD
li
_L
-,
-1
-if
1/8
CE
DIA
1/8
DIA
+.0000
-.0005
+.0000
-.0005
m";;.'/,r-;.>-7~7r//M
Fig.
17-9 {Cont).
Locating pins
with bushing;
k.
"L" or "T"
pins;
1,
locator bushing for plastic tooling; m. L-pin; n. T-pin; o. Double-action captive L-pin,
Float direction
is
defined
Dia-
mounted
means of
the diamond
same purpose as
With a mating round pin they provide a close
tolerance in one direction and a wide tolerance
( 1 /8-inch travel allowed lengthwise in the slot) in the
perpendicular direction. Slotted hole bushings are
a roll pin, serve the
pin.
em-
bedment
Slot
in plastic
ment of
drill
jig
plate
first
hole or the first two holes have been drilled. Conventional L- and T-pins are loose parts and are re-
moved from
the fixture
when not
in use.
They can
214
in
press
bushing
Ch. 17
a precision sliding
fit.
The
bedment
their bushings.
in plastic tooling.
The
pushed
IP
LINK
'
BELL CRANK
BELL CRANK
THREADED
TAPPED
LINK
f
I
BUSHING
7
BUSHING NOT INCLUDED; ORDER SEPARATELY
Fig. 17-10.
Indexing components.*
standard mounting; b.
a.
Ch. 17
down
215
Fig.
17-10
through
i.)
\\\\\WM\\
-B
Fig.
17-10 (Cont.).
&
Illustrations courtesy
Drill
f.
tSpring
i.
tSpring
216
Ch. 17
-c
2
A 0002
'3ALLDIA
*B
"
6-32x1/4 DEEP
.2S00DIA
+.0000
DIA
-49
.31
DIA
a.
Plungers are
actuating devices.
made without
is
soft so that
Ch. 17
mounted
standard
in a
reamed hole
in the fixture,
from 3/4 to
2 inches, length
up to 3
inches.
vice.
is
threaded"
mounting
in a blind
modification
the plunger is a steel
wall.
a self-contained unit
is
ball
{low alloy
steel or stain-
down
lar
to 4-48), length
Spring stops
(i)
217
ment
reading).
immediately
(e) provides
ball
(f)
center
is
defined
The shoulder
sion
ball
axial adjustments.
maker's construction
ball center.
The
tool-
meter from
The
/4 to
Range:
Ball dia-
inch.
is
a supplement to the
not provide
ball shank.
The tooling
is
ball
by
shank.
against locators
Range:
from
1
is
Miscellaneous
Components (See
Fig.
17-11 a through
locked
by
is
pushed
When
slightly past
in this position.
When
released, the
The following
sections are
and T-sections,
flats, and
hollow squares and rectangles. T-sections are available in equal and unequal shapes. The material is
high- tensile-strength cast iron; the stock is machined
square and parallel to within 0.005 inch per foot
on all external surfaces. The interior of hoEow
shapes is left unmachined. Range: V-sections have a
90 degree included angle, an opening width from
1 1/2 to 4 1/2 inches, and height from
1
1/8 to 3
inches. Other sections have overall dimensions from
3 to 8 inches, rectangular hollow blocks have up to
a 10-inch-width, wall thickness of open shapes from
5/8 to
1/4 inches, wall thickness of hollow blocks
from 1/2 to 1 inch. 1
Other commercial products in larger sizes and for
available:
more
universal fixtures,
on
They
and automatic
fixtures.
Machinery's
in Eric
218
Ch. 17
\.-
:::''
^P
l*ig.
V-Sections;
f.
a.
U-Sections; b. L-Sections;
c.
i.
T-Sections (equal);
>
18
CHAPTER
Design Studies
Drill
Jigs
From
construct the
The Fixture
Design Procedure,
great
it
is
procedures for
jig
employ
to
or fixture.
For the purpose of evaluating the degree of sophiswhich the fixture should
be designed, production quantities can be classified
tication and perfection to
as follows:
Number
Type of Production
of Pieces
is
Small
medium
comprised of
up to 40
from 40 to 100
from 100 to 1000
over 1 000
lot
lot
large lot
mass
1
Designing
fixture
which
method of
on
the
number of
steps to a
drill jigs;
workpiece
firmly
against
the
locators
and
cases.
[f
supports that
may be needed
when
it is
subjected
5.
jig
or fixture
body
to consolidate
These
In
Case Series
Case
J,
Design
by 22 mm),
cut
to
is
length,
by 2 1/2
steel,
is
The
simplest and
made
to the
shown
in Fig.
a plate jig
as the part, as
as follows:
219
220
Ch. 18
_1 J
Fig. 18-1
Fig.
18-2
L'ig.
18-3
Fig. 18-4
Fig. 18-5.
Fig. 18-6.
The
Fig. 18-1
Fig. 18-2
Fig. 18-4
fig- 18-5
development of open
drill jig
Fig. 18-6
designs
shown
in this group.
located by laying
it
Fig. 18-3
is
it
further
located
This step
is
drill
press
3.
its
made with
and it is made
For minimum
holes to match the
without bushings.
This
4.
drill
to be used,
is
is
In a conventionally
dimensions
b, c,
be given.
mensions are transferred to coordinates, as explained
in detail in Chapter 16. The upper long side and the
design, a
more
number of
DESIGN STUDIES
Ch, 18
Since the
so that
piece
is
drilled at a time, as
shown
in Fig,
18-5,
The
- DRILL JIGS
221
which
shown
legs, as
can be
18-8,
in Fig.
defined by shoulder A.
by means of
are made of
locked
The
legs
locat-
Such points
fit.
are cither
with
flat
machined
The addition
all
parts
Case
jig plate
This eliminates
A jig
Fig. 18-8.
2.
An Open
Design
Drill Jig
diameter holes
in the part
The
jig
with
attached to the
all
jig,
known
"open
drill
jig"
which
is,
as the
A jig
shown
as
it is
in Fig. 18-9.
Since
it is
no core work.
The
design
open to one
requires
it
shown
is
cast,
side,
little
or
and pro-
ceeds as follows:
such
as the
has a machined
ing against a
flat
surface that
is
side.
The
part
DESIGN STUDIES
222
- DRILL JIGS
Ch. 18
IU-
j
!
Fig. 18-9,
An open
part.
downward extension
strap
is
formed into
components
enough
to
table.
lift all
with
rigidity
minimum
is
legs
with
made
long
clear of the
weight, as
machine
maximum
shown
in
the
Width b at
which again
Face Area of
up
4000
to 6
as a
6 to
60
Three finger
over
60
Jig
mm
Square inches
drill jig.
The
4000
to
40,000
over 40,000
Thickness a
Inches
5/16 to 3/8
mn>
8 to 10
1/2 to 5/8
13 to 16
3/4 to
19 to 38
1/2
part
No
is
its
entire area.
The
locating pins.
is
1/4 inches
(two
jig
mm), and
and
reaming.
1/4-inch
(6-mm) bosses
are
Case
On
the four
An Open
3.
It
is
Support
Design
part
is
a jig for a
shown
in
DESIGN STUDIES
Ch. 18
Fig. 18-10.
(330
mm)
mm)
wide, weigh-
pounds (16 kg), with a large boss for a 2 1/4inch (57~mm)-diameter bearing hole A, to be faced
on both ends. It has a flange, already machined flat
on its free side, to be provided with three screw holes
B and two dowel-pin holes C, bosses for screw holes
B to be spot faced. The initial lot will be 300 pieces
and may be repeated at a later date. The awkward
shape, weight, and quantity, call for a good jig without excessive frills.
All operations, except a few
facings, can be done from one side which also offers
an excellent, flat, machined locating surface. The solution is an open jig that can be turned upside down
for the few facing operations from the other side.
ing 35
The
jig plate
can
- DRILL JIGS
now be drawn.
It is
offset
jig
223
hear on
screw
at the
The
the
The
part
is
jig plate
with
by 5/8 inches
(38 X 16 mm) with slots for 5/8-inch (16-mm)
clamping screws to allow them to be pulled back
and clear the part.
3. The boss is overhanging and not sufficiently
three strap clamps D, measuring
1/2
by
F which
a
is
sup-
Strap
F has a hole at
slot at the
DESIGN STUDIES
224
quire
press-fit
wearing bushings.
mm)
Hole A
is
first
B, are guided
by
The
result
light as
Case
4.
it
is
and as
drastic saving in
by
Ch. 18
boss
drilled,
is
faced, either
on a faceplate
accomplished
jig plate
in a large lathe,
erably,
or pref-
vertical boring
Case
Design of a Closed Jig (Box Jig), of a RelaSimple Type, with Positive Locating Means
5,
tively
Design a
drill
jig for
four 5/8-inch
drilling the
inexpensive
jig.
positions
and
Holes
their
is
not
and must be
drilling operations.
DfllLL-FRESS TAGLE
Fig. 18-11.
drilling operations.
drilled
from
- DRILL JIGS
opposite sides.
it
has to be turned
closed, or box,
DESIGN STUDIES
Ch. 18
- DRILL JIGS
225
=-:"
-7-
Hh
!
Fig. 18-12.
jig
Since the
have
with a large
To
flat
head or
a fully
may be
sufficient.
jroj
.4
1 j
?.
?i
r,
"
..J- i.
j_;i
17
ft !
is
11
r^*
ft
well-dcvclopcd closed
Fig. 18-14.
installed in
jig.
pins.
3.
all
Components
Integral
The
part
inU-tnu'tliiLlc
4.
6.
dimensions
central position
countersunk, hex-
one of the
Holes are drilled in the lower plate
opposite the bushings for holes A to provide clearance
for the drill and for the escape of chips.
Case
dowel
in
locating pins.
Fig. 18-13.
closed
is
(16-mm)
5/8-inch
press-fit
Bushings are
Design a
drill jig
be manufactured
in
Upper
plate
can
mm),
drill
mm)
now be drawn;
is
cause there
a bear-
thickness
end clearance
is
long for
diameter.
F=&-
pan and
the plate.
-*T-TT
JU=
TT
1
^-fi-
is
No
^U=
226
Ch. 18
tion),
made
integral
illustra/,
the
mercial leaf
it
jig
when
shift
is
tightened, causing
drill
Case
7.
A Closed Jig
Design
with Legs
rangement
with integral
two operating
Case
5,
positions.
Machined surfaces
are
marked
is
:~j
O--
<S_M
f.
ii
it ft
Fig. 18-17.
flr-fr
The
<=
Fig. 18-16.
leaf
is
it
here a
1/2-
by
by 25-mm)
1-inch (38-
closed
jig
legs.
means of
quarter-turn screw.
Case
9.
A Closed
Body and
No Swinging Parts
safe grip.
drilling directions
Occasionally,
it
is
is
required
Case
8.
as
an Improved Type
of Leaf Jig
Design a drill
with a swinging
jig for
leaf,
An
example
is
shown
in Fig. 18-18.
The part
An examination
is
of
DESIGN STUDIES
Ch. 18
- DRILL JIGS
227
forces.
and
f^\
drilling,
reaming.
Ftg. 18-18.
closed jig
with a
port
for
loading
and
Fig.
to the
hole
with the
drilled
jig
is
now
jig
jig in
is
is
carried
strengthened by
by
boss held
The
on a
a rib B.
sisting
fiber, or
ings,
holding
it
but
many
in
is
used on a
The next
means
step in
may
now are
jig
it
in position.
still
be a plate
jig,
but
if
box
it
jig
is
over 90 degrees or
is
jig,
The
that
is,
simply turned
side
Operating with
Before a
jig is
Drill Jigs
designed,
it
closed
jig
for drilling
from four
sides.
drill
DESIGN STUDIES
228
one bushing
at a
time in
line
with the
drill
- DRILL JIGS
and
a larger
Ch. 18
all
drill
spindle.
operator.
shifting of
indexing
jig.
less
some
if
it
is
rigidity
A most
even
by hand.
Any drill jig, If it is not
clamped to the machine table, must be
held
safely
physically
may
be sufficient for
contacting one
two such
them,
parallel rails,
drilling
Even
full side
holes of
of the
jig, is
with the
better.
jig sliding
rail,
set
rule-of-
/4-inch (6-mm)-diameter or
less.
drill
bushing
Courtesy of LeBlond
Fig.
8-20.
of
between
in this
size that
stop block
is
ihumb
this,
Using a medium-size
drill jig.
Inc.
DESIGN STUDIES
Ch. 18
Maximum
Drill
Diameter^
Drill
mm
inch
10 x
A=
1/4
mm
3/4
19
8 x.4
50
60
2 1/2
= 6
150
xA = 10
250
work
first
are
shown
in Figs.
shows
illustration
is
supported on
drill-
The
is
to
jig.
When
the jig
is
of the
The
jig
is
mounted on
the indexis
- DRILL JIGS
not part
jig.
recurring problem
Jig
is
In extreme cases
sides in contact.
it is
necessary to
work
to provide
maximum
When
guidance to the
drill.
tight close-up
fit
fit is
full
support and
contact with a
part can be
preferable because
it
It
jigs.
Bushings
is
18-28, view
Placement of
229
Spindle Travel
inch
In
all
A, and
also in
other cases.it
is
many
The
DESIGN STUDIES
230
- DRILL JIGS
EXTRA-TH1NWALL
BUSHINGS WITH OD'S
LESS THAN THOSE OF
Ch. 18
STANDARD HEADLESS OR
HEADED BUSHINGS WITH
GROUND FLATS ON
USA BUSHINGS OF
SAME ID
OD'S
Fig. 18-22.
Drilling
work.
is
continuously guided
the bushing.
terials,
such as copper,
is
0.5 times
drill
diameter.
NO CLEARANCE
(MAXIMUM PRECISION
the workpiece.
drill
NORMAL CHIP
EXCESSIVE CHIP
CLEARANCE
CLEARANCE
DRILLING ONLY)
CUTTING TOOL
WITH NORMAL
BACK TAPER
JIG
GUIDING
EFFECT
OF BUSHING
REDUCED
WORKPIECE
EQUAL TO
172 ID (SMALL CHIPS)
WORKPIECE
1
TO
1-1/2 ID (LONG,
STRINGY C
CLEARANCE
WORKPIECE
SECONDARY BURR
Courtesy of American Drill Bushing Co,
:
ig.
end clearance.
DESIGN STUDIES
Ch. 18
IRREGULAR
FIXED
RENEWABLE
BUSHtNG
END OF BUSHING
FORMED TO
WORKPIECE
CONTOUR
-DRILL JIGS
231
WORK SURFACES
FIXED
LOCK SCREW
RENEWABLE
BUSHING
^1
'
J I6
END OF BUSHING
CHAMFERED TO
CONFORM TO
RENEWABLE
BUSHING USED FOR
HIGH PRODUCTION
FIXED
SLOPE OF
APPLICATION
WORK PIECE
SLOPED
WORKPIECE
Fig. 18-24.
The
obtained.
side load
point
is
Bushings for
exerted by the
drilling
in
of the
jig
shown
at
drill
Except
in short
production runs, the use of fixed renewable bushings should be considered, to simplify replacement
of worn bushings and to facilitate proper orientation
of the bushing with respect to the contoured
When
surface.
press-fit
WORKPIECE
Courtesy of American Drill Bushing Co.
through non-perpendicular surfaces.
usually concentrated at a
work
This type of
if
jig is
made
of matching parts.
in Fig,
18-25
is
is
The ring-shaped
jig
shown
at
in a cylinder flange
head, which
The
position
relation
to
the
When
cylinder,
the jig
As the holes
is
is
in the
when
drilling
the otheT
is
which
fits
shown
As the holes
locate the
slightly
jig.
larger in
being drilled
A
Fig. 18-25.
is
opposite side
An
B.
at C.
and can,
when
holes.
The Open
LINER
232
Ch. 18
Fig. 18-26.
The
jig
shown
in Fig,
The
and
is
a centralizing
10-46
jig
is
shown
it
shown
18-26 at
in Fig.
open-plate
An
and
jig
is
used
For centralizing
ZJ, which
are held against the conical point of wing screw E
by springs F, In operation, the wing screw E is
turned back until the plungers D are well within the
body G, at points H. The ring C is then slipped on
and the wing screw is turned down until the plungers
D are forced out and into contact with the inside
surface of the ring. The ring is then drilled on a
sensitive
drilling
at C.
machine,
e.g.,
an upright drilling
The Box
in Fig. 18-27.
A,
is
by the dotted
indicated
shown enlarged
at
thrown back,
as
is
is
The cover
lines.
is
then
position
of the hole
shown
The
is
drilled
jig is
bushing
B on
jig in the
is
drill
spindle
down
to a certain position,
as
The work
feeding the
with the
it is
if
the
preferably used.
two guide
jig body
and in the upper bushing, as shown. The work can
be inserted and removed quickly, and a large number
is
Jig
The
leaf jig
is
box
a commercially available
for drilling a
and
hole having two
ball,
is
jig
shown
typical,
positions in
>'\
^"*
U
Kig. 18-27.
A box jig
in Fig. 18-28,
with
leaf.
DESIGN STUDIES
Ch. 18
Fig. 18-28.
typical
box jig
case,
is
a small casting
with
its
The work,
in this
brings
The
cover.
casting
is
is
drilled at
with a slot
in
the
clamped by tightening
this
in
line
- DRILL JIGS
233
two
A, B, and C.
and provide a
work
move
all
in a jig, care
which
The .work
is
is
easily
changed.
locating screws
L ,
against
finished
work has
is
is
shown
in Fig.
8-29.
The
an angle of
The
re-
surfaces
When
upon those
clamped and
solid support.
should be taken to
inserting
body
is
The
casting
the
also
is
c, is drilled in
Jigs for
placed in more than one position for drilling different holes are usually provided with feet or exten-
sions, as
align
the
drill.
Angular Drilling
For
must be supported in an
only one angular hole,
drilling
234
DESIGN STUDIES
- DRILL JIGS
Ch. 18
-0=P-
tHfA
-r '-VU
.1
A jig
Fig. 18-31.
with
which
is
the feet
Fig. 18-29.
on
here as
work and
it
required to
are
of per-
drill
one
shown
in Fig.
angular hole
is
side,
18-31
is
On
when
the perpendi-
to support the
jig in
accommodate
drilling,
but sometimes
jig
it
machine
The use of
almost any
Fig. 18-30.
table.
a separate base
size.
It
L_
A jig
with
feet,
on the
is
applicable to jigs of
holes at an angle.
Fig. 18-32.
would
with either
at
various angles.
is
DESIGN STUDIES
Ch. 18
large cored hole in the panel
and with
ribs
and webs
for rigidity.
Manual handling
with
jig
is
which
is
at
jig is in
an angle.
When
shown
the position
at
18-32. This
in Fig.
jig is
the
jig,
be drilled in
shown
line
leg
at B,
with the
lifts
falls,
bringing the
jig
drill.
By
using this
jig,
Jigs for
Large
is
very quickly
moved
advantageous to have
it
235
Work
- DRILL JIGS
of the curved contour does not require high precision, since the jig does not rest on the rockers
a special device
attached to
over.
is
y^<l
The Vise
as a Drill Jig
The machine
planing operations
ings
to
may
guide
the
vise
proper location
at the
The
drills
C is
plate
is
adjusted to the
is
placed in the
holes are
drilled
available.
to be turned
over.
lig. 18-33.
A jig
for turning.
A represents
The two studs B
is
with
a gravity axis.
Fig.
manner.
jig
angle
is
work
out the
is
illustrated
in
Fig.
18-37.
not it
Fig. 18-34-
drill jig
its
position.
In this case, a
"
DESIGN STUDIES
236
- DRILL JIGS
Ch. 18
*
(_
"o"
^
i
Fig. 18-35,
Vise with a
swivel vise
at the
When no such
drill
heads need
This
many
is
particularly important
Multiple-spindle
drill
jig plate.
supporting the
spindle
OO
the
drills,
in
cases, are
on the
drill jig is
pattern.
Some
own
drill
heads
carry their
drill jig,
with
drill
Fig.
fixture.
Fig. 18-36.
viae with
Indexing
Drill Jigs
V-blocks and
removable jig
plate.
DESIGN STUDIES
Ch. 18
Fig. 18-37.
are
shown
ing plate,
is
and 6-36,
where the part
in Figs. 6-35
an indexing
drill jig
shown
in Fig.
tilting vise
special case of
is its
own
index-
- DRILL JIGS
jig
Fig. 18-38.
An
237
ent
jig.
8-38,
was
The
indexing
plate
fit
properly
drill jig.
238
driven into the center hole.
was machined to
the
Ch. 18
fit
The top of
stud
of
arm
box
jig
jig.
The next
punch
of the
versatile jig
Figs. 10-37
could be set
it
before clamp-
Where
is
shown
details.
Drill jigs
drill jig
shown
in
and 10-38.
a large
number of parallel
all
in
proper notch
in
G which
was
all slip
are
is
fast,
it is
that
ping pawl
the
jig
shown
in Fig.
down
to the
minimum
The
re-
machined
The
18-39
drill
jig
Fig.
1-2 is a clear-cut
example of
Wortrpfoc*
Fig. 18-39.
bayonet clamp.
DESIGN STUDIES
Ch. 18
- DRILL JIGS
239
a great variety
jig,
jigs
of parts.
high-pressure valve and stud for a sensitive aircontrol valve which is part of an air brake.
The body of the jig is bored to a slip fit for the
a
workpiece.
on both
this bore.
through
this
The
workpiece.
at
and
clearance hole
is
for
also
the
in
drill
The clamp
Bayonet
slots
on the
body
sides of the
slots
have
a radius
bend and
are
made
clamp. These
which
a lateral section
when
rests
drilling the
angular hole.
This
flat
pro-
of the
line
Fig. 18-40.
with an equalizing
jig
a pin
is
work
In job shop
this
done
is
manufacturing conditions
these operations
it is
on the two
hub
at the
end of the
it to fit an
tight-
ened or loosened.
The
shown
jig
member
for
the
operation, and
A, which
is
cold-drawn
in
is
that will
not cutting.
8-41,
such
drill
assembly; under
"half" hole,
in
is
accomplished,
as
usually
it is
work
the
some
in
drill
shown
that
is
in Fig.
by means of
Fig.
closing
steel.
1/4-inch (6
X 6-mm)
is
milled
of the
drill.
backs up the
drill
to
The work
hole
is
attached to stud
is
by bolt C; plate B
on the drill bushing which is slightly counterbored to provide clearance for the tap. The interesting feature of the jig is that the cover and clamping
mechanism are both secured by the same knob;
clamp C is swung around its pivot to hold the stud
securely in place when the knob is screwed down,
and the same operation tightens the cover. This
rests
way
To
at
preferable to perform
and
assembly.
to tip. Because
for combined
member
is
also
doweled
in place.
remainder of the
drill in
jig
bushing
consists of the
key
An
and held
The
which
key
is
E until
key
ping
it
it
binds on the
lightly,
the
jig
is
flat
of the
work then
tap-
DESIGN STUDIES
240
Fig. 18-41.
When
on the
work
is
A jig
up on end
set
then fed
the usual manner, the bush-
in
drill
is
it
starts to
hole
is
drilled
Even with a
When
drilling
- DRILL JIGS
Ch. 18
traverse which,
by spring pressure,
is
forced
down
work.
a difficult operation.
drill
there
is
a
In
N/C
drilling machines, the locating of the spinautomatically controlled from a tape- or card-
operated electronic
drill
to
drill
A jig that
is
shown
in Fig.
18-42.
ample of a homemade
empty. A drill bushing
It
is
dle
of
is
drill jig
tive
to
control unit.
Consequently,
with bushings for locating the drill relaMost, but not all, N/C drilling
the work.
a representative ex-
Fig. 18-43.
Fig. 18-42.
drilling
Inc.
N/C
in a circular part.
DESIGN STUDIES
Ch.18
tions.
is
a highly
work.
is
done
entirely without
- DRILL JIGS
stack drilled.
vices
are,
clamps.
as
241
different sizes and are
de-
vertically adjustable
in
Fig.
18-45.
The
carriage provides the horizontal adjustment for varying board sizes, and the air clamp cylinder has sufficient
special tooling.
operated
length of travel to
accommodate
stacks of
Another general
require-
ment
is
Figs.
consists
carries
is
In
Fig.
(vis-
on the right-hand
side)
ONE Of FOUR
ADJUSTABLE CIRCUIT
BOARD CLAMPS
FIXTURE RANGE BOARD
SIZE Z" 3" TO 12" x 24"
FRICTION CLAMP
(NOT SHOWN
I
LOCKS CARRIAGE
IN
POSITION
^CLAMP
CYLINDER
duction,
boards.
Fig. 18-44.
in fairly
Fig. 18-45.
Inc.
242
DESIGN STUDIES
device should comprise a safety feature against accident or damage in case of failure of the operating
pressure.
is
accomplished
N/C
drill
usually
N/C
fixtures,
of
all
- DRILL
JIGS
Ch. 18
machine
shown
is
pump
required for
N/C
drilling
The
in Fig. 18-46.
N/C
part
is
of
of a
was
various
drill
was over
An
The
of this
total cost
fix-
less
conventional drilling
S 5000. 00.
additional case
in Fig. 18-47a,
programmed sequence
the
is
use of bushings.
If the position
+ 0.25 mm), a total posi(
necessary
center
first
drill,
Fig. 18-47.
mm)
drill
less, it is
and
with a
Fuel-pump housing
spiral
\4
:
_SL
J5
ti.
illustrative
b.
An
rigid
a.
'
or
or to use a twist
ground point.
A drastic and
fixture cost
--h
0.010 inch
An example
that
drilling
of simplification
be realized
can
with
in fixture
the
design
use of
N/C
equipment.
in
DESIGN STUDIES
Ch. 18
of holes
some of which
These
N/C machine
tool
in the
built
part,
- DRILL JIGS
243
which
are here
shown
in their retracted
positions,
19
CHAPTER
Design Studies
Milling
operations
II
Milling
by
characterized
are
Fixtures
large,
volume of
may be
chips,
The
The operation
is
tool
of gutters.
cutter.
In
curve
may
milling.
To meet
is
Wherever
may
To reduce
possible,
under
vi-
air,
made with
mounted
vertically
on
an angle plate.
of open design,
i.e.,
open
away
is
at the
a box, preferably
top or
one
at
side
vertically
milling operation
fixtures.
drawn
chips.
in Fig. 1-3
These
shown
244
features
in Fig.
are
19-1.
machined
The
seen in
fixture base
the
is
fixture
mounted
is
usually
by
string
milling,
is
9-2.
con-
accomplished
DESIGN STUDIES
Ch. 19
II
- MILLING FIXTURES
<K
+-
on
faces
V.
Design
11.
the
Milling of a single part, and string milling, showing the significance of cutter run-in and cutter
run-out.
of milling cutters
set
operation
possible, in a line,
ing,
i.e.,
common
milling of
on a
two
common
parts in
base.
Duplex, mill-
one operation,
is
Multiple-
example
is
^3
K
v
-H
Fig. 19-2.
Case
245
shown
in Fig.
9-3.
stitutes
shown
selected as the
is
Fig.
in
first
single operation
the major
This
19-4.
step because
on the
it
con-
part,
and
provides excellent locating surfaces for all subsequent procedures. The design develops as follows:
it
1.
For the
first
operation,
the
must be
part
with large
regular geometry,
flat
surfaces at right
angles
cating, supporting,
hardened spherical
The
shown
in
19-5
Fig,
and
locators are
identified
are
by.
The
part
is
UNC
arranged
(16 X 2mm) bolts,
opposite the side and end locators. The clamping
bolts are inclined 5 degrees, so that they aim below
three 5/8-1
down on
3.
the
critical
part
is
examination
at this stage
If
shows that
Fig. 19-3.
in
ports
rectangular,
and very
will
provide the
efficient,
classical,
support pattern;
however, such supports must be individually adjustable, as they must act on raw surfaces. Screw jacks
may be ruled out since they would not be easily
Spring loaded jacks are quite long and
accessible.
would therefore
raise
dis-
DESIGN STUDIES
246
II
- MILLING FIXTURES
Ch. 19
MtOiiNINS
cn'.Ol
REFTYP
.38
.12
ffff
ALLOWANCE TYP
TYP
TYP
MACHINING
AlLOMNCt
E&SPTASSHOWH |
:l
l.&MAXREF~i
6,3751005
9.SO0:.009
;00S
-.000
MIUtHG
CUTTER
ffff
3&
comouR
10&.0I
r-53SPF-
zzzzzz
SECTION A-A
Fig. 19-4.
such
jack
Endwise, there is no
and a spring loaded
mounted symmetrically with, and parallel to,
dimensional
is
limitation,
The jack
face
The
surfaces
by Q)
then
These
is
is
is
laid
the
cutter guide
when
the cutter
The
and cutter guidance. The components are numbered to indicate the corresponding step in the
shown
from the
pattern of the previously described components. It
is a rectangular box with ribs beneath the bottom,
and heavy section uprights on the sides for added
rigidity. It lends itself well to casting and does not
require
5.
in Fig.
Fig. 19-5.
against
adjusted.
Components
much
core work.
The base
locators are
DESIGN STUDIES
Ch. 19
- MILLING FIXTURES
II
247
WHIPS
AVAIL
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SECTION D-D
The complete
facilitate
ma-
The
fixture
T-bolts,
The
is
and
closest
trolled
windows
The
is
^@" M
t.oozD3
'
\-OS*OS
the
arbor;
Therefore, there
mm) or
multiples thereof.
n_
73~
MA J ERIAL: GRAY CAST IRON
UND/MEHSIONEB RADII 25' 02 R
'
Lggy'jiKWjaa
milling fixture.
Fig. 19-7.
nfl
. ,j,bjl
*3' X-W'
GRINDING ALLOWANCE
^-l_-.2-*tf,
.010 REE
JTJ-'OW
=f|
Fig. 19-6.
__
SASE-.\
001
USOWF-
lifted
PCFSICTION S-S
-4.75
special
L-
machine
325W toot.
DESIGN STUDIES
248
Case 12.
II
upper and
side
the
of
surfaces
shown
part
in
Fig, 19-7.
clamp
strap
are
shown
in
Figs,
is
19-g
shown
Fig 19-10.
in
- MILLING FIXTURES
Ch. 19
clamping surface for the subsequent milling operations of the upper surfaces.
The outline of the
milling cutter assembly for this operation is shown
in Fig. 19-7. The design proceeds as follows:
1. With some modifications, the 3-2-1 principle
can be applied. The fixture body has a large ma-
JSi'.Ol
I
*J
10010/
4 iS&M
t~-TW3 K
ZiQt.ai
mamuL-eiurctsi iron
Tig. 19-8.
The
part
<6 kg).
is
pounds
chined
flat
This
is
machined bottom
first
three locators.
the
part
symmetry
the
slide.
The
first
bottom
is,
surface. This
machined,
machine
it
offers
to be securely
it
vise.
an
And once
excellent
clamped
the bottom
locating and
ecxxim misolggatk
strips
indicate
is
considerable
degree of
two un-
9-9.
slot
with a sliding
fit
which is guided,
also with a sliding fit, in the rest block which is integral with the fixture body. When the two V's are
^iooo*-SSP
tail
flanges
motion
is
still
possible.
-"-'.&'
su&ttS
Fjg.
T^
9-9.
To
button,
1JS--.W
in
DESIGN STUDIES
Ch. 19
II
- MILLING FIXTURES
249
ALLOWANCE
FOSFFElFUCAGf
ciampmvbA
tointe-tessoi-
CU7 T04-IKtriMGm
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CAPXREn'
mtwtoaHBB
SECTION A-A
Fig. 19-10.
block under
stud
its
tail
located
is
end.
The complete
is
The design
approximately
in
is
clamping force
is
is
the
of
center
so that the
on
di-
directions.
The
press
fit
is
setting the
make
is
provided
recommended
it is
that the
a complete drawing of
5.
shown
body,
discussion.
with
the
locating
it
consists of
surface
heavy base
two
rest
blocks at the ends, and slots for the keys and T- bolts
All
equally
v^
recommended
exercise), are
quite liberal.
well
suited
welded
construction.
''-
==j=l
*3I
^r
in
detail in Fig.
10,
fixture
if
tolerances.
19-10,
mounted with
when
cutter.
in Fig.
in Fig, 19-7.
rJ^
is
shown
-1+T^
H*VF^
r Mt.03
Hg. 19-11.
250
DESIGN STUDIES
AND RCAM AT ASSEMBLY
FOR JS DIA DOWEL PIN, 2PL
DRILL
- MILLING FIXTURES
II
Ch. 19
-fr-tltmC-t
ZSQ&jOQQ fyp
2,00
{-20UHC
~IOD:.0l KErSEAT
30
a*
mpi
J-- SOUjVC
in typ
75fl
UOOOI
-f-HUNCTYP-i
7i CIA
f
Case 13.
as
shown
is
is
helix,
in Fig. 19-11.
19-12 and
shown
in Fig. 19-14.
a bracket with
straps, are
shown
in Figs.
19-13,
The
two bearing
and weighs 28
pounds (13 kg).
In comparison, the complete
fixture, empty, weighs 136 pounds (62 kg).
The part comes unmachined, and it is natural to
select the machining of the base surface as the first
bosses,
gether
spindle,
with
the
rotation
side
component of
flat
surfaces
on which
first
it
operation.
ing holes are cored out to 1 3/8-inch (35 mm)- diameter, so that the part can be well clamped in the
cored holes while it is located and carried on the
cylindrical
method of
plane with
the
outer
surfaces
of
the
bosses.
its
bosses.
This
no parting
inherent danger of mismatch across
Depending on the type of milling
is
is
ai t
vertical),
sv*FAcejJ~mAs /.orft?
the
' fiAO Rr
f
twEftm rtisi toio met
UHTOl 10AI& BtNEHSfONl HAVE 10/
fff -ENYAAHT COAMAS HXVf.oSft fitf
width of the
rGtASlJStZE
MiQ
m*MH*Of*
jo JH-*-*z L
CLAHI
V-BiOCfr
Fig. 19-13.
clamp
strap.
DESIGN STUDIES
Ch. 19
MM NUT
- MILLING FIXTURES
li
4--IWNC
/i mm
-It
(*DB-25*20)
251
aw
i*b
COMMERCIAL COMPOHEHTS
AREIOE/JT/FIEDBY MAHUFACTURERS
NUMBER INPAQIHTHESIS
grwng
ro height
2f LOW ,'iO5-:-0C9J,
FOR
EJZO'i&LALLQWANCE
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wm-ffasG
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-"XT"
~
I
FLAT WASHER
400 REF
SJLOIP SCREW
a-tlUHCILONG
LSXTOfIT
+ JWO
Fig. 19-14.
is
The complete
I,
The part can be located and carried with the
two bosses supported in a double V-block, shown in
detail in Fig. 19-13.
The, 3- 2-1 principle is not
V-block
two
in
side stop
is
formed by a
5/8-1
The screw
is
locked
in position
by
jam
nut.
this
adjusted
the V's.
locating
Fig. 19-14.
is
a spherical button.
are
identified
by
The
(T)
in
in Fig. 19-11.
The
two
as follows:
shown
JAMNlTT^-IOtlMC
rtky
t*0S-Z34g
ZfLOHGtADB-SiOlQi
part
is
finger-type
as
the
and to adjust
when
for
stop.
screw
the
is
stop.
Here
cause
it
hand-operated screw
is
preferred be-
a hexagonal
screw operated
with
down
wrench.
In
and
DESIGN STUDIES
252
3.
The
area to be
force
cutting
large
stantial side-force
is
generated,
including a sub-
machined
is
component.
to -supplement
II
- MILLING FIXTURES
therefore neces-
It is
and
its
mating
clamping screw with additional supporting means,
sary
equivalent
to
supports."
Ch. 19
is
it
held by the
knob screws,
(3) in
Fig.
hand-
each other.
4.
The
since
it is
is
The
part.
done with
vertical
guide
a cutter
fit
in
mm)
1/8 inch (3
is
exercise,
is
detail
in
fixture
on the height
in
Fig.
Fig.
19-14.
body, shown in
in
Fig.
chine table.
The four
WORKPlECE
daSf.
fix tunc
HI CH TABLE
_(u-rmri
TONGUE STRIP
Fig. 19-15. a.
manual clamping,
b.
line
DESIGN STUDIES
Ch. 19
II
- MILLING FIXTURES
lends
to
253
itself
struction.
is a
precision part,
body
itself are
all
quite
The only dimension that requires a somewhat close tolerance is the height of the cutter guide.
liberal.
shown
is
in Fig. 19-15, a
Hg,
9-16.
The
In
gage
is
This fixture
ture.
cutter setting
fix-
The
two
may
It is, in
be different on different machines.
this sense, more practical to use end clamps, as
shown
The
in Fig.
milling
provides
many
19-16.
machine
vise
modified jaws
An example
String milling
19-17.
with
is
is
shown
in
Contour and
Contour or
Fig. 19-17.
vise.
profile
on
These fixtures are basically similar to other fixtures; however, a distinctive characteristic of this type of
profiling or contour milling machines.
Examples of
string milling.
254
DESIGN STUDIES
Fig, 19-19.
II
- MILLING FIXTURES
Milling fixtures and template bracket for profile milling cylinder heads.
Ch. 19
mounted.
equipment
is
holding the
that
cam
it
must provide
spindles, as explained in
Two
tracer
identical
example
is
are used to
bracket
An
In
this
case,
An
made
shown
in
Fig.
19-20,
is
illustrated in
Fig.
19-21.
The
which
on the
fixture.
is
mounted
is
in
Plate
are a forced
na
_j_
l
ig.
19-20.
Part
to
be
milled
on
The
fixture
is
shown
set
A,
B,
and
C.
work.
and F, which
DESIGN STUDIES
Ch. 19
II
- MILLING FIXTURES
255
ri^-ia
The
Fig. 19-21.
tion.
inserted in hole
is
work
required posi-
in the
work, pin
shown
Similarly, pin
in
provided to secure
are
the fixture
is set
it
and
E is inserted
and pin
in hole /,
C
in
and
at the
work
by a template and
required off-
to be milled
Locating Pins
in
by
cutter
The
to
on the arbor.
locating pins
above
is,
in
sense,
function.
Movable
milling
fixtures
are
those
perform
that
move
Radial fix-
fixed center
The
final
is
described
fixture
Milling Fixtures
ing
mo-
therefore, capable of
retractable.
side
are,
generating
is
//
required position.
in the
Plate
located in
is
When
in Fig. 19-20.
Other movable
fixtures, similarly
can engage.
An
is
is
operated by a hand
as the
lever
is
DESIGN STUDIES
256
Fig. 19-22.
II
- MILLING FIXTURES
rotating fixture for milling cooling fins on a cylinder head with one fixed
der
which
picture).
is
Ch, 19
a cylin-
shown
in
the
WORKPIECE
HANDLE TO
OPERATE BAR
REST BLOCK
Side stop
ECCNTRIC{ENGA6ED
POSITION}
SECTION
Fig, 19-23.
A-A
DESIGN STUDIES
Ch. 19
II
- MILLING FIXTURES
257
The
9-24.
The same
milling fixture
position.
When
the
work
is
moved
into position,
and
To
re-
are
shown
in position
on
(tie
Inc.
milling machine.
is
by
dial indicator.
To
The movement
surfaces
to
be milled.
N/C
Milling
The
fixture (Fig,
hobbing
fixture.
typical
hobbing
led
is
clamped
in its fixture,
258
DESIGN STUDIES
II
- MILLING FIXTURES
Ch. 19
euttlnf]'
/
LTIB
^
HI
Hob Slide
I'ig.
19-25.
Fig. 19-26.
The
a,
Plain,
b.
is
operation
is
seen
in Fig.
An example
fix-
of this type of
19-26,
20
CHAPTER
Design Studies
Lathe Fixtures
in
III
Miscellaneous
General
Fixtures
principle.
Chuck Fixtures
lathe
jaws and
tures,
special fixtures.
and
For the main fixture body, gray cast
strong clamps.
iron
is
however,
for
high-speed
strength considerations
damping
vibrations;
weight and
require the use of steel
operation,
may
(in
jecting screws
trifugal
medium and high spindle speeds, cenforces become significant and must be taken
shielded.
At
They
affect
shown
in
Figs.
lathe fixture
is
the standard
in
high-speed pro-
is
solution
is
clamping.
machine
to
make use
An example
is a
shown
in Fig, 20-1.
The
is
a cast-iron
brake
259
260
DESIGN STUDIES
III
- MISCELLANEOUS FIXTURES
Ch. 20
r~r-
Fig. 20-1.
by centrifugal force
(inertia fingers).
The
result
is
that
when
forced out-
is
The
chatter
Fig. 9-3,
is
drum
the
is
machined.
accompanying
fingers
when
The
text.
determined by
is,
in
in
the
Fig. 20-2.
collet-type lathe
Courtesy' of E. Tlmulow
chuck for internal clamping.
jaws.
out.
shown
in Fig.
with
20-3.
The
part
is
a pinion, integral
For the same reason, the collet chuck procentering of the part and is well
adapted to precision work. An application example
chuck.
vides
is
excellent
shown
in Fig. 9-24.
deformation within
is
fixtures in general,
Any chuck
is
now
that actuates
its
used in
wider sense.
chuck.
The two chucks for the centering of gear wheels
shown in Figs, 9-22 and 9-23 are collet chucks. They
are grinding chucks, but that is a matter of application rather than of design.
is
The
a collet-type
ing.
collet-type lathe
'
The
sliding
The
is
It is
on the
vertical
made
in lots
of ten or twelve.
An
angle plate
B,
is
of the table
bracket
is
it.
The
11.
G.E.C. Gad's
that tongue
fits into the groove, and bolts / are
passed through the holes in the bracket and tightened
by nuts K.
Clearance
is
Ch.
DESIGN STUDIES
20
['ig.
20-3.
collet-type lathe
HI
- MISCELLANEOUS FIXTURES
261
Fig. 20-4.
Inc.
262
DESIGN STUDIES
Fig. 20-5.
II!
- MISCELLANEOUS FIXTURES
pump
body.
essary, to bring
keyed
at
R, so that the
The
used to bore the hole, and the side
are tightened
surface to be machined
is
by nuts
boring bar L is
head tool
faces the pad.
that
lathe
fixtures can
at
clear of interferences.
be
made
to
accommodate
on
20-5a and h.
The
fixture base
The
is
is shown in Fig.
mounted on the
part
is
located and
a.
shown
20-6.
which, because of
its
The work A
typical
is
example
a large casting
supports.
F on clamping screws D and the adjustF are shielded against chips; screws D
screwthreads
able points
are
plate
their tips
in Fig.
and wall thickness), could not be adequately supported and driven by a conventional chuck. The
variations in dimensions which may be expected in
large castings require a liberal clearance between the
work and the fixture. In the present case, a clearance of one inch was provided. The pot fixture
is
centered on the lathe tabic by the locator / and
bolted down in the T-slots with bolts O. The part is
located by its cylindrical surface against three screws
B, B, and C, and is first positioned against these
clamped
Ch. 20
the
damping of vibration
Ch.
DESIGN STUDIES
20
- MISCELLANEOUS FIXTURES
III
263
=3
Courtesy of E. Thautow
Fig. 20-7.
with
mandrel
an expanding
split
sleeve.
is
with
slit,
The
either end.
slots
large
drels are
This type of
perhaps the most satisfactory of
mandrel fixture
is
It locates and centers well and the sleeve remains practically cylindrical as it expands, exerting
a uniform pressure on the part. Sleeves of different
sizes can be used on the same mandrel body. For
satisfactory results, the number of slots must be
related to the sleeve diameter as follows:
all.
Number
Diameter
SECTioti x-y-2
Fig. 20-6.
inches
mm
up to 2
up to 3
up to 5
up to 7
up to 50
up to 75
up to 125
up to 175
is
is
shown
in Fig.
When
E. Thaulow,
Maskmarbe/de (Copenhagen:
I.
cylin-
mandrel body.
is
part.
G.E.C.
The
Gad\
clamp
is
2X12
now commercially
avail-
hydraulically
shown
design
2X8
recent development,
able,
2X
2X
of Slots
in Fig.
a part
expanded sleeves.
20-8, where two
with
An example
is
generated by means of
a piston
hydraulic
fluid
An AEC-NASA Tech
Brief
DESIGN STUDIES
264
III
- MISCELLANEOUS FIXTURES
Ch. 20
-ACTUATING SCREW
HYDRAULIC PISTON
An
arbor
with
sleeves.
supported on
sleeve
is
end.
The
part
is
washer and nut are put in place, and when the nut
is
tightened,
the
sleeve
expands on
its
diameter
Fig, 20-10.
work.
Workpieces with
IzBB
A mandrel
Fig. 20-9.
while
interior
surfaces,
as
NUT
WASHER
W0RKPIEC6
ELASTOMER SLEEVE
unmachined
such
shoulder.
part,
supports,
part.
and centers,
The elastomer must
part
on
inside
its
the part.
It
The
RTV, PVC
An improved type of
can be Teused.
E.
Forlag,
G.E.C, Gad's
DESIGN STUDIES
Ch. 20
III
- MISCELLANEOUS FIXTURES
265
is
binding
pressure
on
the
part's
screw
thread
is
eliminated.
Miscellaneous Fixtures
of time
few examples
Courtesy of t\ Tkautow
the
Boring Fixtures
drilled.
Two
air.
crankshafts are
example
with
hole that
self,
The
called
is
fixture
"Y-joint," which
is
all
the
way around
to allow the
an ordinary steady
Tbid.
is
11.
or
numerically
many
controlled
types of
machine
practically a
Ibid., vol.
rest.
is
accessories,
this
DESIGN STUDIES
266
III
- MISCELLANEOUS FIXTURES
Ch. 20
sembly
Its
spindle as-
is
and with experienced and careful operaproduces holes that are exactly parallel to
for
machining
laigc missile
components.
jobs; however,
particular
for
design,
tion,
it
the surface of
performed on
its table.
jig borers to
parts
is
relatively small.
on jig
on the machine or where the part cannot be
conveniently held by any other means.
High-production boring is often done on special
machine tools. Some are special purpose machines
such as those found in the automotive industry.
Often the part is automatically moved to and from
the boring station by machines called "transfer
machines." A different class of boring machine is
are used
is
part
comprised of the highly automated, high-speed production boring machines, known as "Bore- Ma tics,"
Case 14.
part with
Design
The part
tangular
sequently,
this
here again,
variety of
20-14.
Fig,
type of fixture
The
distance
a line
is
called
"line
most boring
fix-
tures.
1
on one or
and supported on
base.
pins,
already machined
is
stops,
is
sufficient
in
boring fixture."
machine
be adapted to do
components
may
is
outline
it is
located by
means of
if
such
at
each
it is
located to provide
Ch.
2.
DESIGN STUDIES
20
The
part
- MISCELLANEOUS FIXTURES
III
of clamp
is
it
to
the fixture.
3.
The
is
well supported
The
boring bar.
on
its base.
cutter
fixture
is
slip
5.
with
The
fixture
body
may
Side lugs
needed,
the
machined exactly
parallel
to the
measuring and
the machine table,
checking the clearance B, to the end surfaces G, of
the work. B must be large enough to allow for
Bosses
if
cutters or the
arc for
raw
of chips, and,
mounting of
shell
reamers on the
bar.
The
fixture
is
possibility of elastic
on -the same
operations the fixture can be provided with a multiple spindle gearbox which rotates and feeds the
boring
bars.
It
deformation (springing)
in
accom-
are
brackets
its
267
somewhat
when
the
damping
its
excellent
properties.
V
n F
-k
Fig. 20-15.
Example
a
hole
Many
outline.
20-14.
one piece.
is
impractical.
It
also provides
of the workpiece as
assumed that
in two
already existing carriages or brackets, and in this
case these same holes serve as guides for the boring
bar, if necessary by the use of liner bushings.
Finally, the front elevation shows how hole ./ is
boTed in the carriage and apron / by using the three
l'ig.
B should be
spindle.
Next
it is
F and G
mounted
way that
at the
bushing by
it is
DESIGN STUDIES
268
III
- MISCELLANEOUS FIXTURES
The workpiece
is
Ch. 20
is
When
5.
located,
The
it is
fixture has
body
The
drill jig,
fixture
and
all
drill.
The
is
de-
< IQD
L
for stub boring bars
L
Courtesy of E. Thaulow
Fig. 20-16.
hole.
<6D
Courtesy of E, Thaulow
Fig. 20-17.
The boring
The boring
This detail
Fig. 20-17.*
G.E.C. Gad's
arrangement
bar
is
is
is
shown
in
Fig, 20-1 6.
shown
II,
in Fig.
20-16.
ing bars
is
shown
greatly (up to
carbide grade.
200
to
300 percent)
in
any given
DESIGN STUDIES
Ch. 20
- MISCELLANEOUS FIXTURES
III
269
bars
countcrboring,
ing)
The
As an example,
Fig.
20-18 shows
125
to
part
is
RMS
at a rate
positioned from
The
clamped
opening
rear side
and
is
An
indexing
boring
fixture
for
two
parts.
The magnetic
face
Grinding Fixtures
is
characterized by small
flow of coolant.
no
sumps or pockets where sludge can accumulate.
Magnetic face plates and chucks, supplemented by
electrostatic and vacuum operated devices for nonwell as free drainage of the used coolant, with
The
is
very
are lighter.
>>*jn
"t
WW,
* UttF
'>
^^1
*JrM*fy !ni
s
wM*
-.-fgtfB&MI
Fig,
20-18.
DESIGN STUDIES
270
III
- MISCELLANEOUS FIXTURES
Ch. 20
The
is
motion
kind
of operation
is
is
shown
fixture for
7
Fig. 20-2 1.
in
is
end walls.
clamped by its base surface
on the angle plate which has openings for the
plate with stiffening
is
jig
til
90 degree,
is
grinding fixtures.
An
angle
plate
many
has sufficient
to a milling fixture
is
shown
in Fig.
An
20-20.
is
The machine
The
two
is a jig
rigidity to
and
is
machine
The
table, in the
fixture
is
same manner
as
on
a jig borer.
a sloping front.
To
E.
1'orlag,
1930)
vol. II.
G.E.C. Gad's
DESIGN STUDIES
Ch. 20
III
- MISCELLANEOUS FIXTURES
is nested in bearings B, and one crankbrought into contact with a retractable locator F, which brings one crankpin center line to
coincide with the work spindle center line. These
They
shaft and
crankshaft
pin
Of
industry,
two
special
their
design
features
shown
somewhat
schematically, and
20-22.
Fig.
The work
simplified,
is
in
the
anism, here
271
shown
is
when
feet
that position
close; the
pin
t-'ig.
20-23.
is
grinding
crankpin
with
fixture
work
positioner.
On most crankpin
The operations:
machine.
loading and positioning the crankshaft, clamping,
integral
is
indexing,
with
start
the
retracting,
all
and
mechani-
The locator
a
provided
The
at
the
locators are
C.
and
similar locator
is
mounted
is
in such a
offset
way
that the
crankpin centers.
adjustable so that
it
This distance
can be changed,
other crankshafts.
ment
is
is
when needed,
In the case
to
accommodate
B.
The
20-23.
of cam grinding
24.
A common
is
shown schematically
the shaft
in Fig.
20-
a spring
The principle
B and C
The
cradle,
for, respec-
mounted the
DESIGN STUDIES
272
III
- MISCELLANEOUS FIXTURES
Ch. 20
many
shaping,
broaching have
and
slotting,
common which
features in
are reflected in
They
are straight-line
performed by a single-point tool and a reciprocatIn planing, the work moves, while in
the other operations, the cutter moves. In planing
are
ing motion.
ing).
Fig, 20-24.
master cam
set
the camshaft K.
is
known
as the "foot-
cam contour
is
transferred to
the camshaft.
seen in Fig.
cradle with
work
20-25.
its
The
illustration
is
shows the
left in the
photograph.
They require
substantial
machine
table,
The
recipro-
cating operations require ample end clearance relative to the cut surface at
run-out distance
end
at the exit
relatively small
is
work and be
lifted
least
inch (25
mm)
at the
rest
it
size,
depending on the
Tool
to 2 inches (25 to 50
mm)
For the machining (planing and shaping) of composuch as a dovetail or the inverted V's on
a lathe bed, the setting block is formed as a template
site shapes,
Planing Fixtures
Fig. 20-25.
A camshaft grinding
fixture.
Ch,
DESIGN STUDIES
20
Kig. 20-26.
is
directed downwards.
table
is
horizontal,
III
- MISCELLANEOUS FIXTURES
this
cutting
force
assists
in
stabilizing
Ff
is
fixtures
the
for
tall
with a
for
surface
the
average,
The
broaching.
is
to
steel forgings.
same value
the
as
Fq
as
the cutting
work.
horizontal
wide base.
crease
273
equal to
Fj on
Fq and may in-
thrust force
1/2 of
Broaching Fixtures
for
identical workpieces.
in the design of
double and
shaft.
in
is
In b,
is
controlled by a con-
a,
the clamp
is
Fig. 20-27.
slotting fixture.
274
DESIGN STUDIES
III
- MISCELLANEOUS FIXTURES
Ch. 20
and
b.
Two
Inc.
work support
(Figs.
A broach
now
its
reaction
By means
For tapered
of the
Fig. 20-29.
An
A
of a
mits
as
Fig. 20-30.
DESIGN STUDIES
Ch. 20
III
- MISCELLANEOUS FIXTURES
275
dimensions and in the integration of different fixtures into one master fixture system. The following
description of a typical aircraft fixture system
refers to the tooling for the aft
wing section of a
The
section
is
structure.
wing
Fig. 20-31.
thin-walled
part.
mounted on the
is
Stops and locators, including locators for the fuel lines, are installed by means of tooling gages, which simulate the items to be installed.
With the tooling gages in position, skin panel tooling
samples are located and fabricated to minimum gap
clearances at plane intersection joints. Hole loca-
main structure.
for a
typical operation
is
shown
in
Fig.
20-34.
By means of
structure
is
gages,
and
riveted.
Fig, 20-32.
hom
for keyseat
broaching.
The
prcdrilled
bulkheads and
skin
spars.
panels
are
ing,
ing primarily
portant exception
is
is
im-
Aircraft Tooling
No
size.
Attachment
in
Master tooling
is de burred and cleaned.
gages simulating the main landing gear are used to
establish the hole patterns for attaching the landing
structure
space
the
closely
One
same
to
located
other industry exceeds the aircraft and aeroindustries in the use of fixtures of large
is
carried
by a positioner
DESIGN STUDIES
276
Fig. 20-33.
III
and rotated.
- MISCELLANEOUS FIXTURES
tilted,
The
20-35.
An example
is
shown
in
fixture can
The balancing of
the fixture
is
facilitated
in
transient;
and
is
parts
Ch. 20
it
To
harmless.
may
be firmly clamped
at
in directions
Shrinkage distortion
is
is
of a different nature.
metrical
Minimum
lateral
shrinkage
The
is
essentially
distortion
is
in as
is
parts.
asymIt
is
is obtained by welding
few passes as possible.
Distortion
is
during welding,
is
fixed locators,
distortion,
and stops
and also
by
rigidity
and strength.
The
DESIGN STUDIES
Ch. 20
III
- MISCELLANEOUS FIXTURES
277
Fig. 20-34.
fixture
is
Locating and
fitting
split
door.
may
pieces.
An are-welding
fixture
mounted on
boom
type positioner.
DESIGN STUDIES
278
The
III
- MISCELLANEOUS FIXTURES
A
most
weld material.
in
cases.
Class II
copper
is
preferred.
This
is
ing electrodes.
is
heating
or
oxidation.
Stainless steel
postheating
To
required
is
as
prevent contamination,
it
resists
some exotic
materials, notably
different technique
is
Ch. 20
followed
length,
together
of a Titan missile.
"magnetic
It
is
two
fixtures
be used.
may
known
is
bar.
The
For large
first
fixture
as the
"holding" fixture,
flux
mends
members
DESIGN STUDIES
Ch. 2C
III
- MISCELLANEOUS FIXTURES
279
As a general
chining.
the
all
rule,
torsional
must be
bolts
size limitations
can
The
and clamps.
have satisfactory
dimensional
stability,
minimum
PUSH-PULL TOGCLi
'AKLOMS
-
sij-,tt>Lotte
KoKl
Btmms!
SSa-taio!
MATERIALS: SQ TUBIHSANUPLATE, LOW CARBON STEEL
OTHER ITEMS, COLD ROILEO STEEL
DIMENSIONS ARE fiF IUNTOLERANCELHANO TfR NUHBFBS
IH PARENTHESIS A BE MANUFACTURER'S SERIAL NUMBERS
p-*
IQQQf
SECTION ANU yiewa-a
deterioration,
combustion.
Case 15, Design a fixture for the arc welding of the
structure
shown
The weight
is
shown
the fixture, as
in Fig.
in
comparison,
kg).
Fig. 20-37.
cross bars.
is
Fig. 20-38.
in Fig. 20-37.
rotated primarily around one axis which will successively bring each of these welds into a
As
Thus,
design
it is
shown
If
The
4100 RCf
'
2.SO TYP
UNaMENSlCNEO RADII:
CORNERS lOOiJi
binds, msise so net
Fig. 20-37.
An
TOLERANCES ON'
THKKNMSStS
Z0I5
M!>TH!t)tANLEL.eS
WSTAHCM
-*J*
c-0i
bars.
on the positioner
it
O0
it
in the fixture,
iJOO
In the
-7ZOO-
convenient
on the narrow
angle flanges, if the fixture is mounted on a commercial positioner, there may be at least one additional
axis of rotation whereby the fixture can be laid
down flat, or the part can simply be removed from
the fixture and placed on a bench for these welds.
position.
lines.
fixture
parts.
In this
DESIGN STUDIES
280
when
secured
members and
III
- MISCELLANEOUS FIXTURES
members
The end
side
slide longitudinally
tortion
is
not
significant, as the
The
apart.
is
result
essentially a
is
and outside
of, the
transient,
is slight,
is
They could have been designed as Tsection brackets, saving some steel, but would cost
significantly more in cutting, fitting, and welding.
The fixture body consists of square tubing, 4 by 4
inches ( 00 X
00 mm),
gage (. 1 20 inch or
3.05 mm).
With the weight of the part and the
thickness.
All
dimensions shown
Fig.
in
20-38
are
REF
shown
in Fig, 20-37,
Some
welding lathe
shown
in Fig. 20-39.
is
The
is
seen* in
rests.
There is no physical upper limit to the size of welding equipment. Probably the largest existing welding
positioner is shown in Fig. 20-40. It weighs 200,000
pounds (91,000 kg) and is designed for use at the
U.S. Naval Shipyard on Mare Island. It rotates the
work at speeds ranging from 0.052 RPM (19,2
minutes for one revolution) to 0.0052 RPM and in
four minutes can tilt the table 60 degrees from the
the height,
the
often possible to
of square tub-
this size
areas for
flat
is
supporting the
pans and permits assembly without the use of gusset
plates.
The width of the tubes provides areas for
it
Ch. 20
The pads
The width may seem
somewhat
clamp,
Mm ^i
|M||HMpMHnH|
HM
Hb
W-i
SHU
Fig. 20-39.
20-40.
33
21
CHAPTER
The term
The
types of equipment.
drill
jig
two
body with
first
different
type consists of a
quick-acting
clamping and
drill
ing
movement
jig,
the
bushing
drill
When
pressure.
following sections.
the handle
is
is
cal posts.
The posts
are raised
a lever
zontal position at
all
times.
The length of
The merits of
an adapter, to
the machine tool vise (and other
Examples of how various types of vises, not only machine tool vises, can
be converted to universal drill jigs were shown in
Figs. 18-35 through 18-37. The vise drill jig shown
in Fig. 8-36 includes, in addition, two V-blocks and
at length in other chapters.
drill jigs
from
more commonly used type by having the V-block
installed with horizontal Vs. The usual type consists of a V-block with a vertical V, one or more
of a simple type for cylindrical parts.
It differs
the
stop.
diameter of cylin-
lift
them up so
When
This condition
unmachined
adapter
on
its
is
shown
in the illustration.
is
side, the
made
large
entire width.
is
concentric locator
attached to that
is
is
the
operated by a pump-
member
established. Pref-
in
tors.
shown
as
Internal location
Jigs
known
Pump
a hori-
travel (the
top
with
top plate
Examples of sim-
is
in Fig.
A commercial
"in-house" to advantage.
shown
in Fig. 21 -la.
built
is
A pump
is
attached to
attached to or
made
is
281
282
to prevent
opposite end
is
Ch. 21
is
be necessary to
adapter
if
the lead
Loca-
visible to the
lead
may
in the
would
when
when
the jig
is
open.
TOP PLATE
WORK
LOCATOR
long
components
ADAPTER
i.e.,
correct position.
dial locators,
Fig. 21-2.
c
Courtesy ofJergens Inc.
Fig. 21-1.
a.
Sectional view of a
pump
jig with three posts, showing the rack and pinion movement, b, A pinion shaft with
rack and pinion locking unit with bearing bushing and operating handle.
shown
in Fig. 21 -la, b,
tioned view
a,
and
As seen
in the sec-
The pinion
c.
is
is
Such units
are
mercially available.
work.
mechanism
drill jig
is
shown
in Fig. 21-4.
Some
is
drill jigs
mounted on
Ch. 21
down on
two
its
283
drilling of holes in
directions,
drill jig,
Advantages
Speed of operation
universal drill
type of
this
is
It is
jig.
jig as a
permanent component of
The
single
jig
operation
sweep of the
it is operated by a
which eliminates the
and clamping parts. This man-
is
fast since
lever handle,
Fig. 21-3.
Pump
for
Some
feed.
have the clamping area located between the posts while still others provide the feature
of improved access to the clamping area by allowing
the top plate to swing 1 80 degrees out of the way in
drill jigs
and calculating
all,
The
drilling
which
results in pro-
and bushing life. Top plates and adapters can often be so designed lhat chip cleaning is
greatly simplified if not completely eliminated.
longing
The
less
drill
is
generally
complete single-purpose
drill
jig,
and top
plates
An
air-operated
Some
tilt
Wis.
drill jig.
45 degrees
in the vertical
have the rear side of the body precision-machined square with the bottom surface. In
this way the jig becomes a tumbling jig; it can be laid
plane.
jigs
drill
bushings.
284
Ch. 21
When
OjOsf
ooo
o ex ojf
UNIVERSAL FIXTURES
Commercial Universal Fixtures
A
is
shown
in Fig. 21-5.
It
is
in
essence a glorified
face plate.
the
universal fixture
is
the
and number of components. The elements in genof steel, hardened and ground to tolerances
eral are
(Stop Element
Adaptor Block
Simple and
&
Thrust Element
Die Co.,
Inc., Buffalo,
N.Y.
more representative type of fixThe principal component is the base plate. Edge strips are bolted on, so
that a lying V-block is formed, and a part is clamped
in this V by means of clamping screws of the same
type as those shown in Fig. 21-5. It is used here
for precision drilling. The drill bushing, mounted in
a large boss, is located from the sides of the V by
means of gage blocks.
ture
different and
is
shown
in Fig. 21-6.
Universal
elements.
fixture
Ch. 21
285
by means of an eccen-
tric),
drill
cast steel
fixture
is
shown
made
T-slots of
of nickel
in square, rectangular,
completed milling
21-10.
Eccentric Pin
Serrated Pads
Stop Elements
Element
The
mm)
Height Element
on the
Stop Element
Sub -Base
Fig. 21-10.
1951
milling fixture built with universal fixture
components.
built
1951
Fig. 21-9.
Universal
details.
fixture
components;
miscellaneous
drill
jig
components.
built
with
universal
fixture
286
or a replica of a part.
When
the
dummy
fixture
Ch. 21
is
completed, it is photographed in detail. The photographs are used in the toolroom for assembling the
actual fixture, and provide a permanent record for
filing.
The holes
T-slots for
An application
Fig. 21-13,
of the toolmaker's
jig,
jig
or fixture.
construction
is
shown
An example
It is
of a universal
in Fig. 21-12.
drill
sizes.
The
known
and the
and consists of a
jig
clamped
shown
is
in Fig. 21-13.
is
When
the bushing C, is
clamped to the die
spotted, drilled, and reamed.
is
;
.
borer by installing
right angles,
on the
compound
drill
jig
press table.
An
upright with
the
B
B
Pig. 21-12.
The toolmaker's
universal
first
task
is
Any
mounting holes
base
will
drill jig.
~s
iirr-
&
Ch. 21
ribs
as that
shown
slot pattern is
more
and diagonal
versatile,
AUTOMATIC FIXTURES
in Fig. 21-14,"
287
Some
larger tooling
To
in a
3.
universal fixture.
is
possible by
manual operation
set.
is
made according
to
its
ad-
what
is
its first
set
is
ready
4.
To clamp
tiple fixtures
5. To be able to incorporate the fixture into an
automated program (transfer machines, convey orized production lines, or numerical control [N/C]
machine tools).
The actuating member is always a cylinder with a
assignment.
to in the following
power
cylinder).
<g^-
-^
Common
*
--
!*irs
C--
Fig. 21-16.
E.
G.E.C. Gad's
Hydraulic
limited.
Permissible flow
second (4.6
is
temperatures
11.
fixtures.
fixture.
ing forces
_i3
pneumatic
G.E.C. Gad's
and, in the
288
leak.
air
The
rod, Dft
Pneumatic fixtures are used where medium clamping forces with almost any length of stroke are reQuired, and where ample design space is available.
mechanical efficiency.
millimeter.
cantly
mm
per second) to
0.
In Metric units
millimeters,
and
factor (0.85
is in
is
is
no piston
0.90)
is
the
Dp and Dr are in
newtons per square
newtons,
in
pistons in air
oil;
per second (6
Ch. 21
feet per
second
Pneumatic Fixtures
(3
torily
temperatures.
The
use of a power
medium
(air
or oil) under
first,
is
is
initial
higher
nificant.
is
cheap.
air,
are insig-
air in
a factory
$0.12 to
is
SO. 15
The dominating,
if
The
is
is
is
In addition, operator
virtually eliminated.
Dp
Dr
(inches),
and
F=
0.7854 (Dp 2
..
0.90)
mm
mm)
and lengths up
to 3 to 4 feet (0,9 to
part
.2
part, or for
another, etc.
To
Ch. 21
289
if
The introduction of a
the
crease
language
it
is
now
possible to in-
this
clamping force
this
is
on many semiautomatic and automatic lathes. Nonrotating air cylinders are used on commercially
available vises.
fixtures.
shown
in
Fig.
21^.
power cylinder,
mostly for air operation, some of them capable of
air operation and oil operation in the same cylinder
are built with an attached or integral
can be supplied with single-end and double-end piston rods, protruding from one end only, or from
For cylinders with
both ends of the cylinder.
single-end piston rods, where possible, clamping with
pressure on the piston-rod side of the piston, and
clamps.
that
is
When dimensioning
air
cylinders a length
travel
recommended to
future changes in work
is
sources and
many
a variety
in
A power
in advance for
dimensions and for other unforeseen changes.
An air-operated clamping device with integral
shown
with
accessories).
advantage that
components (end
pres-
Air Cylinders
is
compensate
^
Z77TZ
~Zt =z
An air-operated
Inc.
290
actuating element
which
is
double-acting
cam
at
end and
middle portion.
its
a sloping
This
cam
hydraulic drive
is
power source for the fixture. The operating pressures used in machine tools are low (1000 pounds
2
per -square inch [7N per mm
or less) compared to
the previously quoted values, and the fixture designer must always carefully check the available
pressure. Separate and individual hydraulic pumps
are available with almost any desired pressure, but
]
right.
the cost
preferred
to
release
is
admitted to the
full
which
The
initial
moves the
large
piston to the
left.
movement
cam
surfaces to
lift it
is
is
the booster.
It is
is
now
The
widely used
commercially available.
The booster consists of two coaxial cylinders with
different diameters and a common piston. A lowpressure
medium
is
is
maximum
fixture
for fixtures,
Hydraulic Fixtures
Ch. 21
pressure
medium
Representa-
and 30:1.
Output
and 7000 pounds per square inch (10, 20, and 50N
2
They supply from 1 to 14 cubic inches
per
).
is,
mm
cm 3
(16 to 230
Some models
valve
square inch
(103N per
mm 2
when
a plastic
1500, 3000,
of high-pressure
oil
per stroke.
(PVC)
is
Many
mm 2
(69N per
when
oil is
used.
00
250 pounds per square inch (0.7 to 1.7N per
mm 2 ) or oil pressures up to 500 pounds per square
are designed for operation with air pressures of
to
mm 2
).
per
mm 2
mm
Hydraulic fixtures can be powered from the mahas a hydraulic drive, from a separate
chine tool,
if it
hydraulic
pneumatic-hydraulic
air/ hydraulic
A machine
tool.
tool with
booster
Ch. 21
291
mount
to
in Fig.
It is
shown
21-19,
Power cylinders
imum working
and rated
at
max-
mm 2 )
mm) plunger
shown
travel.
in Fig,
21-21.
ated
in
typical
of the rated
low
When power
maximum
workpiece variations,
An
profile
clamping unit
is
recommended.
etc., is
clamped.
in Fig,
An
The
21-22.
fixture
is
or plastic) that
sleeve.
is
confined
is
shown
completely self-con-
medium
(oil
21-21
jig
with
mm
is
built
in sizes
It may be
noted that when larger expansion is needed, the
sleeve can be made of nylon with steel inserts.
Pressure
drill
hydraulic clamps.
lathe spindle
in the axis
shown
in Fig.
1-16.
The
EXPANDED EJUHETER
-v
O^
JUNIUL REFILL
lUTOIUTIC EF ILL
An
expanded
sleeve.
MACHINE TOOLS
N/C Machining
292
duction
in
non-cutting time
of
is
a re-
importance.
first
One way
Ch. 21
tapped holes in a regular pattern. Keyseats and Tslots are spaced at 6-inch (150-mm) intervals, and
possibility
is
Fixtures for
covered
in the
N/C
itself.
This
initial
preset
operation
is
tools,
not always
it is
is
accurately
also positioned
this
purpose.
fix-
most machines.
An
mounting of
tances.
(strips
For
vices.
fast
cally operated
all
it
provides the
and
all
In this way,
oil.
clamps are actuated simultaneously and with the
same pressure, yet still independently so that they
automatically equalize for any variations in part dimensions. The source of high-pressure oil can be a
booster, but since the total oil volume is relatively
all
it is
the oil
With automatic
in
endangers the
collide with the
a fixture
may
One
is
is
that there
fixture,
ingly simplified
T -slots,
typical
and low
N/C
profile
swinging
hydraulic clamps.
realized
one fixture
is
Ch. 21
mum
A
machine "on-time"
straps
is
lift
pressure
little
achieved.
setup with dual fixtures and hyshown in Fig. 21-23. The clamp
N/C
typical
draulic clamps
is
as the oil
released.
is
modern requirement of a
N/C machining, the machine follows,
without human supervision or interference, the path
through which the cutter is programmed and returns
To
to the starting point after a completed cut.
prevent collision and damage it is therefore imporThis clamp
low
satisfies the
293
24.
shown
in Fig. 21-
profile. In
free of
is
obstructions.
The
fixture
The
veyor,
fixture.
is
either
moved on
con-
is
is
clamped
at
is
At
--
L.
Fig. 21-24.
The
veyor or
transfer
When
or several
mode
Regardless of the
tures have a
is
that
is
cylindrical
They
are in a
as
position
retracted
tion and
movable
known
locators,
the part
is
stopped
is
"shot pins."
the fixture;
tooling holes.
tapered (conical
different
cators and to
fixture.
is
All
294
retract
the
damage
as the
typical
Fig, 21-25.
gage correctly,
machine
is
shut down.
used to indicate
unclamp, the
work
If a
warning signal
movements required to
pallet,
Ch. 21
if
is
actuated or the
a part
is
incorrectly located at a
station.
typical detail
in Fig. 21-26.
in the
The
foreground serves to
raise, transfer,
and lower
Fig, 21-25.
blocks.
chips
parts
is
part
is tilted
fall
Fig. 21-26.
22
CHAPTER
Economics
Classification of Fixtures
However,
by Grade
it is
clearer to calcu-
late separately
is
affected
hy
by the
level of simplicity or
produced
year
yy*
number of
parts
in a
single clamping,
replaced by the
new
fixture) the
is
unamor-
value (dollars)
fixture.
lically
air
or hydrau-
The
factors L,
i,
operated.
Mass production, over 1000 pieces, uses, in principle, the same power operated clamping devices hut
with the addition of such refinements as electrical
control, remote control, or semiautomatic control
The annual
cost
is
(a)
Y = C (i + m +
+ -)
is
(b)
or, if the
cost
and
X = Ns(l +)
Estimate of Profit
u,
not as percents.
The annual saving by using the fixture
fractions,
new
Y(
An economic
or not
it
will
Y'f = C{i +
+ t+-)+Si
(c)
295
ECONOMICS
296
If
is
is
the
is
substantial,
it is
number of
(b)or(c)
money.
0.04,
how many
$0.10,
C=
0.90,
$600.00,
The
X{1 +0,90)=
iy=$600X
$2700
0.12
- $1 164 =
$0.1
(a)
(0.06
51164
$o"l9~
known
own
$1536
is
or estimated.
to
rate
(c)
is
closely
total cost
233?
'
ff
What
n/3
=A
where
A =
Example -'With
= 3000 parts per year and other
values as in the previous example, the fixture is
the profit?
is
day technology
is
$570
Yf = $444
$570
profit:
$444 =
X=
Yf =
2000 X
CX
+
hence 0.72
n*
Maximum
C of
SO.]
(0.06
(c)
calculated
as length
OX
(1
0.04
$1 2
what
is
the
maximum
+0.90) = $380
+ 0.1 2 + 1/2)
= 0.72 C+ 12
height or
C=
o
o
(c)
$380-512
0.72
$511.11
width
cubic inches.
(350%);
(a)
$380
allowable cost:
in
$126
the fixture?
$200 X 0.06
C+
overall
allowable cost
(a)
* = $0.20;
L = 3.5
other values as before, is
if
so,
what
is
the profit?
Fig. 22-1.
in hours,
Annual
(c)
S444
N=
X=
(a)
1/2)
The
profitable.
0.04
10.10
is
the drawings.
0.06,
break even?
X = NX
$2700
profit:
this figure
0.12, a
parts
+3.5)
+ $200X0.06 =
cost
(0.06
(1
Example -W\th
$0.20 X
Yf = $1600 X
Annual
(a)
is
X =3000 X
setups in a year.
Depending on whether
the fixture
Ch. 22
is
is
the
is
ECONOMICS
Ch. 22
diameter
height.
The dimensions
are
measured
one
297
disregarded.
Fig. 22-1
For the
the volume
fixture
V= A
is
shown
X BX C
.
in outline in
defined by
,.
Appendix
Measuring Angles
Radians
in
For most applications, angles are measured in deand seconds. However, another meas-
Consequently,
grees, minutes,
applications, e.g.,
is
when the
preferred for
angle
is
80 degrees
=n
radians
ft
con-
degree
= tt^=
radian
and
is
arc
is
a circle
it
r,
of radius
and
it
r the
length of a
measures
80-degree
same
For
=57.2958, or
rr
radians.
to
when
readily
simplification
measured
in
in radians,
calculations,
298
because
Appendix
II
Transfer of Tolerances
from the Conventional Dimensioning System
to the Coordinate System
The coordinate system of dimensioning, with the
point of origin for the reference lines (the coordi-
die
jig
usually given to .0001 inch without specified tolerances, as the jig borer operator will
work
to the limit
An example
is
The
shown in Fig.
shown in view B is
1 1 - 1
obtained,
for
individual
change
is
made
The
toler-
REF
I000_
2000.
The new
The
3.000
UJj
a:;
.
4-iG-
-0
will result.
Oi Oi
O! 0<
be stated as follows:
o a
in.
oi
When
transferring tolerances
sum of
rol
on the
Fig. 11-1
co-
ordinate system must not exceed the tolerance of the dimension that they replace
KS
without tolerances.
A, Conventional dimensions. 8, Coordinate dim-
Transfer
of
dimensions
ensions,
(Karl H.
Practice, vol, 1,
New
Mollrecht.
Machine Shop
Inc.,
1971.)
As the
first
step,
all
make
all
nate dimensions.
are transferred to
principle stated
above.
299
TRANSFER OF TOLERANCES
300
The application of the
is
II- 2,
App.
II
REF.
0005
1.0000
0005
2.0000
trjcus
3.0000
e
i
a
+IO
o
o
Fig. II-2, Transfer of toleranced dimensions,
8.
+i
00
CM
to
B.
Conventional dim-
ensions with equal, bilateral tolerances. C, Toleranced coordinate dimensions. (Karl H. Moltrecht. Machine
Practice, vol. 1,
New
Inc.,
1971.)
Shop
App.
TRANSFER OF TOLERANCES
II
301
The
Step 1.
sion
is
2,125
__*__. tolerance
is
2.000-inch dimension
in
a toler-
+ .003
2.128
.001
2.125
Step 2.
.002
2 126
"
2.124
is
obtained by the
addition
.8750
Step
The
3.
and must
2.126
3.0010
available tolerance
on 2.126
is
.002
now
dimensions.
3.00 lO-0010
dimension on the
affected by more than
is
8 7SQJ>010
jhe .0010
When
is less
3.0010 001 :
a tolerance
is
new
toler-
bound by
a small tolerance, as
sometimes
increase an adjacent tolerance on the
possible to
the
dimension,
it
is
3.5030 OOOS
4.6280 OOOS
1.0000
0005
2.0000 ooos
sum of
in
This
is
summarized below:
above.
3.0000*'0045
The .0045
Appendix
The Dimensioning
The Dimensioning of Fixtures by
400-mm)
III
is
of the order of
They are:
Eg, The main cutting force or, simply, the cutting
force. It is the force component acting in the direcIII-l.
This
force.
is
the force
is
i.e.,
component
parallel to
it is
the
component,
it is
broaches) there
is
a set
which
is
of force components
actively cutting.
Fq
into hundreds,
if
cutting force.
Eric
Oberg and F,
(New York:
335-337.
302
D.
Jones, Machinery's
Handbook
197 T) 19th
ed,, pp.
Fig. Hl-l.
tool.
App.
is
DIMENSIONING OF FIXTURES
Ill
2
FF F c to F c
1
FT
Fp
is
is
minimum when
the side-
(SCEA)
efficients.
/ and
d) and
and
*^F c io-F c
maximum and F T
cutting-edge angle
303
is
cutters
it
is
For twist
2.
creased by a factor of
resistance caused
drills,
Fp
is
further in-
by the
chisel edge.
Data for
drilling
The clamping
forces
'
The
fixtures
are given in
Fc
multiplied
cases
feed
or
found that
a safety factor
of 2 or
fixture can
where.
=
=
will be
10.
Fc = p c A Q =p c fd
it
Chapter
mm
2
)
mm)
mm)
curved plates of square, rectangular, or circular circumference, cylinders, angles, and, occasionally, columns. Formulas for dimensioning these are found
in
Machinery
's
Handbook.
and other
brittle materials,
Appendix
(Based on
inch
25.4 mil
I i
meters exactly)
b
In.
Mi
Ht
0.79-V
Ht
1.191
1.588
1.984
2.381
2.778
3.175
3.572
^2
Mm.
In.
mt
397
Hi
Hi
M*
39*o
ffa
mt
?i*
mt
X,
m*
)i
1;**
Hit
'Hz
'Hi
2J|l
1453
sjii
4 366
4,76a
S.t59
5-556
5 953
6. 350
lAi
2)4*
a ?6t
3 iii
ii
13*97
1^2
13.494
14.288
14.684
15.081
IS. 478
15.87s
16.272
16.669
17.066
17.462
17.859
ts. 356
18.653
19.050
m*
'ISa
*Hi
*E
*
Mm,
In.
Hi
Mi
13.891
*$i*
ff*
lit
H
<H*
'Ha
Hi
Ma
Mm.
In.
6.747
7-144
7,541
7.938
8. 334
8.731
9.128
9 525
9-922
io.3r9
10.716
11. 112
11 509
11.906
12.303
12 700
Hj
*J4
'
>3*4
>M3
'Hi
nu
nu
'M
w*
m*
k>
'Hi
19,447
19.844
20. 241
20.638
21.034
21 431
21.828
22,225
23.623
23.0I9
23.416
23.813
24.209
24.606
25.O03
25.400
INCHES TO MILLIMETERS
In.
I
a
Mm.
In.
25.4
So. 8
Mm.
76.2
10I.6
In.
Mm,
In.
5
6
127.0
1S2.4
1
8
Mm.
In.
Mm.
In,
Mm.
177.8
203,2
9
10
328.6
254.0
11
12
279.4
304.8
FEET TO MILLIMETERS
Mm.
Ft.
Mm.
30,480
10
20
600
60,960
91.440
731,920
152,400
182.830
no
M3.36a
Boo
243,040
274.320
304.800
3.048
6,096
9,144
52.192
15,240
1 8.288
31,336
24,384
27.432
30.480
Ft.
ioa
20a
30a
400
Boo
1,000
Example
i:
30
40
50
60
70
80
90
100
Mm.
Ft,
1
2
3
4
5
6
7
8
9
10
90
3
ft
ft
5 in.
*%<
393
Example
2:
ft,
1.
ft
=
=
.8
ft
.of
ft-
71. 86 ft
304
in.
S*JtU in-
70,
609.6
0.2
0.3
0.4
0.5
0.6
0.7
o.S
0.9
30.48
60.96
91.44
121.92
IS2.40
182.88
213.36
343.84
274.32
304.80
o 293 feet.
ft
Mm.
0.1
914-4
1,219,2
1,524.0
1,828.8
2,133,6
2,438.4
2,743.2
3,048.0
Ft,
304.
1.0
$*%*
inches.
mm
mm
17.432.
mm
914 4
127.0
mm
18.653 mm
60,960,
89,452.053
of 71.86 feet.
mm
mm
mm
mm
21,902.928 mm
21,336,
304,8
243.84
18.288
nun
Ft.
0.OI
0.02
0.03
0.04
0.05
0.06
0.07
0,08
O.09
O.IO
Mm,
3.04S
6.096
9.144
12.192
IS, 240
18.388
2I.A36
24.384
27.432
30.480
IV
App. IV
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Index
Acme
thread, 125
nuts, 116,195,203-204
Actuators, plunger, 216
Acorn
Adapters, 281-283
for vises,
129-130,235-236,272
298
Angle strap, 113, 120
Angular clamps, 120-123
Angular drilling, 233-2 36, 238
Angular errors (misalignment), 27-28,
54, 55,
91,93
materials for, 22
278
83-84
Ball bearings, 59
Ball knobs, plastic
Ball plunger, 217
Ball, tooling, 217
260
207-208
inertia,
step,
part,
welded, 45
hook,
materials for,
and
steel.
201-202
S3
266
Box-type
drill jigs,
227,232-233, 238
125,228,238
Bracket type
Broaching fixtures, 272-275
Bronze locators, 45
Buckling instability, 141-142
Built-up fixtures, 172, 173, 175-176,
183
Bullet-nosed pins, 2
Burrs, 5, 40, 76-77, 82-83, 95, 230
relief for, 84-86
Bushing holder for slip bushings, 238
Bushing plate, 235
Bushings, American Standard Jig, 155
ceramic coating on 168
circuit board, 169
close together, 158, 163, 229
conventional, 154
crimping of, 169
distance from ends of, 229-230
1
154-169
9S-97
master, 155
materials for, 22-23, 167-168
non-standard, 1S4, 163- 1 64, 165-167
potted, 168, 184
portable power tool, 164-165
retainer,
163
thin-wall,
48,
208
208
22-23
drill, 4,
standard, 154-156
stationary press-fit, 154
template, 168-169
195
latch,
154
special,
spherical,
stop, 46
1 1
index, 59
jig
rest,
jigs,
Backing
208
clamps, 108-111,205-206
Cams, 97, 99-100, 108-1 11, 125-129,
205-207, 290
eccentric, 110-111, 125-128
materials for, 22-23
Cam
77-179
23
nodular, 23
Cast iron fixture stock sections,
Cemented
268
217
Center drill, 94
Centering, single, double, and
Centralizers, 87-104, 232
automatic, 97-101
for gear wheels, 101-104
full,
B7
Channel
Channel
fixture,
jig,
173
227
307
308
Chip
Chip
Chip
Chip
INDEX
breakers, 82
deflector, 84
83-84
disposal,
drill,
ture,
260
269
269
Chutes for chip removal, 83-84
Circuit hoards, bushings for, 169
drilling of, 241-242
Circular locators, 51-58, 254
Clamp assemblies, removable,
Clamping, 19
adhesive, 133
economics of,
5,
(App.), 304-306
90
electrostatic, 132-133,
inserts for lathe, 208
lathe, 208
Drill, center, 94
Drill chuck, 90
fix-
208
Conveyor, 57
Coolant control, 83-84
Coordinate dimensioning system, 186189 (App.), 299-301
Cost of fixtures, 183, 296-297
Coulomb's Law, 133
Coupling nuts, 195
Cradle, 227, 234, 272
Crank arms, materials for, 2 3
Crankpin grinding fixture, 27
252
288
Drill, radial,
Drop
Ductliron, 23
Dummy
Duplex
blocks, 285
milling, 245, 252,
253
128
67,95
multiple, 144-145
Damping
vibrations, 23
Defects in die forgings, minor, 38
Deflector, chip, 84
Deformation analysis of fixtures, stress
and (App.), 302-303
of a package, 141-142
of gas turbine compressor blades, 134-135 Degrees of freedom, 18,26-28, 61,251
of honeycomb with ice, 135
Depth machining, 6
vacuum, 133, 269
Design, of bushings, 16S-167
with low-melting alloys, 134-135, 147
of drill jigs, 219-243
Clamping devices, operating time for
of fixture bodies, 18-24, 170-185
(Table), 1 S
of fixtures (App.), 302-303
Clamping forces, 303
Design rules, for buttons, 48
screws (Table), 108
for welding, 181-182
Clamping screws, 107, 108, 115-1 17,
Detent pins, 214
1*7,202-205
Determinate system, statically, 61, 147
Clamping wedges, 105-106, 122, 147Diamond pins, 56-57, 210, 254-256
149
Die forgings, draft on, 38
dual action, 64-67
flash extension on, 36-38
Cla mps, 105
minor defects in, 38
1
Wm
pUWeted .115
mismatch
angular, 120-123
in,
36-38
beam, 113-115
cam, 108-11
double movement, 121, 139-140
dual pressure, 289, 290
for renewable bushings, 161-162
hydraulically powered, 1 1 S
materials for, 22, 23
quick-acting, 127-1 28,-2 39, 241 281
,
244, 288-289
Straps for, 207-208
/Cfglerrn-l 13, 125. 128-129, 136,
* 216-217,243, 279
Class II copper for backing bars, 278
Clearance in fixtures, 68, 76, 172, 227
Closed jig, 170, 224-227
Components, commercially
194-218
indexing, 215-217
locating, 42-67, 208-209
227-228
227-228, 268
elements, 105-135,207-208
air
236-238
205
available, 4,
Dielectric,
133
50, 152,
160
Double centering, 87
Double locking levers, 202
Double movement clamps, 121, 139140
Double nested, 25
Double or triple screw thread, 135
Dowel pins, application of, 50-51,
173, 174
materials for, 22, 174
Draft, on castings, 34-35
on die forgings, 38
plastic parts,
270
floating, 95-97
295297
and
248
hydraulic, 145-146
plate-type, 138
Errors, angular (misalignment), 27-28,
54, 55,91
in part surface geometry, 27
Estimate, of fixture cost, 296-297
of profit, 295-296
Expanding mandrels and arbors,
elastomers for, 263-264
Eye
bolts,
195
40
patented, 195
propietary, 195
wear on indexing, 58-60
Conical locators, 93-97
288,
FERRO-T1C,
1
Double, (def.) 25
Double-action pins, 214
on molded
309
INDEX
Freedom, degrees
2S1
Fixtures, (def.)
295-297
151,253
set-up, 1 51
Gang milling, 152, 191, 245, 248
Gear hohbing fixtures, 2 56-2 57
Gears, 102-104
mats
of,
293
indexing, 58-61, 86, 254, 273-274,
279
44
24
239-240
58,293-294
patented, 195
273
pneumatic, 287-290
star,
planing,
proprietary, 195
254
179
shaping, 272
slotting,
272-273
space
in,
287
welding, 275-280
Fixture stock sections, cast iron, 217
Flange nuts, 195, 205
Flash extension on die forgings, 36-38
Floating action clamping, lathe fixture
with, 67, 95
Floating drill bushings, 95-97
Floating pin locators, 212-213
Floating principle, 67, 95, 36-140,
I
149-150
Floating screw, 139
Floating zero, 292
Flux, magnetic, 132
Foam, polyurethane, 24
Foolproofing, embracing fork for, 73-7 5
punched
parts,
76
108
Force on magnetic chucks, holding
(Table), 131
Forces, clamping, 303
cutting, 272-273,
inertia,
101-104
5 8,
259, 291-293
radial,
for,
roving s of, 24
Gray cast iron, properties of, 23
Grinding, contour, 272
pallet,
302-303
201
292-293
Index bolt, 59
Indexing, angular, 58-61
manual, 107-108
Fnrgings, see also Die forcings. Drop
draft on die, 38
flash extension on,
36-38
machining allowance on, 33
minor defects in, 38
mismatch in, 36-38
shrinkage tolerances for, 37
tolerances for, 35-38
20
forgings
27
162-163
Integrity, structural, 2
Intensifier, pressure, 290
106
295
classification of,
rapid, 60
straight line, 58
236-238
Indexing fixtures, 58-61, 86, 254, 273-
274,279
Indexing plungers, 216-217
Indexing table, 58-60
Inertia block, 260
Inertia forces, 260,
272, 302
210
Internal broaching, fixtures for, 274
Irregularities in castings, minor, 35, 95
base, 234
borer, 158, 186, 191,
266,299
195
223,226, 227
chanoel, 227
closed, 170, 224-227
custom-made, 281
for large work, 235
leaf, 124, 170, 226, 227, 232
open, 170, 221-224, 227, 231-232
plate, 170, 219-221, 227, 231-232
pump, 170,240, 241, 281
reversible, 231
284
t
54
for aligning fixture to
machine
table,
171-172,247,252
sine fixture, 195
66
INDEX
310
Leaf, 115, 123-125,205,226
swinging, 115, 123-125, 205, 226
Leaf jig, 124, 170, 226, 227, 232
Legs, jig, 209,221, 222, 223, 226, 227
Leveling lugs, eccentric, 210
Levers, locking, 202
159
Linkage controlled centralizers, 89, 97101
Linkages, pantograph systems, 97, 100101
scissor type, 97
"Liquid steel," "liquid aluminum," 24
Loading and unloading the part, 68-81
22,45-46
Locating pins, 48, 210-215, 221, 222,
252,254-256
captive, 214-215, 225
Locating plane, disadvantage of inclined,
30
Locating, preparations for, 32-4
with keys and keyseats, radial, 54
Locating principle 4-2-1, 27
Locating principles, 2 5-31
Locating the part, 8, 68, 87
Locating unmachined surfaces, 32
Location, dual cylinder, 29, 54-58, 293
Locator buttons, 46, 201, 208-209
Locator pins, 48, 210-215, 22!, 222,
1
252,254-256
conical, 93-97
cup, 95
cylindrical, 28-30
floating pin, 212-213
integral, 44-45
jam-free, 51-53
94-95
sliding point type adjustable, 63
sliding,
unhardened, 46
wear on, 45-46
wedge type adjustable, 62-63
with triangular relief, 52-53
Locking clamps for renewable bushings,
161-162
Locking devices for slip bushings, 160
Locking levers, 202
Locking mechanism for universal jigs,
282
Locking tabs for slip bushings.integral
162-163
hold-down
to,
table,
bolts,
179
for, 39-40
259,
291-293
depth,
surface,
22
of, 2
24
306
Milling chips, 82
Milling cutter, face, 25 ]
Milling fixtures, 2,244-258
Milling, duplex, 245, 252, 253
flange.
materials for, 23
speed, 117
T-, 171, 195
wing-, 1 16, 148
1 1
Outboard bearing, 60
Overdefining, 25, 53
Overrunning clutch, 282
Package clamping, 141-142
Pads, 44, 206, 208, 222, 225-226, 227
locating, 48-51, 208
repair of worn, 45
rest,
48-51,208
swivel, 201
tooling ball,
217
293-294
machines, 293-294
Pantograph system linkages, 97, 100101
Parallels, materials for,
23
Parameters, machining, 5
Part, (def.) 25
removal of, 76-80
244
255
Milling machine dividing head, 59, 254
Misalignment (angular errors), 27-28,
54, 55,91
Mismatch, in castings, 35
in die forgings, 36-38
"Missile Maker Lathe," 265-266
Mistake-proofing the fixture, 69
Module, in gears, 102
Molded plastic parts, draft on, 40
159
fixtures, 2 53-2S4
u (coefficients of friction) (Table),
Multiple clamping, 140-146
Multiple milling, 245
213-215
48,210-215,221,222
252,254-256
locating,
shrinkage in, 40
tolerances for, 40-41
Mounting of press-fit bushings, 156-
pilot,
T-,
1
210
retractable, 255-256
shot, 57,293
single-action, 2 14
06
heads, 164, 2 36
213-215
tapered, 50
Pitch in gears, 102
Placement of jig bushings, 229-231
Planing fixtures, 272
Planing, run-in and run-out distance
in,
195,205
tracer,
drill
(Table),
fixtures, classification
Multiple-spindle
threaded, 264-265
Mandrels and arbors, elastomers for
expanding, 263-264
Mandrel type fixtures, 263-265
Manipulation and operator .criteria, 9
Manual forces, 107-108
242
Open
94
materials for,
292-294
clamping fixture
171
lathe,
drilling
240-243
N/C machine
Movable milling
267
Machine tool
L-pins,
Manual work
N/C
Machine
Plastic
272
and steel
ball
knobs, 201-202
79
INDEX
311
146, 290
Plastic parts, draft
41
Plastic sheets, laminated, 24
Plastic tooling, 23-24, 184, 211,213,
214,227.285
in,
repair of,
24
219-221, 224,
225
(i.e.: plate-jig),
170, 219-221,
227,231-232
Plate-type equalizer 138
PlexiglasCH 83
Plunger actuators, 2 1
Plungers, 122, 137, 139, 140, 143,
14S, 147-149, 209-213, 215-217,
232,287
4S-degree, 137, 139
indexing, 216-217
tools,
242
218,279
Shaping fixture, 272
Sheets, laminated plastic, 24
Shields for dirt and dust, 86, 210
Shoe, swiveling, 137, 147, 199
Shot pins, 57, 293
Shoulder screws, 1 97
Shoulder tooling ball, 2
Shrinkage and warpage of castings, 33
Shrinkage in molded plastic parts, 40
Shrinkage tolerances for die forgings,
1
Set-up gages, 1 51
Setting block, tool, 2, 1 51, 244, 292
Setting gages, 151, 253
Shapers, field (for magnets), 32
Shapes, structural, 175, 181-182, 183,
1
N/C machine
23-24
Plate jig
298
Raiser blocks, materials for, 23
Rapid indexing, 60
on molded, 40
shrinkage in, 40
tolerances for, 40-41
Plastics, 23-24, 164, 168, 172
tolerances for prefabricated shapes,
laminates
37
of,
159-163
locking clamps
for, 161-162
Renewable (loose) bushings, 154, 155
Renewable wearing bushings, ) 54-155,
156
Repair of plastic tooling, 24
Repair of worn pads, 45
Residual stresses, 33, 76, 178, 179
25
spring, 2 1
Plywood, application of, 24
Pneumatic fixtures, 287-290
Polyesters, 23-24
Polyuretliane foam, 24
Polyvinyls, 23-24
Resins, laminating, 24
Rest buttons, 48, 208
Rest pads, 48-51, 208
Retainer bushings, 208
Retainers, 208, 211
Retractable pins, 255-256
Reversible
164-165
Pot type lathe fixture, 172, 262
Potted bushings, 168, 184
Potting compounds, 24
for portable,
164-165
Prefabricated shapes, tolerances for
plastic, 41
Preparation for locating, 32-41
Preplanning of fixture design, 5-8
Prcposttioner, receiver as a, 81
Press- fit bushings, 155, 156, 158
mounting
of,
156-159
228
Production boring machines, 266, 269
Production quantities, classification
of, 219
Profile milling fixtures, 252-2S3
Profit estimate, 295-296
Proprietary fixtures and components,
195
Pull broaching, fixtures for,
Pump
170,
jig,
274-275
240,281
76
Push-pull toggle clamps, 216-217
Punched
241,281
devices, 4, 206
screw components, 202
Quick locking, knobs, 202
levers, 202
Quick operation, designs for,
54
Radial locators, 29, 54
Rockers, 137-138
for jigs, 235
Roller bearings, 59
Rollers for multiple clamping, 144-14S
208
welding, 276, 280
Positioner, boring,
jig, 2 3
SAE
steels,
20-21
139
08
half-turn, 201
hand knob, 147, 199,251
jack, 117-118,201,224
268
Size adjustment, lathe fixtures with,
64-67
161-162
integral locking tabs for,
162-163
Spiral cams, 1 10
Split-cylinder type of sliding point
locator, 63-64
Split V-block, 97
Spring jack locks, 209-210
Springback, 39
Spring loaded jack, 246
Spring plungers, 217
Springs, 137, 138, 139, 140, 143, 147,
203, 205, 206, 209-210, 214, 240,
249,251
materials for, 22
Spring stops, 2 1 7
Spur gear, 103
Square screw thread, 125
Stability, 60, 245
Stabilizing treatment
Stainless steels, 2
of castings, 179
INDEX
312
Statically indeterminate system, 61
208
"liquid," 24
material selection, 21-23, 167
Stainless, 2
standard, 20-2
tool, 21, 167, 183
Step blocks, 207-208
Stock sections, east iron fixture, 217
Stop block for preventing rotation, 228
Stop buttons, 41
I
Stop collar on
Stops, 42
159
.frill,
side, 48
spring, 217
Straight line indexing,
Straps, 105, 1 13-1 IS,
S3
118-120, 138,
202-205, 207-208, 222, 223, 226,
241,248-249,251,285
120
clamp, 207-208
angle, 113,
252-253
302-303
Structural integrity, 2
Structural shapes, 175, 181-182, 183,
218, 279
Stub boring bars, 265, 268, 269
Studs, 195,203-204
Subassembly fixtures, welding, 278
Sub-bases, 281, 284-286
Supports, 19
adjustable,
209-210
compatible, 61
incompatible, 61
intermediate, 147-150,209-210
redundant, 61
Surface plate, magnetic, 130-132
Swing bolts, 195
Symmetry
considerations, 69-71
Synthetic sapphire locators, 45
2 S3,
a,
248
Thumb-screws, 119, 123, 147
Titanium carbide for bushings, ferrous,
167
T-nuts, 171, 195
Toggle clamps, 111-113, 12S, 128-129,
136, 216-217, 243, 279
Tolerances, 32-41, 189-1 91, 242, 247,
251, 280,299-301
for castings, 33-35
for die forgings (Table), 36-38
forgings, 35-38
39-40
mill products, 39
molded plastic parts, 40-41
parts,
press products, 39
torch-cut parts, 38-39
locators,
46
Uniformity of Castings, 35
Universal drill jigs, 170, 281-284
Universal fixtures, 284-287
(def.) 2, (def.)
Universal
locking
281
208
mechanism
jigs,
for,
282
Vacuum
281,282,284
sliding, 92-93, 101
split,
97
Vibration damping, 23
Vise jaws, detachable, 130, 244
Vises, adapters for, 129-130, 2 35-236,
272
air-operated machine, 170
machine tool, 90, 244, 252, 281
Volume of chips, 82
castings, shrinkage and, 33
Washers, hardened, 23,
spherical, 137, 196, 203, 206
Wear on indexing components, 58-60
Warpage of
weldments, 38
incompatible, 27
toolroom, 191
Tooling ball, 217
Tooling ball pad, 217
Tooling, castable, 211 -213
template, 68
Tooling for N/C drilling machines, 2401
243
Tooling for tapered holes, 267-268
Tooling holes, 57, 170, 252, 293
Tooling plate, aluminum and magnesium
23, 168, 183
ball,
217
294
pallets for,
Unhardened
materials for, 22
293-294
Transfer of dimensions,
303
229, 233
machined
208
Twist
for
for
for
for
for
for
for
for
for
89, (App.)
299-301
Treatment of
castings, stabilizing, 1 79
relief, locator with, 52-53
Triple screw thread, double or, 1 3S
Trunnions, 60, 235, 253
Triangular
Wear on
locators, 4S-46
adjustment for, 63-67
Wedges, clamping, 64-67, 105-106, 122,
147-149
self-locking, 106
sliding, 97-98
Welded fixture bodies, 45, 172, 173,
179-183
Welded fixtures, tubing in, 182
Welded joints, 179-180
Welding, design rules for, 181>182
fixtures, 275-280
lathe, 280
magnetic flux in, 278
280
276
positioner, 276,
shrinkage
in,
subassembly fixture
tacking fixture for,
for,
278
278
Weldments, distortion
in, 38,
275-278
Worn
Zero, floating,
Turnbuckle principle, 97
292
45