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

15.SENTHIL ME www. (a) Design and sketch any two views of a progressive die to manufacture the outer plate of a cycle — chain links. Determine the diameter of the blank and the drawing force.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. Write short notes on inspection and welding fixtures. Or (b) Discuss briefly any four possible for the component shown in Fig. 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 .chennaituitions.in (b) 14. (a) How the fly press differ from power press? Describe the construction and working of a power press with the help of suitable sketch.

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

chennaituitions. 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. Also determine the work done if the percentage penetration is 25 percent of material thickness.in Or (b) Sketch and explain Box jig. 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. Sketch the scrap strip by layout and determine the percentage of stock used. 14. 13.SENTHIL ME www. if the ultimate shear stress of the material is 450 N/ mm2. Page 6 of 20 . (a) Describe the common mechanism used for ram driving in power presses.5 mm thick metal strip. 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. 15.V.

FIXTURES AND PRESS TOOLS (Common to Automobile Engineering) (Common to B. PART A — (10 x 2 = 20 marks) 1. 3. 2. 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. 10.Tech. (a) What are the various location devices? Explain any four of them in with the aid of suitable sketches. state its advantages. Or Explain with the help of suitable sketches the operation principles of power clamping systems. 8. 6. (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. 4. (b) 12. Page 7 of 20 . 5.V. NOVEMBER/DECEMBER 2007.E.SENTHIL ME www.chennaituitions. Also.(Part-Time) Sixth Semester Regulation 2005) Time : Three hours Maximum : 100 marks Answer ALL questions. Seventh Semester (Regulation 2004) Mechanical Engineering ME 1009 — DESIGN OF JIGS. 7. DEGREE EXAMINATION.l.E/B. 9.in B.

25 mm inside diameter and 1. (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.2. 14.SENTHIL ME www. (ii) Calculate the maximum punch force necessary to blank a steel washer 44 mm outside diameter and 22. (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.chennaituitions. The ultimate shear stress of the material is 320 N/mm2. 15.6 mm thick. 13. (a) (i) Differentiate between progressive die and a compound die.V.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. 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. Page 8 of 20 . Sketch the scrap strip by layout and determine the percentage of stock used. if τs = 400 N/mm2. Or (b) With proper sketch explain the operation of a modular fixture with example used in practice.

b) (i) Sketch and explain V-type locating device having fixed-V and movable-V locator. with suitable sketches. moving jaw and guidway are to be clearly indicated and a parts-list is also to be given.3 Hours MAXIMUM : 100 Marks ANSWER ALL QUESTIONS PART .in ANNA UNIVERSITY. A cup shown in Figure 1 is to be produced using a suitable drawing die. Also indicate how will you fix the vice on the table of a milling machine. (10 x 2 = 20 Marks) When is a diamond-pin used for locations? Sketch a quick acting clamp. MECHANICAL ENGINEERING. 8. Assuming that a milling operation is going to be performed on the block.A 1.E. CHENNAI 25 MODEL QUESTION PAPER B. VI SEMESTER ME339 . What is the purpose of shear angle on a punch or die? What causes spring back in bending? PART . Give a parts list. (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. Is this locating concept limited to rectangular work pieces? (7) 12. (ii) Sketch a simple vise that can be used for clamping work pieces. (8) (ii) Sketch a strap type clamp for clamping a rectangular block. 6.SENTHIL ME www. 3.chennaituitions.B (5 x 16 = 80 Marks) 11 . (i) Find the size of the blank and the number of draws required. Indicate where the clamping forces are to be applied. What is the difference between a jig and a fixture?.V. Give details of guiding the movable-V locator. 2. 5.DESIGN OF JIGS. The fixed jaw. 7. What are modular fixtures? Distinguish between blanking and piercing. Page 9 of 20 . What is meant by fool proofing in the design of a jig? What is the purpose of a setting block in a fixture?. 10. 4. (6) a) (i) Explain the 3-2-1 locating concept using pins. FIXTURES AND PRESS TOOLS TIME . (9) (OR) 12. 9. Give also an example of a component for which this type of locator can be used. Mention the significance of center of pressure as applied to Press tool design.

indicating how the stock is fed. at the middle of its length. • 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.SENTHIL ME www. (10) (OR) b) The component shown in Figure 4 is to be manufactured using a progressive die.in compare the directions of tool force and 13. (4) (OR) b) (i) Design and sketch a drill jig to drill the 10 mm hole in the component shown in Figure 3. (10) Page 10 of 20 .chennaituitions. if the operation is to be done using a vertical milling machine. (8) (ii) Two plates are to be held at right angles to fabricate a L-shaped component by gas welding. the material thickness being 1.5 mm. how a fixture could be designed to broach a keyway in a gear blank.V. 6 mm depth and 45 mm long is to be milled on a 50 mm diameter shaft 150 mm long. (12) State how the cutter will be set before milling (4) (OR) b) (i) Explain with suitable sketch. assuming that this is the last operation to be performed. (8) 15. a) (i) A key way of 16 mm width. (12) (ii) Discuss briefly the location and clamping arrangements used in your design. Sketch a suitable fixture and indicate all the parts. a) (i) Design and sketch a drill jig to drill the 20 mm hole in the component shown in Figure 2. (i) Develop and sketch a suitable strip layout (6) (ii) Sketch the punches and dies of the progressive die. a) (i) Explain briefly the function of the following parts applied to press working. Suggest a suitable fixture. (12) (ii) Discuss the location and clamping method employed in your design (4) 14.

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Tech. Take the die radius as 3 mm. What is spring back in bending? Mention the methods of reducing cutting forces in piercing operation. Write the work holding devices used for the following operations : (a) Eccentric turning (b) Cylindrical grinding (c) Surface grinding (d) T slot milling. Distinguish between a setting block and stepping block.SENTHIL ME www. Sixth Semester Mechanical Engineering ME 339 — DESIGN OF JIGS.5 mm having a width of 1 m to be bent in wiping die. 10. Distinguish between a pot jig and a box jig. 4.E/B. 6. Sketch and write the use of a equalising clamp. 5. 7. PART A — (10 x 2 = 20 marks) 1.V. Prepare part list and number the parts. 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. FIXTURES AND PRESS TOOLS Time : Three hours Maximum : 100 marks Answer ALL questions. DEGREE EXAMINATION. 2. Estimate the force required for a 90° bending of C 50 steel of 1. Explain the term redundant location. Write the specific requirements of a turning fixture. 8. 3. MAY/JUNE 2007. 11.in B.chennaituitions. 1. 9. (b) Or Design and draw atleast 2 views of a jig for drilling 4 holes of size ϕ12 Page 13 of 20 . Distinguish between a blanking die and a bending die.

V. ϕ50 on the bearing bracket shown in Fig. Number the Page 14 of 20 . 2. (a) Design and draw two views of a jig/fixture for machining the boss of size. 12. Number the parts and prepare part list. (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. 3.chennaituitions.in on the Boss shown in Fig.SENTHIL ME www. 4.

Number the parts and prepare part list.V.chennaituitions. 13. 5. (b) Design and draw any two views of a jig to make two holes of ϕ12 mm Page 15 of 20 . (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.SENTHIL ME www.

Page 16 of 20 . (6) (iii)What are the factors to be considered while designing grinding fixture. 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. The thickness of the sheet metal is 0. (a) Sketch and design a progressive die to make a steel washer 30 mm outside diameter with 15 mm hole from 1.SENTHIL ME www.in on the fork given. 15. (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. Material . (a) (i)What is 3-2-1 principle of location? (4) (ii)Explain briefly about the welding fixtures.Mild Steel.6 mm thick steel sheet.75 mm. The ultimate shear stress of the material is 320 N/mm2. Number the parts and prepare bill of material.V.chennaituitions. 14.

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

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

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

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