79 CHAPTER 3 JIGS AND FIXTURES 3.1 Difference Between Jigs and Fixtures In engineering there is often more than one way of manufacturing @ component, and cost is often the criterion of choice of method as discussed in Chapter 1. If 2 component is required in large quantities, then clearly a method which is suitable for producing one-off (such as marking out, setting on machine, clamping to machine table, etc.) would not be suitable for economic reasons. A faster and more profitable method requires some device on which the component(s) can quickly be positioned in the correct relationship to the cutting tool(s) and quickly clamped before machining takes place. Such a device is known as a jig or fixture. A jig is a device usually made of metal which locates and holds the workpiece(s) in a positive manner and also guides the cutting tool(s) such that it is in the correct relationship to the work when machining commences. It is usually necessary for the work to be held in the jig by clamping. The jig is not fixed to the machine table by clamping but is held by hand. Jigs are used for quantity drilling, reaming and tapping for example, A fixture is a device similar to a jig but as the name implies is fixed to the machine bed by clamping in such a position that the work is in the correct relationship to the cutter. A further difference is that the cutter is not guided into position ready for machining wo commence. A setting gauge is often provided to. enable the initial setting of work to the cutter to be quickly and easily accomplished betore production begins. Fixtures are used for quantity milling, turning and grinding for example. These definitions are riot always precisely applied in engineering, and. the terms jig or fixture are often used quite loosely gs and fixtures has been in wide ‘The practice of designing and makin; use for many years, and the numbers of these devices successfully used is legion We are therefore considering a vast subject in which a great deal of personal80 Preference, variety, inventiveness and even engineering dogma may be found. Therefore the student may be puzzled at first sight by the apparent lack of uniformity. However, certain sound design principles arc now well established and will shortly be discussed, and also much standardization has been applied in this field of production engineering leading to cheaper production methods. 3.2 Principles of Location Kinematics is the branch of mechanics relating to problems of motion and Position, and kinematic principles can be applied in considering the location of work in a jig or fixture. Figure 3.1 shows a body in space. Figure 3.1 Body in Space es af freedom. It can roti » YY or ZZ. It is It can be seen that the body has six d about, or have linear movement along each of three axes, not constrained or prevented from moving in any. direction. When located in a jig a workpiece must be constrained from moving in any direction. This can be done by six locations in the case of the body shown in Pig 3.1, this being known as the six point location principle. It is illustrated in Vig. 3.281 Clamping force Clamping force Clamping force’ Figure 3.2 Six point Location Principle The base of the component is resting on three location pegs which is the minimum number of points upon which it will firmly seat. When the closing force is applied (by means of a clamp say) all the six degrees of freedom have been removed, If more than six points are used the additional points will be surplus and unnecessary and would therefore be redundant constraints. Depending upon the shape of the component six location pegs may not be required in practice and may be replaced by other devices, However the same basic principle prevails. Three examples of altemative means of location are given freedom without havis next, each of which has removed the six degrees of redundant constraints. Location upon two Plugs The smaller hardened and ground plug has flats machined on each side to allow for slight variations in centre distance of the two holes in the lever Two completely round location plugs would allow much less variation in the hole centres, thus providing a very precise form of location