VOCATIONAL TRAINING REPORT

On

MACHINES AND JIGS AND FIXTURES

at

MAHAVIR INDUSTRIES
Submitted in partial fulfillment of the requirements for the award
of the
degree of

Bachelor of Engineering
in
MECHANICAL ENGINEERING

Submitted to: Submitted By:

Dr. Jatinder Madan (HOD, ME) Ajay Kashyap
& LCO16165
Er.V.Senthil (Training In-charge) Final Year

Department of Mechanical Engineering

Chandigarh College of Engineering and Technology (Degree Wing), Chandigarh
August, 2018
(Affiliated to Panjab University, Chandigarh)
 DECLARATION

I hereby declare that the work, which has been presented in this Training Report, in partial
fulfillment of the requirements for the awards of degree of Bachelor of Engineering in
Mechanical Engineering submitted to the Mechanical Engineering Department, CCET,
Chandigarh, is an authentic piece of work carried out from 3rd June 2019 to 12th July 2019, under
the supervision of Mr. Rao Sahab.

The matter in this Training Report is not submitted by me for the award of any degree elsewhere.

Ajay Kashyap
LCO16165

Dr Ashwani Kumar Vinod Chauhan

Er.V.Senthil Dr. Jatinder Madan

(Training In-charge) (HOD, ME)

I
II
 ACKNOWLEDGEMENT

I would like to put forth my regardful thanks to all those who had helped me in guiding
me to get the most out of this golden opportunity to learn the most during such a period of my
training at Mahavir Industries...

I pay my special thanks to Mr. Rao Sahab, who gave me chance to work with him and
gave me excellent knowledge. Also I put my special regards to the Parshant, Akshay, Rupinder
who have always been so supporting and ready to help.

I also put forth my special thanks to all the concerned persons as well as Dr. K. G.
Sharma, (Training & Placement Department), Dr. Jatinder Madan, (HOD, Mechanical),
Er.V.Senthil (Training In-charge, Mechanical) and Dr. Manpreet Singh, Principal C.C.E.T.
(Degree Wing), Chandigarh, who have enabled me to have an opportunity to work at the
prestigious organization.

Thankful,

Ajay Kashyap

III
 TABLE OF CONTENTS

Sr. No. Topic Page no.

1 Declaration (i)
2 Certificate (ii)
3 Acknowledgement (iii)
4 List of tables (iv)
5 Chapter -1 01- 05
Introduction
Products Offered
6 Chapter -2 06-21
Machinery-
Press
Drilling
Lathe
Milling
Grinding
7 Chapter – 3 22-28
CNC Machines
8 Chapter-4 29-39
Jigs & Fixtures
9 Chapter-5 40-47
Project: Die Making
10 References 48

IV
 CHAPTER 1 : INRODUCTION

Fig. 1.1 Company Logo

MAHAVIR INDUSTRIES

 Set up and established in the year 2008 by the sole propertiership of Mr. Rao, it servers in
the region of Die Works and Press Die , Job Work, fabrication and Govt. Order Suppliers.

 We are the leading manufacturers and suppliers of various type of dies, Jigs and Fixtures,
sheet metal components, machined components.
 Our product range is very wide and conforms to India, British, JIS, DIN and ANSI
specifications.
 It is located in the heart of industrial area Chandigarh.

 With manpower up to 20-25 people, it ensures in providing best quality service with high
efficiency and on time delivery.

1
1.1 QUALITY STANDARD
1.1.1 Our Quality Policy

Ever Increasing Customer Satisfaction through:

 Continuous Improvements in Product Quality

 Meeting Complete Range of Customer Requirements
 Delivery at Right Time Once & Always
 Timely Communication
 Motivated Staff & Work-force
 Adherence to Set Standards

1.1.2 RESPONSIBILITY TOWARDS ENVIRONMENT

As a responsible member of the society and a caring corporate citizen, we are
committed towards the protection of environment and betterment of human health in
each area of our activities. While recognizing the influence our activities can have on
the local environment in general and the society in particular, we shall make
continuous efforts to fulfill the following principles during our day-to-day activities:

 Control of emissions, effluents and waste disposal arising out of our

manufacturing processes as per pre-defined and laid-down norms.
Furthermore, such efforts will be continuously improved upon as newer and
better treatment processes are made available.
 Adopting means to avoid wastages and conserve energy.
 Creating healthy work place to take care of the health of workers.
 Compliance with statutory requirements.
 Strive hard to enhance our reputation as an Environmentally Responsible
Company.

2
1.2 PRODUCTS OFFERED

1.2.1 Hinges (metal spring loaded)

Fig. 1.2 Hinges

1.2.2 Notched Hinge

Fig. 1.3 Notched Hinge

3
1.2.3 BRASS SHEET COMPONENT

Fig. 1.4 Brass Sheet Component

1.2.4 STRIP LAYOUT

Fig. 1.5 Strip Layout

4
1.2.5 AUTO FEEDING SYSTEM

Fig. 1.6 Auto feeding system

1.2.6 CIRCLIPS

Fig. 1.7 Circlips

5
 CHAPTER 2 : MACHINERY
 Press (Hand and machine press)
 Drilling Machine
 Lathe Machine
 Milling Machine
 Grinding Machine
 Surface Grinder

2.1 PRESS

 A forming press, commonly shortened to press, is a machine tool that changes

the shape of a work piece by the application of pressure.[1] The operator of a
forming press is known as a press-tool setter, often shortened to toolsetter.

Fig. 2.1 Press

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 Fig. 2.2 Elements of Power Press

2.1.1 Elements of power press

 Ram: The ram is a part that has a punch fitted at its bottom and moves up and
down.

 Punch: The punch is a part of die-set which makes direct contact to the work
metal while moving downwards.

 Die-block: The die-block is a part of die-set which contains a hole that has the
same shape & size as the part to be made. The hardened and tempered die-block
involves in actual cutting or shaping process.

 Crank: The crank is a part that converts the rotating motion of motor-shaft into
reciprocating motion of ram and punch.

 Crank shaft: The crank shaft plays an important role and connects between the
crank and the ram.

 Motor-drive: An electric motor is used to run the shaft that rotates the crank and
provide power to operate the ram.

7
 Fly-wheel: The Fly-wheel stores the energy during return stroke and delivers it at
the working stroke.

 Clutch: The clutch engages or disengages the drive from the crank.

 Brake: The brake is attached to the drive shaft to stop the stroke.

 Stock-feeder: The stock-feeder is used to feed the Strip stock from the coil to the
area between punch and die for operation.

2.1.2 Classification of Presses: Presses may be classified as follows:

 According to the source of power:

(i) Manually operated (Fly) press.

(ii) Electric Motor driven press.

(iii) Pneumatic system driven press.

(iv) Hydraulic system driven press.

 According to the design of the frame:

(i) Inclined.

(ii) Straight side.

(iii) Gap.

(iv) Horn.

(v) Arch.

(vi) Inclinable.

8
 According to the drive mechanism:

(i) Crank.

(ii) Eccentric.

(iii) Rack and pinion.

(iv) Screw.

(v) Toggle drive.

(vi) Knuckle joint.

 According to the number of slides:

(i) Single action.

(ii) Double action.

(iii) Multiple actions.

 According to the use:

(i) Shearing.

(ii) Punching.

(iii) Coining.

(iv) Stretching.

(v) Extruding.

(vi) Straightening.

(vii) Bending etc.

9
2.1.3 Specification of a Press:

The specification of a press involves the following items:

 Length of stroke: The length of stroke is defined as the distance between up and
down position the ram

 Shut height: The shut height is defined as the distance between the top of the
bed to the bottom of the ram.

 Die space: The die space is defined as the available area for mounting the
punch and dies components in the press.

 Press adjustment: The press adjustment means the capability of press to

adjust the length of stroke as per need, as in the case of rack and pinion-driven
presses.

 Number of ram head: The number of ram heads provided for simultaneous
operations i.e. single- acting, double-acting or multiple-acting.

 Amount force or press: The size of any press is determined by the maximum
force or pressure that can be exerted by the ram on the work piece without any
failure.

 Capacity of working: The capacity of mechanical press is determined by the

shear strength of the crank shaft material multiplied by the area of the crankshaft
bearings. The capacity of mechanical presses ranges from 50 tons to 4000 tons.
On the other hand, the capacity of a hydraulic press is determined by the piston
area multiplied by the pressure of oil in the cylinder. The capacity of a hydraulic
press ranges from 100 tons to 40,000 tons.

10
2.1.4 Selection of a Press:
The factors considering while selecting the press for particular application are:

 Work piece material.

 Work piece size.

 Work piece thickness.

 Operations to be performed.

 Operational speed required.

 Production rate.

 Power required.

 Dimensional tolerances and accuracy required for parts.

 Die types i.e., single, compound or progressive type etc.

2.1.5 Application of Different Presses:

 Crank or eccentric type presses:Because their small working strokes and high
production rates, these type of presses used for punching, blanking and trimming
operations.

 Knuckle joint type Presses: Because of their large force capacities, these presses
are used for coining and squeezing operations.

 Toggle presses: These are used for operations like heading, perforating, upsetting,
etc.

 Hydraulic presses: Hydraulic presses are best suited for operations require
slower speed, like pressing, forming, drawing, etc.

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2.2 DRILLING MACHINE

 Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-
section in solid materials. The drill bit is usually a rotary cutting tool, often multi-
point. The bit is pressed against the work-piece and rotated at rates from hundreds
to thousands of revolutions per minute. This forces the cutting edge against the
work-piece, cutting off chips (swarf) from the hole as it is drilled.

 A machine for making holes with removal of chips. Drilling machines are use
d for drilling, boring, countersinking, reaming,and tapping. Several types are used
in metalworking: vertical drilling machines, horizontal drilling machines, center-
drilling-machines, gang drilling machines, multiple-
spindle drilling machines, and special-purpose drilling machines.

 Vertical drilling machines are the most widely used in metalworking. They are
used tomake holes in relatively small work-pieces in individual and small-
lot production; they are also used in maintenance shops. The tool, such as a drill,
countersink,or reamer, is fastened on a vertical spindle, and the work-
piece is secured on the table of the machine. The axes of the tooland the hole to b
e drilled are aligned by moving the workpiece.

Fig. 2.3 Drilling Machine

12
2.2.1 Types of drilling machines

 Portable drilling machine

 Sensitive drilling machine

 Upright or column drilling machine

 Radial drilling machine

 Gang drilling machine

 Multi-spindle drilling machine

 Automatic drilling machine

 Deep hole drilling machine

 Vertical drilling machine

13
2.3 LATHE MACHINE
A lathe is a tool that rotates the workpiece about an axis of rotation to perform
various operations such as cutting, sanding, knurling, drilling, deformation, facing,
and turning, with tools that are applied to the workpiece to create an object
with symmetry about that axis.

Lathes are used in woodturning, metalworking, metal spinning, thermal spraying,

parts reclamation, and glass-working. Lathes can be used to shape pottery, the best-
known design being the potter's wheel. Most suitably equipped metalworking lathes
can also be used to produce most solids of revolution, plane surfaces and screw
threads or helices. Ornamental lathes can produce three-dimensional solids of
incredible complexity. The workpiece is usually held in place by either one or
two centers, at least one of which can typically be moved horizontally to
accommodate varying workpiece lengths. Other work-holding methods include
clamping the work about the axis of rotation using a chuck or collet, or to a faceplate,
using clamps or dogs.

Fig. 2.4 Lathe Machine

14
2.3.1 Types of Lathe Machines

There are different types of lathe machines. The four main types of lathes are;

 Speed Lathes:- It is very simple is design. It only has headstock, tailstock and a
very simple tool post. It can operate in 3-4 speeds. The spindle speed is very high.
It is used for light machine works like wood turning, metal spinning and metal
polishing.
 Engine Lathes:- Engine lathes are the most common types of lathe machine. It is
designed for low power operations as well as high power operations. Various
lengths of the machine is available. The length can be up to 60 feet. Engine lathe
is commonly seen in every machine shop.
 Tool Room Lathes:- It is a very versatile lathe machine. It can give better
accuracy and finishing . It has wider range of speeds . It can give different types
of feeds. It can be a great device to manufacture die.
 Turret Lathes:- It is a great machine for quick operations. It has various types of
tool posts mounted on a single structure. As a number of tools are set up on
machine, the job can be completed very quickly with the help of a single setup. A
capstan wheel is used to position the next tool.
 Special Types of Lathe Machines:- These are the machines which are allows the
worker to perform tasks which are not possible in normal lathe machines. These
lathes include –
 Bench type jeweler’s lathe
 Automatic lathes
 Brakedrum lathes
 Multispindle lathes
 Crankshaft lathes

15
2.3.2 LATHE OPERATIONS

Fig. 2.5 Lathe operations

16
2.4 MILLING MACHINE

Fig. 2.6 Universal Milling Machine

 Milling is the machining process of using rotary cutters to remove

material[1] from a workpiece by advancing (or feeding) the cutter into the
workpiece at a certain direction[2]. The cutter may also be held at an angle relative
to the axis of the tool.[3] Milling covers a wide variety of different operations and
machines, on scales from small individual parts to large, heavy-duty gang milling
operations. It is one of the most commonly used processes for machining custom
parts to precise tolerances.

 Milling can be done with a wide range of machine tools. The original class of
machine tools for milling was the milling machine (often called a mill). After the
advent of computer numerical control (CNC), milling machines evolved into
machining centers: milling machines augmented by automatic tool changers, tool
magazines or carousels, CNC capability, coolant systems, and enclosures. Milling
centers are generally classified as vertical machining centers (VMCs) or
horizontal machining centers (HMCs).

17
 Fig. 2.7 Vertical Milling Machine

2.4.1 Types of Milling Machine

 Column and Knee type Milling Machine

 Horizontal Milling Machine

 Vertical Milling Machine

 Universal Milling Machine

 Omniversal Milling Machine

 Bed-type Milling Machine

 Simplex Milling Machine

 Duplex Milling Machine

 Triplex Milling Machine

 Production type Milling Machine

 Rotary Drum Milling Machine

 Tracer controlled Milling Machine

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 Special Purpose Milling Machine

 Planetary Milling Machine

 Profile Milling Machine

 Skin Milling Machine

 Spar Milling Machine

 Thread Milling Machine

2.4.2 DIFFERENT MILLING OPERATIONS

Fig. 2.8 Milling Operations (a) Straddle Milling (b) Step Milling (c) End Milling
(d) Edge Milling (e) Pocket Milling (f) Profile Milling

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2.5 GRINDING MACHINES
A grinding machine, often shortened to grinder, is any of various power
tools or machine tools used for grinding, which is a type of machiningusing
an abrasive wheel as the cutting tool. Each grain of abrasive on the wheel's surface
cuts a small chip from the workpiece via shear deformation.

Grinding is used to finish workpieces that must show high surface quality (e.g.,
low surface roughness) and high accuracy of shape and dimension. As the accuracy in
dimensions in grinding is of the order of 0.000025 mm, in most applications it tends
to be a finishing operation and removes comparatively little metal, about 0.25 to
0.50 mm depth. However, there are some roughing applications in which grinding
removes high volumes of metal quite rapidly.

Fig. 2.9 Surface Grinder

2.5.1 Classification of Grinding Machines

 Belt Grinder

 Bench Grinder

 Pedestial Grinder

 Cylindrical Grinder

 Surface Grinder

 Tool & Cutter Grinder

 Jig Grinder

20
2.6 SURFACE GRINDER

 Surface grinding is the most common of the grinding operations. It is a finishing

process that uses a rotating abrasive wheel to smooth the flat surface of metallic
or nonmetallic materials to give them a more refined look by removing the oxide
layer and impurities on work piece surfaces. This will also attain a desired surface
for a functional purpose.

 The surface grinder is composed of an abrasive wheel, a workholding device

known as a chuck, and a reciprocating or rotary table. The chuck holds the
material in place while it is being worked on. It can do this one of two
ways: ferromagnetic pieces are held in place by a magnetic chuck, while non-
ferromagnetic and nonmetallic pieces are held in place by vacuum or mechanical
means. A machine vise (made from ferromagnetic steel or cast iron) placed on the
magnetic chuck can be used to hold non-ferromagnetic workpieces if only a
magnetic chuck is available.

Fig. 2.10 Surface Grinder

21
 CHAPTER 3 : CNC MACHINES

A CNC, or computer numerical control machine is a high precision tool that’s

computer-controlled and makes repeated, accurate movements. It does so by taking
computer-generated code and converting it with software to electrical signals. The
signals are what control the CNC motors and directs them to move in small
increments that are highly precise and repetitive. In Lathe machines there are 3 motors
(Chuck, cross feed and feed given by compound rest) whereas in milling there are 4
motors (1 – Chuck, 2 – Table motion and 1 – Tool motion). Therefore, there are 4
things to control in CNC i.e.

 Which Motor should be used.

 In which direction should be used.

 Revolution per minutes

 And for how much time

3.1 CNC types

Usually CNC is which controls the machine operations i.e. Turning Centre (Lathe),
Milling, Laser cutting etc. but, in this lab, I practiced upon the Turing centre (Lathe)
and Milling.

 CNC Turning Centre (Lathe) also known as HMC – Horizontal

Machining Centre. In HMC, spindle rotates in a horizontal orientation in which
cylindrical workpiece is rotated around its axis and tool is stationary and all
controls are controlled by the CNC controller. i.e. Turning Centre is HMC.

 CNC Milling also known as VMC – Vertical Machining Centre. In VMC,

the workpiece is hold on the table base and the spindle which contains the cutting
tool is fixed on vertical spindle Z axis. The table moves in X and Y axis and
spindle with cutting tool moves in Z axis.

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3.2 Coordinates Systems

To Understand the CNC, we need to understand coordinates

 Absolute Coordinate – A fixed origin will be there and tool will work with
respect to it.

 Incremental Coordinate – After a origin where ever your tool goes/moves to a

new coordinate/point it becomes a new origin.

For e.g.

Absolute Command can be given like from (0,0) to (2,3) to (4,5) to (-1,-1)

Incremental Command can be given like from (0,0) to (2,3) to (2,2) to (-5,-6)

Fig. 3.1 Coordinate System

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3.3 Coding

There are two basic codes used for coding i.e.

1. Preparatory Codes – G Codes … From G00 – G99

2. Miscellaneous Codes – M Codes … From M00 – M99 (can be upto M300)

 Basically, in starting the coding / controls were manufactured and made by two
companies i.e. Fanuc and Siemen. So therefore, there are minor changes between
the codes used by Fanuc or Siemens rest are same.

 Nowadays, some CNC manufactures are giving an option to generate codes as per
the operator needs. In that operator can generate its own codes as per requirement
and give it own axis, since now there is an option to increase the axis from 3 to 6.

 There are also various software’s like Solid Cam and Master Cam in which the
operator designs its product and the software generates the codes and program
regarding that product. Operator just need to set the machine, tool Offset with
respect to the workpiece

Fig. 3.2 CNC Simulator

24
 Fig. 3.3 CNC Simulator representation

As seen in above area there are there main things i.e.

 Simulation Display Area: Display the complete process of material cutting in 3D

space.

 Controller and Tool Bar: Includes Controlling function in which the program is
given and is edited and touching screen tool bar in which view can be changed,
material size, tool option tool magazine file import and export, operation and
workpiece files can be changed.

 Operation Panel: Panel of controlling the machine’s functioning.

 Mode Select: Mode Switch, Main Operation function. Buttons and switches are
effective by mode switch.

 Spindle Override: Spindle Speed Adjustment Switch. Adjust the spindle speed:
50%-120%.

25
 Feederate Override: Feederate Speed Adjustment Switch. Adjust the feederate
speed of spindle: 0%-200%.

 Rapid Override: Rapid Speed Adjustment Switch. Adjust the rapid speed of
spindle: 0%-100%.

 Auto-run Operation Button.

 Manual Operation Button.

 Aided Button.

3.4 Modes
The mode is divided into two parts

a) Auto Mode Group

EDIT: Edit Mode, edit and check the CNC programs in the controller

DNC: Download CNC program from external device

AUTO: Auto run the CNC program in the controller and cut the part automatically

MDI: Key in CNC program in MDI interface and run instantly

b) Manually Mode Group

HANDLE: Use hand wheel to move the spindle axis manually

JOG: Use axial button to move spindle manually 28

RAPID: Use axial button to move spindle rapidly

ZRN: Return to home position.

3.5 Offset

Offset is a numerical value stored in the CNC controls that repositions machine
components or in simple words the position of job is found with respect to the tool.

There are three types of offsets :-

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3.5.1 Work Offset - The first major offset on the CNC is the workshift offset. To cut
a part held in the chuck or clamp on the table, the operator must shift the reference
point of the turret or spindle of tool from the machine zero to program zero. The
operator manually moves turret with help of handle mode and then records this
position in the controls. A workshift offset is only necessary for distances along the Z-
axis. For the turning center, there is no workshift offset in the X-axis because the X-
axis position of program zero is typically located on the spindle centerline. In milling
centre the X-axis and Y-axis workshift offset is taken of job by just touching the tool
with workpiece. The accuracy built into these machines ensures that the centerline of
every part will be in the same position. Operators can store multiple workshift offsets
by using G codes, which commonly include G54 through G59. If the operator changes
jobs but keeps the same tooling in the turret, he or she will adjust only the workshift
offset to reposition the turret in the Z-axis in turning center but, in milling center
he/she has to change the X-axis and Y-axis.

3.5.2 Geometry Offset - The workshift offset shifts the entire turret, which affects
every tool within it. However, turning tools and inserts, milling tools and inserts,
boring bars, and drills all have their own distinct lengths and orientations. Geometry
offsets shift the turret to account for each tool’s unique dimensions. The geometry
offset for each tool shifts the turret in both the X-axis and Z-axis in case of turning.
But in case of milling the geometry offset shifts only the Z-axis of the tool or spindle.
A Z-axis geometry offset adjusts the turret from the workshift offset location for each
tool. The X-axis geometry offset adjusts the turret from the spindle centerline. The
operator simply touches off every tool against finished part surfaces and stores the Z-
axis and X-axis geometry offsets. Remember, the reference tool already has its Z-axis
position stored as the workshift offset; however, it still requires an X-axis geometry
offset.

3.5.3 Wear Offset - Offset Features for Turning and Milling, the operator must
determine the workshift offset for a specific part and geometry offsets for each tool
before the first run of the program. However, an operator may discover that the
dimensions of the part are slightly undersized or inaccurate after machining. The
operator can then use wear offsets to make slight adjustments and bring the part
within the correct tolerance. However, the distances stored as an offset may be only a
few thousandths of an inch along each axis. Each cutting tool has its own wear offset.

27
Cutting forces, part deflection, tool wear, etc. can potentially cause slight changes to
tool location and variations in measurements. Wear offsets act as the minor
adjustments that compensate for these variables.

Fig 3.4 CNC Machine

28
 CHAPTER 4 : JIGS AND FIXTURES

4.1 Difference Between Jigs and Fixtures

 A fixture holds and position the work but does not guide the tool, whereas a jig
holds, locates and as well as guide the tool.
 The fixtures are heavier in construction and are bolted rigidly on the machine
table, whereas the jigs are made lighter for quicker handling and clamping with
the table is often unnecessary.
 The fixtures are employed for holding work in milling, grinding, planing or
turning operations, whereas the jigs are used for holding the work and guiding the
tool, particularly in drilling reaming or tapping operations.

4.2 Advantages of Jigs and Fixtures

 Increases the machining accuracy because the workpiece is automatically

located and the tool is guided without making any manual adjustment.
 It increases the production capacity by enabling a number of workpieces to be
machined in the single set up and in some cases, a number of tools may be
made to operate simultaneously.
 The handling time is also greatly reduced due to the quick setting and locating
of the work.
 The speed, feed and depth of cut for machining can be increased due to high
clamping rigidity of jigs and fixtures.
 Enables the production of identical parts which are interchangeable. This
facilitates the assembly operation.
 It eliminates the marking out, measuring and other setting methods before
machining.
 These devices reduce the operator’s labour and consequent fatigue handling
operations, are minimized and simplified.
 It reaches the semiskilled operator to perform the operation as the setting
operations of the tool and the work are mechanized. This saves labour cost.
 It reduces the expenditure on the quality control of the finished products.
 Reduces the overall cost of machining by fully or partly automizing the
processes.

29
4.3 Principles of Jigs and Fixtures Design

The successful designing of a jig or a fixture depends upon the analysis of several
factors which must be carefully studied before the actual work is taken in hand. The
following are the essential factors which must be considered in designing a jig or a
fixture,

 Study of the component.

 Study of the type and capacity of the machine.
 Study of the locating elements.
 Study of the loading and unloading arrangement.
 Study of the clamping arrangement.
 Study of the power devices for operating the clamping elements.
 Study of the clearance required between the jig and the component.
 Study of the indexing devices.
 Study of the tool guiding and cutter setting elements.
 Study of the fool-proofing arrangement.
 Study of the ejecting devices.
 Study of the swarf removal arrangement.
 Study of the rigidity and vibration problems.
 Study of the table fixing arrangement.
 Study of the safety devices.
 Study of the methods of manufacturing of the jig base, body or frame.

4.4 Applications of Jigs and Fixtures

4.4.1 Applications of jigs

 Drilling
 Reaming
 Tapping

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4.4.2 Applications of fixtures

 Milling
 Grinding
 Planing
 Turning
 Shaping

4.5 Types of jig

4.5.1 Template Jig

Fig. 4.1 Template Jig

 The template jig is the simplest of all the types. A plate 2 having holes at the
desired positions serves as a which is fixed on component 1 to be drilled. The
drill 21 is guided through these holes of the template 2 and the required holes are
drilled on the workpiece at the same relative positions with each other as on the
template.

31
4.5.2 Plate Jig

Fig. 4.2 Plate Jig

 A fixture holds and positions the work but does not guide the tool. Whereas a
jig holds, locates and as well as guides the tool.
 The fixtures are heavier in construction and are bolted rigidly on the machine
table. Whereas the jigs are made lighter for quicker handling, and clamping
with the table is often unnecessary.
 The fixtures are employed for handling work in milling, grinding, planing, or
turning operations. Whereas the jigs are used for holding work and guiding the
tool particularly in drilling, reaming or tapping operations.

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4.5.3 Channel Jig

Fig. 4.3 Channel Jig

 The channel jig is illustrated in the fig. It is a simple type of jig having a channel-
like cross-section. The component is fitted within the channel and is located and
clamped by rotating the knurled knob . The tool is guided through the drill bush.

4.5.4 Diameter Jig

Fig. 4.4 Diameter Jig

 The diameter jig is shown in fig. It is used to drill radial holes on a cylindrical or
spherical workpiece. The work is placed on the fixed V-block and then clamped
by the clamping plate which is also locate the work. The tool is guided through
the drill bush which is set radially with the work.

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4.5.5 Leaf Jig

Fig. 4.5 Leaf Jig

 The leaf jig is illustrated in the above figure. It has a leaf or a plate hinged on the
body at and the leaf may be swung open or closed on the work for loading or
loading purposes. The work is located by the buttons and is clamped by set
screws. The drill bush guides the tool.

4.5.6 Box Jig

Fig. 4.6 Box Jig

 It is of box-like construction within which the component is located by the

buttons. The work is clamped by rotating the cam handle which also locates it.
The drill bush guides the tool. The box jigs are generally employed to drill a
number of holes on a component from different angles.

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4.6 Types of Fixtures

4.6.1 Turning Fixture

Fig. 4.7 Turning Fixture

 It is quite easy-to hold regular workpieces on lathes in standard job holding

devices like chucks and collects, between the centre and on mandrels or
faceplates. But irregularly shaped components offer a lot of difficulties in holding
them correctly.

 Simple odd shaped jobs can be held in chuck also, say by proper adjustment of
jaws in a four-jaw chuck or by using shaped soft jaws. However, workpieces
having complicated shaped have to be necessarily held in position with the help
of turning fixtures. These fixtures are normally mounted on the nose of the
machine spindle or on a faceplate and the workpieces held them.

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4.6.2 Milling Fixture

Fig. 4.8 Milling Fixture

 These fixtures are used on milling for carrying out different milling operations on
workpieces. The fixture is properly located on the table of the mahince and
secured in position by means of bolts and nuts.

 The table is shifted and set in proper position, in relation to the cutter. The
workpieces are located no the base of the fixture and clamped before starting the
opration.

 Since the cutting forces involved are quite high, and also intermittent, the
clamping elements. Proper loacting of the fixture on the mahine table is usually
achieved with the help of two tenons provided under the fixture base. These
tenons enter a T-slot of the table to provide the required loaction. The fixture base
can then be scured to the table by means of T-bolts and nuts.

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4.6.3 Broaching fixtures

Fig. 4.9 Broaching Fixture

 These fixtures are used on different types of broaching machines to locate, hold
and support the workpieces during the operations, such as
keyway broacing operations, such as keyway broaching, hole broaching, etc. The
use of a clamping plate as a fixture for internal pull-type hole broaching.

4.6.4 Grinding Fixture

 Several different forms of fixtures are used in grinding machines to locate, hold
and support the workpieces during the operations. These fixtures may be the
standard work-holding devices, such as chucks, mandrels, chuck with shaped
jaws, magnetic chucks, etc.

 For example; a vertical surface grinder with a rotary table will normally have a
rotary fixture secured to its table. Similarly, a plain or string fixture may be
provided on a surface grinder with the reciprocating table. A drill grinding
attachment is a glaring example of a standard fixture used for grinding of drill
geometry.

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4.6.5 Boring Fixture

Fig. 4.10 Boring Fixture

 The operation can be performed in one of the following two ways:

1. By keeping the boring bar (tool) stationary and feeding the touting workpiece on
to the bar.

2. By keeping the workpiece stationary and feeding the rotating boring bar into the
work.

 Accordingly, therefore, the boring fixture is made in two common designs. One
of these incorporates the principle of a drilling jig, and in this, the boring bar (tool)
is guided through a pilot bush. such fixture is also often referred to as boring jigs.
the other design facilitates holding of the workpiece incorrect position, relative to
the boring bar.

 Although, this fixture incoporate almost all the common principles of jig and
fixture design, their construction need not be as sturdy as that of the milling
fixtures, because they never have to bear as heavy cutting loads as involved in
milling fixtures, because they never have to bear as heavy cutting loads as
involved in milling operations.

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4.6.6 Indexing Fixture

Fig. 4.11 Indexing Fixture

 Several components need machining on the different surface such that their
machined surface surfaces or forms are evenly spaced.

 Such components are required to be indexed equally as many as the number of

surfaces to be machined. Obviously, the holding devices (jigs or fixtures) used
are made to carry a suitable indexing mechanism. A fixture carrying such a
device is known as an indexing fixture.

4.6.7 Welding fixtures

 Welding fixtures are carefully designed to hold and support the various
components to be welded in proper locations and prevent distortions in welded
structures. For this, the locating element need to be carefully, clamping has to be
light but firm, placement of clamping elements has to be clear of the welding area.
The fixture has to be quite stable and rigid to withstand the welding stresses.

 In many cases, a preferably and commonly used practice is to first tack weld the
structure by holding it in welding jig and then transfer it to a holding fixture for
full welding. This helps in reducing the chances of distortion considerably and the
fixture is subjected to lesser stresses.

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 CHAPTER 5: PROJECT

5.1 DIE MAKING

Tool and die making, the industrial art of manufacturing stamping dies, plastics
molds, and jigs and fixtures to be used in the mass production of solid objects.
The fabrication of pressworking dies constitutes the major part of the work done
in tool and dieshops. Most pressworking dies are utilized in the fabrication of sheet-
metal parts that range in size from the finger stop on a dial telephone to the panels of
an automobile body. Each pressworking die consists of two sections, called punch and
die, or male and female. Both sections are mounted firmly in an electrically or
hydraulically driven press. In a working cycle the press ram, on which the male
section is mounted, descends into the fixed female section. Any metal interposed
between the sections is cut or shaped to a prescribed form. Like the dies, the presses
range in size from extremely small to gigantic. A bench press is often small enough to
be picked up manually; but the press that stamps out the roof of a car is generally
about three stories high and capable of exerting tons of force

Fig. 5.1 Components of Punch and Die assembly

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Fig. 5.2 Strip on the Die blocks

Fig. 5.3 Die

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5.2 CLASSIFICATION OF PRESS TOOLS
5.2.1 Blanking tool

Fig. 5.4 Blanking Tool

 Blanking is a punching operation in which entire periphery is cut out and the cut
out portion required is known as STAMP OR BLANK.
 When a component is produced with one single punch and die where the entire
outer profile is cut in a single stroke the tool is called a blanking tool.
 Blanking is the operation of cutting flat shapes from sheet metal.
 The outer area of metal remaining after a blanking operation is generally
discarded as waste.
 Size of blank or product is the size of the die & clearance is given on punch.
 It is a metal cutting operation.

 In blanking metal obtained after cutting is not a scrap or it is usable.

 The size of the blank depends on the size of the die.

 So the size of the die opening is equal to the blank size.
 Clearance is given to the punch.

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5.2.2 Piercing tool

Fig. 5.5 Piercing tool

 Piercing involves cutting of clean holes with a resulting scrap slug. The operation
is called die cutting and can also produce flat components where the die, the
shaped tool, is pressed into a sheet material employing a shearing action to cut
holes. This method can be used to cut parts of different sizes and shapes in sheet
metal, leather and many other materials.

5.2.3 Cut off tool

Fig. 5.6 Cutoff tool

 It is a shearing operation in which blanks are sperated from a sheet metal .strip by
cutting the opposite sides of the part in sequence .

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5.2.4 Parting off tool

 Partings are similar, in that a discrete part is cut from a sheet or strip of metal
along a desired geometric path. The difference between a cutoff and a parting is
that a cutoff can be nestled perfectly on the sheet metal, due to its geometry. With
cutoffs, the cutting of sheet metal can be done over one path at a time and there is
practically no waste of material. With partings, the shape can not be nestled
precisely. Parting involves cutting the sheet metal along two paths simultaneously.
Partings waste a certain amount of material, that can be significant.

5.2.5 Trimming tool

 When cups and shells are drawn from flat sheet metal the edge is left wavy and
irregular, due to uneven flow of metal. Shown is flanged shell, as well as the
trimmed ring removed from around the edge. While a small amount of Material is
removed from the side of a component in trimming tool.

Fig. 5.7 Trimming Tool

5.2.6 Shaving tool

 Shaving removes a small amount of material around the edges of a previously

blanked stampings or piercing. A straight, smooth edge is provided and therefore
shaving is frequently performed on instrument parts, watch and clock parts and
the like. Shaving is accomplished in shaving tools especially designed for the
purpose.

5.2.7 Forming tool

 Forming is the operation of deforming a part in curved profile. Forming tools

apply more complex forms to work pieces. The line of bend is curved instead of
straight and the metal is subjected to plastic flow or deformation.

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5.2.8 Drawing tool

 Drawing tools transform flat sheets of metal into cups, shells or other drawn
shapes by subjecting the material to severe plastic deformation. Shown in fig is a
rather deep shell that has been drawn from a flat sheet.

Fig. 5.8 Drawing Tool

 This type of Press tool is used to perform only one particular operation therefore
classified under stage tools.

5.2.9 Progressive tool

 A progressive tool differs from a stage tool in the following respect: in a

progressive tool the final component is obtained by progressing the sheet metal or
strip in more than one stage. At each stage the tool will progressively shape the
component towards its final shape, with the final stage normally being cutting-off.

5.2.10 Compound tool

 The compound tool differs from progressive and stage tools by the arrangement
of the punch and die. It is an inverted tool where blanking and piercing takes
place in a single stage and also the blanking punch will act as the piercing die.

5.2.11 Combination tool

 In a combination tool two or more operations such as bending and trimming will
be performed simultaneously. Two or more operations such as forming, drawing,
extruding, embossing may be combined on the component with various cutting
operations like blanking, piercing, broaching and cut off takes place- it can
perform a cutting and non cutting operations in a single tool.

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5.3 General press tool construction

The general press tool construction will have following elements:-

 Shank: It is used to locate the press tool in press for alignment purpose.
 Top Plate: It is used to hold top half of the press tool with press slide.
 Punch Back Plate : This plate prevents the hardened punches penetrating into top
plate.
 Punch Holder: This plate is used to accommodate the punches of press tool.
 Punches : To perform cutting and non cutting operations either plain or profiled
punches are used.
 Die Plate: Die plate will have similar profile of the component where cutting dies
usually have holes with land and angular clearance and non cutting dies will have
profiles.
 Die Back Plate:This plate prevents the hardened Die inserts penetrating into
bottom plate.
 Guide Pillar & Guide Bush : Used for alignment between top and bottom halves
of the press tools.
 Bottom plate:It is used to hold bottom half of the press tool with press slide.
 Stripper plate: it is used to strip off the component from punches.
 Strip guides: It is used to guide the strip into the press tool to perform the
operation.

Fig. 5.9 Press tool

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5.4 Cutting force in press tool

In general cutting force (CF) can be calculated using formula: CF =L x S x ζmax

cutting force will be in Newton(N) Where, L = Cut length in mm,(perimeter of profile

to be cut) Ex: 40 mm square to be cut will have cut length of 160 mm

S = Sheet metal thickness in mm,

ζmax = Maximum shear strength of sheet metal MPa

 Stripping force

Stripping force will be usually 10 to 20 % of cutting force

 Press force

Press force will be cutting force with stripping force Press Force = Cutting force +
Stripping force

5.5 Fits in press tools

 Punch holder and Punches =H7/k6

 Punch and Stripper = H7/K6
 Guide Pillar and Guide bush = H7/g6
 Guide bush and Top plate = H7/p6
 Guide pillar and bottom plate = H7/p6
 Dowel and plate = H7/m6
 Dowel holes = H7/r6

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REFERENCES

1- Original pictures from MAHAVIR INDUSTRIES

2- Wikipedia.org.in
3- Google Images
4- Google
5- Indiamart
6- Slideshare
7- Workshop Technology by B.S. Raguwanshi

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