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B.E./B.Tech. DEGREE EXAMINATION, MAY/JUNE 2009. Seventh Semester Mechanical Engineering ME 1009 — DESIGN OF JIGS, FIXTURES AND PRESS TOOLS (Regulation 2004) (Common to B.E. (Part-Time) Sixth Semester -Mechanical Engineering Regulation 2005) Time : Three hours Answer ALL questions. PART A — (10 x 2 = 20 marks) 1. Distinguish between jigs and fixtures. 2. List the standard parts used in jigs and fixtures fabrication. 3. What is the primary function of linear bushing? 4. How can the relation of the jig plate and vise jaw be accurately controlled? 5. What are boring fixtures? How do you classify them? 6. What are welding fixtures? State the general purpose of a welding fixture. 7. What factors should be considered for selecting an appropriate press for a given job? 8. What is the function of a stripper? 9. Distinguish between a compound die and a combination die. 10. Find die clearance range for shearing a 2 mm thick aluminum sheet. PART B — (5 x 16 = 80 marks) 11. (a) What is meant by clamping? Explain the principles involved in the design of clamps? Or (b) Explain briefly the various types of errors accounted for in jigs and fixtures design. 12. (a) Design and draw a suitable drill jig to drill 4 holes of 5 mm diameter at 70 PCD on ϕ 120 mm diameter 60 mm thickness mild steel plate. Or Maximum : 100 marks

(b) Sketch and explain air operated drilling jig components. 13. (a) Design a broaching fixture to perform broaching operation on sides of a square block of size 50 mm x 50 mm. Or
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(b) 14.

Describe the various classification of milling fixtures. Describe

(a) How are the dies classified according to their construction? the different types.

Or (b) Find the total pressure, dimensions of tools to produce a washer 50 mm outside diameter with a 24 mm hole, from material 4 mm thick, having a shear strength of 360 N/mm2. 15. (a) Design and draw a suitable die for 25 mm x 20 mm mild steel plate with a 8 mm hole in the centre. Stock thickness is 0.75 mm Or (b) A shell shown in figure below has a height of 48mm and diameter of 48 mm. The corner radius 2 mm and sheet thickness 1 mm. Material : mild carbon steel. Design a die for drawing operation.

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E. 10. DEGREE EXAMINATION./B.Tech. 9.chennaituitions. PART B — (5 x 16 = 80 marks) 11. 7. FIXTURES AND PRESS TOOLS (Common to Automobile Engineering) (Common to B. Seventh Semester (Regulation 2004) Mechanical Engineering ME 1009 — DESIGN OF JIGS. (a) (i) (ii) Illustrate the working of a lathe fixture. PART A — (10 x 2 = 20 marks) 1. 4. 6. Or (b) Explain the advantages to be obtained from the use of pneumatic and hydraulic clamping devices. How will you select the proper material for press tools? What is the effect of excessive clearance upon die-cut metals? Differentiate between a cutting die and forming die. 5. (a) What is the primary function of a linear bushing? List out any four types of drill bushes with its method of fixing and locking. 8.E.V. NOVEMBER/DECEMBER 2008. Name any two materials commonly used in jigs and fixtures and their Hardness range. 2. Name any four essential features of a milling fixture. (Part-Time) Sixth Semester Regulation 2005) Time : Three hours Maximum : 100 marks (Approved design Data book is permitted) Answer ALL questions. How can a lathe fixture be clamped to the lathe? List out the main parts of a power press. Write any two requirements of clamping devices. .SENTHIL ME www. Illustrate the working of Gang milling fixture. 3. Or Page 3 of 20 12. Or (b) Sketch and explain any eight parts of a Box jig with suitable diagram. Distinguish between the channel and box jigs? Illustrate the working of an automatic drill Jig.in B. (a) List any four types of jigs and fixture construction? State the advantages of each and discuss the relative merits of each. 13.

15.chennaituitions. (a) How the fly press differ from power press? Describe the construction and working of a power press with the help of suitable sketch. Write short notes on inspection and welding fixtures. (a) Design and sketch any two views of a progressive die to manufacture the outer plate of a cycle — chain links.V. Or (b) A steel cup of height 30mm and internal diameter 40mm with a flange width of 10mm is to be deep drawn from a sheet lmm thick. What is the draw ratio? Can the cup be drawn in a single operation and sketch any two views of a draw die? Page 4 of 20 . Or (b) Discuss briefly any four possible for the component shown in Fig. Determine the diameter of the blank and the drawing force.SENTHIL ME www.in (b) 14.

What devices are mainly used to assemble modular elements? 7. APRIL/MAY2008. 1. What is the use of clutch in a power press? 8.E. What is the primary function of a linear bushing? 5. 12.Time) Sixth Semester Regulation 2005) Time : Three hours Answer ALL questions.chennaituitions.DESIGN OF JIGS.SENTHIL ME www.V. Seventh Semester (Regulation 2004) Mechanical Engineering ME 1009 . What is the function of a stripper? When should a spring-load stripper be used? 9. DEGREE EXAMINATION. How can a lathe fixture be clamped to the lathe? 6. What are the main differences between a jig and a fixture? 2.in B.E (Part . (a) Maximum : 100 marks Page 5 of 20 ./B. What is a progressive die? When should a progressive die be used? PART B — (5 x 16 = 8(Xmarks) What is six-point location principle? Explain it with the help of suitable sketches? Or (b) Explain the advantages to be obtained from the use of pneumatic and hydraulic clamping devices. (a) Design and draw to scale any two views of a suitable drill jig for drilling the holes in the component shown in fig. Why should a jig have four feet and not three? 4. How can the fabrication tolerance for jigs and fixture be calculated? 3.Tech. 11. What are the effects of inadequate clearance and excessive clearance upon die-cut metals? 10. FIXTURES AND PRESS TOOLS (Common to B. PART A — (10 x 2 = 20 marks) 1.

Or (b) What is strip layout? What are the different ways of making strip layout for regular and irregular shaped blanks? (a) A rectangular steel component of size 20 mm x 60 mm is to be made from 4 mm thick sheet. Or (b) Estimate the blanking force to cut a blank of 25 mm wide and 30 mm long from a 1. (a) Explain the working of milling fixture with example used in practice. Page 6 of 20 . if the ultimate shear stress of the material is 450 N/ mm2.in Or (b) Sketch and explain Box jig.V. 13. Sketch the scrap strip by layout and determine the percentage of stock used. (a) Describe the common mechanism used for ram driving in power presses. Or (b) Design a welding fixture for welding a door main frame of dimensions (100 x 20 x 4) Welding must be done on front and rear side of the plates.SENTHIL ME www.chennaituitions. 14.5 mm thick metal strip. 15. Also determine the work done if the percentage penetration is 25 percent of material thickness.

l. NOVEMBER/DECEMBER 2007. 3.E/B. PART A — (10 x 2 = 20 marks) 1. Or Explain with the help of suitable sketches the operation principles of power clamping systems.E. Seventh Semester (Regulation 2004) Mechanical Engineering ME 1009 — DESIGN OF JIGS. 5. 10. 6. Also.(Part-Time) Sixth Semester Regulation 2005) Time : Three hours Maximum : 100 marks Answer ALL questions.in B. 4. 9. (b) 12.Tech. 7. Page 7 of 20 .chennaituitions. FIXTURES AND PRESS TOOLS (Common to Automobile Engineering) (Common to B. state its advantages.SENTHIL ME www. 8. What is meant by angular location? Where should locators contact the part? Why? What class of jig would normally be used to tap holes? What is the primary function of a linear bushing? How are cutters set in relation to the work in a milling fixture? List any three basic types of jigs used for welding? What is meant by clearance? Why is it important in shearing operation? What is the purpose of the shear angle found on a punch or die? Why is the wheel dressing often attached directly to the grinding fixture? What is a progressive die? When should a progressive die be used? PART B — (5 x 16 = 80 marks) 11.V. (a) Design and draw to scale any two views of a suitable drill jig to drill two ϕ 10 mm hole on the component shown in fig. DEGREE EXAMINATION. (a) What are the various location devices? Explain any four of them in with the aid of suitable sketches. 2.

6 mm thick steel sheet.in Or (b) Design and sketch any two views of a suitable drill jig to drill an oil hole of size 3 mm for the given job shown in fig. if τs = 400 N/mm2. Sketch the scrap strip by layout and determine the percentage of stock used.chennaituitions.6 mm thick. 13. Or (b) Design and draw any two view of a progressive die to make a steel washer of 30 mm outside diameter with 15 mm hole from 1. (a) (i) Differentiate between progressive die and a compound die. (a) Design a suitable milling fixture to cut a keyway of size 3x3 mm on a solid shaft of <p 30 mm diameter and 100 mm length. (ii) Calculate the maximum punch force necessary to blank a steel washer 44 mm outside diameter and 22.2. The ultimate shear stress of the material is 320 N/mm2. Or (b) With proper sketch explain the operation of a modular fixture with example used in practice.25 mm inside diameter and 1. 14. Page 8 of 20 . (8+8) Or (b) What is strip layout? What are the different ways of making strip layout for regular and irregular shaped blanks? (a) A rectangular steel component of size 20 mm x 60 mm is to be made from 4 mm thick sheet.SENTHIL ME www. 15.V.

(10 x 2 = 20 Marks) When is a diamond-pin used for locations? Sketch a quick acting clamp. MECHANICAL ENGINEERING.b) (i) Sketch and explain V-type locating device having fixed-V and movable-V locator. What is meant by fool proofing in the design of a jig? What is the purpose of a setting block in a fixture?. 10. VI SEMESTER ME339 . What are modular fixtures? Distinguish between blanking and piercing. (8) (ii) Sketch a strap type clamp for clamping a rectangular block. Indicate where the clamping forces are to be applied. Is this locating concept limited to rectangular work pieces? (7) 12.V. What is the purpose of shear angle on a punch or die? What causes spring back in bending? PART . The fixed jaw. CHENNAI 25 MODEL QUESTION PAPER B. 7. 6. Give a parts list. A cup shown in Figure 1 is to be produced using a suitable drawing die.chennaituitions. Give also an example of a component for which this type of locator can be used. (9) (OR) 12. 4.3 Hours MAXIMUM : 100 Marks ANSWER ALL QUESTIONS PART . 3. 2.E.B (5 x 16 = 80 Marks) 11 . (6) a) (i) Explain the 3-2-1 locating concept using pins.A 1. (i) Find the size of the blank and the number of draws required.in ANNA UNIVERSITY. Also indicate how will you fix the vice on the table of a milling machine. Assuming that a milling operation is going to be performed on the block. with suitable sketches. Give details of guiding the movable-V locator. (ii) Sketch a simple vise that can be used for clamping work pieces. Mention the significance of center of pressure as applied to Press tool design. 9. 8. What is the difference between a jig and a fixture?. FIXTURES AND PRESS TOOLS TIME . moving jaw and guidway are to be clearly indicated and a parts-list is also to be given.SENTHIL ME www.DESIGN OF JIGS. 5. Page 9 of 20 . (4) (ii) Sketch (without dimensions) the sectional front view of punch and die assembly and name the parts (6) (iii)Sketch the punch and die separately and indicate their dimensions.

V. (i) Develop and sketch a suitable strip layout (6) (ii) Sketch the punches and dies of the progressive die. 6 mm depth and 45 mm long is to be milled on a 50 mm diameter shaft 150 mm long. a) (i) Design and sketch a drill jig to drill the 20 mm hole in the component shown in Figure 2.in compare the directions of tool force and 13. (12) State how the cutter will be set before milling (4) (OR) b) (i) Explain with suitable sketch. Sketch a suitable fixture and indicate all the parts. a) (i) Explain briefly the function of the following parts applied to press working. (10) Page 10 of 20 . (4) (OR) b) (i) Design and sketch a drill jig to drill the 10 mm hole in the component shown in Figure 3. Suggest a suitable fixture. the material thickness being 1. • Pilots • Stock stop • Knockout rod (6) (ii) Sketch a suitable press tool to manufacture square component 40 mm side having a central square hole 20 mm side.chennaituitions. a) (i) A key way of 16 mm width. at the middle of its length. if the operation is to be done using a vertical milling machine. (12) (ii) Discuss the location and clamping method employed in your design (4) 14. how a fixture could be designed to broach a keyway in a gear blank. assuming that this is the last operation to be performed. (10) (OR) b) The component shown in Figure 4 is to be manufactured using a progressive die. (12) (ii) Discuss briefly the location and clamping arrangements used in your design. (8) (ii) Two plates are to be held at right angles to fabricate a L-shaped component by gas welding. indicating how the stock is fed. (8) 15.SENTHIL ME www.5 mm.

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FIXTURES AND PRESS TOOLS Time : Three hours Maximum : 100 marks Answer ALL questions. Distinguish between a pot jig and a box jig.E/B. Prepare part list and number the parts. 9. Explain the term redundant location. 2. Distinguish between a setting block and stepping block. PART B — (5 x 16 = 80 marks) (a) Design and draw any two views of a jig for drilling 4 holes of diameter ϕ 4 mm at 90 mm PCD on the 3 sides of a 'Y ' flange as shown in Fig.in B. Estimate the force required for a 90° bending of C 50 steel of 1. 10. MAY/JUNE 2007. Sketch and write the use of a equalising clamp. 3. Write the work holding devices used for the following operations : (a) Eccentric turning (b) Cylindrical grinding (c) Surface grinding (d) T slot milling. PART A — (10 x 2 = 20 marks) 1.5 mm having a width of 1 m to be bent in wiping die. 5. 1.Tech. 6. (b) Or Design and draw atleast 2 views of a jig for drilling 4 holes of size ϕ12 Page 13 of 20 . Sixth Semester Mechanical Engineering ME 339 — DESIGN OF JIGS. 4.V. DEGREE EXAMINATION. Distinguish between a blanking die and a bending die. Take the die radius as 3 mm.chennaituitions. What is spring back in bending? Mention the methods of reducing cutting forces in piercing operation.SENTHIL ME www. 7. 11. 8. Write the specific requirements of a turning fixture.

(a) Design and draw two views of a jig/fixture for machining the boss of size.SENTHIL ME www.in on the Boss shown in Fig. Number the parts and prepare part list. Number the Page 14 of 20 . ϕ50 on the bearing bracket shown in Fig. (b) Design and draw atleast two views of a milling fixture for making a slot of 8 mm wide x 15 mm deep on a dome pin as shown in Fig. 2. 4. 12. 3.chennaituitions.V.

(b) Design and draw any two views of a jig to make two holes of ϕ12 mm Page 15 of 20 .chennaituitions.V.SENTHIL ME www. 13. (a) Design and draw any two views of a jig for drilling 4 holes of ϕ6 mm diameter at the 4 corners of a rectangular flange as shown in Fig.in parts and prepare part list. 5. Number the parts and prepare part list.

in on the fork given. (a) Sketch and design a progressive die to make a steel washer 30 mm outside diameter with 15 mm hole from 1. Number the parts and prepare bill of material.chennaituitions. (6) Or (b) Write short notes on the following : (i) Materials used in jigs and fixtures (ii) Compound and combination dies (iii) Stretch forming (iv) Stripper and pilots.6 mm thick steel sheet. (6) (iii)What are the factors to be considered while designing grinding fixture. 15.75 mm. 14.V. (a) (i)What is 3-2-1 principle of location? (4) (ii)Explain briefly about the welding fixtures.Mild Steel. Or (b) Design a drawing die set for the production of cylindrical cups having a outer diameter of 50 mm and shell height of 40 mm.SENTHIL ME www. The ultimate shear stress of the material is 320 N/mm2. The thickness of the sheet metal is 0. Page 16 of 20 . Material .

SENTHIL ME www. What is the advantage of swing plate clamp? Sketch the channel Jig. Explain the function of bolster plate in press tool. Differentiate between jigs and fixtures. (i) (ii) (a) Discuss the advantage of jigs and fixtures. 9. (8) (ii)Explain briefly 3-2-1 location of principle. .chennaituitions. all dimensions are in mm. Define j ack pin locator.V. In figures. DEGREE EXAMINATION. (8) Or (b) (i)Explain briefly with neat sketch cylindrical and adjustable locators. What is the purpose of pilot? Differentiate between punching and piercing operation. 3. Sixth Semester Mechanical Engineering ME 339 — DESIGN OF JIGS./B. 8. PART B — (5 x 16 = 80 marks) 11. (8) Page 17 of 20 . Assume any missing data suitably wherever it is necessary. 4. Out line the principles of jigs and fixtures design. (8) (8) Maximum : 100 marks 12. FIXTURES AND PRESS TOOLS Time : Three hours Answer ALL questions. Explain the function of fool proofing. Mention any two advantages of fabricated Jig. Mention the application of turning fixture. PART A — (10 x 2 = 20 marks) 1. 2. (8) (a) (i)Design a drill jig to make hole of ϕ 10 mm as shown in Figure 1 and also mention the part list. 7.in B. 6. 10.E. MAY/JUNE 2006.Tech. (ii) Explain briefly with neat sketch latch and wedge clamping. 13. (i)Explain briefly with neat sketch non-conventional clamping. 5.

Take Fs = 32 kg/mm2. Or Write short notes on the following : Bending and forming die. (16) (a) (i) Sketch and design a drawing die as shown in Figure 4 from medium carbon steel Ft. (8) 2 and also 14.in (ii) Explain briefly any four types of drill bushes with neat sketches. (8) (ii) (b) (i) (ii) (iii) Discuss the various inspection devices. (8) Or (b) (i) Design a drill jig to make hole of O 10 mm as shown in Figure mention the part list. (8) (ii) Design a milling fixture to make a slot of O 70 x 10 x 10 mm shown in Figure 3.chennaituitions.V.3600 kg/cm2 . Or (b) Sketch and design a blanking die to make <D 30 mm part from 3 mm thick Carbon steel sheet metal.SENTHIL ME www. Page 18 of 20 (8) (5) (6) (5) . Calculation of centre of pressure with example. (8) as 15. Combination and compound die. (8) (i) Explain briefly mechanical and hydraulic presses. (ii) (a) Explain briefly welding fixture and grinding fixture.

7. 11. Mention the application of turning fixture. How is die life gauged? PART B — (5 x 16 = 80 marks) (i) What are the main objectives to be consider while designing jig and f(8) fixture? (ii)Explain briefly main elements of jig and fixture. (ii) Explain with neat sketch any two types of clamping device. 5./B. DEGREE EXAMINATION.Tech. 4. What is meant by 3-2-1 principle of location? What is best method to locate a rough surface? What is advantage of conical locators? Explain the importance of clamping force. What is the purpose of stripper? Define deep drawing. 10. Sixth Semester Mechanical Engineering ME 339 — DESIGN OF JIGS. 9. (8) Or (b) (i) Explain briefly neat sketch unconventional clamping. also (ii) Explain briefly universal jig and plastic jig. (8) (ii) Explain the important accessories of jig and fixture. 13. (8) also Or (b) (i) Design a drill jig to make hole of 10 mm as shown figure 2 and mention the part list.chennaituitions.SENTHIL ME www. Answer ALL questions. (8) Page 19 of 20 .V. (8) (a) (i) Design a drill jig to make hole of 10 mm as shown figure 1 and mention the part list. In figures. Define plate jigs. 6. Sketch the indexing jig. 3. NOVEMBER/DECEMBER 2005. 8. (8) (a) (i) Explain with neat sketch any two types of locating device. PART A — (10 x 2 = 20 marks) 1.in B.E. FIXTURES AND PRESS TOOLS Time : Three hours Maximum : 100 marks Assume any missing data suitably wherever it is necessary. 2. (8) 12. all dimensions are in mm.

(a) Sketch and design a piercing die to make 35 mm square part from 2 mm thick carbon steel sheet metal.chennaituitions. Design a milling fixture to make a slot of 70 x 10 x 10 mm as (8) shown in (ii) Write short notes on shaping fixture and broaching fixture. Explain briefly box jig and turnover jig. (6) Page 20 of 20 . Or (b) (i) figure 4. (6) (iii) Discuss the design procedure of drawing die.V. (8) (ii) Design a milling fixture to make a slot of 70 x 10 x 10 mm as shown in (8) figure 3. (8) (a) (i) Explain briefly welding fixture and grinding fixture.in (ii) 14. (16) Or (b) Write short notes on following : (i) Sketch combination die.SENTHIL ME www. (4) (ii) Describe various type of cutting operation. (8) 15.

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