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(b) The workpiece and tool are relatively located at their exact positions automatically
before the operation within negligible time. So it reduces product cycle time.
(d) Due to low variability in dimension assembly operation becomes easy, low rejection
due to less defective production is observed.
(e) Simultaneous working by more than one tool on the same workpiece is possible.
(f) The operating conditions like speed, feed rate and depth of cut can be set to higher
values due to rigidity of clamping of workpiece by jigs and fixtures.
(g) Operators working become comfortable as his efforts in setting the workpiece can be eliminated.
(h) Semi-skilled operators can be assigned the work so it saves the cost of manpower also.
(i) There is no need to examine the quality of products once quality of employed jigs and
fixtures is ensured.
JIGS
It is a work holding device that holds, supports and locates the workpiece and
guides the cutting tool for a specific operation. Jigs are usually fitted with
hardened steel bushings for guiding cutting tools. A jig's primary purpose is to
provide repeatability, accuracy, and interchangeability in the manufacturing of
products. A device that does both functions (holding the work and guiding a tool)
is called a jig.
An example of a jig is when a key is duplicated, the original is used as a jig so the
new key can have the same path as the old one.
Fixtures
It is a work holding device that holds, supports and locates the workpiece for a
specific operation but does not guide the cutting tool. It provides only a reference
surface or a device. What makes a fixture unique is that each one is built to fit a
particular part or shape. The main purpose of a fixture is to locate and in some
cases hold a workpiece during either a machining operation or some other
industrial process.
Examples: Vises, chucks
Jigs and Fixtures differ in the following ways
S.no Jigs Fixtures
Fixture is a work holding device that
Jig is a work holding device that holds,
holds, supports and locates the workpiece
1 supports and locates the workpiece and
for a specific operation but does not
guides the cutting tool for a specific
guide the cutting tool
operation.
Jigs are not clamped to the drill press table
Fixtures should be securely clamped to
unless large diameters to be drilled and there
2 the table of the machine upon which the
is a necessity to move the jig to bring one
work is done.
each bush directly under the drill.
The jigs are special tools particularly in Fixtures are specific tools used
3 drilling, reaming, tapping and boring particularly in milling machine, shapers
operation. and slotting machine.
Gauge blocks may be provided for
4 Gauge blocks are not necessary.
effective handling.
5 Jigs are lighter in construction. Fixtures are heavier in construction.
"degrees of freedom."
3-2-1 PRINCIPLE OF LOCATION
3-2-1 principle may be stated as:
“To locate an object fully, place and hold it against three points in a base plane,
two
points in a vertical plane, and one point in a plane square with the first two.”
The 3-2-1 principle of location (six point location principle) is used to constrain the
movement of workpiece along the three axes XX, YY, and ZZ. This is achieved by
providing six locating points, 3 pins in base plate, 2 pins in vertical plane and 1 pin in a
plane which is perpendicular to first two planes.
Pins A, B, C on the base plane ( a plane parallel to the plane which contains X and Y axis)
restrict the rotation of component about X axis and Y axis. It also limit the downward
movement of component along z axis ie, 1,2,3,4 and 4 degrees of freedom is restricted.
Pins D, E is in plane parallel to the plane containing X and Z axes. It prevents the rotation
of component about Z axis (6, 7 degree of freedom) and the movement of the body in
along Y axis towards one direction (8 degree of freedom).
The last pin F is in a plane parallel to plane contains Y and Z axes. It restricts the
movement of component along X axis in one direction.
Three remaining degree of freedom 10, 11, 12 is unrestricted. It facilitates the loading of
the component in the fixture. This three degree of freedom may restrict after loading of
component by using clamping devices.
A flat surface locator can be used as shown in first figure. In this case an undercut is
provided at the bottom where two perpendicular surfaces intersect each other. This is
made for swarf clearance (chip removal). The middle figure shows flat headed button type
locator. There is no need to make undercut for swarf clearance. The button can be adjusted
to decide very fine location of the workpiece. There can be a vertical button support as
shown in third figure, which is a better arrangement due to its capacity to bear end load
and there is a provision for swarf clearance automatically.
Cylindrical Locators
A cylindrical locator is shown in Figure . It is used for locating components having drilled
holes. The cylindrical component to be located is gripped by a cylindrical locator fitted to
the jig‟s body and inserted in the drilled hole of the component. The face of the jig‟s body
around the locator is undercut to provide space for swarf clearance.
Conical Locator
A conical locator is illustrated in Figure 4.5. This is used for locating the workpieces
having cylindrical hole in the workpiece. The workpiece is found located by supporting it
over the conical locator inserted into the drilled hole of the workpiece. A conical locator is
considered as superior as it has a capacity to accommodate a slight variation in the hole
diameter of the component without affecting the accuracy of location. Degree of freedom
along z-axis can also be restrained by putting a template over the workpiece with the help
of screws.
CLAMPING DEVICES
Definition
A clamp is a device that
(a) Holds the workpiece firmly against the locators provided, and
(b) Also, resists all forces generated by the cutting action of the tool on the
workpiece or it can use the cutting forces to its own advantage.
A clamping device ensures proper location and centering of the workpiece
(i) The workpiece must be clamped over a solid supporting point, and not at a
position which is liable to cause distortion.
(ii) There should be dependable contact between the work- piece and the clamping
elements in order to prevent displacement and vibration of the workpiece during
operation.
(iii) The clamping devices of jigs and fixtures must be reliable in operation, simple
in design and convenient for maintenance.
(iv) The clamping devices must not deform, bend, or damage the workpiece.
(v) The clamping devices should be such that the workpieces can be clamped and
unclamped with minimum effort of the operator and minimum loss of his time.
(vi) Clamping devices should be wear resistant, and the parts subject to most wear
should be renewable.
(vii) Clamps must be situated in such a manner that they may be tightened or
loosened without danger to the operator.
(viii) Clamp forces should be exerted only on positively supported (or very rigid)
parts of the workpiece.
(x) Clamps should be placed in such a manner that a number of operations can be
performed in one setting.
(xi) Fluted nuts, levers, handles, hydraulic or pneumatic devices are more
convenient means of clamping than the use of spanners, but if for cheapness or
heavy duty hexagonal nuts are used, one size of spanner should be used
throughout.
Types of Clamps
Bridge Clamp
The bridge clamp is illustrated in Figure. 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.
2. Screw clamps
The screw clamp is illustrated in Figure. It is also known as clamp screw. This clamping
apply 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.
Latch Clamp
Latch clamps are used to clamp the workpiece, the clamping system is normally locked
with the help of a latch provided. To unload the workpiece the tail end of the latch is
pushed that causes the leaf to swung open, so releasing the workpiece. Here time
consumed in loading and unloading is very less as no screw is tightened but clamping
pressure is not so high as in other clamping devices. Life of this type of clamping device
is small.
Latch clamp is known for its advantage in the speed of manipulation. It is limited to light
work as it is difficult to secure rigidly.
Types of latch clamps are:
a) Simple latch clamp
b) Cam type latch
c) Self-locking clamp
d) Thumb screw latch
Wedge clamp:
A plain wedge clamp consists of a movable inclined plane which forces the work piece
against a fixed stop. These clamps tend to loosen under vibration. The taper end of the
plain wedge ranges from 6-8 deg depending upon the coefficient of friction of the metal.
Equalizing Clamps
Equalizing clamp is illustrated in Figure. It is recommended to apply equal pressure on the
two faces of the work. The pressure applied can be varied by tightened or loosening the
screw provided for the purpose.
Cam clamps
They are popular as quick action clamps. Cams tend to shift their mating faces. There is a
risk of the cam clamp getting loose due to vibrations. The co-efficient of friction between
the cam and the mating surface must be taken into account while determining the
eccentricity of the cam. The most common forms of Cam Clamps are the Eccentric
Cam and Spiral Cam. Depending on their arrangement, these cams can be used as
direct pressure Clamps or Indirect pressure Clamps.
3. Magnetic clamping
Pneumatic Clamping
Uses air-actuated cylinders to operate the clamping device. They are ideal for
quick clamping in repetitive production operations. Available in many styles,
including swing cylinders, hold- down and straight-line action, and retracting
clamps.
Hydraulic Clamping
Ideal for machining applications where extremely high clamping forces arerequired
for part holding.
Vacuum Clamping
This is particularly convenient for securing thin flat sheets which are vulnerable to
distortion under heavy clamping force. Vacuum clamping provides light clamping. The
holding face is provided with
0.025 mm deep grooves which serve as vacuum ducts. The clamping face is circumscribed
by a rubber seal groove all around. The seal in the groove segregates the clamping
vacuum area from the space outside the seal. The vacuum pressure is usually limited to 1
kg/cm2. Figure shows a vacuum-holding fixture, distribution grooves and rubber seal.
mm deep vacuum grooves
Magnetic Clamping
Magnetic clamping force can be developed by permanent magnets and electromagnets.
(a) Permanent magnets They are mounted on a sliding member which can be
moved under a non magnetic material on a table to block magnetic flux.
This releases the workpiece. For clamping the workpiece, permanent
magnets are moved under the magnetic part of the table. This allows the
magnetic flux to pass through the workpiece and hold it magnetically. The
permanent magnets are slid in the clamping and unclamping positions by a
lever.
1: Template Jig:
This is the simplest type of jig; It is simply a plate made to the shape and size of
the work piece; with the require number of holes made it. It is placed on the work
piece and the hole will be made by the drill; which will be guided through the
holes in the template plate should be hardened to avoid its frequent replacement
This type of jig is suitable if only a few part are to be made.
4 Channel jig:
The channel jig is a simple type of jig having channel like cross section. The
component is fitted within the channel is located and clamped by locating the
knob. The tool is guided through the drill bush.
5: Leaf Jig:
It is also a sort of open type jig , in which the top plate is arrange to swing about a
fulcrum point , so that it is completely clears the jig for easy loading and
unloading of the work piece. The drill bushes are fitted into the plates, which is
also known as leaf , latch or lid.
6: Box Type Jig:
When the holes are to drill more than one plane of the work piece , the jig has to
be provided with equivalent number of bush plates. For positioning jig on the
machine table feet have to be provided opposite each drilling bush plate. One side
of the jig will be provided with a swinging leaf for loading and unloading the work
piece, such a jig would take the form of a box. Such a jig should be as light as
possible. Since it will have lifted again and again. Typical figure of box type jig is
shown:
7. Angle-Plate Jigs
Angle-Plate Jigs are used to hold parts which are machined at right angles to their
mounting locators. Pulleys, collars and gears are some of the parts which use this
type of Jig as shown in the figure.
A variation of this jig is the modified Angle-Plate Jig. This jig is used for
machining angles other than 90° as shown in figure.
INDEXING JIGS:
Indexing Jigs are used for circular hole patterns in which the part is indexed
successively to the different positions under a single bushing. The location of the
holes may be taken from the first hole drilled, or from other holes in the part.
Sometimes an indexing plate or device is incorporated in the Jig.
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.
Types
a. Plain or headless bush
b. Headed or flanged bush
Headed bushings are preferable to headless bushings because the collar provides
positive stop against the jig plate. Moreover, it is found that the chances of the bushing
getting loose in the jig plate and sliding axially with the drill are lesser in the collared
bushings. However, when the spacing of the bushings is close or the top surface of the jig
plate is required to be free from the projecting collars, headless bushings are used.
Press fit bushings are also used as liners for renewable and slip bushings.
2. Liner Bushes:
These are known as master bushes. They are permanently fixed to jig body. They act as guide for
renewable type of bushes. They may be bushes with or without head.
3. Renewable bushes:
When the guide bushes requires periodic replacement (due to wear of the inside
diameter of the bush), its replacement is done simply by using a renewable bush.
These are of the flanged types and sliding fit into the liner bush. The liner bush
provides hardened wear resistance, mating surface to the renewable bush. The
renewable bushes must be prevented from rotating or lifting with the drill. One
common method is to use a retaining screw.
4. Slip Bushings
When a hole in the workpiece requires two operations such as drilling and reaming, it is
necessary to use two different guide bushings for the different tools. The hole is first
drilled using a bushing having a bore suitable for the drill. After drilling, the drill bushing
is removed and a reaming bushing is used to guide the reamer. In mass production, the
changeover of these bushings should be effected quickly. This is accomplished by
provision of slip bushings. There are a number of different types of slip bushings in use.
In the most common type, the bushing is provided with a flat on the head similar to the
renewable bushing and a circular cutout in the flange to facilitate quick assembly and
removal.
For loading or unloading of the slip bushing, the cutout in the flange is aligned with the
collar of the retainer shoulder screw.
5. Threaded Bushings
The bushings used for clamping the workpiece are threaded on the outside. There should
be another plain guiding diameter for accurate location of the bushing. The collar of the
liner bushing is usually placed on the opposite side to take the axial thrust of the screw.
The liner bushing should be prevented from rotation by a grub screw or a flat on the
collar. The flat mates with a machined step on the jig plate.
Materials used in Jigs and Fixtures
Jigs and fixtures are made from a variety of materials, some of which can be hardened to
resist wear. It is sometimes necessary to use nonferrous metals like phospher bronze to
reduce wear of the mating parts, or nylons or fibre to prevent damage to the workpiece.
Given below are the materials often used in jigs, fixtures, press tools, collets, etc.
1. High Speed Steels (HSS) These contain 18% (or 22%) tungsten for toughness and
cutting strength, 4-3% chromium for better hardenability and wear resistance and 1%
vandadium for retention of hardness at high temperature (red hardness) and impact
resistance. HSS can be air or oil hardened to RC 64-65 and are suitable for cutting tools
such as drills, reamers and cutters.
2. Die Steels These are also called high carbon (1.5—2.3%) high chromium (12%)
(HCHC) cold working steels and are used for cutting press tools and thread forming rolls.
Hot die steels with lesser carbon (0.35%) and chromium (5%) but alloyed with
molybdenum (1%) and vanadium (0.3-1%) for retention of hardness at high temperature
are used for high temperature work like forging, casting and extrusion.
3. Carbon Steels These contain 0.85-1.18% carbon and can be oil hardened to
RC62-63. These can be used for tools for cutting softer materials like woodwork,
agriculture, etc. and also for hand tools such as files, chisels and razors. The parts of jigs
and fixtures like bushings and locators, which are subjected to heavy wear can also be
made from carbon steels and hardened.
4. Collet Steels (Spring Steels) These contain about 1% carbon and 0.5%
Manganese. Spring steels are usually tempered to RC 47 hardness.