Magnetic chucks are the most efficient, secure, and simple way to hold workpieces in place for machining applications. While some magnetic chucks are powerful enough to hold both small and large workpieces, there are cases where we need specialized fixtures or extensions to hold irregularly shaped workpieces. These simple fixtures extend the functionality of a magnetic chuck and make it more versatile and suitable for a wide range of scenarios.
However, many machine operators and facilities that are adopting magnetic chucks aren't sure what magnetic work-holding fixtures are and how they work. This article dives into the usage, benefits, and basics of magnetic work-holding fixtures. We will also explain some tips to help you choose the best possible magnetic work-holding fixtures for your machining needs. By the end of this article, you will know everything there is to know about magnetic workholding fixtures and how they enhance the performance of magnetic chucks.
1. What Are Magnetic Work-holding Fixtures?
Magnetic chucks greatly reduce the amount of time required to secure and release workpieces from the machine. However, with the need for more complex machining applications, machinists have to use magnetic workholding fixtures as a way to adapt the magnetic chuck to a wide range of usages. A magnetic chuck fixture is essentially an extension or accessory that optimizes the work-holding capacity of a magnetic chuck.
When it comes to the actual design and size options the magnetic workholding extensions vary in terms of these metrics. So you can use different types of magnetic work-holding fixtures to extend the functionality of your magnetic chuck. A high-quality magnetic work holding fixture is going to extend the useability of a magnetic chuck with little to no loss of holding power.
2. Different Types Of Magnetic Work Holding Fixtures You Can Buy
When it comes to the actual types of magnetic workholding fixtures, you can choose from a wide range of options. The type of magnetic chuck extension you will use depends upon the workpiece's shape, size, and nature. Since magnetic chucks can only hold ferrous materials the magnetic work-holding fixtures are also made of high-quality steel and other conductive metals. With that said here are the different types of work-holding fixtures you can get for your magnetic chuck:
2.1 Magnetic V-Blocks
As the name suggests the Magnetic V Block workholding fixtures for magnetic chucks create a V-shaped slot for holding a workpiece. These workholding fixtures can be easily attached to a magnetic chuck's surface and make it easy to hold cylindrical, or round workpieces that would normally slip on a flat chuck surface.
When installed correctly a V-shaped magnetic chuck extension can be used for grinding, milling, and cutting applications. Made from durable materials these V-shaped magnetic workholding fixtures can withstand heavy-duty usage without getting chipped or damaged.
2.2 Magnetic Parallels
Magnetic parallels are another common type of magnetic workholding fixture that can be used to raise the height of a workpiece so it can make full contact with the tool. Magnetic chucks are usually completely flat on the surface which means there are no means to raise or lower the contact point of a magnetic chuck. However, with these parallel magnetic workholding fixtures, you can easily raise the workpiece and you can use multiple parallel fixtures to firmly secure a workpiece.
Since these types of magnetic work-holding fixtures are completely flat they allow for even magnetic fields to pass through them and keep the workpiece in place.
2.3 Pole extensions
A pole extension as the name suggests is a type of extension that is used to extend the poles of a magnetic chuck. These types of extensions attach directly to the square poles of the magnetic chuck and serve as the primary poles with similar magnetic holding power.
2.4 Subplates
Subplates are wide and thin plate-like fixtures that allow for smaller workpieces to be held securely to the magnetic chuck. Subplates also offer an additional layer on top of the main magnetic chuck plate making them ideal for rough usage scenarios where there is a risk of damage to the chuck's surface.
You can use the sub-plates to extend the functionality of the magnetic chuck and to keep the top plate of the magnetic chuck safe.
Apart from these commonly used shapes of magnetic workholding fixtures, you can find additional options depending on your needs. In most cases, these magnetic work-holding fixtures are universal and can be fitted on any type of magnetic chuck. So once you buy a set of workholding fixtures you can use it on multiple magnetic chucks making them a great investment for machinists.
3. What Are Some Of The Most Common Uses Of Magnetic Workholding Fixtures?
Magnetic workholding fixtures can be used for a wide range of applications however there are some areas of machining where they are almost essential to achieve high precision. Any machining job that requires the workpiece to remain perfectly still can benefit from magnetic workholding fixtures. Some of the most common machining applications where magnetic work holding fixtures shine include:
3.1 Grinding
Grinding requires a workpiece to be smoothened from every part of the surface which results in a lot of vibrations due to constant contact with the grinder. V block work holding fixtures are a great combination for magnetic chucks as they minimize the movement of the workpiece and ensure a smooth even finish.
3.2 Milling
Milling machines generate a lot of force to shave away solid metal workpieces and it is no surprise that using magnetic fixtures with magnetic chucks enhances milling efficiency. Keeping the workpiece steady using parallel or v-block magnetic chuck extensions is a great way to stabilize a workpiece during milling.
3.3 Turning
Turning is another common machining application that involves turning a workpiece against a sharp tool to shape it. It is also the most heavy-duty machining function that requires more than just a high-quality lathe magnetic chuck. While high-quality round magnetic chucks do have specialized slots for concentrating the magnetic power to provide maximum stability during turning adding fixtures further enhances the reliability of a magnetic chuck.
4. Benefits Of Using Magnetic Work Holding Fixtures With Magnetic Chucks
If you buy a magnetic chuck from a reputed provider such as GME Magnet you can rest assured that your magnetic chuck won't fail as long as it is used for the intended purposes. However, when you use workholding fixtures with magnetic chucks it does bring certain benefits for the manufacturing process. Without further ado here are some lesser-known benefits of using magnetic work-holding fixtures with magnetic chucks:
4.1. Improved Precision and Accuracy
Since magnetic fixtures improve the stability of the workpiece by providing a more secure holding mechanism they greatly enhance the precision of a magnetic chuck. Any minor vibrations or slippage can cause significant deviations from the required specifications during machining. So by using magnetic workholding fixtures, you can greatly enhance the machining accuracy.
4.2. Fast Setup and Reduced Downtime
Since magnetic workholding fixtures are also made from ferrous metals they can be secured and removed by turning the magnetism of the chuck on or off. You can secure both the workpiece as well as the magnetic workholding fixture in one go enhancing productivity and reducing setup time.
4.3 Enhance functionality
Magnetic workholding fixtures are a great way to enhance the functionality of a magnetic chuck by adapting it to a wide range of uses. For example, if you have a large enough chuck you can use magnetic work-holding fixtures to hold multiple workpieces at a safe distance from each other for batch machining.
Similarly, you can use the same magnetic chuck for different types of machines by switching to the correct magnetic work-holding extensions.
4.4 There is no clamping involved
Another major benefit of using magnetic workholding fixtures is that there is no clamping or fastening required to fit an extension on your magnetic chuck. In the case of pole extensions, you may need to secure the poles to the main poles of the magnetic chuck. However, once secured you don't have to worry about constantly removing and fitting them.
4.5 Prolonged lifespan of the magnetic chuck
Last but not least a magnetic chuck's top plate can remain protected thanks to magnetic workholding fixtures prolonging its lifespan in the process. At GME Magnet all magnetic chucks are made from high-quality and conductive steel. However, once the top plate comes in contact with tools and forces involved in machining they can develop irregularities in the surface.
By using workholding fixtures with your magnetic chuck you are essentially adding a protective layer to the top plate.
5. How To Select The Right Magnetic Workholding Fixtures For Your Application?
When you are picking a magnetic workholding fixture for your application you have to make sure that you choose the correct type of fixture to maximize efficiency. Not to mention the right type of fixture is going to enhance the accuracy and reduce the time for machining operations. As explained earlier there are different types of magnetic workholding fixtures available for magnetic chucks. With that said here are some simple ways to choose the right magnetic work-holding fixtures for your application:
5.1 Match the fixtures to the workpieces
The first thing you need to consider when choosing a work-holding fixture for your machining applications is whether the fixture matches the type of workpieces you work with. This includes matching the shape, size, and even the material of the workpiece with the work-holding fixture.
For example, in the case of cylindrical workpieces, the V-block design provides the best stability since V-block fixtures have the V shape to securely hold cylindrical or irregular pieces. Not to mention the workholding fixture shouldn't raise the workpiece too high above the magnetic chuck's surface as it can reduce the holding capacity of the chuck.
5.2 Conductivity of the work-holding fixture
Conductivity is an important thing to consider when choosing work-holding fixtures. Choosing a work-holding fixture made out of highly conductive material will ensure that there is no loss of magnetism when you extend the magnetic chuck's useability. This is especially important when you are planning on using the magnetic chuck for heavy-duty machining applications.
You can always test multiple work-holding fixtures to assess their conductivity when picking one that suits your needs. Using a magnetic chuck with high magnetic power is another way to minimize the loss of magnetism. GME Magnet offers powerful magnetic chucks that are ideal for use with work-holding fixtures.
5.3 Material quality and durability
When you use magnetic workholding fixtures for grinding, milling, and drilling purposes they are bound to come in contact with the tool. This is where the durability of the material used for making the workholding fixture comes into play.
You should always choose high-quality work-holding fixtures made from high-grade steel to make sure they can withstand continuous machining applications.
5.4 Look for versatile magnetic work-holding fixtures
Buying work-holding fixtures that can be used for multiple machining applications can save cost and assembly time. Magnetic workholding fixtures with a modular design allow them to be adopted for a wide range of machining applications.
6. Conclusion
Working with magnetic chucks already cuts down the preparation and setup time significantly and using magnetic workholding fixtures further improves their useability. With a wide range of magnetic workholding fixtures as explained above you can get a lot more usage out of a single high-quality magnetic chuck.
This article has covered all the major types of magnetic workholding fixtures and how they improve the functionality of a magnetic chuck. Not to mention we have listed all the top magnetic chucks that work well with magnetic workholding fixtures. If you have questions regarding which magnetic chuck will suit your needs feel free to reach out for further assistance.