Tool Design 1/3

Unit #2 LOCATING AND CLAMPING

A large portion of the tool designer’s time is spent in the solution of locating and clamping
problems. The term locating, as use in the language of the tool designer, refers to the dimensional and
positional relationship between the work piece and the cutting tool used on the machine. A work holding
and positioning device is usually employed to establish this relationship.
The various forces acting upon the work piece during a machining operation necessitate a means
of clamping it in position after it has been correctly located. In theory, clamping and locating are
individual and distinct_____ problems, but in practice they cannot be separated. The method of clamping
may depend upon the type of locating device and vice versa______. It should be remembered, however,
that the selection of locating and clamping method and device will depend upon the machining operation.

The Basic Principles of Location :

Configuration is the major factor in determining how a work piece will be located. Examination of
the typical work piece from the metal industries shows that the configuration is determined by a
combination of flat, circular, and irregular surfaces.
A flat surface is one that lies in one plane, and a circular surface is one that is made from the
segment of a circle. The inside surface of the circle segment may be used to from a concave surface.
Irregular surfaces are nit flat or circular. They may or may not be geometrically true.
Each of the three preceding surface types may be rough or finished. The tool designer should study the
work piece carefully before deciding which surfaces are best suited for locating.
☻ Locating from plane surface
☻ Locating from circular surface
☻ Locating from irregular surface

Locating from plane surface:

The basic reference for location is a flat plane, generally a machine table. The machine table is
usually at right angles parallel with the machine feed movement. Most machines have three standard
movements up and down (vertical), right or left (longitudinal), and in or out (cross wise).
In minimum of three points or locators must be used to locate the work piece, also four or more may be
used to provide adequate______ support. It should be noted that a minimum of three locators will always
theoretically establish the some location of the work piece. Four or more locators do not establish this
theoretical location because if the work piece surface is not true, the position is still determined by three
locators.

Locating from circular surfaces:

Here again the basic reference for location is the flat plane of the machine-tool table surface.
However, instead of locating the flat plane of the work piece parallel to the reference plane, it is necessary
to locate the axis of the circular work piece. One of the common method of locating from a circular
surface is by using cones.
Closely related to conical location is the V method, used primarily to locate round work piece with
convex circular surfaces. it has been found that the best general V angle is 90.

Locating from irregular surface:

Irregular surfaces are neither flat nor circular. They may or may not be geometrically true. For
example, a parabolic or elliptical surface would be considered an irregular surface. A surface of a work
piece that may vary____ dimensionally from time to time would also be an irregular surface.
The degree of roughness may determine whether a surface would be considered flat, circular, or
irregular. Locating methods used for flat and circular surfaces may be used for some irregular surfaces.
For example, V locating methods may be used to for parabolic surfaces, and button locators used for
elliptical surfaces.

Locating Methods and Devices:

Through the year tool designers developed locating methods and devices that have proved
efficient and simple. The majority of work piece can be located with these methods, and the result has
been that they have been adopted throughout the country. Many companies stock quantities of standard
tool components and require that the tool designers specify only their designs and sizing and dimension.
¾ In and button locators
¾ Rest pads and plates
¾ Nest or cavity location
¾ Locating methods control and chip
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Pin and button locators:

One of the common methods of location is to use pins and buttons. A round pin or button is used
to firmly support or hold the work piece in position. The main difference between pins and buttons is in
length. Buttons are generally shorter than pins and are used for vertical locations. Pins are used for
horizontal location. Larger sizes are sometimes referred to as plugs.
The simplest form of pin locator is a short length of steel grill rod pressed into a hole in a jig or
fixture base. Buttons and pins are available commercially as standard parts.

Rest pads and plates:

Rest pads and plates are used to support and locate work vertically in a manner similar to rest
buttons, but they are used with large and heavier______ work piece. Rest pads are similar to rest buttons
but do not have a shank .They held to the jig or fixture base plate. They are used to support larger parts on
previously machined surfaces.

Nest or cavity location:

The term nest is loosely used by tool designers and toolmakers when referring to the area of the jig
and fixture that the work piece. The nest of a jig and fixture should be a pocket or cavity into which the
work piece is placed and located. Nests may be milled directly into a base plate to the same contour as the
work piece. For blanked parts a nest may be pierced directly________ into a piece of sheet.
Properly designed nests should be locating the work piece without any supplementary but locating
pins are used. One disadvantage of nest location is that the work piece is often difficult to lift out of the
cavity because it is completely surrounded.

Locating methods control and chip:

Machining metal involves removal of waste material in the form of chip. Large chip can be
removed quickly from the work-location area by various, but small chip tend to collect in corners and
other inaccessible areas and cause error in location. The tool designer should keep this problem in mind
when selecting locating devices and either use locating methods.

The Basic Principles of Clamping:

Once a work piece is located, it is necessary to press it against the locating surfaces and hold it
there against the forces acting upon it. The tool designer refers to this action as clamping and the
mechanisms used for this action are known as clamp. Many types of clamp have been developed, and it is
sometimes difficult to choose between two types when designing a specific tool. In general, the choice of
clamp is largely determined by the work piece and the kind of operation to which it is applied.
However, simple or complex, all clamps must fulfill four essential requirements:
1. The work piece must be held rigidly while the cutting tools are in operation.
2. The time required for loading or unloading the tool must be as short as possible, which means the
clamping device must be quick-acting.
3. When subjected to vibration, chatter, or heavy pressure, the clamping must be positive.
4. The clamp must not damage the work piece.

Type of Clamp:
While the types of clamps are many type, but they can be classified in eight basic groups:-
▪ Strap clamps ▪ cam clamps ▪ screw clamps ▪ latch clamps ▪ wedge or key clamps
▪ Toggle clamps ▪ rack and pinion clamps ▪ Hydraulic and pneumatic
Commonly used clamps are readily available from tool specialty companies.

Strap clamps :
This simplest and probably most commonly used clamp is the strap clamp. All strap
clamps employ the principles of levers. Many styles and shapes are available as standard parts to suit
different applications. Strap clamps are used foe easy removal of work piece. In strap clamps compression
spring between the base and clamping bar hold the bar in position when the clamping knob is loosened.
A two-piece spherical washer is sometimes used to provide proper seating of the nut, washer, and bar
when the work piece height varies________. The upper part of the spherical washer fits properly under
the nut, and the lower part fits on the bar, even the stud and bar are not perpendicular to each other.
The ASTME “Tool Engineers Handbook” recommends that the central slot in a typical strap clamp be
1/16 inch wider than the bolt or stud passing through it. Nominal diameter of stud “d”, the width of the
strap may be W=1/16'' +2.3d. Thickness for the strap h=0.92√abd/l.
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Cam clamps:
Properly designed cam clamps provide an effective and rapid means of clamping but they are not a
positive-clamping method and may loosen under vibrating forces. They should not be used where heavy
clamping force is required. Two main type of cam clamps are spiral and eccentric. Cam is easier to make
but does not lock as well as spiral cam.

Screw clamps:
Screw clamps incorporate a screw thread to clamp a work piece they have the advantage of
exerting adequate____ force besides resisting loosening tendencies_______ set up by vibration. They are
relatively slow and may not be suitable for high production. Screw clamps vary____ from a simple set
screw to complicated clamping assembly actuated by a screw thread.

Latch clamps:
This type of construction is limited to relatively light work, as it is difficult to secure rigidly. The
main advantage is in the ease and speed of manipulation. The construction of latch clamp is simple and
easy to operation. In operation in jig is loaded and unloaded is very easy. Latch clamp is self lock which
is very rapid in action. The operator can open the jig with one hand by pushing down on the pin as he
raises the leaf.

Wedge or key clamps :

A plain wedge clamp consists of a movable inclined plane which forces the work piece against a
fixed stop. Plain wedge clamp are crude and rarely satisfactory. A plain wedge clamp can be improved by
adding levers and links. The taper angle clamp of a plain wedge may range from 6° to 8°, depending upon
the coefficient of friction of the metal.

Toggle clamps :
Toggle clamps depend upon the movement of rigid links for their movement. Several companies
have developed standard toggle clamps, specifications are readily____ available from catalogs. An
adjustment is usually provided for variation in stock thickness.

Rack and Pinion clamps :

Rack and pinion clamps are used extensively ______ on universal jigs. A rack and pinion is not
irreversible, a lock must be incorporated to lock or hold the shaft while it is being clamped. Universal jigs
and rack and pinion fixture units produced commercially as standard components contain patented
______ locking machines.

Hydraulic and Pneumatic:

Many of the previously mentioned clamps may be actuated by hydraulic or pneumatic methods
when large production quantities justify them.
The advantage are faster clamping, uniform and equalized clamping pressure, and less operator.
Generally, pneumatically operated clamps are not used where heavy clamping pressure is required
because extremely large cylinder would be required.
If the air-cylinder piston is subjected to 100 psi air pressure and the area of the piston is 10 sq inch., a
force of 1000 lb is placed upon the arm.