Mansoura University

Department of Production &Mechanical Design

Engineering Dept.
Production Tools and Equipment Design

PRE 5412

4th year, first term

2021/2022

Modular fixture
Group (3):
Amira Mahmoud Eman Mansur
Ayman Mohamed Hatem Ashraf
Anwar Wagdi Hossam Shawky
Eman Mahmoud Hossam El Hossain

Supervisor: dr. Hazem [Link]

Dr. Mona AbouEleaz
Table of contents

1. Introduction.............................................................................................. 2
2. Definition of Modular Fixturing: ................................................................ 2
3. Type of fixture .......................................................................................... 3
4. Basic features of modular fixture ............................................................... 5
5. Design of modular fixture .......................................................................... 8
6. Applications ............................................................................................ 15
7. Advantage and limitations: ..................................................................... 16
8. References .............................................................................................. 17

Table of figure
Figure [Link] work holders [1] .................................................................................................................................. 2
Figure [Link] hierarchy of work holding options.[1] ........................................................................................................ 3
Figure 3..Typical components of a modular work holding system.[1] ............................................................................. 4
Figure [Link] of modular fixture elements.[2]................................................................................................... 5
Figure [Link] systems with grid holes T slots.[1] ...................................................................................................... 5
Figure [Link] of freedom (DOF).[5]........................................................................................................................... 6
Figure [Link] locating forms: a) plan, b) concentric, c) radial.[5] ................................................................................. 6
Figure [Link] machining forces.[5] ............................................................................................................................. 7
Figure [Link] Property Manager.[6] .............................................................................................................................. 9
Figure [Link] body diagram for a fixtured workpiece.[3] ............................................................................................ 14

1
 1. Introduction

The need for improved productivity and reduced time to market has been increased significantly
in manufacturing processes in recent decades. There are many factors that play a role in providing
manufacturing processes with more productivity. One is the use of modular fixtures (MFs). MFs have
brought many benefits to manufacturing industries including reduced costs and times of production.
An MF can be defined as a complete system that consist different elements for effectively and
securely holding the workpiece in place for performing various machining operations. Generally, an
MF is made by assembling several fixture elements in a feasible sequence that is properly determined.
In general, and based on flexibility, fixture elements (or work holding tools) are classified into
general purpose and special purpose work holders. Flexibility is of great importance in making use
of each type of fixture. Because of their flexibility, MFs have become an important factor in flexible
manufacturing systems (FMSs).[5]

2. Definition of Modular Fixturing:

Modular fixturing is a work holding system using a series of standardized components for
building specialized work holders. As shown in Fig.1, a modular work holder is assembled from a
variety of standard off-the-shelf tooling plates, supports, locating elements, clamps, and similar
components. The components are assembled with socket-head cap screws and locating screws. A
modular-fixturing system may have hundreds of different elements. The components can be
assembled in different combinations to build an unlimited variety of work holders.[1]
The assembly process is quite simple. Components are designed to be used together, so each
has an identical hole pattern. To build a work holder, the components are simply positioned as
required and attached with locating or fastening screws. The simplicity reduces training time and
permits technicians to begin building work holders almost immediately. Regardless of the
manufacturing operations, a modular-fixturing system can provide work holders for almost any
workpiece.[1]

Figure [Link] work holders [1]

2
 3. Type of fixture
To understand how modular fixtures relate to work holding in general, an awareness of the
various forms of work holders is necessary. Work holder forms can be grouped into three general
categories, Fig. 2. The least-complicated tools are the general-purpose work holders. The most-
complex and most-detailed work holders are the special-purpose, or permanent, fixtures. Between
the two are modular fixtures. Modular fixturing bridges the gap between the general-purpose and
special purpose work holders. Although the three forms of fixturing may seem completely different,
each is a further development, or refinement, in the work holding process.[1]

General-purpose:
This category includes a wide variety of standard clamps, vises, chucks, and similar standard
off-the-shelf components. General-purpose components are reusable and normally the least
expensive. Although these components represent a smaller initial investment, they are often
inadequate or unsatisfactory for complex parts or high- volume production.[1]

Figure [Link] hierarchy of work holding options.[1]

3
Permanent work holders:

They are specifically designed and constructed for a single workpiece or family of parts.
These work holders, though usually the most efficient, are also the most expensive. Permanent
work holders are built with a variety of standard and custom-made parts to meet specific
requirements. These fixtures are the best choice for high-volume or repeated production
runs.[1]

Modular work holders:

In the most-basic sense, can be described as special-purpose work holders assembled from
general-purpose components. Fig.3 shows a typical system of modular-fixturing components. The
concept of modular fixturing, rather than a departure from conventional fixturing methods, is a
combination of the best attributes of both special- and general-purpose work holding methods.
Modular fixtures are built with the accuracy and detail of special purpose work holders, but with
reusable and universal components, these fixtures compare favorably in cost to general-purpose
work holders.[1]

Figure 3..Typical components of a modular work holding system.[1]

4
 4. Basic features of modular fixture
Modular fixture systems classifications as shown in Fig. 4.

Figure [Link] of modular fixture elements.[2]

1. Baseplates

There are two primary forms of modular systems available today are as shown in Fig. 5:
a. Grid-pattern holes.
b. T-slots to mount components.

• Grid holes offer several advantages over T slots. The T slots are generally spaced further
apart and offer fewer mounting positions.

• The grid holes offer many more positional possibilities. Even though the T-slot system
permits movement along the slot, nothing but friction holds components in place.
Sudden jarring or excessive cutting force applied to components can cause
movement.[1]

Figure [Link] systems with grid holes T slots.[1]

5
2. Locators:
Locating is a crucial factor that should be considered to position and orientate the workpiece
in a way that completes the desired machining process thoroughly. To achieve the desired locating,
locators are used to restrict the degrees of freedom (DOF) of the workpiece as shown in Fig. 6.[5]

Figure [Link] of freedom (DOF).[5]

These locators should be strong enough against the cutting forces to keep the workpiece in
place. In general, three locating forms can be considered, as shown in the Fig. 7:

a. Plane locators:
For plane locating form, locators are used to
locate the workpiece on any surface such as
flat, circular, or irregular surfaces.
b. Concentric locators:
For concentric locating form, pin- hole
locators are used.
c. Radial locators:
For radial locating form, locators restrict the
workpiece movement around the concentric
locators.

Figure [Link] locating forms: a) plan, b) concentric, c)

radial.[5]

locating methods are divided into five main categories namely 3-2-1 principle, plane and
pinhole locating, long-pin locating, V-block, and V-pad locating and others. The 3-2-1
principle is the most commonly method used.[5]

6
3. Clamps:
As the locating is important to restrict the movement of the workpiece, clamping is also crucial
to clamp it against the locators and to resist the effects of cutting forces. The direction of clamps
should be determined according to cutting forces direction to perform machining operations
securely. As shown in Fig.8, clamping forces are in the same direction of the machining forces
which try to push the workpiece down onto the locators and supporters.[5]

Figure [Link] machining forces.[5]

Moreover, the size of the clamp should be considered in MFs design; the clamp should be
large enough to hold the workpiece; yet small enough to stay away of the cutting tool path. There
are some other factors that should also be considered in use of clamps. These include machine tool
vibration, loads and stresses, damage preventing of the workpiece, and improving loading/unloading
speed.[5]
For MFs, two major categories are defined for clamping method; these are:
a) Top clamping.
b) Side clamping.

7
 5. Design of modular fixture
Since the workpiece is subjected to the external cutting forces and torque, the three above
fixture elements must make sure that the workpiece is positively located, is rigid and assures
repeatability. Repeatability refers to the workpiece and subsequent workpieces can be located by the
fixture in precisely the same place.

Requirements of design modular fixtures:

The requirements for designing traditional fixtures also apply to the design of a flexible
fixturing system. These include positive location, rigidity, repeatability, minimum distortion of
workpieces, tolerance to small variations in workpiece geometry and reliability.[3]
1. Positive location: A fixture must hold the workpiece precisely in space to prevent each of
the spatial movements, i.e., linear movement in either direction along X, Y and Z axes and
rotational movement in either direction about each axis.

2. Repeatability: Identical workpieces should be located by the fixture in precisely the same
place on repeated loading and unloading cycles.

3. Rigidity: The fixture must ideally hold the workpiece rigidly fixed against all external force
fields.

4. Interference: The fixturing elements must ensure that the part is accessible to the cutting
tool and in addition, must provide for ease of loading and unloading.

CAMFD (Computer assisted modular fixture design) principles

1. Workpiece Holding Principles [5]

• Locating principle
• Clamping principle
• Fixture Elements Structure

2. The Methodology [5]

Step 1: Analyze workpiece information and machining features and define workpiece set-up.
Locating and clamping surfaces of the workpiece should also be defined.

Step 2: Define the locating method depending on the geometry and the shape of the workpiece.
• Use either 3-2-1 principle or plane-pin hole method for plane surfaces.
• Use long-pin method for a primary inner cylindrical surface.
• Use V-block method for primary external cylindrical surfaces.
• Use V-pad method for secondary external cylindrical surfaces.
8
 Step 3: Select the clamping method by considering the geometry and the shape of the workpiece
and the type of machining operations.

Step 4: Select the baseplate from the database depending on the type of the MF system, T-slot, or
dowel-hole. Then, define the locating and supporting points on the baseplate.

Step 5: Select all fixture elements for the locating and clamping purposes from the database
depending on the type of the baseplate determined in Step 4.

Step 6: In SolidWorks modelling environment orientate the workpiece as required considering the
baseplate and machining operations, and then assemble the locating and supporting elements on the
baseplate.

Step 7: Assemble the workpiece with locating and supporting fixture elements by applying
appropriate mating features of SolidWorks.

Step 8: Construct clamping units and assemble them on the baseplate to prevent workpiece movements. It
should be noted that there are three types of mate features in SolidWorks, namely standard mates,
advanced mates, and mechanical mates. These mate features provide different methods for restricting DOF
of the workpiece as required.
Mates
How are parts “put together”? Well, they fasten together, go
into each other, become flush with each other, are pressed into each
other, are allowed movement in specific directions, are made to touch in
a specific way. There are all kinds of ways in which we put parts
together, but how do we represent that in SolidWorks? The answer is
through geometric constraints called Mates.[6]
Parts within a SolidWorks assembly are constrained to one
another through mates which are very similar to geometric sketch
relations used in the sketch environment: coincident, concentric,
tangent, distance dimension, angular dimension, etc. The most
common mates in SolidWorks assemblies are coincident and
concentric due to how often things are made to be flush or aligned
with one another.[6]
To apply mates, activate the mate command from the
Assembly tab of the Command Manager, click on the features you
want to add a mate between, and then verify your mate type.
SolidWorks is usually great at knowing what kind of mate you want to
add based on what you select so it will usually already be selected as
shown in Fig.9.[6]

Figure [Link] Property Manager.[6]

9
1. Standard mates:
will be the ones you use most often and are shown by default when you activate the Mates
Command. They appear in the Property Manager under the heading “Standard Mates”.[6]

Coincident:
Positions selected planes, edges, and faces on the same infinite plane. If two
vertices are chosen, then will position them so that they touch.

Parallel:
Keeps selected items at a constant distance from each other.

Perpendicular:
Places selected items at a 90-degree angle from each other.

Tangent:
Places a cylindrical, spherical, or conical face tangent with another
component.

Concentric:
Places two cylindrical, spherical, or conical faces of a part so that they share
the same centerline.

Lock:
Keeps two components at the same position and orientation.

Distance:
Specify a distance between two components planes, faces, or edges.

Angle:
Place components at a desired angle from another component. Can select an
edge, face, or plane

Mate alignment:

Select the desired alignment for the components being mated. This will flip the
components so that the face, edge, or plane is aligned correctly with its mating
component.

10
2. Advanced mates:
Advanced mates allow you more control and more specified constraints for constraining
parts to other parts. The main ones here are Width and Limit mates. There is also symmetric,
linear coupler, profile center and path mates here. They work very similar to standard mates; they
are just more options and more selected entities to use them.[7]

Symmetric:
Make two similar entities be symmetric about a planar face or plane.

Width:
Centers a tab reference, a parallel planar face, a drafted face, or cylindrical
face, within the width of a groove.

Path Mate:
Constrains a single point or vertex to a component path. The user can
define the pitch, yaw and roll of the component.

Linear/Linear Coupler:
Establishes a relationship between the uniform movements of one
component to another.

Distance:
Add a limiting distance between components by giving it a maximum and
minimum distance between components faces, edges, or planes.

Angle:
Adds a limiting angle between component faces, edges, or planes by
specifying a minimum and maximum angle.

11
3. Mechanical mates
Mechanical mates are also available for more specific mechanical relationships between
parts such as screw/thread mate (a part turns as it is translated along another part), gear mate (as
one part turns at one speed, another part turns at a different speed), rack and pinion, cam, slot,
hinge, and universal joints.[7]

Cam:
A type of tangent or coincident mate. Asks the user to select all of the cam face
to which the follower will lie on and the face of the follower that will touch the
cam.

Hinge:
Constrain two components rotational degrees of freedom. Asks user to input two
concentric sections, coincident faces, and the angle limit (how far the
components can move from each other – identical to angle mate)

Gear:
Mates two gears or cylindrical faces so that the two components rotate
relative to one another about an axis.

Note: Select the inside bore hole of the gear or the axis, do not select the face
of the gear.

Rack Pinion:
Like the gear mate except that the revolution of one component corresponds to
the linear movement of the mating component. This mate does not require gear
teeth.

Screw:
Constrains two components with a concentric mate and defines a pitch
relationship between the rotation of one component and the translation of
another.
Universal Joint:
The rotation of a component about its axis is controlled by the rotation of the
mating component about its axis

12
Fixture analysis:
1. Workpiece orientation using 3-2-1 principle.
The fixture must position the workpiece in each of three planes to meet the positive location
criterion. This criterion involves defining the first plane to provide support at three points, which is
followed by assigning a second plane which is perpendicular to the first. This is accomplished by
orienting the part against any two points in the second plane. A third plane perpendicular to each of
the other two is then defined by designating one point in it. Positive location of a part is guaranteed
if it is in contact with three points in the first plane, two points in thesecond plane, and a single
point in the third plane.
In practice, the support points in each plane are selected to be as far apart as possible to
ensuremaximum stability. In addition, it may be necessary to provide redundant supports to
satisfy additional constraints imposed on vibration levels and deflections.[3]

2. Elastic deformation analysis (forces and moments).

Attention is now focused on determining the force field that the fixturing system must provide
to ensure static equilibrium of the part being fixtured. The external forces and torques imposed on
the part by the manufacturing operation, such as metal cutting for example, must be
mathematically modeled. These external disturbances, in addition to the clamping and friction
forces, can be expressed by a resultant load vector R and a resultant moment vector M about the
center of mass of the workpiece.[3]
A free-body diagram of a part supported in a fixture is shown in Fig.10. The first plane which
provides three support points is denoted as the xy plane, and the three reactions associated with the
three supports are denoted as P11, P12 and P13. The second plane is denoted as the yz plane. The
corresponding reactions in these planes are P21, P22 and P31 respectively. The conditions of static
equilibrium are:

where F, and M are the cartesian components of the resultant force and moment vectors. It
may be combined as a matrix as shown:

13
Where the components of the resultant load and moment vectors are known
quantities for each fixturing application. The reactions Pij are the unknown non-
negative quantities which must be determined to design the fixture. The solution
this matrix can be accomplished usingstandard numerical methods such as
Gaussian elimination. In order that a unique solution exists, it is necessary for
the determinant of the matrix to be nonsingular.[3]

Figure [Link] body diagram for a fixtured workpiece.[3]

14
 6. Applications

Modular work holders are particularly well suited for one-time jobs, infrequent
productions run, prototype parts, replacement parts, trial fixturing, and temporary
tooling.[1]
[Link]-Time Jobs:
One-time jobs, found especially in job shops, are ideal for modular fixturing. With modular
fixturing, a work holder can be economically built even for a one-part run. In most job
shops, each machine tool does a variety of tasks in a single day. With modular fixturing,
jobs can be performed with specialized work holders at a cost very competitive with crude
machine-table setups. Here, modular fixtures increase quality and accuracy, yet still
maintain competitive costs.
[Link] Parts:
Prototype or experimental parts frequently require special work holders. Since prototype
workpieces are often changed or redesigned, the cost of building jigs or fixtures for each
new variation is prohibitive. Modular fixturing is the best alternative. With modular work
holders, each variation of the workpiece can be quickly fixtured with little or no downtime.
[Link] Parts That Are Made to Order:
Replacement parts are an expensive problem in many companies. In the past, these parts
were made in large lots and placed in storage. Some parts were quickly sold while others
were never ordered. Modular fixturing eliminates the need for an inventory of slow-moving
replacement parts. Modular fixturing permits a company to respond to orders as they are
received. Instead of shipping parts from an inventory, parts can be made as needed.
[Link] Fixturing Techniques:
Trial fixturing is common throughout manufacturing organizations. Before any product
goes into production, work holders must be designed, built, and tested. Assembling a
modular work holder for workpiece allows the tool designed to test new tool designs and
find problem areas. Modular work holders allow a designer to fine tune tooling ideas before
a final production work holder is built.
[Link] Permanent Fixtures Are Built or Repaired:
No matter how well a permanent jig or fixture is built, most require repair or maintenance.
A modular work holder can easily be assembled and placed into production while the
permanent work holder is repaired. Modular fixtures also buy time for initial building of
permanent fixtures without delaying production.

15
 7. Advantage and limitations:

Advantages of modular fixtures:

1. Modular tooling components offer a wide range of features and components
that greatly reduce the costs of building special tooling. Despite its rather high
initial cost, modular toolingcan and does save money and time. [4]

2. Reduced lead time is the chief advantage of modular tooling systems. Savings
of 80 percent ormore over conventional tooling are common. Generally, each
hour of lead time required for a modular tool equals 6 hours of lead time for a
conventional jig or fixture. [4]

3. Reusability is another advantage of modular fixturing. Once a tool has been

built and used, it can be disassembled, and its elements used for other fixtures.
Although a tool may be stored rather than disassembled, the more common
method is to return the components to active use for other tools. Since building
time is minimal, the time required to rebuild fixture is often lessthan that
required to find the existing work holder. [4]

Limitation of modular fixtures:

Just as conventional machine tools are better suited for some tasks than
expensive CNC machines, the selection and application of work holders is
determined by the work to be [Link] work holders are not intended for
every job. Two limiting factors with modular work holders are the frequency of
production runs and the size of the work holder. [1]
1. Jobs That Will Repeat Many Times: Recurring production runs are those
that repeat on a regular basis. Modular work holders are usually
disassembled after each job. Each time a job isrun, the modular fixture
requires reassembly.
2. Where Fixture Compactness Is Important: Another factor to consider
in the selection of awork holder is the size of the completed fixture. As a
rule, modular work holders tend to be larger than their special-purpose
counterparts. So, when space is limited, such as with multiple-part setups,
modular work holders may prove to be too large.

16
 8. References

1. Co., C. L. (n.d.). JIG AND FIXTURE HANDBOOK. Carr Lane Manufacturing Co.
2. J R Dai, A. Y. (2016). An approach to automating modular fixture design.
Singapore: National University of Singapore.
3. M.V. Gandhi, B. T. (n.d.). Automated Design of Modular Fixtures for Flexible.
Journal of Manuficturing Systems.
4. Man, E. G. (2004). Jig and Fixture Design. Delmar, Cengage Learning.
5. Tolouei-Rad, U. F.-R. ( 2011, January). Design of modular fixtures using a 3D-
modelling approach.

6. (n.d.). Retrieved from [Link]

mates/
7. (n.d). Retrieved from
[Link]
pes%20of%[Link]

17