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Types and Functions of Jigs and Fixtures

OBJECTIVES After completing this unit, the student should be able to: Identify the classes of jigs and fixtures. Identify the types of jigs and fixtures. Choose a class and type of jig and fixture for selected operations on sample parts.

JIGS AND FIXTURES Jigs and fixtures are production-workholding devices used to manufacture duplicate parts accurately. The correct relationship and alignment between the cutter, or other tool, and the workpiece must be maintained. To do this, a jig or fixture is designed and built to hold, support, and locate every part to ensure that each is drilled or machined within the specified limits. Jigs and fixtures are so closely related that the terms are sometimes confused or used interchangeably. The difference is in the way the tool is guided to the workpiece. A jig is a special device that holds, supports, or is placed on a part to be machined. It is a production tool made so that it not only locates and holds the workpiece but also guides the cutting tool as the oper-

ation is performed. Jigs are usually fitted with hardened steel bushings for guiding drills or other cutting tools (Figure 21A). As a rule, small jigs are not fastened to the drill press table. If, however, holes above .25 inch in diameter are to be drilled, it is usually necessary to fasten the jig to the table securely. A fixture is a production tool that locates, holds, and supports the work securely so the required machining operations can be performed. Set blocks and feeler or thickness gauges are used with fixtures to reference the cutter to the workpiece (Figure 21B). A fixture should be securely fastened to the table of the machine upon which the work is done. Though largely used on milling machines, fixtures are also designed to hold work for various operations on most of the standard machine tools. Fixtures vary in design from relatively simple tools to expensive, complicated devices. Fixtures also help to simplify metalworking operations performed on special equipment. CLASSES OF JIGS Jigs may be divided into two general classes: boring jigs and drill jigs. Boring jigs are used to bore holes that either are too large to drill or must be made an odd size (Figure 22). Drill jigs are used to drill,

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Figure 21 Referencing the tool to the work.

ream, tap, chamfer, counterbore, countersink, reverse spotface, or reverse countersink (Figure 23). The basic jig is almost the same for either machining operation. The only difference is in the size of the bushings used. TYPES OF JIGS Drill jigs may be divided into two general types, open and closed. Open jigs are for simple operations where work is done on only one side of the part. Closed, or

box, jigs are used for parts that must be machined on more than one side. The names used to identify these jigs refer to how the tool is built. Template jigs are normally used for accuracy rather than speed. This type of jig fits over, on, or into the work and is not usually clamped (Figure 24). Templates are the least expensive and simplest type of jig to use. They may or may not have bushings. When bushings are not used, the whole jig plate is normally hardened.

Figure 22 Boring jig.

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Figure 23 Operations common to a drill jig.

Figure 24 Template jigs.

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Figure 25 Plate jig.

Plate jigs are similar to templates (Figure 25). The only difference is that plate jigs have built-in clamps to hold the work. These jigs can also be made with or without bushings, depending on the number of parts to be made. Plate jigs are sometimes made with legs to raise the jig off the table for large work. This style is called a table jig (Figure 26). Sandwich jigs are a form of plate jig with a back plate (Figure 27). This type of jig is ideal for thin or soft parts that could bend or warp in another style of jig. Here again, the use of bushings is determined by the number of parts to be made. Angle-plate jigs are used to hold parts that are machined at right angles to their mounting locators (Figure 28). Pulleys, collars, and gears are some of the parts that use this type of jig. A variation is the modified angle-plate jig, which is used for machining angles other than 90 degrees (Figure 29). Both of these examples have clearance problems with the cutting tool. As the drill exits the product being drilled, it has little or no room for the drill point to clear the product completely, produce a round hole all the way through the part wall, and avoid drilling the part locator. This is most noticeable in Figure 29, where an angled hole requires additional clearance to the relieved portion of the part locator. Additional clearance here would allow the drill to complete the hole and avoid drilling the relieved portion of the locator. The part locator will most likely be hardened and the

Figure 26 Table jig.

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Figure 27 Sandwich jig.

Figure 28 Angle-plate jig.

Figure 29 Modified angle-plate jig.

drill will be lost as a result of any attempted drilling. Additional clearance on the relieved diameter of the part locator may be possible. A larger clearance hole in the locator could also be added if the relieved diameter cannot be reduced. The additional design consideration added to the locator would include the feature to provide the correct orientation of this clearance hole or machined relief to line up with the bushing location. Box jigs, or tumble jigs, usually totally surround the part (Figure 210). This style of jig allows the part to be completely machined on every surface without the need to reposition the work in the jig.

Channel jigs are the simplest form of box jig (Figure 211). The work is held between two sides and machined from the third side. In some cases, where jig feet are used, the work can be machined on three sides. Leaf jigs are small box jigs with a hinged leaf to allow for easier loading and unloading (Figure 212). The main differences between leaf jigs and box jigs are size and part location. Leaf jigs are normally smaller than box jigs and are sometimes made so that they do not completely surround the part. They are usually equipped with a handle for easier movement. Indexing jigs are used to accurately space holes or other machined areas around a part. To do this, the

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Figure 210 Box or tumble jig.

Figure 211 Channel jig.

drilled, another can be reamed and a third counterbored. The final station is used for unloading the finished parts and loading fresh parts. This jig is commonly used on multiple-spindle machines. It could also work on single-spindle models. There are several other jigs that are combinations of the types described. These complex jigs are often so specialized that they cannot be classified. Regardless of the jig selected, it must suit the part, perform the operation accurately, and be simple and safe to operate. TYPES OF FIXTURES The names used to describe the various types of fixtures are determined mainly by how the tool is built. Jigs and fixtures are made basically the same way as far as locators and positioners are concerned. The main construction difference is mass. Because of the increased tool forces, fixtures are built stronger and heavier than a jig would be for the same part. Plate fixtures are the simplest form of fixture (Figure 217). The basic fixture is made from a flat plate that has a variety of clamps and locators to hold and locate the part. The simplicity of this fixture makes it useful for most machining operations. Its adaptability makes it popular. The angle-plate fixture is a variation of the plate fixture (Figure 218). With this tool, the part is normally machined at a right angle to its locator. While

jig uses either the part itself or a reference plate and a plunger (Figure 213). Larger indexing jigs are called rotary jigs. Trunnion jigs are a form of rotary jig for very large or odd-shaped parts (Figure 214). The part is first put into a box-type carrier and then loaded on the trunnion. This jig is well suited for large, heavy parts that must be machined with several separate platetype jigs. Pump jigs are commercially made jigs that must be adapted by the user (Figure 215). The lever-activated plate makes this tool very fast to load and unload. Since the tool is already made and only needs to be modified, a great deal of time is saved by using this jig. Multistation jigs are made in any of the forms already discussed (Figure 216). The main feature of this jig is how it locates the work. While one part is

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Figure 212 Leaf jig.

Figure 213 Indexing jig.

most angle-plate fixtures are made at 90 degrees, there are times when other angles are needed. In these cases, a modified angle-plate fixture can be used (Figure 219).

Vise-jaw fixtures are used for machining small parts (Figure 220). With this type of tool, the standard vise jaws are replaced with jaws that are formed to fit the part. Vise-jaw fixtures are the least expen-

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Figure 214 Trunnion jig.

Figure 215 Pump jig.

sive type of fixture to make. Their use is limited only by the sizes of the vises available. Indexing fixtures are very similar to indexing jigs (Figure 221). These fixtures are used for machining parts that must have machined details evenly spaced.

The parts shown in Figure 222 are examples of the uses of an indexing fixture. Multistation fixtures are used primarily for highspeed, high-volume production runs, where the machining cycle must be continuous. Duplex fixtures are the simplest form of multistation fixture, using only two stations (Figure 223). This form allows the loading and unloading operations to be performed while the machining operation is in progress. For example, once the machining operation is complete at station 1, the tool is revolved and the cycle is repeated at station 2. At the same time, the part is unloaded at station 1 and a fresh part is loaded. Profiling fixtures are used to guide tools for machining contours that the machine cannot normally follow. These contours can be either internal or external. Since the fixture continuously contacts the tool, an incorrectly cut shape is almost impossible. The operation in Figure 224 shows how the cam is accurately cut by maintaining contact between the fixture and the bearing on the milling cutter. This bearing is an important part of the tool and must always be used.

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Figure 216 Multistation jig.

Figure 217 Plate fixture.

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Figure 218 Angle-plate fixture.

CLASSIFICATION OF FIXTURES Fixtures are normally classified by the type of machine on which they are used. Fixtures can also be identified by a subclassification. For example, if a fixture is designed to be used on a milling machine, it is called a milling fixture. If the task it is intended to perform is straddle milling, it is called a straddlemilling fixture. The same principle applies to a lathe fixture that is designed to machine radii. It is called a lathe-radius fixture.
Figure 219 Modified angle-plate fixture.

Figure 220 Vise-jaw fixture.

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Figure 221 Indexing fixture.

Figure 222 Parts machined with an indexing fixture.

Figure 223 Duplex fixture.

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The type of jig is determined by how it is built. The two types of jigs are open and closed. Template, plate, table, sandwich, and angleplate jigs are all open jigs. Box, channel, and leaf jigs are all closed jigs. Other variations, such as indexing, rotary, trunnion, pump, and multistation jigs, are made as either open or closed jigs. Fixture types are determined by the way they are built. The most common types are plate, angleplate, vise-jaw, indexing, and multistation fixtures. Fixture classes are determined by the machine tools on which they are used and sometimes by the operations performed. A fixture used for a straddlemilling operation is classed as a mill fixture, but it may also be classed as a straddle-milling fixture.
Figure 224 Profiling fixture.

REVIEW 1. 2. 3. 4. What is the difference between a jig and a fixture? How are jigs and fixtures normally identified? What are set blocks used for? What class of jig would normally be used to tap holes? 5. A gang-milling fixture is actually what class of tool? 6. Analyze the following part drawings and operations to be performed and select the best jig or fixture for each. A. Figure 225. Operation: Mill a slot .250 inch by .250 inch. 1. Box fixture 2. Duplex fixture 3. Vise-jaw fixture

The following is a partial list of production operations that use fixtures: Assembling Boring Broaching Drilling Forming Gauging Grinding Heat treating Honing Inspecting SUMMARY The following important concepts were presented in this unit: Jigs and fixtures are production workholding devices designed to hold, support, and locate a workpiece. A jig guides the cutting tool with a drill bushing. A fixture references the cutting tool with a set block and feeler, or thickness gauges. Jigs are divided into two general classes: drill jigs and boring jigs. Lapping Milling Planing Sawing Shaping Stamping Tapping Testing Turning Welding

Figure 225

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B. Figure 226. Operation: Drill four .500-inchdiameter holes. 1. Plate jig 2. Angle-plate jig 3. Channel jig

D. Figure 228. Operation: Drill four holes, .50 inch in diameter. 1. Box jig 2. Angle-plate jig 3. Template jig

Figure 226

C. Figure 227. Operation: Drill four holes (two .62-inch and two .25-inch). 1. Channel jig 2. Plate jig 3. Box jig

Figure 228

E. Figure 229. Operation: Mill a shoulder .75 inch by .75 inch by .38 inch. 1. Plate fixture 2. Angle-plate fixture 3. Indexing fixture

Figure 227

Figure 229