F -X C h a n ge F -X C h a n ge

PD PD

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TM 437
Tool Design
Lesson 5
Basic Rules for Clamping
 F -X C h a n ge F -X C h a n ge
PD PD

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OBJECTIVES

After completing this section you should

be able to:

1. Explain the basic principles of work holding.

2. Identify work holding devices.
3. Match characteristics and applications to a
particular clamping device.
 F -X C h a n ge F -X C h a n ge
PD PD

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CONTENT

Work Holders
Basic Rules of Clamping
Types of Clamps
Modifying Chucks and Vises
 F -X C h a n ge F -X C h a n ge
PD PD

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WORK HOLDERS

The term “workholder” as applied to a jig or

fixture has 2 similar but different meanings:
1. In general terms, “workholder” can describe
the complete jig and fixture family.
2. When “clamping” is discussed the term
“workholder” describes those parts of the jig
or fixture that clamp, chuck, hold or grip the
part.
 F -X C h a n ge F -X C h a n ge
PD PD

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BASIC PURPOSE

The primary purpose of the “workholder” or clamping

device, is to securely hold the position of the part
against the locators throughout the machining cycle.
And MUST meet the following conditions:
1. Must be strong enough to hold part and resist all
movement.
2. Clamp must not damage or deform parts.
3. Should be fast acting to allow rapid loading and un-
loading of parts.
 F -X C h a n ge F -X C h a n ge
PD PD

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BASIC RULES

Positioning the clamps:

1. Always contact work at most rigid point
2. Prevent clamping forces from damaging
parts
3. Clamps should never interfere with the
machining operations
4. Position clamps so that operators can work
safely
 F -X C h a n ge F -X C h a n ge
PD PD

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NEVER distort the part

 F -X C h a n ge F -X C h a n ge
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SUPPORT the PART

 F -X C h a n ge F -X C h a n ge
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TOOL FORCES
Tool forces are forces generated by the cutting action and are
caused by:
-Resistance of workpiece being cut or sheared by the tool
To clamp a part properly the Tool Designer MUST know how the
tool forces or cutting forces act in reference to the tool.

PRIMARY

SECONDARY
 F -X C h a n ge F -X C h a n ge
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CLAMPING FORCES

Forces are required to hold a part against the locators

on the fixture or jig.
Clamping prevents the part from shifting or being pulled
from the fixture or jig
Type and amount of clamping needed is determined by
the tool forces working on the part
Operations being performed are factors of the
requirement for clamping
 F -X C h a n ge F -X C h a n ge
PD PD

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CLAMPING FORCES

The locators should be

positioned to resist the
bulk of the thrust
generated by the cutting
tool
 F -X C h a n ge F -X C h a n ge
PD PD

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TYPES OF CLAMP

Tool Designers should choose the CLAMP

that is:
SIMPLEST
EASIEST TO USE 1) Strap Clamps
2) Screw Clamps
MOST EFFICIENT 3) Swing Clamps
4) Hook Clamps
5) Cam-Action Clamps
6) Wedge Clamps
7) Toggle Clamps
 F -X C h a n ge F -X C h a n ge
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STRAP CLAMPS
Simplest clamp available
Basic operation same as the LEVER
 F -X C h a n ge F -X C h a n ge
PD PD

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CLASSES OF STRAP CLAMP

Strap clamps can be grouped into 3 classifications

1st Class has the 2nd Class places the 3rd Class places the
fulcrum between the work between the effort between the
work and the effort fulcrum and the effort work and the fulcrum
 F -X C h a n ge F -X C h a n ge
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Strap Clamps

Most strap clamps use the 3rd class

lever arrangement.
Spacing of the elements is important
Distance between the fastener and
the work should always be less than
the space between the fastener and
the fulcrum (heel pin)
This increases the mechanical
advantage of the clamp and increases
the holding force on the workpiece
 F -X C h a n ge F -X C h a n ge
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Clamping Arrangements

If the stud were positioned

exactly in the center of the
strap, the pressure generated
by the fastener would be
distributed equally between
the workpiece and the heel
support.
 F -X C h a n ge F -X C h a n ge
PD PD

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Clamping Arrangements

This arrangement might be

desirable when clamping two
parts side by side.
 F -X C h a n ge F -X C h a n ge
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Clamping Arrangements

This is a preferred way to use a strap

clamp on a single part
The fastener is positioned so one-third
of the strap length is between the
fastener and the heel support
The clamping pressure on the
workpiece with this setup is twice as
great as that on the heel support.
 F -X C h a n ge F -X C h a n ge
PD PD

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Common Types of Strap Clamps

 F -X C h a n ge F -X C h a n ge
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HOLDING POWER

The holding power of the clamp is determined by the

size of the threaded member binding the clamp.

Recommended clamping
pressures for the 6 most
common clamp screws

Minimum bolt tensile strengths for tooling bolts range from

75,000 to 100,000 psi
 F -X C h a n ge F -X C h a n ge
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SCREW CLAMPS

Commonly used on both jigs and fixtures

Offer unlimited application potential
Lower costs
Less complex in design
Basic clamp uses a screw thread to develop
torque to hold part in place
Numerous commercial clamps developed
Only disadvantage is they are slow
 F -X C h a n ge F -X C h a n ge
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EXAMPLE – Screw Clamp

(indirect clamping force)
 F -X C h a n ge F -X C h a n ge
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SWING CLAMPS

Combine the screw clamp with

a swinging arm that pivots on
its mounting stud.
Holding power is generated by the
screw
Rapid action is achieved by the swing
arm
 F -X C h a n ge F -X C h a n ge
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HOOK CLAMPS

Similar to swing clamps but

much smaller footprint
Useful in tight places or where
several small clamps are used
rather than one large clamp

Modified hook clamps is made

to operate from opposite side
of the tool
 F -X C h a n ge F -X C h a n ge
PD PD

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CAM ACTION CLAMPS

Provide fast, efficient and simple

way to hold work
Because of their construction are
limited in use
They apply pressure directly to the
work
Vibration may cause clamp to loosen
Direct-pressure cam action clamps
must be positioned to resist the natural
tendencies of the clamp to shift or
move the work when the clamp is
engaged
 F -X C h a n ge F -X C h a n ge
PD PD

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WEDGE CLAMPS

Wedge clamps apply basic principle of using an inclined

plane to hold work, similar to a cam action clamps
Found in 2 general forms:
1. Flat wedges: Hold the part by using binding action.
2. Conical wedges: Hold work through a hole.
 F -X C h a n ge F -X C h a n ge
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Self Holding Wedge Clamps

Wedges having a slight angle of 1 degree to 4 degrees adequately hold the work in place
 F -X C h a n ge F -X C h a n ge
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Large-Angle Wedge Clamps

Large-angle or self-releasing wedges are used in
conjunction with a screw to hold them in place.
 F -X C h a n ge F -X C h a n ge
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Conical Wedges

Conical wedges are

used for holding work
through a hole
Mandrels are available in:
Solid – limited to one
size hole
Expansion – made to fit
a range of size holes
 F -X C h a n ge F -X C h a n ge
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Four Basic Toggle Clamping Actions

Made with four basic clamping actions:
1. Hold down
2. Squeeze
3. Pull
4. Straight Line
All are fast acting
Have natural ability to move completely free of the
work.
High ratio of holding force to application force.
Operate on a system of levers and pivot points.
Versatile and very popular.
 F -X C h a n ge F -X C h a n ge
PD PD

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Four Basic Toggle Clamping Actions

 F -X C h a n ge F -X C h a n ge
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TOGGLE ACTION

Toggle clamps operate on a

system of levers and three
pivot points
When the clamp is locked,
the points are in line
Toggle clamps are available
in a variety of configurations
with special mounts,
handles, and feet
 F -X C h a n ge F -X C h a n ge
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POWER ACTION CLAMPS

Alternative to manually operated clamps.

Normally operate under Hydraulic or Pneumatic
power or both.
Air over Hydraulic is popular because it can
operate using normal shop air (90psi)
Better control of clamping pressures.
Less wear.
Faster operating cycles.
Main disadvantage is COST.
High costs offset by Volume Production.
 F -X C h a n ge F -X C h a n ge
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POWER ACTION CLAMPS

 F -X C h a n ge F -X C h a n ge
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CHUCKS AND VISES

Commercially available ‘off the shelf’

Offer design flexibility
Greatly reduce tooling costs
A single chuck or vice can be used for several
applications
Simple modifications to “Blank” jaws to suit
every tooling application
 F -X C h a n ge F -X C h a n ge
PD PD

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CHUCKS AND VISES

 F -X C h a n ge F -X C h a n ge
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CLAMPING ODD SHAPES

MODIFIED VISE JAWS

EPOXY RESIN CAST

VISE JAWS
 F -X C h a n ge F -X C h a n ge
PD PD

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LOW MELT ALLOYS

LEAD, TIN AND

ANTIMONY ARE USED
TO CAST AROUND
SPECIAL SHAPES.
PART IS SUSPENDED IN
A SHELL AND LOW
MELT ALLOY IS POURED
AROUND IT.
 F -X C h a n ge F -X C h a n ge
PD PD

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 F -X C h a n ge F -X C h a n ge
PD PD

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 F -X C h a n ge F -X C h a n ge
PD PD

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TASK

Tooling-U Lessons Clamping Basics #131