Client
Our client is a precision work holding devises manufacturer specializing in modular fixturing systems and self-centering vises used in CNC machining applications.
Scope
The scope was to design a hydraulic vise using the client’s existing standard jaw and truck assembly (originally designed for a manual self-centering vise) — ensuring complete compatibility without any design modifications to these standard components.
Why APA?
APA Engineering has extensive experience in the design and development of hydraulic and pneumatic clamping systems, precision fixtures, and automation components.
Our team’s expertise in SolidWorks-based design, FEA validation, and tolerance analysis enables us to deliver highly reliable and performance-optimized solutions tailored to customer standards
Design Challenges
● Retaining the existing jaw and truck design without modification to connect with piston & cylinder base
● Achieving a clamping pressure of 1500 psi using a compact hydraulic actuation system.
● Ensuring consistent and balanced clamping force for both jaws under repeated cycles.
● Maintaining leak-free operation under high pressure within limited envelope dimensions.
Design Process
● Requirement Study: Reviewed the client’s manual vise assembly to identify key interfaces and dimensional constraints for hydraulic integration.
● Concept Development: Developed several actuator concepts ensuring the piston and bore design fit within the existing vise housing.
● Design Calculation: Performed hydraulic force calculations and piston area optimization to meet the required 1500 psi clamping load.
● 3D Modeling: Created a detailed SolidWorks model incorporating the piston, seals, and hydraulic ports (Clamp / Release).
● FEA Analysis: Conducted finite element analysis (FEA) on the piston and housing to verify structural integrity and stress distribution under operating pressure.
● Tolerance Stack up Analysis: Ensured smooth operation of moving components through detailed fit and clearance checks.
● Detail Drawings & BOM: Prepared manufacturing drawings with bill of materials and standard part selection for hydraulic fittings and seals.
Value Delivered
● Developed a compact hydraulic vise fully compatible with the client’s standard jaw and truck — eliminating the need for costly redesign.
● Achieved 1500 psi clamping pressure with high repeatability and minimal leakage.
● Reduced manual effort and clamping time by converting a mechanical vise into a fully hydraulic system.
● Improved operator safety and productivity through reliable and ergonomic hydraulic operation.
● Provided cost-effective and manufacturable design ready for production with minimal setup modification.
Looking to upgrade your manual fixtures to hydraulic systems?