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DFM Lecture Notes

This document discusses principles of clamping and work holding. It covers basic clamping functions and rules, types of clamps including strap, screw, swing and wedge clamps. It also discusses positioning clamps, tool and clamping forces. Non-mechanical clamping methods like magnetic and vacuum clamping are described. Multiple clamping devices are also addressed.

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Shreya Uppu
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34 views20 pages

DFM Lecture Notes

This document discusses principles of clamping and work holding. It covers basic clamping functions and rules, types of clamps including strap, screw, swing and wedge clamps. It also discusses positioning clamps, tool and clamping forces. Non-mechanical clamping methods like magnetic and vacuum clamping are described. Multiple clamping devices are also addressed.

Uploaded by

Shreya Uppu
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Clamping and Work Holding Principles

1
Basic principles and functionality of clamping
The basic function of a clamp is to hold a part against the
locators during the machining operation.
The clamp must be strong enough to hold the part and to
resist the movement.
The clamp must not damage or deform the part.
The clamp must be fast-acting and allow rapid loading and
unloading of parts.
Clamps are also positioned so they do not interfere with the
tool or machine tool.
To be effective and efficient, the clamps must be planned
into the tool design (important element in tool design).
2
Basic Rules of Clamping
Positioning the clamps, Tool forces and Clamping forces

Positioning the clamps:


 Clamp must be in contact with the work at its most rigid
point to prevent bending or damaging the part.
 The part must be supported if the work is clamped at a
point where the force could bend the part.

Fig. Wrong fixture design Fig. Acceptable fixture design


3
Basic Rules of Clamping
Tool Forces:
 Tool forces generated by the cutting action. A properly
designed tool can use the cutting forces to its own advantage.
 To clamp a part correctly, the tool designer must know how
tool forces, or cutting forces act in reference to the tool.

Fig. Using cutting force to hold a part


4
Basic Rules of Clamping
Clamping Forces:
 Clamping force is to hold the part against the locators.
 Clamping prevents the part from shifting or being pulled from
the jig or fixture during the machining operation.
 The type and amount of clamping force needed to hold a part
is usually determined by the tool forces.

Clamping force calculations: Click Here


5
*Locators not shown

Fig. Wrong clamping configuration Fig. Acceptable clamping configuration


6
TYPES OF CLAMPS
The type of clamp the tool designer chooses is determined by
(i) shape and size of the part, (ii) type of jig or fixture being
used, and (iii) work to be done.
Strap Clamps:
 Strap clamps are the simplest clamps used for jigs and
fixtures. Their basic operation is the same as that of a lever.
 Strap clamps can be grouped into three Classes.

7
 Most strap clamps use the third-class lever arrangement. When
these strap clamps are used, the spacing of the three elements
is also important.
 The distance between the fastener (effort) and the workpiece
should always be less than that between the fastener and the
heel pin (fulcrum). 8
Types of Strap Clamps:
 Common types are the hinge clamp, the sliding clamp, and
the latch clamp.

 The fulcrum is positioned so that the clamp bar is parallel to


the base of the tool at all times.

9
Strap Clamp Elements:

The fulcrum is positioned so that the


clamp bar is parallel to the base.

To make up the differences, spherical


washers/nuts are used to reduce
stresses in the threaded members. Spherical Nuts and Washers

Strap clamps operated by either manual


devices or power-driven devices.

Manual devices include hexagonal nuts,


hand knobs, and cams.
Power Clamping System
Power devices include hydraulic systems
and pneumatic systems. Mechanical Holding Devices
10
Screw Size and Holding Force:

 Although standard high-strength fastening devices


may be used for many workholding tasks, the
commercially available jig and fixture studs, bolts,
nuts, washers, and other hardware should be used
whenever possible.

 At no time should the long threaded rods available


from a hardware store be used for workholding.
These rods do not have sufficient strength to be used
for jig and fixture applications.

11
Other Types of Clamps:
 Screw clamps offer the tool designer almost unlimited application
potential and lower costs, limited by slow operating speeds.
 Screw clamp uses the torque developed by a screw to hold a part
in place—either by direct pressure or by action on another clamp.
 Swing clamps combine the screw clamp with a swinging arm that
pivots on its mounting stud for quick loading.

Fig. Screw Clamp Fig. Swing Clamp


12
Hook Clamps:
 Similar to swing clamps but much smaller. Useful in close
places or where several small clamps must be used.
 Modified hook clamp is made to be operated from the
opposite side of the tool. Useful where a safety hazard exists.
Quick-Acting Knobs:
Quick-acting knobs are useful for increasing the output of low-
cost tools. These knobs are made so that when pressure is
released, they can be tilted and slid off a stud.

Fig. Hook clamps Fig. Quick-acting knob 13


Cam-action Clamps
 Cam-action clamps, when properly selected and used, provide
a fast, efficient, and simple way to hold work. Direct clamping
is less effective and can loosen up in case of vibrations.

 Commercial cam clamp assemblies use cam action rather than


screw threads to bind strap clamps. This indirect clamping has
all the advantages of cam action.

14
Wedge Clamps
 Wedge clamps apply the basic principle of the inclined plane
to hold work in a manner similar to a cam.
 These clamps are normally found in two general forms, flat
wedges and conical wedges.
 Wedges having a slight angle, from 1 to 4 degrees, normally
hold the work without additional attachments. This type of
wedge is considered to be self-holding.

15
Power Clamping Systems
 Normally operate under hydraulic power or pneumatic power, or
with an air-to-hydraulic booster.
 The air-to-hydraulic system is preferred as it can operated from
the regular shop line pressure and no extra pumps are needed.
 Advantages: better control of clamping pressures, less wear on
moving parts of the clamp, and faster operating cycles.
 Disadvantage is cost, however it can be easily compensated by
increased production speeds and higher efficiency.

16
NON-MECHANICAL CLAMPING
Workholding devices used to hold parts by means of other than
direct mechanical mechanisms.

Mainly where the clamping forces must be applied evenly across


the entire part to minimize any possible workpiece distortion.

(i) Magnetic clamping & (ii)Vacuum clamping

 Magnetic chucks are most often used to


hold ferrous metals or workpieces made
from other magnetic materials.

 However, there are also some magnetic


chuck setups that can be used for
holding nonmagnetic workpieces.
17
 Vacuum chucks are another style of chuck used for nonmagnetic
materials or when parts that must be clamped uniformly.
 Vacuum chucks, like magnetic chucks, equalize the clamping pressure
over the entire clamping surface.
 In operation the holding forces are generated by a vacuum pump that
draws out the air between the chuck face and the workpiece.

 It increases the process reliability when clamping large, flat metal-


workpieces with smooth bottom surfaces on CNC machining centers.

18
Vacuum Clamping Technology: Link

Clamping with vacuum technology is


efficient and universal. Vacuum clamping
guarantees very short set-up times.

Even components which are difficult to


clamp mechanically can be easily and
quickly clamped without any distortion.
19
Multiple Clamping Devices
Many times production operations call for making more than one
part at a time. The tool designer must know how to design
clamps that are capable of holding several parts.
Using the basic ideas and rules for single-part clamping, the tool
designer can easily design clamps to hold any number of parts.

The main points to remember in


multiple clamping are that the
clamping pressure must be equal
on all parts and that the clamp
must have only one operating, or
locking, point.

Next Topic: 06 Design of Jigs & Fixtures


20

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