biw fixture

2. Definitions
• Jig: A device that holds
the work and locates the
path of the tool.
• Fixture: A device fixed to
the worktable of a
machine and locates the
work in an exact position
relative to the cutting
tool.
Superior Jig
Flexible Fixturing Systems

3. Fixtures
• More of a permanent tool that is used for assembly purposes.
• Typically does not have as much flexibility as a jig.
• Most likely used for high volume production.
• Made of durable materials such as tool steel, iron, aluminum alloys,
etc.

4. Other Fixture Examples
• Used most commonly for welding
and metal assembly work.
• Typically used for products that
must be very precise.
• Sometimes are exposed to high
temperatures and stresses

5. Type of Fixtures
(a) Turning fixtures
(b) Milling fixtures
(c) Fixture for grinding
(d) Fixture for broaching
(e) Fixture for boring/drilling
(f) Tapping fixture
(g) Fixture for welding
(h) Assembling fixture
Standard Parts Co.

6. Fixture components
• Fixture base
• Fixture components and the workpiece are usually
located on a base, which is securely fastened to the
milling machine table.
Standard Parts Co.

7. Fixture components
• Clamps
• Clamps counteract forces from the feed of the table and
rotation of the cutter.
American Drill Bushing Co.

8. Fixture components
• Set blocks
• Cutter set blocks are mounted on the fixture to
properly position the milling cutter in relation to the
workpiece.

10. • Detailed design of locators
• Detailed design of clamps
• Detailed design of supports
• Positions of locators
• Positions of clamps
• Positions of supports, if any
• Type of locators
• Type of clamps
• Type of supports
• Clamping forces and sequence
The following outputs are included in the
fixture element design:

11. Fixture Design Criteria
• Design specifications
• Factory standards
• Ease of use and safety
• Economy

12. Body In White (BIW)
Fixtures
Example :
Fixture For Welding

13. Various Aspects Of Fixture Design

14. BIW – Weld Fixtures
 Design Process/Methodology .
 Different Types of Welding Fixture Units.
 Design Inputs.
 Design Outputs.

15. Design Input
 Functional and Performance Requirements.
 Car Product.
 System Layout.
 Tool Information Sheet.
 Weld Study Information.
 Miscellaneous Information.

16. Design Input
1. Functional and Performance Requirements
 Product Assembly Process Sheet
(Product Assembly Process Sheet is a sheet that gives
the following information about the Car Product)
 Parts Assembly Sequence.
 Sequence Of Operation.
 Cycle Time.
2. System Layout
The following Points are to be
considered while studying a
System Layout .
 Flow Of Parts.
 Station Pitch.

17. 3. Car Product
The following Points are to be considered
for the Car Product .
 GD&T Sheet.
 Part List.
 CAD Files of the car part.
Design Input
4. Tool Information Sheet
The Tool Information Sheet
consists of the following.
 Tool Summary.
 Tool Content Sheet .

18. 5. Weld Study Information
The Weld Study Information
consists of the following.
 Welding Spots.
 Welding Guns.
Design Input
6. Miscellaneous Information
 Customer preferences. Standard parts to
be used.
 Informations derived from previous
Designs and Development .
 Title Sheet Informations to be filled.

19. STAGE 1
 Study the System Layout thoroughly.
 Reviewing Customer Input Data.
 Determine the No. of Tools required.
 Study the GD &T Sheet.
 Study the PLP position.
 Rough concept of tool.
Design Methodology
STAGE 2
 Retrieve Car Part.
 Create Keysheet ( Final Tool / Station with all the Units ).
 Determine the Base Height from the Car part surface.
 Check for interference with adjacent units or Tools.
 Cut final sections and offset metal thickness .

20. STAGE 3
 Retrieve Customer approved
Standard sheets.
 Detail the unit according to the
customer specification.
 Fill out Title Block Information .
 Create BOM .
 Create LAYOUT .
 Create all necessary Views .
 Fully Dimension all the Details .
Design Methodology
STAGE 4
 Review information ,Customer
input data and Key sheet.
 Complete check.
 Updating the errors.
 Back Check.
 Plot job for Check.

21. Design Output
3D Model & 2D Drawings
 Non Unitized Tools.
 Unitized Tools require 2 types of drawing sheets.
1. Key sheets.
2. Layout Sheets.
3. Part Detailing's.
 Tool Level detailing i.e. Key Sheet Layout
 Unit Level Detailing i.e. Layout & BOM
 Part Level Detailing

22. Type of Welding Fixtures Units
1) CLAMP UNIT.
2) PIN UNIT.
3) REST UNIT.
4) COMBINATION OF CLAMP & REST UNIT.
5) DUMP UNIT.

23. Typical Clamp Unit
CYLINDICATOR
SUB-PLATE
RISER
FLOW CONTROL
CYLINDER
L-BLOCK
NC-BLOCK
CLAMP ARM
BLADE

24. A COMBINED LOCATING, CLAMPING AND RESTING UNIT
RISER BRACKET
PIN
PROXIMITY SWITCH

25. A Typical Welding fixture-after assembly

26. A Typical Welding fixture-in shop floor
Locating Pin Unit
Clamping Unit
Weld Gun
Robot
Welding
Electrodes
Car Part

28. Thanks

29. Design Example :

30. Key Sheet Layout:

31. Key Sheet Layout:

32. Key Sheet Layout:

33. Unit Level Layout:

34. Unit Level Layout:

35. Unit Level Layout:

36. Make Part Detailing:

37. Make Part Detailing:

38. Unit BOM (Commercial):

39. Unit BOM (Make Parts):

40. Thanks