Project Jig & Fixture 20112012

7/30/2019 Project Jig & Fixture 20112012

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SMR 4712

TOOLING FOR PRODUCTION

GROUP ASSIGNMENT: FIXTURE

2011/2012-SEM 1

LECTURER

PM ZAINAL ABBIDIN

SECTION 02

NO. GROUP MEMBERS MATRIX NO

1. EDWIN LEONG FUH ZHENG AM080173

2. JAZIZ AMIRUDDIN B. JAMALUDDIN BM083002

Faculty ofMechanicalEngineering


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TABLE OF CONTENTS

CHAPTER TITLE PAGE

1 INTRODUCTION 1

1.1 Project Title 1

1.2 Introduction to Tool Design 2

1.3 Tool Design Objectives 2

2 TOOL DESIGN 3

2.1 Tool Design Process 3

2.1.1 Definisg Requirements 4

2.1.2 Gathering and Analyzing Information 42.1.3 Developing Several Options 5

2.1.4 Choosing the Best Options 6

2.1.5 Implementing the Design 6

2.2 Guidelines for Economical Design 6

3 JIG AND FIXTURE 7

3.1 Introduction 7

3.2 Elements of Jigs and Fixtures 7

3.3 Advantages of Jigs and Fixtures 8

3.4 Fixture 9

4 MACHINING 10

4.1 Introduction 10

4.2 Milling 10

4.2.1 Horizontal Milling Machine 11

4.2.2 Vertical Milling Machine 12


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5 SUPPORT AND LOCATOR 14

5.1 Type of Support 14

5.1.1 Adjustable Support 14

5.1.2 Solid Support 15

5.2 Type of Locator 15

5.2.1 Pin-Type Locator 15

5.2.2 Diamond or Relieved Locator 17

6 MODULAR FIXTURING AND CLAMP 18

6.1 Modular Fixture 18

6.2 Tooling Plate and Blocks 19

6.2.1 Grid Address System 19

6.3 Clamp 20

6.3.1 Toogle Clamps 20

7 OPERATION 21

7.1 Operation Description 21

7.2 Tool 22

7.3 Production Plan 22

7.4 Part Drawing 24

7.5 Fixture 1 26

7.6 Fixture 2 36

8 CONCLUSION 47

Appendices 48


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CHAPTER 1

INTRODUCTION

1.1 Project Title

Design a modular fixture(s) to machine the six faces indicated by the arrows.

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1.2 Introduction to Tool Design

Tool design is the process of designing and developing the tools, methods, and

techniques necessary to improve manufacturing productivityandefficiency. It plays an

important role in manufacturing industry by providing the right machine and special tooling

needed for todays fast paced and high-volume production.

Moreover, it does this at the lowest cost as possible but still maintains its top level of

quality. Tool design is an engineering art because it involves a process of creative and also

technical problem solving skills due to the fact that almost every product needs different kind

of tool and process to be manufactured.

Tool design is also an integral part of the product-planning process, interacting with

product design, manufacturing, and marketing to ensure that the product produced will

satisfy customers requirements.

1.3Tool Design Objectives

The main objective of tool design is to lower manufacturing costs while maintaining top

quality and increase the rate of production.

The following objectives need to be satisfied:

i. Provide simple, easy-to-operate tools for maximum efficiency.

ii. Reduce manufacturing expenses by producing parts at the lowest possible cost.

iii. Design tools that consistently produce parts of high quality.

iv. Increase the rate of production with existing machine tools.

v. Design the tool to make it foolproof and to prevent improper use.

vi. Select the materials that will give adequate tool life.

vii. Provide protection in the design of the tools for maximum safety for operators

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2.1.1 Defining Requirements

The design problem to be solved and the specification needed must be stated clearly

in this step. Therequirements should be stated as broad as possible but to the extent that

specifically enough to define the scope of the design project. A new type of tooling might be

required for first-time production of a new product, or to improve the production of an

existing part. Tooling can be designed either for only one part or the whole product.

2.1.2 Gathering and Analyzing Information

The data will be collected and assembled for further evaluation. When collecting the

information, ensure that the part documents and records such as part print, process sheets, and

machine specifications are current or the latest. The most important part of this step is note-

taking because it allows the tool designer to keep a record of important data for future

references. By doing so, the loss of brilliant ideas or thoughts will be prevented

Four aspects to be taken into considerations:

i. Workpiece Consideration The most important factor. Create the largest impact on the work-holders final design. Considerations include:

- Part size and shape.- Required accuracy.-

Part material properties.- Locating and clamping surfaces.- Number of pieces.

ii. Manufacturing Operations Consideration Considerations include:

- Type of operations required.- Number of operation performed.- Sequence of operations.- Inspection requirements.

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- Time restrictions.iii. Equipment Consideration

Controls the type of equipment needed for machining, assembly, andinspection operations.

Determines whether the work-holder is designed for single or multipleparts.

Typically, equipment criteria include factors such as:- Types and sizes of machine tools.- Inspection equipment.- Scheduling.- Cutting tools.- General plant facilities.

iv. Personnel Consideration Deal with the end user or operator. The first and most important consideration in this phase is safety.

Therefore, all tools must be designed with complete safety to protect to

operator.

Operator fatigue, efficiency, economy of motion, and operation speedshould be considered too.

Designer must understand well the general aspects of design safety andall appropriate government and company safety rules and codes.

2.1.3 Developing Several Options

Imagination and creativity is crucial in this step since a workpiece can be located andclamped in different ways therefore a brainstorming session should be conducted to devise a

strategy for developing a successful tool design.

Several good tooling alternatives should be brainstormed. Besides, more options

should be added during this phase to ensure that they are feasible.

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2.1.4 Choosing the Best Options

This step is a cost or benefit analysis of different tooling options such as tooling

durability, operator comfort and safety, and etc.

2.1.5 Implementing the Design

This phase consists of turning the chose design approach into reality. Final details will

be decided, detailed drawings will be made, and the tooling will be built and tested.

2.2 Guidelines for Economical Design

i. Simplify tooling operations.ii. Use standard tooling components.

iii. Use prefinished materials.iv. Eliminate unneeded finishing operations.v. Keep tolerances as liberal as possible.

vi. Keep the function and operation of a work-holder as simple as possible.vii. Reduce the design complexity and thus reduce the misunderstandings between

the designer and machine operator.

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CHAPTER 3

JIG AND FIXTURE

3.1 Introduction

Jigs and fixtures are production-workholding devices used to manufacture duplicate

parts accurately. The correct relationship and alignment between the cutter, or other tool, and

the workpiece must be maintained. In order to do so, a jig or fixture is designed and built to

support, hold, and locate every part to ensure that each is drilled according to its

specifications. Both terms are frequently used incorrectly in shops. A jig is a guiding device

and a fixture a holding device.

Jigs and fixtures are used to locate and hold the work that is to be machined. These

devices are provided with attachments for guiding, setting, and supporting the tools in such a

way that all the workpieces produced in a given jig or fixture will be exactly identical in

every way. The employment of unskilled labor is possible when jigs and fixtures can be used

in production work. A jig or fixture can be designed for a particular job. The form to be used

depends on the requirement and shape of the workpiece to be machined.

3.2Elements of Jigs and Fixtures

Basically, all the jigs and fixtures were made of:-

i. Clamping Elements To hold the workpiece securely in the located position during operations.

ii. Locating Elements To position the workpiece accurately with respect to the tool guiding or

setting elements.

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iii. Tool Guiding and Setting Elements To aid the setting or guiding of the tools in the correct position with

respect to the workpiece

3.3Advantages of Jigs and Fixtures

i. Cost ReductionReduction in scrap, higher production rate, easy assembly and savings in labor

costs result in substantial reduction in the cost of workpieces produced with

jigs and fixtures. All of these combines and decrease the expenditure on the

quality controls of the machine parts.

ii. ProductivityThe use of jigs and fixtures eliminate individual marking, positioning, and

frequent checking. This can reduce operation time and increase productivity.

Two or more workpieces can be machined simultaneously. Besides, jigs and

fixtures enable complex parts to be machined by being held rigidly to the

machine.

iii. InterchangeabilityJigs and fixtures facilitate uniform quality in manufacturing. There is no need

of selective assembly. Any parts of the machine fit properly in assembly and

all similar components are interchangeable. Marking out and setting before

machining can be eliminated.

iv. Skill ReductionJigs and fixtures simplify locating and clamping of the workpieces. Tool

guiding elements ensure correct positioning of the tools with respect to the

workpieces, the make the use of lower skilled labor possible.

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3.4Fixture

Fixture is a production tool that locates, holds, and supports the work securely so that

the required machining can be performed effectively. What makes a fixture unique is that

each one is built to fit a particular part or shape. Set blocks and feeler or thickness gauges are

used with fixtures to reference the cutter to the workpiece. A fixture anchors the workpiece

firmly in place for the machining operation, but it does not form a guide for the tool.

A fixture supposed to be securely fastened to the table of the machine where the work

is being done. Fixtures design vary significantly from its purpose and cost such as simple,

expensive and also complicated devices. Moreover, fixtures also make metalworkingoperations performed on special equipment to be much more simple.

Fixtures are usually classified by the type of machine on which they are used. It can

also be identified by a sub classification. As an example, a fixture which is designed to be

used on a milling machine will be called a milling fixture.

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CHAPTER 4

MACHINING

4.1 Introduction

Machining processes are often necessary in order to impart the desired dimensional

accuracy geometric features, and surface finish characteristics to components, especially

those with complex shapes that cannot be produced economically or with other shaping

techniques. On the other hand, these processes generally takes time, waste some material in

the form of chips, and may have adverse effects on surfaces produced. Material is very

expensive for high volume production. However, machining has very low set-up cost

compared to forming, molding and casting processes.

4.2 Milling

Milling is the process of cutting away material by feeding a workpiece past a rotating

multiple tooth cutter. The cutting action of the many teeth around the milling cutter provides

a fast method of machining. There are several type of machined surface like angular, flat, or

curved and many other shape combinations. A milling machine is a machine tool used tomachine solid materials. Milling machines are often classed in two basic forms, horizontal

and vertical, which refers to the orientation of the main spindle. Both types range in size from

small, bench-mounted devices to room-sized machines

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4.2.1 Horizontal Milling Machine

A horizontal mill has the same sort of xy table, but the cutters are mounted on a

horizontal arbor across the table. Many horizontal mills also feature a built-in rotary table that

allows milling at various angles; this feature is called a universal table. Horizontal milling

machine normally used when a lot of material has to be removed by the cutters or there is less

of need for accuracy for the shape material.

Picture of Horizontal Milling Machine

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4.2.2 Vertical Milling Machine

This milling machine produce machined surfaces by progressively removing material

from a work piece uses a rotating milling cutter. In the vertical mill the spindle axis is

vertically oriented. Milling cutters are held in the spindle and rotate on its axis. The spindle

can generally be extended (or the table can be raised/lowered, giving the same effect),

allowing plunge cuts and drilling. There are two subcategories of vertical mills: the bed mill

and the turret mill. This milling machine can also act like a drill press because the spindle is

perpendicular to the table and be adjust to the workpiece.

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Diffrence between horizontal and vertical milling

Other Types of Milling

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CHAPTER 5

SUPPORT AND LOCATER

5.1 Types of support

5.1.1 Adjustable Support

Adjustable Support is used when the surface is rough or uneven. Normally used with

one or more solid locator to allow any adjustment needed to level the work.

Screw rest button Gripper Swivel Contact Bolts

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5.1.2 Solid Support

Solid support is the simplest type of support to use on tool base. This type of support

can be machined or installed into the tool base. It is used when a machined surface acts as a

locating point.

Rest Button

5.2 Types of Locator

5.2.1 Pin-type

Pin-type locator is a precision locating pins with a tapered tip for easy part loading, and a

shoulder to resist downward forces. Diamond pins are relieved, to locate only in 1 axis.

Round Pins are also useful as side locators.

Pin Type Locator

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Positioning of the locator

A series of locating pins can take the place of a locating plug. The pins are positioned

at three points, 120 degrees apart, around the internal diameter of the hole. This arrangement

is usually much more economical than making a custom plug.

Foolproofing.

Foolproofing is a method to ensure that the part will fit or match into the tool only in

its correct position. The simplest way to foolproof a workholder is to position one or two pins

in a location that ensures correct orientation.

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5.2.2 Diamond or Relieved Locator

Another style of pin is the diamond or relieved pin, which is usually used along with

ther round pin to reduce the time it takes to load and unload the tool. It is easier to locate a

part on one round pin and one diamond pin than to locate it on two round pins.

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CHAPTER 6

MODULAR FIXTURE AND CLAMP

6.1 Modular Fixture

Modular fixture is a permanent fixture, except for a few key differences. First,

modular fixtures can be assembled entirely from reusable off-the-shelf components, without

machining. Next, many modular components are adjustable and universal. Finally, specially

designed tooling plates and blocks, with a standard grid pattern, are the foundation of a good

modular system.

By using modular fixture, a workholder can be economically built even for a one-part

run. Jobs that do not repeat on a regular basis are well suited to modular fixturing; modular

fixturing permits rapid setup of short-notice production runs.

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6.2 Tooling Plate and Blocks

Tooling plates and blocks are the main structural elements of any modular-fixturing

system. The type, style, and number of plates and blocks available determine the variety of

fixtures that can be built, and also the number of machine tools that can be used.

Tooling plates and blocks

6.1.1 Grid Address System

The grid pattern of multipurpose holes on every tooling plate and tooling block face is

labelled with letters in one direction and numbers in the perpendicular direction. Tooling-

block faces are numbered (counter-clockwise) with Roman numerals. This allows recording

the mounting-hole location of each component (e.g., A2, B3, D7, etc.) as part of permanent

documentation. Multipurpose holes are spaced within .0008 inches of true position on all

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tooling plates and blocks. The mini system is even more accurate, with all holes spaced

within .0004 inches.

6.3 Clamp

The function of a clamp is to hold a part against the locators during the machining

cycle. To be effective and efficient, clamps must be planned into the tool design. Clamp

should always contact the work at its most rigid point. This prevents the clamping force from

bending or damaging the part. In modular clamps, toggle clamps are widely used.

6.3.1 Toggle Clamps

A toggle clamp is a quick-acting mechanical linkage where two of the elements make

up a toggle action. Actuating the clamp first moves it into position, then applies clamping

force by compressing or stretching the linkage elements after contacting the workpiece, then

positively locks it by moving the toggle actions center pivot past the centreline of the other

two pivots, against a stop.

Horizontal-Handle Hold-Down Clamps .... Vertical-Handle Hold-Down Clamps

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CHAPTER 7

OPERATION

7.1 Operation Description

A vibrator arm which is shown in chapter 1 is already machined to the desired

shape. The process that we will carry on is the finishing process using a CNC milling

machine of the six surfaces that is indicated. In order to maintain the accuracy of the

product, two milling modular fixtures have been design to carry out the finishing milling

processes. Standard parts were chosen from the Carrlane catalog and a few parts were

customized to suit the processes. Both fixtures are design to hold the part and to restrict

the movement of the part so that it could be mill to get it required specification. The

following operation will be performed using the designed fixtures.

Milling Operation 1 using Fixture 1

i. Milling of surface 1.56 x 1.62ii. Milling of surface 3.37 x 1.94

iii. Milling of surface 4.93 x 1.94;

Milling Operation 2 using Fixture 2

i. Milling of surface 1.62 x 1,50ii. Milling of surface 1.447 x 1.50

iii. Milling of surface 2.24 x 1.25

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Fixture 1 locates the part by using a round pin and a diamond pin. This reduces the

time it takes to load and unload the tool Also, the diamond pin work as a relieved locator.

Relieved locators reduce the area of contact between the vibrator arm and the locator. By

locating the work piece by using two internal holes, eleven direction of movement have

been restricted. Finally, the last direction is restricted by a strap clamp.

Fixture 2 locates the part by using a round pin and a few supports. By locating the

work piece using an internal hole, nine direction of movement have been restricted.

Another two solid support that is place horizontally relative to the work piece further

restrict two direction of movement. Finally a toggle clamp is use to restrict the lastdirection.

7.2 Tool

The milling cutting tool is selected from ITS catalog. We choose one of the

finishing end mills cutters with the following specification:

Code No S314DU

Cutter Diameter 20 mm

No of Flute 4

Total Length 110 mm

Flute Length 45 mm

7.3 Production Plan

Below shows a production plan for the operations

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PART NO QUANTITY ORDER NO

2735 7500

DRW NO PROCESS PLANNAR REV DATE PAGE 1 OF 12735 Edwin A 21-Nov-11

OPR NO DEPT. MACH TOOL

1 #7 Horiz. Mill

Finishing TSU-03

2 #7 Horiz. Mill

Finishing TSU-03

3 #7 Horiz. Mill

Finishing TSU-03

4 #7 Horiz. Mill

Finishing TSU-03

5 #7 Horiz. Mill

Finishing TSU-03

6 #7 Horiz. Mill

Finishing TSU-03

6 20 mm Modular Fixture

#002


#002


#002


#001


#001


#001

OPR NO SIZE SPECIAL TOOL NO

PRODUCTION PLAN

Vibrator Arm

PART NAME

DESCRIPTION

Mill Face

4.93' x 1.94'

Mill Face

1.62' x 1.50'

Mill Face

1.56' x 1.62'

Mill Face

3.37' x 1.94'

Mill Face

ITS Finishing End Mill


1.447' x 1.50'

Mill Face

2.24' x 1.25'



TOOL DESCRIPTION



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7.4 PART DRAWING


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7.5 FIXTURE 1


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7.6 FIXTURE 2


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CHAPTER 8

CONCLUSION

As a future engineer majoring in manufacturing, we should be able to design a

simple and yet effective tool that simplified the work of operator. A tool that is

functioning well will lower the cost while maintaining the quality of the product. Other

than that, it should be able to increase the production rate.

Other than that, certain basic knowledge such as machine tool and cutter for

different operation should be familiarize so that we are prepare to put these knowledge

into practice during out future career,

Last but not the least; we succeed in designing two modular fixtures that could

function properly. We apply all the basic principles that we learn into this project. This

helps us to understand more and would be a good experience in designing jig and fixture

if we are to become a tool engineer in our future career

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Appendices.

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Standard Parts Used in Fixture 1

No Part Name Part Number Quantity

1 Rectangular Tooling Plate CL-MF25-0151 12 0.625 Round Locating Pin CL-624-RLT 1

3 0.5 Diamond Locating Pin CL-4990-DLT 1

4 Socket Head Cap Screw CL-1/2-13X1.50-SHCS 2

5 Clamp Rest Screw CL-6-CRS 1

6 Clamping Studs CL-1/2-13X4.5-STUD-S 1

7 Jam Nut CL-8-JN 2

8 Clamping Spring CL-9-SPG 1

9 Flat Washer CL-2-FW 1

10 Spherical Nut & Washer CL-3-SNW 1 SET

1. Rectangular Tooling Plate : CL-MF25-0151

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2. 0.625 Round Locating Pin: CL-624-RLT3. 0.5 Diamond Locating Pin: CL-4990-DLT

4. Socket Head Cap Screw: CL-1/2-13x1.50-SHCS

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5. Clamp Rest Screw: CL-6-CRS

6. Clamping Studs: CL-1/2-13x4.5-STUD-S

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7. Jam Nut: CL-8-JN

8. Clamp Spring: CL-9-SPG

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9. Flat Washer: CL-2-FW

10.Spherical Nut & Washer: CL-3-SNW

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Standard Parts Used in Fixture 2

No Part Name Part number Quantity

1 Rectangular Tooling Plate CL-MF25-0151 12 0.625 Round Locating Pin CL-624-RLT 1

3 Rest Button CL-12-RB 4

4 Socket Head Cap Screw 1.38 CL-5/16-18x1.38-SHCS 2

5 Socket Head Cap Screw 1.12 CL-5/16-18x1.12-SHCS 1

6 Socket Head Cap Screw 0.62 CL-1/4-20x.62-SHCS 4

7 Halfway Extension Support CL-MF25-3605 1

8 Locating Bush CL-MF25-4300 2

9 Toogle Clamp Adapter CL-MF25-5401 1

10 Toogle Clamp CL-450-VTC-S 1

11 Jam Nut CL-3-FJN-S 212 Hex Head Spindles CL-516212-SA-S 1

1. Rectangular Tooling Plate: CL-MF25-0151

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2. 0.625 Round Locating Pin: CL-624-RLT

3. Rest Button: CL-12-RB

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4. Socket Head Cap Screw 1.38: CL-5/16-18x1.38-SHCS5. Socket Head Cap Screw 1.12: CL-5/16-18x1.12-SHCS6.

Socket Head Cap Screw 0.62: CL-1/4-20x.62-SHCS

7. Halfway Extension Supports: CL-MF25-3605

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8. Locating Bush: CL-MF25-4300

9. Toogle Clamp Adapter: CL-MF25-5401

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10.Toogle Clamp: CL-450-VTC-S

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11.Jam Nut: CL-3-FJN-S

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12.Hex Head Spindles: CL-516212-SA-S

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Milling Cutter: Dc = 20 mm

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Project Jig & Fixture 20112012

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