Design of Jigs and Fixtures and Press Tools

1. For a selected example component of your choice, design a turnover jig.

(or)
Sketch and explain the turnover jig.

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 (if it is asked for 7 marks draw the above diagram)

2. Discuss in details any four principles of location with neat sketches.

1.Workpiece Requisites
2.Accuracy
3.Constraints
4.Foolproofing

1.Workpiece Requisites

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2.Accuracy

3.Constraints

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 4.Foolproofing
Ensures that the part fits into the tool, in its correct position only.

The simplest and most cost effective method is positioning a fool proof pin.

3. Sketch and explain any two of the mechanically actuated clamps.

Heel Clamp

The simple form of a heel clamp is shown in Figure Rotation of the clamp in clockwise
direction is prevented and it is allowed in anticlockwise direction. For releasing the
workpiece the clamping nut is unscrewed. The free movements in anticlockwise direction
takes place before un-securing the nut to release the workpiece.

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 Bridge Clamp

The bridge clamp is illustrated in Figure 4.10. It applies more clamping pressure as
compared to heel clamp. The clamping pressure experienced by the workpiece depends on
the distances ‗x‘and ‗y‘ marked in the Figure To release the workpiece the nut named as
clamping nut is unscrewed. The spring lifts the lever to release the workpiece.

4. Sketch and explain a clamping device which uses mechanical and pneumatic actuators.

Edge Clamp or Side Clamp

A side clamp is also known as edge clamp. In this case the surface to be machined is
always clamped above the clamping device. This clamping device is recommended for fixed
length workpiece. Releasing and clamping of the workpiece can be accomplished by
unscrewing and screwing of the clamping nut respectively.

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 Screw Clamp

The screw clamp is illustrated in Figure 4.12. It is also known as clamp screw.
This clamping applies pressure directly on the side faces of the workpiece.

There is a floating pad at their end to serve the following purposes:

(a) It prevents displacement of workpiece and slip.
(b) It prevents denting of clamping area of workpiece.
(c) The available cushion prevents deflection of screw.

In addition to the above there are some disadvantages associated with this method. The
clamping pressure largely depends on the workpiece, it varies from one workpiece to other.
It is more time consuming and more efforts are required.

5. How are jigs classified? Explain the constructional details of a type of jig with a component your choice.
Classifications of Jigs:

• Post or angle plate Jig

• Turnover
• Channel
• Latch
• Box & Pot
• Angular Post Jigs
• Indexing Jigs

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 Elements of Jigs:

• Jig body -
i. Build up body
ii. Welded body.
iii. cast body.

• Jig feet (write at least two points in your own)

• Drill bush (write at least two points in your own)
• Jig plate (write at least two points in your own)
• Locators (write at least two points in your own)
• Clamps (write at least two points in your own)

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6. Explain the various principles involved in clamping. (write any 10 points)
a. clamping need to be strong and rigid enough to hold the blank firmly during
machining
b. clamping should be easy, quick and consistently adequate
c. clamping should be such that it is not affected by vibration, chatter or heavy
pressure
d. the way of clamping and unclamping should not hinder loading and unloading the
blank in the jig or fixture
e. the clamp and clamping force must not damage or deform the workpiece
f. clamping operation should be very simple and quick acting when the jig or fixture is
to be used more frequently and for large volume of work
g. clamps, which move by slide or slip or tend to do so during applying clamping
forces, should be avoided
h. clamping system should comprise of less number of parts for ease of design,
operation and maintenance
i. the wearing parts should be hard or hardened and also be easily replaceable
j. clamping force should act on heavy part(s) and against supporting and locating
surfaces
k. clamping force should be away from the machining thrust forces
l. clamping method should be fool proof and safe
m.clamping must be reliable but also inexpensive

7. Sketch and explain the latch jig.

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(If it is asked for two marks or four marks draw this)
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