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N.B.: (1) (2) (3) (4) (5)
(4 Hours) Q. Nos. 1 and 2 are compulsory.
Attempt any three question out of question Nos. 3 to 7. Use half imperial sheets wherever necessary.
Give your answers with neat sketches wherever applicable. Assume suitable additional data if necessary.
1, Design and draw a drill jig to drill ~ 15 - 4 holes as shown in figure. Draw two views 20 to the scale with dimensions. The part material is steel - low alloy. Also write sequence
of operations and Bill of materials. (Refer figure Support Bracket)
2. (a) Explain the clamping method selected in the drill jig design for the part shown 5 in figure briefly.
(b) Draw free hand sketch for milling fixture for the component shown in figure for 15 gaug milling the faces marked in figure (marked ~). Milling upto distance 42 mm only as indicated in the figure.
Show clearly method of tool guide and clamping to the machine table. Prepare Bill of materials.
3. Draw neat sketches of the following (any four) :- 20
(a) Plate ,Jig
(b) Liner bush and ship type renewable bushes in jig design for drilling and
reaming operations. (c) Turning fixture
(d) Eccentric clamping system
(e) Cutter setting device in milling fixture design.
4. State whether the following statements are 'True' or 'False' giving suitable explanation. 20 Attempt any five :-
(a) Tapered dowel pins do not produce and maintain accurate alignment between parts as does the straight dowel pins.
(b) Slip bushes need special care during manufacturing and mounting.
(c) Whenever tennons are provided in milling fixtures, setting blocks are not
(d) Eccentric cam clamps are always self locking.
(e) Welded construction of fixture body is not so strong as cast body.
(f) Locators must be placed against cutting forces exerted by the tool.
(g) Turning fixtures need balancing.
5. (a) Compare the construction principles, applications and limitations of fixture bodies 10 produced by built-up, cast and welding processes.
(b) What do you understand by fool proofing ? When it is required? Explain with 10 suitable examples methods of fool proofing.
6. (a) State which materials are used forthe following components used in the manufacture 15
of jigs and fixtures. State also the reasons :(i) Jig plate
(ii) Diamond pin
(iii) Fixed renewable drills bush (iv) Expanding mandrels
(v) Resting pads. ~
(b) Explain the 4-1 and 3-2 principle used in cylindrical surface locations. Give examples 5
for both the cases. '
7. Explain briefly :-
(a) Radial locators (b) Multiple clamp
(d) Quick action clamping.
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Question Nos. 1 and 2 are compulsory. (Use of drawing sheets 15 permitted'i. Attempt any three questions out of remaining five questions,
Answers to questions should be grouped and written together.
Assume suitable data wherever required-
Figures 10 the right indicate full marks.
Support your answers with free hand sketches wherever rquired.
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1. Figure "C.l.flange· is to be manufactured in batches of 400 Nos. Design and draw the drill jig to drill ~ 5 mm x 5 no. holes on BU.C.D. as shown in the drawing. Your design should
include two views with: .
(i) Locating system.
(ii) Clamping system.
(iii) Fool proofing; if required.' (iv) Cutting tool guiding system. (v) Bill of material.
(vi) Minimum 7 important Assembly dimensions.
(vii) Logical sequence of manufacturing 11)(; 1iril:;IIt!U part U~ r~H uruwil\g.
(viii) Type of the drill j19 and about 2 line justification for yourchoice.
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2. For the component "C.l.flange"; sketch with a neat free hand; two views of a milling fixture to mill the slot 8 wide x 8 deep at 45° to vertical as shown in the drawing. Your sketch should contain:
(i) Location system. 4
(ii) Clamping system. 4
(iii) Cutter/tool setting. 3
(lv) Working position of the right cutting tool and feed direction. 2
(v) Provision for the fixture Location and Clamping on the m/c bed. 2
( Refer to Question No.1 for Figure)
3. State your views clearly in point form with neat free hand sketches; on any four of the 20
(i) Box drill jig and its applications. (ii) Economics of Jigs and Fixtures. (iii) Quick acting clamps.
(v) Fool proofing in Jigs/Fixtures.
4. Answer to the point in brief. Attempt any five of the followings ;-
(i) State the importance of sequence of machining and component while designing jigs and fixtures for that manufacturing. Support with your own example.
(ii) Comment on the advantages and limitations of standardization in J/F development. (iii) How will you address the problem of chip removal/disposal while designing a Jig or a Fixture?
(iv) Suggest with a proper justification of a line or two; the most appropriate heat treatment you will choose for the following J/F parts.
(a) Strap clamps (c) Base plate
(b) Drill bushings (d) Tool/cutter setting block in milling fixture.
(v) What is purpose of providing ejector in J/F? Briefly describe with a sketch. any one type of an ejector.
(vi) Are 4-2-1 and 4-1 (for cylindrical work) location principles contradictory to the basic 3-2-1 principle location? Justify in brief with working sketches of each type.
5. Comment in point form with supporting sketches on any four :- 20
(i) Salient features of Indexable milling fixtures
(ii) Redundancy in work piece location.
(iii) Jamming of work and means to prevent Jamming. (iv) Balancing of turning fixtures
(v) Low cost Jig/Fixture development. (vi) Dual cylindrical pin location.
6. (a) Calculate the possible location errors in locating a circular work of 4> 100 ±O·25 (with suitable 12,. thickness) with 90° "V" locator in horizontal and vertical position of the "V" axis respectively. What is the effect of changing the "V" angle from 900 to 600 and 1200 respectively
on these errors? Support your answer with suitable working sketches and calculations.
(b) . Explain in brief the application of spherical washer assembly in stack clamping and multiple 8
clamping. Draw neat sketches.
(4 Hours) [Total Marks ; 1 ()(1
N.B.: (1) Question Nos. 1 and 2 are compulsory.
(2) Solve any three. questions out of questions Nos. 3 to 7. (3) Use half imperial sheets wherever necessary.
(4) Support your answers with neat sketches.
(5) Assume suitable additional data if needed.
1. Design and draw a drilljig to drill ~ 10 two holes as shown in figure A. Draw two views 20 to the scale with dimesions. The component material is Cast Iron. Also write sequence
of operations and Bill of material.
Explain locating and clamping method in the above design briefly. 5 Draw free hand sketch for milling fixture for the component shown in figure A 15 for milling the two end faces to maintain dimension 40- 0·100 mm as shown in the sketch (market A). Show clearly method of tool guide, clamping to machine table and fool proofing in your design.
2. (a) (b)
6 10 "It'
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3. (a) Derive equation for selflocking Cam Clamp. What is the significance of sclf locking 10 in cam/wedge type clamps?
(b) What is the method of "dual cylinder location"? Explain with reference to 10 dimensions decided for diamond pin while using a pair of sound pin and diamond
(ii) As side and base locator.
4. (a) What is the difference in centralizer and equalizer? Explain with neat sketches. 10
(b) Determine the errors when V block is used as-
5. Draw neat sketches of the following (any four) :(a) Tumble jig
(b) F oolproofing
(L:) Turning fixture
(d) Allen Caps Screw and Dowel pins used for fixture construction. (e) Ejectors.
6. (a) What is Jamming?
Discuss different methods of preventing jamming with neat sektches. (b) Draw a sketch of indexing jig.
How it may differ constructionally from indexing fixture?
7. How material is selected for different parts of Jigs and Fixtures? Explain particularly wi t h 20 reference to the following parts :-(any four)
(i) Drill bushes (ii) Base plate
(iii) Locator of diameter 60 mm (iv) Quick action nut
(v) 'C' washer.
2. Figure No .. 2 isa C.1. BLock. Monthly production is 500 pieces/month. Desig'l a millin~rffxti.rre to mill 8 mm x 5 mm slot. Assume that the slot is the last operation.
In your design you should show the following. Write the sequence of operations from the Basic Casting.
(a) Proper Location System 4
(b) Proper Clampng System 4
(c) Cutting tool positioning device 3
(d) Bill of material 3
(e) Positioning of the cutting tool and its way movement with respect to 3
the machine table.
(f) Location of the fixture on to the machine table. 3
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2. For the above component "Belt drive Bracket" design a Milling Fixture to mill slot of 20 58 ± 0·1 wide and show followfng ':-
(i) Tool setting block
(iii) Cutter position and direction (iv) Location, clamping principle.
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