SolidMasters is here to provide your company with comprehensive solutions for assembling any type of components. Our extensive knowledge of tool design, solid modeling, design analysis and manufacturing processes will give you an edge over the competition.
Design, Plan, Create, and build a cost-effective and time-saving process with SolidMasters as your Jig and Fixture Design Partner.
Some companies have multiple product lines with very similar but different parts that could be welded together. In these types of assemblies, it is economical and efficient to have fixtures that can accommodate various parts. Having a quick change over process reduces time spent in moving from workstation to workstation, and reduces cost in fabricating multiple fixtures for different parts.
It is possible to design a fixture to hold multiple parts that are to be welded. However simple or complex the assembly, we can design the right fixture to allow the best welding position.
Design considerations in making fixtures include specifying whether it will be automated or manual. We have the capabilities to design your fixtures to adapt to new or existing mechanized workflow, or for a manual setup.
Jig design and detail standards are essential tools for any company producing welded assemblies. In addition to having a Jig design inspector to provide guidelines for development, these standards offer the use of quality control.
3D models are invaluable tools in creating the overall assembly for jigs. The exact geometry, positioning, and orientation of joined components are essential in creating the jig. If your company does not have the models, SolidMasters can create them for you. Critical dimensions are also important in designing jigs and fixtures, since variations in features (diameters, for example) are controlled by the tolerances. Certain metals expand and contract during welding and quenching. Proper placement of shims to restrict movement within those tolerances must be planned and executed carefully.
Having the right vendors can result in cost savings and top-notch service for your company’s jig and fixture fabrication. If you have a list of preferred vendors, we will work in a cooperative way to match your vendor’s capabilities. In addition, we can assist your company in sourcing manufacturers and fabricators. SolidMasters has an extensive list of vendors who can provide outstanding work, and give you the option for obtaining competitive prices.
It is a work holding device that holds, supports and locates the work piece and guides the cutting tool for a specific operation. Jigs are usually fitted with hardened steel bushings for guiding or other cutting tools. A jig is a type of tool used to control the location and or motion of another tool. A jig's primary purpose is to provide repeatability, accuracy, and interchangeability in the manufacturing of products.
A device that does both functions (holding the work and guiding a tool) is called a jig, a special class of fixture which in addition to providing all the functions above, also guides the cutting tool during machining. Used for drilling, boring, reaming, tapping, counter boring, etc.
A welding jig is used to weld objects into the desired shape so that each product can be made the same dimensions and shape as others of the same design. This type of welding accessory can be quite simple and manually operated or very complex and fully powered. The jig design is driven by the exact size and shape of material being welded and the desired shape.
Jigs for welding are used by welders in all locations. A good fixture can make all the difference in the weld produced and product accuracy. You may need a jig with positions so that welds can be brought to a position that provides easy access to the area being joined. Ideally, you want to choose a fixture that is easy and fast to position and insert the material for welding. It should allow you to align the material and eject the final assembly with relative ease.
Types of Jigs
Drill jigs: 1) Open 2) Closed or Box jig Template jigs- no clamps Plate jigs- built in clamps if raised is called Table jig Sandwich jigs- Plate jig with back plate: for thin and soft parts Angle plate jigs-at right angles also modified angle plate for other angles
Box jigs: Channel jigs: work held between two sides and clamped by a screw clamp Leaf jigs-small box jigs Indexing jigs-rotary jigs using plunger and reference plate for indexing Trunion jigs- a rotary jig for very large or odd shaped parts Pump jigs clamping by pumping action Multi-station jigs-on multi-spindle m/c doing different operations at same time.
It is a work holding device that holds supports and locates the work piece for a specific operation but does not guide the cutting tool. It provides only a reference surface or a device. 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. A jig differs from a fixture in that guides the tool to its correct position in addition to locating and supporting the work piece. 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.
Types of fixtures
Plate fixtures Angle fixtures Vise jaw fix.- for small parts Indexing fix Multi station fix Profiling fixtures- to guide tools for machining contours that m/c normally cannot follow. Assembly fixtures Welding fixture Inspection fixture Modular fixturing
A jig used for welding is normally a fixed-position tool; a fixture is a tool made to rotate around either a horizontal or vertical axis. Three basic types of jigs and fixtures are:
1) Tacking jigs and fixtures: are used to hold the parts of an assembly in their proper position so as to tack weld them together. They prevent warping or distortion of assemblies when welding is complete.
2) Welding jigs and fixtures: are used to hold the parts of an assembly in their proper position for complete welding. They are normally built heavier than tacking tools to resist the added forces caused by the heat within the part.
3) Holding jigs and fixtures: are used to finish tack-welded assemblies. They must be made rigid enough to prevent warping and distortion.
Basic Tool design considerations
Heat dissipation is controlled by either using cutaway portions to prevent rapid heat loss (for good heat conductors) or installing an insert to absorb excess heat (for poor heat conductors).
Clamping supports must be provided to prevent distorting the work in a heated condition. Locators should be positioned so that the distortion will cause the part to loosen rather than tighten against the locators. Otherwise install power or manual ejectors into the tool.
Fool proofing is very necessary so that the part/assembly will only fit into its proper position.
Objectives in Design
General objectives of tool design for welding are: proper position of parts, repeatability and accuracy, proper heat control, fool proofing, easy access to all welding areas, rigid locating and clamping, welding in a flat horizontal plane, and mechanical devices for heavy tools.
The main requirement of an inspection fixture is accuracy. Two general types of inspection fixtures are:
1) Gauging Fixtures: check the part against a known preset standard size and only tells if a part is in or out of tolerance. Mostly they are used in shop for quick check on the machine.
2) Measuring Fixtures: actually measure a part and can indicate exactly where and how much a part is out of tolerance. They are often too fragile for shop use and must remain in the inspection room.
Flush-pin. Fixed-limit. Template gauges.
1) Flush-pin: gauges are used mostly as depth indicators.
2) Fixed-limit: gauges are used to check the upper and lower limits of size. Common go-no-go gauges are: snap, ring, and plug gauges.
3) Template: gauges are mainly used to check contour forms like radii, angles, or threads. They compare a surface against a master of the exact shape and can easily detect any variation.
MODULAR WORK HOLDING
Modular fixturing is a work holding system that uses a series of reusable standard components to build a wide variety of special-purpose work holding devices.
Three types are:
1) Sub plate system: uses flat grid plates, angle plates, or multisided tooling block and similar components as major structural elements.
2) "T"-slot system: uses components with a variety of precisely machined "T"-slots to mount and align each element.
3) Dowel-pin system: is available with either alternating tapped holes and dowel-pin holes or a combination of the two.
Construction: methods of modular work holder are: Building the work holder around the part. Building the work holder around a mockup or model of the part. Building the work holder to specific dimensions without the part.
Advantages of modular work holder are:
Reduced lead-time in building work holders. Reusability of the various components Versatility of the modular construction.