JIGS AND JIG BUSHES

A drill jig is a device for ensuring that a hole to be

drilled, tapped or reamed in a workpiece will be
machined in the proper place.
The position of each hole on the workpiece need not
be located with the aid of a square, straight edge,
scriber and centre punch.
In addition to locating and clamping elements, jig
has bushings to guide the tool (drill).
Locating and clamping elements in drill jigs are
subjected to high torque along the axis (force in the
direction perpendicular to the axis) of the cutting
tool.
Requirements of a good drill jig:
1. Quick and accurate location of the workpiece.
2. Easy loading and unloading of the workpiece and
prevention of wrong loading.
3. Prevention of bending or movement of the
workpiece during drilling.
4. Ample chip clearance with facilities for swarf
removal and cleaning.
5. Light weight to minimize operator fatigue due to
repeated handling.
6. Prevention of loss of loose parts by chaining
them to the jig body.
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7. Clearance for overshoot of the drill.
 DRILL BUSHES
Bushes are made up of water hardened carbon steel
with 0.85 to 1% carbon and 0.5 to 0.9% manganese.
The material is hardened to HRC60-64 to minimize wear
due to contact with hard rotating tools.
Inside and outside bore are ground within 0.001mm
concentricity.
Inside diameter is ground precision running fit (F7) with
the drill/reamer.
Outside diameter is made press fit (p6), precision
location fit (h6) or precision running fit (f6), depending
upon the function and application of the bush. 3
 PRESS FIT BUSHES
These are the most common type of bushes.
Pressed (interference fit) in the bush plate (jig plate).
Two types: Headed bush, headless bush
Headed bushes are preferred to headless because
headless bush may slide axially into the bush plate

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 RENEWABLE BUSHES

Used for continuous or large batch production.

After wear and tear these bushes are replaced.

Replacement is simplified by making the outside

diameter precision location fit (h6).

The use of liner in the jig plate provides hardened
wear resistant mating surface to the renewable bush.

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SLIP BUSHES

When a hole in the workpiece
requires two operations such
as drilling and reaming, slip
bushes are used.

In mass production the
changeover of these bushes
should be effected quickly.

The bush is provided with a
flat on the head similar to the
renewable bush and a circular
cutout in the flange to
facilitate quick assembly and
removal.
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 THREADED BUSHES
These bushes are part of the clamping system.
Along with the threaded bush a liner bush is used for
accurate location.
Collar of the liner bush is placed in the opposite side to
take the axial thrust of the screw.
The liner bush is prevented from rotation by a grub
screw.

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 SPECIAL BUSHES
Some workpieces/ operations require unusual type
of bushes.
Ex: Drill bush for curved surface, drill bush for
inclined surface, plate bush (when centre distance
between two holes is less)
These are modified forms of standard bushes.

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 VARIOUS TYPES OF JIGS
Depending upon their construction and method of
operation, drill jigs can be classified as follows:
1. Plate jigs and channel jigs with workpiece pots
2. Angle plate jigs
3. Turn-over jigs
4. Leaf or latch jigs
5. Box jigs
6. Trunnion-type indexing jigs
7. Sandwich and pump jigs
8. Jigs for multi-spindle machines
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PLATE JIG AND CHANNEL JIG

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 PLATE JIG AND CHANNEL JIG
1. Plate-type jigs mainly consist of a single bush
plate with a provision for location and the
clamping of workpiece.
2. The workpiece profile is located by six location
pins and clamped by two knurled screws
against the location pins.
3. Sometimes, the jig is made channel shaped.
4. There should be enough clearance below the
workpiece for overshoot of the drill after
passing through the workpiece. This can be
achieved by providing a resting pot for the
workpiece. 11
LEAF OR LATCH JIG

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 LEAF OR LATCH JIG
1. These have a hinged jig (bush) plate.
2. The jig plate can be swung aside to provide
clear path for loading and unloading the
workpiece from the top.
3. The jig plate must have a positive resting face
to ensure that the axes of bushes are vertical
during drilling.
4. The jig plate is clamped against the resting
face by an eyebolt.
5. The open slot in the jig plate quick clamping
and unclamping of the jig plate. 13
BOX JIG

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 BOX JIG
1. Workpieces having holes on a number of sides
can be drilled economically with box jigs.
2. One side is open for loading and unloading of
the job.
3. The open side is provided with a hinged latch
which often houses bushes and clamping
screws.
4. The jig is fitted with bushes on various sides
and suitable jig feet on the opposite sides.
5. It reduces number of setting steps, thereby
increasing the accuracy of location. 15
TUMBLE JIG

When a box jig
contains bushings on
two or more sides for
the purpose of
drilling, it is known as
a tumble jig.

It has sets of jig feet
on opposite sides of
the workpiece faces.

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 TRUNNION JIG
1. Used for drilling from a number of sides on large and
heavy workpieces.
2. It is similar to box jig.
3. For easy tumbling, the jig body is provided with
pivots at both ends.
4. The pivots are supported with ball bearings in
supporting brackets at both ends.
5. The heavy jig and the trunnion remain stationary
during drilling.
6. The drill machine spindle must be moved to align
with the drill bushes in the jig.
7. Consequently, trunnion type jigs can be used on only
moveable spindle machines such as radial drilling
machine. 18
LEAF TYPE DIAMETER JIG

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SANDWICH JIG

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 SANDWICH JIG
1. These are plate jigs with guide pillars for
alignment of jig plate with the base plate.
2. The workpiece is located on the base plate by
pins. The base is aligned with the jig plate by
guide pillars.
3. In sandwich jig, the workpiece is clamped like a
sandwich between the base plate and the jig
plate.
4. The jig plate can be removed to load and unload
the workpiece.
5. Theses jigs are best suited to workpieces having
two parallel machined surface square to the axis
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of drilling.
PUMP JIG

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 PUMP JIG
1. These are smaller versions of sandwich jig.
2. Instead of removing the jig plate completely
from guide pillars, it is merely raised above to
provide passage for loading and unloading of
the workpiece.
3. The guide pillars attached to the jig plate have
rack gear teeth on one side.
4. The pinion gear meshing with the rack can be
rotated by a handle to raise or lower the rack
pillars and jig plate attached to them.
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Thank You

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Fig. 2. Hardness of cutting tool materials as a function of 27
temperature