Introduction to

JIGS AND FIXTURES

Introduction
The successful running of any mass production depends
upon the interchangeability to facilitate easy assembly
and reduction of unit cost. Mass production methods
demand a fast and easy method of positioning work for
accurate operations on it.
Jigs and fixtures are production tools used to
accurately manufacture duplicate and interchangeable
parts. Jigs and fixtures are specially designed so that large
numbers of components can be machined or assembled
identically, and to ensure interchangeability of
components.
JIGS
It is a work holding deice that holds, supports and locates the workpiece
and guides the cutting tool for a specific operation. Jigs are usually fitted
with hardened steel bushings for guiding or other cutting tools. a !ig is a
type of tool used to control the location and"or motion of another tool. #
!ig$s primary purpose is to proide repeatability, accuracy, and
interchangeability in the manufacturing of products. # deice that does
both functions %holding the work and guiding a tool& is called a !ig.
#n example of a !ig is when a key is duplicated, the original is used as a !ig
so the new key can hae the same path as the old one.
'()I*G JIG
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It is a work holding deice that holds, supports and locates the workpiece
for a specific operation but does not guide the cutting tool. It proides
only a reference surface or a deice. /hat makes a fixture uni0ue is that
each one is built to fit a particular part or shape. The main purpose of a
fixture is to locate and in some cases hold a workpiece during either a
machining operation or some other industrial process. # !ig differs from a
fixture in that a it guides the tool to its correct position in addition to
locating and supporting the workpiece.
.xamples1 2ises, chucks
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4ow do !igs and fixtures differ
JIGS FIXTURES
5. It is a work holding deice that holds,
supports and locates the workpiece and
guides the cutting tool for a specific
operation
5. It is a work holding deice that holds,
supports and locates the workpiece for a
specific operation but does not guide the
cutting tool
6. Jigs are not clamped to the drill press
table unless large diameters to be drilled
and there is a necessity to moe the !ig to
bring one each bush directly under the drill.
6. +ixtures should be securely clamped to
the table of the machine upon which the
work is done.
JIGS FIXTURES
7. The !igs are special tools particularly in
drilling, reaming, tapping and boring
operation.
7. +ixtures are specific tools used
particularly in milling machine, shapers and
slotting machine.
8. Gauge blocks are not necessary. 8. Gauge blocks may be proided for
effectie handling.
9. :ighter in construction. 9. 4eaier in construction.
#dantages of Jigs and +ixtures
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Jigs and fixtures increases the productiity by eliminating the
indiidual marking, positioning and fre0uent checking. The
operation time is also reduced due to increase in speed, feed
and depth of cut because of high clamping rigidity.

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Jigs and fixtures facilitate the production of articles in large
0uantities with high degree of accuracy, uniform 0uality and
interchangeability at a competitie cost .

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There is no need for skillful setting of work on tool. Jigs and
fixtures makes possible to employ unskilled or semi skilled
machine operator to make saings in labour cost.

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4igher production, reduction in scrap, easy assembly and
saings in labour cost results in ultimate reduction in unit
cost.
+undamental principles of Jigs
and +ixtures design
:(=#TI*G ;(I*TS1 Good facilities should be proided for
locating the work. The article to be machined must be easily
inserted and 0uickly taken out from the !ig so that no time is
wasted in placing the workpiece in position to perform
operations. The position of workpiece should be accurate with
respect to tool guiding in the !ig or setting elements in fixture.
+((: ;)((+1 The design of !igs and fixtures should be such
that it would not permit the workpiece or the tool to inserted in
any position other than the correct one.
).<-=TI(* (+ I<:. TIM.1 <esign of Jigs and +ixtures should be
such that the process, loading, clamping and unloading time of the
workpiece takes minimum as far as possible.
/.IG4T (+ JIGS #*< +I,T-).S1 It should be easy to handle,
smaller in siAe and low cost in regard to amount of material used
without sacrificing rigidity and stiffness.
JIGS ;)(2I<.< /IT4 +..T1 Jigs sometimes are proided with feet
so that it can be placed on the table of the machine.
M#T.)I#:S +() JIGS #*< +I,T-).S1 -sually made of hardened
materials to aoid fre0uent damage and to resist wear. .xample3
MS, =ast iron, <iesteel, =S, 4SS.

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It should be as simple as possible without sacrificing
effectieness. The strength of clamp should be such that not
only to hold the workpiece firmly in place but also to take the
strain of the cutting tool without springing when designing
the !igs and fixtures.
.ssential features of Jigs and +ixtures

)eduction of idle time B Should enable easy clamping and

unloading such that idle time is minimum

=leanliness of machining process B <esign must be such that not

much time is wasted in cleaning of scarfs, burrs, chips etc.

)eplaceable part or standardiAation B The locating and supporting

surfaces as far as possible should be replaceable, should be
standardiAed so that their interchangeable manufacture is possible

;roision for coolant B ;roision should be there so that the tool is

cooled and the swarfs and chips are washed away

4ardened surfaces B #ll locating and supporting surfaces

should be hardened materials as far as conditions permit so
that they are not 0uickly worn out and accuracy is retained
for a long time

Inserts and pads B Should always be rieted to those faces of

the clamps which will come in contact with finished surfaces
of the workpiece so that they are not spoilt

+ool3proofing B ;ins and other deices of simple nature

incorporated in such a position that they will always spoil the
placement of the component or hinder the fitting of the
cutting tool until the latter are in correct pos

.conomic soundness B .0uipment should be economically

sound, cost of design and manufacture should be in
proportion to the 0uantity and price of producer

.asy manipulation B It should be as light in weight as possible

and easy to handle so that workman is not sub!ected to
fatigue, should be proided with ade0uate lift aids

Initial location B Should be ensured that workpiece is not

located on more than 7 points in anyone plane test to aoid
rocking, spring loading should be done

;osition of clamps B =lamping should occur directly aboe

the points supporting the workpiece to aoid distortion and
springing

=learance B Sufficient amount of clearance should be proided

around the work so that operatorCs hands can easily enter the
body for placing the workpiece and any ariations of work can be
accommodated

.!ecting deices B ;roper e!ecting deices should be incorporated

in the body to push the workpiece out after operation

)igidity and stability B It should remain perfectly rigid and stable

during operation. ;roision should be made for proper positioning
and rigidly holding the !igs and fixtures

Safety B The design should assure perfect safety of the operator

General rules for designing
=ompare the cost of production of work with present
tools with the expected cost of production, using the
tool to be made and see that the cost of buildings is not
in excess of expected gain.
<ecide upon locating points and outline clamping
arrangement
Make all clamping and binding deices as 0uick acting as
possible
Make the !ig fool proof
Make some locating points ad!ustable
#oid complicated clamping arrangements
)ound all corners
;roide handles whereer these will make handling easy
;roide abundant clearance
;roide holes on escapes for chips
:ocate clamps so that they will be in best position to
resist the pressure of the cutting tool when at work
;lace all clamps as nearly as possible opposite some
bearing point of the work to aoid springing action
'efore using in the shop, test all !igs as soon as made
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Jigs and +ixtures are made of ariety of materials, some of

which can be hardened to resist wear.

Materials generally used1

4igh speed Steel1 =utting tools like drills, reamers and milling
cutters.

<ie steels1 -sed for press tools, contain 5D carbon, E.9 to 5D

tungsten and less 0uantities of silicon and manganese.

=arbon steels1 -sed for standard cutting tools.

=ollet steels1 Spring steels containing 5D carbon, E.9D

manganese and less of silicon.
9. *on shrinking tool steels1
4igh carbon or high chromium
2ery little distortion during heat treatment.
-sed widely for fine, intricate press tools.
F. *ickel chrome steels1 -sed for gears.
G. 4igh tensile steels1 -sed for fasteners like high tensile
screws
H. Mild steel1
-sed in most part of Jigs and +ixtures
=heapest material
=ontains less than E.7D carbon

I. =ast Iron1
-sed for odd shapes to some machining and
laborious fabrication
=I usage re0uires a pattern for casting
=ontains more than 6D carbon
4as self lubricating properties
=an withstand ibrations and suitable for base
5E. *ylon and +iber1 -sed for soft lining for clamps to
damage to workpiece due to clamping pressure
55. ;hospher bronAe1
used for nuts as hae high tensile strength
-sed for nuts of the lead screw
+actors to be considered for design of
Jigs and +ixtures
5. =omponent3
<esign to be studied carefully
.nsure work is performed in a proper se0uence
Maximum operations should be performed on a machine in
single setting
6. =apacity of the machine3
=areful consideration to be performed on type and capacity
of machine.
7. ;roduction re0uirements3
<esign to be made on basis of actual production
re0uirements. Then comes decision on manual and automatic
tooling arrangements.
8. :ocation3

:ocation should ensure e0ual distribution of forces

throughout all se0uence of operation.

:ocation should be hard resistant, wear resistant and

high degree of accuracy.

Moement of workpiece should be restricted.

Should be fool proofed to aoid improper locations of

the workpiece.

Should facilitate easy and 0uick loading of workpiece.

)edundant locators should be aoided.

Sharp corners must be aoided.

#t least one datum surface should be establised.

9. :oading and -nloading arrangements3
There should be ade0uate clearance for loading and
unloading. 4ence process becomes 0uick and easy.
SiAe ariation must be accepted.
It should be hardened material and non sticky.
F. =lamping arrangements3
?uick acting clamps must be used as far as possible.
The clamping should not cause any deformation to the
workpiece
It should always be arranged directly aboe points supporting
the work.
;ower drien clamps are faoured as they are 0uick acting,
controllable, reliable and operated without causing any
fatigue to the operators.
+eatures of clamps1
=lamping pressure should be low
Should not cause distortion
Simple and fool proof
Moement of clamp should be minimum
=ase hardened to preent wear
Sufficiently robust to aoid bending
G. =learance between Jig and =omponent3
To accommodate arious siAes if work
=hips to pass out of the opening between them
H. .!ectors3
To remoe work from close fitting locators.
Speeds up unloading of the part from the tool and hence
production rate.

I. 'ase and 'ody construction3
Methods used1 Machining, +orging and machining, =asting,
+abricating, /elding.
5E. Tool guiding and cutter setting3
'y ad!usting the machine or using cutter setting block, the
cutter is set relatie to the work in a fixture. The drill bushes
fitted on !ig plates guides the tools.
55. )igidity and ibration3
Must possess enough rigidity and robustness.
Should not ibrate as it may lead to unwanted moement of
workpiece and tools.
56. Safety3
(peration should be assured full safety.
57. =ost3
Should be simple as possible.
=ost incurred should be optimum.
58. Materials generally used3

Sl. No Part Name Material
5 Jig body =I
6 Stud MS
7 <rill"'ush Gun metal
8 ;in MS
9 *ut MS