German MAEDLER workpiece fixtures MAEDLER model MAEDLER price

MAEDLER workpiece fixtures are devices used in the manufacturing process to secure the workpiece in the correct position for machining or inspection, also known as jigs. In a broad sense, any device used to quickly, conveniently, and safely install workpieces during any stage of the process can be called a fixture. Fixtures typically consist of locating elements (to determine the correct position of the workpiece within the fixture), clamping devices, tool-setting guide elements (to determine the relative position of the tool and workpiece or guide the tool direction), indexing devices (to allow the workpiece to undergo machining at several stations in a single setup, including rotary indexing devices and linear indexing devices), connecting elements, and fixture bodies (fixture bases). Examples include welding fixtures, inspection fixtures, assembly fixtures, and machine tool fixtures, among which machine tool fixtures are the most common and are often simply referred to as fixtures. When machining workpieces on machine tools, to ensure that the surface of the workpiece meets the technical requirements specified in the drawings, such as dimensions, geometric shapes, and mutual positional accuracy with other surfaces, the workpiece must be properly located (positioned) and securely clamped (clamped) before machining.

MAEDLER workpiece fixture structure

The cross-sectional shape and distribution of the magnetic poles vary depending on the workpiece. Common structures of electromagnetic chucks include rectangular and circular types. Rectangular magnetic poles are arranged either longitudinally or transversely. Longitudinal arrangement of rectangular magnetic poles is suitable for securing larger workpieces; transverse arrangement is suitable for securing smaller workpieces. Circular chucks are suitable for securing ring-shaped workpieces or workpieces with complex shapes. The main characteristics of standard electromagnetic chucks are: magnetic flux lines are evenly distributed across the surface of the chuck, magnetic attraction cannot be concentrated, and the magnetic force per unit area is relatively small; the direction of the magnetic force is perpendicular to the chuck surface and difficult to change, producing only one type of magnetic force for workpieces with the same contact area; the point of application of the magnetic force is limited to the contact surface between the workpiece and the chuck and cannot be arbitrarily changed. Therefore, disadvantages during machining include low positioning accuracy, insufficient clamping force, narrow scope of application, and low production efficiency.

MAEDLER workpiece fixture features

Workpieces from small-batch, high-variety production account for approximately 85% of the total number of workpiece types. Modern production requires companies to frequently update their product varieties to adapt to market demands and competition. However, most companies are still accustomed to extensively using traditional dedicated fixtures. In factories with medium production capacity, there are typically thousands to nearly ten thousand sets of dedicated fixtures. On the other hand, in companies with high-variety production, approximately 50~80% of dedicated fixtures need to be updated every 3~4 years, while the actual wear of these fixtures is only about 10~20%. To meet the application of new machining technologies such as CNC machine tools, machining centers, group technology, and Flexible Manufacturing Systems (FMS), machine tool fixtures have the following characteristics: 1) They can quickly and conveniently equip new products for production, shortening the production preparation cycle and reducing production costs; 2) They can clamp a group of workpieces with similar characteristics; 3) They can be used as high-precision machine tool fixtures suitable for precision machining; 4) They can be used as new types of machine tool fixtures suitable for various modern manufacturing technologies; 5) They adopt efficient clamping devices powered by hydraulic stations and other power sources to further reduce labor intensity and improve labor productivity; 6) They increase the standardization level of machine tool fixtures. This is mainly reflected in four aspects: standardization, precision, efficiency, and flexibility.

MAEDLER workpiece fixture selection

When selecting pneumatic grippers and jaw designs, these are the main factors to consider: 1) Part shape, orientation, and dimensional differences: If the object has two opposing flat surfaces, a parallel two-jaw gripper can be used to address dimensional deviations. For cylindrical objects, a two-jaw gripper can also be used for clamping. Note that retaining or encompassing clamping requires less force. 2) Part weight: The clamping force must be sufficient to hold the object securely during the required operations. The type of jaw design must be considered when calculating the required clamping force. Please note that safety factors should be considered when selecting the required force, and air pressure is also a factor to consider. 3) Accessibility: This relates both to the operation being performed and the spatial size of the gripper jaws. If external operations are to be performed on the object, internal clamping is required. Scissor-type grippers are usually cheaper but require more space for jaw movement. 4) Environment: Grippers used in harsh environments or cleanrooms require corresponding designs. 5) Object retention: When air pressure is no longer supplied, the gripper will release the object, causing it to drop. For such applications, spring-assisted grippers can be used.

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