Fixture Design Handbook
A practical engineering reference for jigs and fixtures used in machining. Locating, clamping, calculations, standard components, materials, tolerances and design review — workshop-ready.
How to use this handbook
Start from the operating principle of your operation (drilling, milling, turning, grinding), then design locating and clamping, size standard components, and finish with the review checklist. The Calculations page provides interactive calculators for cutting force and clamp force.
Contents
📌Locating & Datums
Six-point principle, 3-2-1 rule, locator types (pins, V-blocks, cones) and positioning error control.
Open⚙Fixture Types
Drilling jigs, milling, turning, grinding and inspection fixtures with selection criteria.
Open🖨Calculations
Cutting force, required clamp force, bolt torque. Interactive calculators included.
Open⏱Cutting Parameters
Speeds, feeds and spindle speeds for turning, milling, drilling and tapping.
Open⚡Power Clamping
Hydraulic and pneumatic clamping: actuators, circuits, force calculation and safety.
Open♻Self-Centering Clamping
Scroll chucks, spring collets, wedge-driven and V-block self-centering mechanisms.
Open⬅Magnetic & Vacuum
Electric, electromagnetic, permanent-magnet, vacuum and self-clamping devices.
Open🔗Setting, Guiding & Indexing
Tool-setting devices, drill bushings, boring guides and indexing mechanisms.
Open🛠Body & Modular Systems
Fixture body design, universal-adjustable, group, modular and assembly fixtures.
Open⚙️Fixtures by Machine
Lathe, milling, drilling, boring, broaching, gear cutting, grinding, modular machine and line fixtures.
Open🛡Standard Components
Jig bushings, locator pins, T-slot sizes, metric bolt data and reference standards.
Open🔔Materials & Heat Treatment
Steels, cast iron, aluminum and hardening processes for fixture components.
Open📏Tolerances & Fits
IT grades, preferred fits, recommended fits for fixture parts and surface roughness.
Open✓Design Checklist
Final review: locating, clamping, loading, chips, accuracy, safety and maintenance.
Open🔨Design Method & Steps
Step-by-step fixture design process from process analysis to assembly drawing.
Open⚙️Special & Automated Tooling
CNC fixtures, automated clamping, pallets, robots and flexible workholding.
Open🔨Welding Fixtures
Fixtures that resist weld heat, control distortion and give repeatable fit-up for weldments.
Open🛠Assembly Fixtures
Positioning and clamping fixtures for press-fit, insertion, riveting and bonding operations.
Open🔍Inspection Gages
GO/NO-GO gages, functional gages and checking fixtures for fast production acceptance.
Open📊Deep-Dive Cases
Four fully worked fixture designs with cutting force, clamping force and error-budget calculations.
Open🔍Components Library
Searchable GB / DIN / ISO tables for drill bushings, locator pins, strap clamps and metric bolts.
OpenQuick reference formulas
| Item | Formula |
|---|---|
| Screw clamp force | F = T / (0.2 · d) |
| Required clamp force | Fcl = K · Fc / μ |
| Cutting force (turning) | Fc = kc · ap · f |
| Unit conversion | 1 kgf = 9.81 N, 1 MPa = 1 N/mm² |