FIXTURES

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Definition
Introduction
Purpose/Advantages
Classification
Design considerations
Tooling cost
Tooling operation
Tooling details
Materials

1. DEFINITION
A fixture is a work-holding or support device used in
the manufacturing industry. What makes a fixture
unique is that each one is built to fit a particular part
or shape. The main purpose of a fixture is to locate
and in some cases hold a work piece during either a
machining operation or some other industrial process.
2. INTRODUCTION
A jig differs from a fixture in that it guides the
tool to its correct position in addition to locating and
supporting the work piece.
A fixture is a means through which a part is
securely fastened to the machine tool table to
accurately locate, support and hold the part during
the machining operation.
In addition to the function of holding the work
piece, the fixtures also provide for setting the cutting

2. INTRODUCTION
Fixtures are widely used in large batch production to
ensure the easy setup and achieving the desired
accuracy. It can be used in a variety of machine tools
such as Lathe, milling, grinding, etc. though the
milling fixtures are the most widely used in view of
the complex requirements for the milling operation.
3. PURPOSE/ADVANTAGES
The primary purposes of jigs and fixtures is to:
Reduce the cost of production
Maintain consistent quality
Maximize efficiency
Enable a variety of parts to be made to correct
specifications
Reduce operator errors

4. CLASSIFICATION
CLASSIFICATION OF FIXTURES
1.Based on standardisation
2. Based on process
3. Based on construction
4. Based on production application
CLASSIFICATION - STANDARDISATION
A. General Purpose
B. Special purpose
1. General Purpose
They are usually relatively inexpensive and can
be used to hold a variety and range of sizes of
work pieces (examples: Vises, chucks, split collets
Standard Fixtures).

A. General Purpose
In many instances, the shape of the part and the
machining to be performed allow for the use of a
general-purpose work holder such as a vise, collet,
or chuck. These work holders are adaptable to
different machines and many different parts. Since
they are not part-specific, their versatility allows for
repeated use on a variety of different or limitedproduction runs. The cost of these work holders
would usually be averaged over years and might
not even be a factor in job-cost calculations. The
general-purpose nature of these work holders
necessitates a higher level of operator care and
attention to maintain consistency and accuracy. For
these reasons, general-purpose work holders are
not preferred for lengthy production runs.

CLASSIFICATION - STANDARDISATION
B. Special Purpose
They are designed and built to hold a particular
work piece for a specific operation on a specific
machine or process. Fixtures vary in design from
relatively simple tools to expensive, complicated
devices. Fixtures also help to simplify metalworking
operations performed on special equipment.
Fixtures have a much-wider scope of application
than jigs. These work holders are designed for
applications where the cutting tools cannot be
guided as easily as a drill. A fixture can be used in
almost any operation that requires a precise
CLASSIFICATION
relationship
in the- PROCESS
position of a tool to a work piece.
Fixtures are classified either by the machine they
are used on, or by the process they perform on a
particular machine tool.

CLASSIFICATION - PROCESS
More-common classifications of fixtures used for
manufacturing:
EXTERNAL-MACHINING APPLICATIONS:
Flat-Surface Machining
Milling fixtures
Surface-grinding fixtures
Planing fixtures
Shaping fixtures
Cylindrical-Surface Machining
Lathe fixtures
Cylindrical-grinding fixtures
Irregular-Surface Machining
Band-sawing fixtures
External-broaching fixtures

CLASSIFICATION - PROCESS
Milling Fixtures:
A Milling fixture is a work holding device which is
firmly clamped to the table of the milling machine. It
holds the work piece in correct position as the table
movement carries it past the cutter or cutters.
Essentials of Milling Fixtures:
A. Base:
A heavy base is the most important element of a
milling fixture. It is a plate with a flat and smooth
under face. The complete fixture is built up from this
plate. Keys are provided on the under face of the
plate which are used for easy and accurate aligning of
the fixture on the milling machine table. By inserting
them into one the T slot in the table. These keys are
usually set in keyways on the under face of the plate

CLASSIFICATION - PROCESS
B. Setting Blocks:
After the fixture has been securely clamped to the
machine table , the work piece which is correctly
located in the fixture , has to be set in correct
relationship to the cutters. This is achieved by the
use of setting blocks and feeler gauges. The setting
blocks is fixed to the fixture. Feeler gauges are placed
between the cutter and reference planes on the
setting block so that the correct depth of the cut and
correct lateral setting is obtained. The block is made
of hardened steel and with the reference
planes(feeler surfaces) grooved. In it correct setting ,
the cutter should clear the feeler surfaces by at least
0.08cm to avoid any damage to the block when the
machine table is moved back to unload the fixture.
The thickness of the feeler gauge to be used should

CLASSIFICATION - PROCESS

CLASSIFICATION - PROCESS
Fixtures
Milling fixtures
Fixture components
Fixture design
considerations
Sequence in laying out a
fixture
Fixture components
Fixture base
Fixture components and
the work piece are
usually located on a
base, which is securely
fastened to the milling
machine table.

CLASSIFICATION - PROCESS

3: Locating and Clamping Elements:

The same design principles of location and clamping
apply for milling fixtures have been discussed above.
Some Design Principles for Milling Fixtures:
1: Pressure of cut should always be against the solid
part of the
fixture(fig a).
2: Clamps should always operate from the front of the
fixture (fig B)
3: The work piece should be supported as near the tool
thrust as
possible(fig c)

2: Lathe Fixtures(Turning fixtures)

The standard work holding devices or fixtures for lathe
are:
Three and four jaw chucks
Collets
Face plate
Mandrels
Milling vice
If the job can be held easily and quickly in the above
mentioned standard devices, then there is no need for
special work holding devices. However many jobs
particularly casting and forging, because of their
shapes, cannot be conveniently held by any of the
standard devices. It then becomes necessary to build
a special work holding device for the job. Such a
device is called lathe fixture.

A lathe fixture consists of a base , location and

clamping devices. A lathe fixture can be fixed to the
lathe either by holding in the chuck jaws or fixing to a
face plate.

Basic Design Principles for Turning or Lathe Fixtures:

1.To avoid vibration while revolving , the fixture
should be
accurately balanced.
2.There should be no projections of the fixture which
may cause
injury to the operator.
3.The fixture should be rigid and overhang should be
kept
minimum possible so that there is no bending
action.
4.Clamps used to fix the fixture to the lathe should
be designed
properly so that they dont get loosed by
centrifugal force.
5.The fixture should be as light weight as possible
since it is

3:Grinding Fixtures:
The work holding devices for grinding operations will
depend upon the type of the grinding operation and
the machine used.
(A): Fixture for External Grinding:
A mandrel is the most common fixture used for
grinding external surface of the work piece, a
mandrel is hardened and is held between centers of a
machine. The mandrel is used for internal chucking or
round work piece with bores. The work piece is
located and held on the mandrel with the help of the
bore so that the external surface may be machined
truly concentric to the bore. The various types of
mandrel are:

Taper Mandrel:
In this type of mandrel, the outer chucking surface is
given a slender taper of about 0.5mm per meter

Straight Mandrel:
It differs from the taper mandrel in that it has straight
or un tapered chucking surface.
Combination taper and straight:
In this type of mandrel , a portion of the outer
diameter of the mandrel is straight and the rest of the
is tapered.

B: Fixtures for Internal Grinding:

For grinding internal surfaces of simple circular work
piece, the chuck may be used as a standard work
holding device. It required special jaws can be
provided for the chuck. However , for many
components special fixtures may have to be made
which are designed on same lines, as the lathe
C: Fixtures for Surface Grinding:
fixtures.
The work piece can be held for machining on a
surface grinder in the following ways
It may be clamped directly to the machine table or
to an angle plate and so on
It may be held in a vice
The work piece may be held by means of a
magnetic chuck or a vacuum chuck. Here the work
piece is held without any mechanical clamping
The work piece may be held in a special fixture

CLASSIFICATION - PROCESS

CLASSIFICATION - PROCESS

3: Locating and Clamping Elements:

The same design principles of location and clamping
apply for milling fixtures have been discussed above

CLASSIFICATION - PROCESS
Clamps
Clamps counteract forces
from the feed of the
table and rotation of the
Setcutter.
blocks
Cutter set blocks are mounted
on the fixture to properly
position the milling cutter in
relation to the work piece.

CLASSIFICATION - PROCESS
INTERNAL-MACHINING APPLICATIONS:
Cylindrical- and Irregular-Hole Machining
Drill jigs
Boring jigs
Electrical-discharge-machining fixtures
Punching fixtures
Internal-broaching fixtures
NON-MACHINING APPLICATIONS:
Assembly
Welding fixtures
Mechanical-assembly fixtures
(Riveting, stapling, stitching, pinning, etc.)
Soldering fixtures

CLASSIFICATION - PROCESS
NON-MACHINING APPLICATIONS:
Inspection
Mechanical-inspection fixtures
Optical-inspection fixtures
Electronic-inspection fixtures
Finishing
Painting fixtures
Plating fixtures
Polishing fixtures
Lapping fixtures
Honing fixtures
Miscellaneous
Layout templates
Testing fixtures
Heat-treating fixtures

CLASSIFICATION
CONSTRUCTION
Fixtures also may be identified by their basic
construction features. For example, a lathe fixture
made to turn radii is classified as a lathe radius
turning fixture. But if this same fixture were a
simple plate with a variety of locators and clamps
mounted on a faceplate, it is also a plate fixture.
Like jigs fixtures are made in a variety of different
forms. While many fixtures use a combination of
different features, almost all can be divided into
five distinct groups. These include plate fixtures,
angle plate fixtures, vise jaw fixtures, indexing
fixtures, and multi part, or multi station

CLASSIFICATION
CONSTRUCTION

Plate fixtures, as their name implies, are constructed

from a plate with a variety of locators, supports, and
clamps (Figure 5-8). Plate fixtures are the most
common type of fixture. Their versatility makes them
adaptable for a wide range of different machine tools.
Plate fixtures may be made from any number of
different materials, depending on the application of the

CLASSIFICATION
CONSTRUCTION
The angle plate fixture (Figure 5-9) is a modified form
of plate fixture. Here rather than having a reference
surface parallel to the mounting surface, the angle
plate fixture has a reference surface perpendicular to
its mounting surface. This construction is very useful
for those machining operations which are performed
perpendicular to the primary reference surface of the
fixture.

CLASSIFICATION
Vise
jaw fixtures are basically modified vise jaw
CONSTRUCTION
inserts
which are machined to suit a particular work
piece. In use, these modified vise jaws are installed in
place of the Vise jaw fixtures are basically modified
vise jaw inserts standard, hardened jaws normally
furnished with milling machine vises. Vise jaw fixtures
are the least expensive type of fixture to produce,
and since there are so few parts involved, they
arealso the simplest to modify. Figure 5-1) shows
several examples of parts which could easily be
fixtured with this type of work holder.
Indexing fixture, like indexing jigs, are used to
reference work pieces which must have machine
details located at prescribed spacings.

CLASSIFICATION PRODUCTION
APPLICATION Permanent and
temporary work holders
PERMANENT AND TEMPORARY WORKHOLDERS
Jigs and fixtures are most often found where parts
are produced in large quantities, or produced to
complex specifications for a moderate quantity.
With the same design principles and logic, work
holding devices can be adapted for limitedproduction applications. The major difference
between permanent and temporary work holders is
the cost/benefit relationship between the work
holder and the process. Some applications require
jigs and fixtures solely for speed; others require less
speed and higher precision. The requirements of the
application have a direct impact on the type of jig or
fixture built and, consequently, the cost.

CLASSIFICATION PRODUCTION APPLICATION

PERMANENT JIGS AND FIXTURES
Work holders for high-volume production are usually
permanent tools. These permanent jigs and fixtures
are most often intended for a single operation on one
particular part. The increased complexity of
permanent work holders yields benefits in improved
productivity and reduced operator decision-making,
which result in the tool having a lower average cost
per unit or per run. Therefore, more time and money
can be justified for these work holders.
In the case of hydraulic or pneumatic fixtures,
inherent design advantages can dramatically improve
productivity and, hence, reduce per-unit costs even
further, even though the initial cost to construct these
fixtures is the most expensive of all fixture
alternatives. In some cases, where machine-loading

CLASSIFICATION PRODUCTION APPLICATION

Permanent jigs and fixtures are typically constructed
from standard tooling components and custom-made
parts. Figure 1-3 shows a typical permanent work
holder for a drilling operation.

Figure 1-3.
A permanent
work holder
used for a
drilling
operation.

5. DESIGN CONSIDERATIONS
Fixtures vary in design from relatively simple tools to
expensive, complicated devices. Fixtures also help to
simplify metalworking operations performed on special
equipment.
Fixtures have a much-wider scope of application than
jigs. These work holders are designed for applications
where the cutting tools cannot be guided as easily as
a drill. With fixtures, an edge finder, center finder, or
gage blocks position the cutter.
The principal considerations when choosing among
work holder varieties fall into three general categories:
tooling cost, tooling details, and tooling operation.
Although each of these categories is separated here,
in practice they are interdependent. The following are
some design differences and considerations for
permanent, general-purpose, and modular work

5. DESIGN CONSIDERATIONS
Work holders are sometimes designed to serve
multiple functions. For example, it is possible to have
a work holder that acts both as a drill jig and a milling
fixture. These tools are called combination tools or
multiple-function work holders. Figure 1-6 shows a
typical temporary work holder for drilling and milling
operations on the same part. In this example, since
the work holder has provisions for both milling and
drilling, it is classified as both a drill jig and milling
fixture.

Figure 1-6. A
combination drill
jig/milling fixture
used for both types
of operations on the

5. DESIGN CONSIDERATIONS
With temporary work holders, the design drawings are
often sent to the tool room as simple freehand
sketches. Permanent tools are normally designed for
long-term use. This being the case, the drawings and
engineering data for the permanent jig or fixture then
become a permanent record. With modular work
holders, the designer may either construct drawings or
specify building the work holder directly around the
part. Here only a parts list and photographs or video
tape are kept as a permanent record. Certain work
holding
applications
require
special
fixture
characteristics. For example, a particularly corrosive
environment may require stainless steel components
and clamps to deliver a satisfactory life cycle. In other
cases, variable work piece dimensions, as in a casting,
necessitate clamping devices which can compensate
for these variations. Appearance of a finished part

5. DESIGN CONSIDERATIONS
They also typically reduce machine setup time,
machine cycle time, and the level of operator skill
required to produce satisfactory quality output. Over a
long production run, or a series of runs in the life of a
tool, the average cost of the tool per piece produced
can be quite low.
6. TOOLING COSTS
General-purpose work holders are more expensive
than temporary tools in most cases, but their utility
and flexibility often allow these work holders to be
regarded as a capital cost to be amortized over a
period of time without regard to actual usage.
Similarly, modular fixturing is typically a capital
investment to be amortized over a set lifespan, with
an average cost assigned to usage for each
anticipated job. Another cost to be considered is work

6. TOOLING COSTS
General-purpose tools are reused extensively, but still
incur some costs for maintenance and storage.
Similarly, modular fixtures will be disassembled, and
the components maintained, stored, and reused
frequently.
The total cost of any jig or fixture is frequently the
major area of consideration in many work holder
designs. Although initial cost is a major element, it
should not be the basis for accepting or rejecting any
tooling option. A more-proper economic evaluation of
the work holder design takes into consideration many
other factors. Permanent fixtures have distinct
advantages in the production of high-volume and
high-precision parts.

7. TOOLING DETAILS
Tooling details are the overall construction
characteristics and special features incorporated
into the jig or fixture. Permanent work holders are
designed and built to last longer than temporary
work holders. So, permanent jigs and fixtures
usually contain more-elaborate parts and features
than temporary work holders.
Other
differences
between
permanent
and
temporary work holders include the type and
complexity of the individual tooling elements, the
extent of secondary machining and finishing
operations on the tool, the tool-design process, and
the amount of detail in the work holder drawings.
Since the elements for modular work holders are
usually part of a complete set, or system, only

7. TOOLING DETAILS
Permanent work holders contain different commercial
tooling components based on expected tool usage.
Permanent jigs intended for a high-volume drilling
operation, for example, often use a renewable
bushing and liner bushing together. A throwaway jig
for a smaller production run often uses a simple
press-fit bushing. The secondary operations normally
associated with tooling include hardening, grinding,
and similar operations to finish the work holder.
Usually, permanent work holders are hardened and
ground to assure their accuracy over a long
production run. Since they are intended only for short
production runs, throwaway jigs and fixtures do not
require
these
operations.
Another
secondary
operation frequently performed on permanent tools,
but not temporary tools, is applying a protective
finish, such as black oxide, chrome plating, or enamel

7. TOOLING DETAILS
For example, utilizing small hydraulic clamps may
allow loading many parts on a work holder due to the
compactness of the design. This would enhance
productivity by reducing load/unload time as a
percentage of total cycle time. Duplicate fixtures are
sometimes justified for machining centers because
they allow loading of parts on one pallet during the
machining cycle on the other pallet.
8. TOOLING OPERATION
The performance of any work holder is critical to the
complete usefulness of the tool. If the work holder
cannot perform the functions desired in the manner
intended, it is completely useless, regardless of the
cost or the extent of the detail. As the performance
of a permanent, modular, or general-purpose work
holder is considered, several factors about the
machine tools must be known. These factors include

tool with the benefits of permanent tooling (setup

reduction, durability, productivity improvements, and
reduced operator decision-making) can be built from a
set of standard components. The fixture can be
disassembled when the run is complete, to allow the
reuse of the components in a different fixture. At a
later time the original can be readily reconstructed
from drawings, instructions, and photographic
records. This reuse enables the construction of a
complex, high-precision tool without requiring the
corresponding dedication of the fixture components.
Figure 1-5 shows how modular fixturing fits into the
hierarchy of work holding options, ranking below
permanent fixturing yet above general-purpose work
holders. Virtually every manufacturer has good
applications for each of these three options at one
time or another.

Figure 1-5. The hierarchy of work holding

options.

MODULAR FIXTURES
Modular fixtures achieve many of the advantages of a
permanent tool using only a temporary setup.
Depicted in Figure 1-4, these work holders combine
Figure 1-4.
ideas and elements of permanent and general-purpose
Modular work
work holding.
holders combine
ideas and
elements of both
permanent and
temporary work
holding to make
inexpensive-yetdurable work
holders.

Other machine considerations may come into play as

well. On numerically controlled machines, for example,
care must be taken in fixture design to position clamps
out of the cutting tool's path. Pallet machines require
different fixtures than other machines. Obviously,
vertical mills would be tooled differently than
horizontal mills. Likewise, the way parts are loaded
onto the fixture has implications for fixture design.
Despite the work holder design or the size of the
production run, every jig or fixture must meet certain
criteria to be useful. These criteria include accuracy,
durability, and safety. Accuracy, with regard to jigs and
fixtures, is the ability of a work holder to produce the
desired result, within the required limits and
specifications, part after part, throughout the
production run.
To perform to this minimum level of accuracy, the
work holder must also be durable. So, the jig or fixture
must be designed and built to maintain the required

If part production is continuous, year after year, the jig

or fixture must be more durable than is necessary for
only one production run. The final consideration,
safety, is actually the most important. No matter how
good the design or construction, or how well it
produces the desired accuracy, if the work holder is
not safe, it is useless. Safety is a primary concern in
the design of any work holder.
Safety, as well as speed and reliability of part loading,
can often be improved by the use of power clamping,
either pneumatic or hydraulic. Once set, power clamps
will repeatedly clamp with the identical force. This is
not always true with manual clamps, which depend on
operator diligence for the proper application of
clamping force. In addition, power-clamping systems
can have interlocks to the machine control which will

Pneumatically operated
machining

Fixture for gauge components