DIFFERENT TYPES OF JIGS

AND FIXTURES
 INTRODUCTION
Jig and Fixture are production work holding
devices used to manufacture duplicate parts
accurately.
They are special purpose tools used for large
scale production by semi skilled operator.
They can also be used for small scale
production when interchangeability is important
by skilled machinist when the workpiece is
difficult to hold without special equipment.
 INTRODUCTION
They are used in industry:
To reduce cost of production
To increase productivity
To assure accuracy of component
For mass production of component on its
repeatability basis
For fully or partial automation of work
To increase the versatility of the machine tool
improve quality with greater machining accuracy
 INTRODUCTION
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 work piece.
Fixture locates, holds and supports the work
securely so the required machining operation
can be performed
Jig not only locates and supports the workpiece
but also guides the cutting tool
 INTRODUCTION
The main construction difference between a jig
and a fixture is mass

Because of the increased tool forces , fixtures

are built stronger and heavier than a jig would
be for the same part

They are made basically the same way as far

as locators and positioners are concerned
 INTRODUCTION
The term jig should be used only for devices
employed while drilling, reaming or tapping holes
It is not fastened to the machined on which it is
used
So it may be moved around on the table of the
drilling machine to bring each bushing under the
drill
It is not fastened to the drill press table for small
w.p, however holes above 0.25 mm inch in
diameter are to be drilled, it is usually necessary to
fasten the jig to the table securely.
 INTRODUCTION
Jigs make it possible to drill, ream and tap
holes at much greater speeds and with
greater accuracy
Skilled workers are not required
Responsibility for the accuracy of hole
location is taken from the operator and given
to the jig
Jigs physically limit and control the path of
the cutting tool with the help of bushings
 INTRODUCTION
For machining operations like milling,
shaping, turning, broaching, etc., the term
fixture should be used
A fixture hold and locates the work during
machining but does not contain special
arrangements for guiding the cutting tools
A fixture is also fixed to the machine
The accuracy of machining depends upon
the operator and construction of machine tool
 TYPES OF DRILL JIGS
Open Jigs:
Used for simple operations
Work is done only on one side of the part

Closed or Box Jigs:

Used for parts that must be machined on
more than one side
Operations Common to a Drill Jig
 TEMPLATE JIGS
It is the form of jig consisting of a suitable material having
holes for correct location
The plate serve as a template which is fixed on the
component to be drilled
Temple jigs are normally used for accuracy rather than
speed.
Used for locating hole pattern on large workpieces
Usually not clamped (self-clamping)
It is the least expensive
Simplest type of jigs
They may or may not have bushings. When the bushings
are not used, the whole jig plate is normally hardened.
TEMPLATE JIGS
 PLATE JIGS
It is the modified form of the template jig
with jig bushes incorporated on the temple
Consist of a single bush plate with a
provision for locating and clamping of w.p.
They have built-in clamps to hold the work
They use a flat plate containing bushing as
their main structural member
All the details are attached and referenced
to this plate
May or may not have legs
 PLATE JIGS
Easy part loading and unloading, chip removal by
providing clearance b/w plate and the w.p.
Also called open jig
Slip bushings for operations other than drilling
Thin parts stacked for drilling several parts at one time
These jigs are sometimes made with legs to raise the jig
off the table for large work.
This style is called a table jig
The feet provide square resting surface to the jig.
The diameter of the jig feet should be bigger than the
slot of machining table to prevent the feet from falling
into the slots.
PLATE JIG
PLATE JIG
TABLE JIG
 SANDWICH JIGS
A form of plate jig with a back plate
The w.p is clamped like a sandwich b/w
the base plate and the jig plate.
This type of jig is ideal for thin or soft parts
that could bend or wrap in another style of
jig.
Here, the use of bushings is determined
by the number of parts to be made and
diameter of the hole.
SANDWICH JIG
 ANGLE-PLATE JIGS
Used to machine parts at right angles to
their locators
Pulleys and Gears use this type of jig
MODIFIED ANGLE-PLATE JIG
which is used for machining angles
other than 90 degrees.
Both of these examples have clearance
problems with the cutting tool.
MODIFIED ANGLE-PLATE JIG
MODIFIED ANGLE-PLATE JIG
 BOX JIGS
Surround the part totally
Shape resembles a box
In the figure, for loading, the cam rod is taken
out of the jig and the w.p placed in position
inside the jig
The cam rod is then replaced and rotated to its
locking position
This holds the work-piece firmly so that the
drilling operation can be performed
Such jigs are generally used for components
having irregular shapes or that cannot be held
by common methods.
 BOX JIGS
Number of holes can be drilled
economically with box jig.
One side is open for loading and
unloading the w.p and provided bushing
arrangements.
The box jig can permits drilling of holes in
three sides of the work-piece and saves
times and increase production.
BOX JIG
 Trunnion Jig
Jig is constructed like a box with jig bushes on
various sides.
It is generally used for large and odd shaped
parts.
The jig is well suited for large, heavy parts that
must be machined with several separate plate
type jig.
Due to large size and weight of the workpiece
and the jig, it is not possible to move jig
manually for drilling the hole on the various
sides.
 CHANNEL JIGS
The work-piece is mounted against the top and
one side of the jig
It is clamped from the third side
Its a type of box jig
Provides better stability and support for work-
piece
This type is limited to work-pieces of simple
symmetrical shapes
It mainly consist of the jig body, jig bush and
screws and w.p is clamped inside the channel
with the help of screw.
CHANNEL JIGS
 LEAF JIGS
They are similar to box jigs, but main differences
are size and part location.
Distinguished by their hinged cover, or leaf
Leaf carrying the bushing can be swung open to
load and unload quickly
Suitable for complicated workpieces with irregular
contours
Equipped with a handle for easy movement
It consist of drill bush, hinge pin, set screw leaf
Chips may accumulate inside and cause trouble
LEAF JIGS
LEAF JIGS
 INDEXING JIGS
Many components require holes at stated
angular positions.
Used to drill a series of holes in a circle on the
face of a work-piece under a single bushing
Brings the hole portion under the drill each time
it is indexed
To do this a reference plate and a plunger is
used
For this purpose multi head machine is used at
regular intervals.
The operation can also be performed on single
spindle machine
INDEXING JIGS
 PUMP or UNIVERSAL JIGS
They are similar version of sandwich jig.
Produced commercially as basic units and are
adapted to specific jobs by tool makers
The lever activated plate makes this tool very
fast to load and unload
Rigid, low weight, ample chip clearance and
ease of operation
Handle connected to a cam or rack to clamp
workpiece
It is also known as universal jig used for any
given part by adding the necessary locators and
bushes.
 PUMP or UNIVERSAL JIGS
The guide pillars attached to the jig plate have
rack gear teeth on one side.
Purpose of gear meshing by rotating the handle
is to raise or lower the rack pillar with the jig
plate.
Pump jigs are suitable for drilling only a single
hole on a fixed spindle drilling machine.
One pump can be used for number of
workpieces by providing detachable jig plate and
base plate for different workpieces..
PUMP JIG
 MULTISTATION JIGS
Commonly used on multi-spindle machines
Facilitates more than one workpieces at a time
For example one part being drilled, another can
be reamed and third counter-bored
The final station is used for unloading the finished
part and loading fresh part
It is the complex and specialized type of the jig
that cannot be further classified and skilled
worker is required to operate,
 V-BLOCK JIGS
Used to drilling radial holes in cylindrical or
spherical workpiece.
It mainly consist of the V-block clamping plate.
The component is placed on the V-block and
clamped rigidly by means of a clamping plate
and bolt.
 V-BLOCK JIGS
These jigs may also be called diameter
jigs by some toolmakers.
 VISE JIGS
Constructed by attaching special inserts to the
jaws of a regular machine vise
Generally used for low volume and short
production runs.
It is generally used for drilling the shafts and
consists of a pair of specially designed jaws,
setting stops and support.
 GENERAL CONSIDERATIONS IN
THE DESIGN OF DRILL JIGS
Rigidity:
Jig must be strong enough to withstand all forces
applied to it
It must also resist deflections that may be the result
of excessive tightening of clamps that hold the w.p
in place
The work must also be supported so that it does
not bend under drilling pressure
Cast iron is generally used because it absorb
shocks and compressive forces.
GENERAL CONSIDERATIONS IN
THE DESIGN OF DRILL JIGS
The type of machine in which operation is
performed needs careful considerations
The layout of the jig must provide adequate
hand clearance for easily loading and unloading
and process for loading and unloading must be
quick
Errors arise in components due to wear, dirt,
chips burns and wear resistance surfaces
should be small and easily replaceable.
Bushes are provided on a jig for guiding drills,
reamers and borings, for the desired positioning
GENERAL CONSIDERATIONS IN
THE DESIGN OF DRILL JIGS
To increase tool life and keep the components
cool, a coolant is provided in cutting edge in
sufficient quantity.
Design considerations require easy ejection of
the component from jig (particularly for heavy
ones) to save the operation time and increase
the productivity, pneumatic devices are very
suitable for easy and quick ejection.
 GENERAL CONSIDERATIONS IN
THE DESIGN OF DRILL JIGS
Chip Control:
Types of chips: segmental and continuous
The segmental chip is preferred
Space between the work and bottom of drill
bushings to allow chips to pass b/w the work
and busing plate (1- 11/2 times dia. of drill)
Three ways of chip removal: coolant,
manually with brush or hook, compressed air
Chip Control:
GENERAL CONSIDERATIONS IN
THE DESIGN OF DRILL JIGS
Jig feet and legs:
A drill jig should stand on four feet (Or legs)
rather than a flat surface
Jig feet may be built into the jig body or purchased as
standard parts
They are usually placed on the extremities of the jig
Feet should be ground so that they are all in one
plane after they are mounted on the jig base
When jig is bolted to machine table, usually provides
with four feet instead of a flat bottom, squaring
provides easily chip removal and sustainability.
Types of Standard Jig Feet:
GENERAL CONSIDERATIONS IN
THE DESIGN OF DRILL JIGS
Miscellaneous considerations:
Sharp corners should be eliminated
Provisions should be made for the coolant to get
to the drill
Holes or passages for escape of the coolant
Gripping surfaces should be knurled
The jig should be large enough to hold it against
the torque of the drilling machine
It must be easy to handle
METHODS OF CONSTRUCTION
Generally jigs are constructed by holding the
components together mechanically
This is referred to as built-up construction
Adv.: All parts can be completely machined before
assembly and worn parts can be easily replaced
Minor adjustments can be made during assembly
Jigs of this type are held together by socket-head
cap screws and dowels
Screw serve to hold the components together while
the dowels serve to hold the parts in alignment
METHODS OF CONSTRUCTION
Welded construction is also used in
building a drill jig
Drill jigs are sometimes constructed by a
combination of welding and mechanical
assembly
The main body may be of welded
construction with the smaller components
attached by screws and dowels
The main body of a drill jig may also be
cast
 Materials for Jigs and fixtures
Following points for selection:
Easily available
Ability to withstand the stress expected in service
Ability to retain its shape and size
Corrosion resistance
Cast iron is generally used as materials for jig and
fixture, light materials like brass, bronze, steels,
plastic can also be used.
The choice of the proper material can also be
selected when the operating conditions are known.
 FIXTURES
Used to hold workpiece during machining

Fixture is always fixed to the m/c table

Classified by the type of machine on which

they are used
VISE FIXTURES
MILLING MACHINE VISES
 VISE FIXTURES
Sometimes standard m/c vises are adapted
with special jaws

Special jaws are designed for workpieces

with irregular contours

Used with various types of m/c tools

SPECIAL VISE JAWS
 MILLING FIXTURES
Used to hold the w.piece in correct relation
to the cutter
Attached to m/c table with T-slots

PARTS OF MILLING FIXTURE:

(1) Base (2) Clamps (3) Rest Blocks
(4) Locating Points (5) Gaging Surfaces
BASE:
Consists of base plate with flat & accurate under
surface
Various components are mounted on it
It mates with the surface of milling m/c table
Used as reference plane
Has slots to clamp fixture to the table
It has a keyway running lengthwise in the base for
two keys used to align the fixture on the milling
machine table
The keys are pressed into the keyway at both
ends of the fixture and held there by socket-head
cap screws
BASE:
The fixture is attached to the milling-
machine table and held in alignment by
two keys attached to the fixture base
These keys fit very closely into the T slot
of the mill table
The fixture is held firmly to the table by T
bolts or hold-down clamps
Underside of Mill-fixture Base
Data required before starting the
design of a milling fixture
The type of milling machine
Dimensions of T slots
The center-to-center distance of T slots
The dimensions of the milling machine table
The length of table travel in all three feed
movements

The center-to-center distance of T slots varies

from machine to machine
If the fixture is to be used on more than one
machine, it may be well to hold the fixture with
strap clamps
Strap Clamp Holding Fixture to
Machine Table
 Effect of Cutting Forces on
Workpiece at Beginning of Cut
Cutting forces exerted by a milling cutter
change as the cutter leaves or enters the
work and throw an extra load on clamps
Clamps must not loosen by vibration
caused by interrupted cutting of mill cutter
Interrupted cutting occurs at the beginning
and end of the cut
 Effect of Cutting Forces on
Workpiece at Beginning of Cut
(a) Conventional milling: work is lifted up at
beginning of cut
(b) Climb milling: work is forced down at one
end but lifted up at the other
 Accuracy of Contact Between
Bearing Surface and Workpiece
A feeler gage of predetermined thickness
is inserted between the bearing surface
and the workpiece resting upon it
Bearing surfaces are usually in the form of
pins, pads and plates
 Use of Setting Gages to Locate Mill
Fixture in Correct Relationship to Cutter
 TYPES OF MILLING FIXTURES

Milling Fixtures can be classified in a

variety of ways:
(1) According to the way the workpiece is
clamped, such as hand-clamping fixtures,
power-clamping fixtures, toggle fixtures
etc.
(2) According to the way the workpiece is
located, such as center fixtures, V-block
fixtures etc.
 TYPES OF MILLING FIXTURES

(3) According to the method of presenting the

workpiece to the cutter, as rotary fixtures
where the workpiece is rotated under the
cutter. Indexing fixtures where the workpiece
is indexed into the next position during the
machining cycle.
(4) According to the milling operation performed
on work, such as face-milling fixtures, slab-
milling fixtures, slotting fixtures, string-milling
fixtures etc.
 MILLING FIXTURES
STRING or LINE MILLING FIXTURES:
A number of components strung behind each other in
a line
The fixture moves relative to the cutters
 MILLING FIXTURES
HYDRAULIC CLAMPING FIXTURE:
 MILLING FIXTURES
SPRING TYPE FIXTURE:
 MILLING FIXTURES
CLAMP TYPE FIXTURE:
 MILLING FIXTURES
VACUUM FIXTURE:
Its a suction holding device
Used where holding without distortion is
vital
Uses a vacuum pump
Part acted upon by atm. Pressure
It exerts a downward force on all sides
exposed to vacuum
VACUUM FIXTURE
 BROACHING FIXTURES
A broach is a series of progressively taller
chisel points mounted on a single piece of
steel
Use of a broach is to cut splines or a
square keyway on objects such as gears,
driveshafts, pulleys etc.
INTERNAL BROACHING FIXTURES
INTERNAL BROACHING FIXTURES
EXTERNAL BROACHING
FIXTURES
GRINDING FIXTURES (Magnetic
chucking devices)
Workpiece can be quickly mounted &
removed
Distortion caused by mechanical clamping
eliminated
Mild steel plates separated by nonferrous
ones
Magnetic flux passes from magnetic chuck
through steel plates and workpiece
GRINDING FIXTURES
GRINDING FIXTURES (use of
magnetic chuck parallels)
GRINDING FIXTURES (use of
magnetic-chuck V block)
GRINDING FIXTURES
 LATHE FIXTURES
Three-jaw Universal Chucks:
Three-jaw chucks used for circular and
hexagonal work
Three-jaw chucks are usually self-centering
Three jaws move simultaneously when adjusted
This simultaneous movement is caused by a
scroll plate into which all three jaws fit
They are usually provided with two set of jaws,
one for outside chucking and the other for
inside chucking
THREE-JAW UNIVERSAL
CHUCK
 LATHE FIXTURES
Four-jaw Independent Chucks:
4-jaw chucks are usually non-self-centering
Each jaw can be moved independently
Ideal for gripping round, square, hexagonal and
irregularly shaped workpieces
The jaws can be reversed to hold work by
inside diameter
Multi-jaw chucks (6 or 8 jaws) for special
purpose and high standards of accuracy
FOUR-JAW AND SIX-JAW
CHUCKS
 LATHE FIXTURES
Magnetic Chuck:
It has the advantage of holding iron or steel
parts
The parts that are too thin or that may be
damaged if held in a conventional chuck
Suitable only for light operations
A magnetic chuck consists of an accurately
centered permanent magnet face
MAGNETIC CHUCKS
 LATHE FIXTURES
Faceplates:
Circular metal plate fixed to the end of spindle
Used to hold work that is too large or of such a
shape that it cannot be held in a chuck or
between centers
It has slots or threaded holes
W.piece is clamped using T-nuts in the slots or
threaded holes
FACEPLATE AND T-NUTS
FACEPLATES
FACEPLATES
 LATHE FIXTURES
Collet Chucks:
that forms a collar around the object to be held and exerts a strong
clamping force on the object when it is tightened.
A external collet is a sleeve with a (normally) cylindrical inner
surface and a conical outer surface
Used for very small parts
 LATHE FIXTURES
Collet Chucks:
 LATHE FIXTURES
Mandrels:
Mandrels are internal locators used for machining of the
outside diameter of the workpiece concentric with finished
bores.
Mandrels are shafts specially made to hold work to be
machined concentrically around a previously bored or drilled
hole
There are two general types, plain and expanding
Plain mandrels have a 0.006-in. taper per foot
There must be a mandrel for each hole size
 LATHE FIXTURES
Plain Mandrels:
 LATHE FIXTURES
Sleeve-type Expanding Mandrels:
It is used for high degree of concentricity.
It provides the adjustment of locating
diameter to suite the variation in the bore
size of the workpiece.
 LATHE FIXTURES
Mandrel for Threaded Parts:
Used for holding previously threaded
workpiece or w.p with internal threads