IGTR-Ahmadabad Subject: Jigs, Fixture & Gauge Design

Class-1

Introduction of tools used in Mass Production:

Topic Outline:

A1.1a Jigs
A1.1b Fixtures
A1.1c Gauges
A1.1d Press Tools
A1.1e Moulds
A1.1f Pressure Die Casting Tools

Production of quality goods in large quantities at high speeds is the requirement of

the day.

To meet this, there have been considerable changes and developments in the
manufacturing industries, with an emphasis on increased efficiency and productivity.

As a sequel to these changes the tool technology has also undergone changes, leading to the
designing and development of special tools, methods and techniques for the benefit of
industry, to ensure quality products at economical rates.
Jigs and fixtures are the special production tools which make the standard machine
tool, more versatile to work as specialized machine tools.

They are normally used in large scale production by semi-skilled operators, however they are
also used in small scale production, when interchangeability is important.

Manufacturing industries in India, on par with their counterpart elsewhere, have brought lot of
revolution in manufacturing technology, during the (last 20 years, as a consequence of which
several developments like CNC Lathes, CNC Machine Centers, Flexible Manufacturing
Systems, Fabrications Centre, Transfer Machines, Robotics, etc. took place).

Our Engineers and Technologists are deeply involved in devising innovative 7 techniques. Lot of
modernization has taken place in Indian Industry.

Even with these advancements in the manufacturing industries, there is a continued use of jigs
and fixtures in some form or the other either independently or in combination with other systems.
IGTR-Ahmadabad Subject: Jigs, Fixture & Gauge Design

Introduction:

The work tooling refers to the hardware necessary to produce a particular product. The
most common classification of types of tooling is as follows:

1. Sheet metal press working tools.

2. Moulds and dies for plastic molding and die casting.
3. Forging dies for hot and cold forging,
4. Jigs and fixtures for guiding the tool and holding the work piece.
5. Gauges and measuring instruments.
6. Cutting tools such as drills, reamers, milling cutters, broaches, taps etc.

The tool maker manufactures the above item from the design supplied to him. On gaining
experience the tool maker will be able, to design and manufacture simple tools.

A1.1a Jigs:
A jig is a device that locates and holds the work piece.

It also guides and controls one or more cutting tools.

Jigs are fitted with hardened steel bushings for guiding drills or other tools. Small jigs are not
usually clamped to the machine.
IGTR-Ahmadabad Subject: Jigs, Fixture & Gauge Design

For holes above 6mm jigs are usually clamped.

Drill jigs are used while drilling reaming counter boring, tapping, chamfering etc.

There is hardly a product produced that does not contain one or more holes. The
location finish and size of these holes may be critical as in the case of a component for a
missile or they may be holes like those punched in a template for the purpose of hanging it
on the wall when not in use.

Holes are produced and finished in a number of ways:

They are drilled, reamed, bored, punched, ground, flame cut etc.
Drilling is by far the most common method.

A1.1b Fixtures:
A fixture is a device that locates and holds the work piece. Setting blocks and feeler
gauges are used for setting the cutter in relation to the work piece. Fixtures designated for
machining operations always clamped on to the machine.

A fixtures is a device for holding a work piece during machining operations.

The name is derived from the fact that a fixture is always fastened to a machine or bench in a
fixed position.

Many machining operations can be performed by clamping the work piece to the
machine table without using a fixture, especially when a few parts are to be machined.

However when the number of parts is large enough to justify its cost, a fixture is used for
IGTR-Ahmadabad Subject: Jigs, Fixture & Gauge Design

holding and locating the work. Further, when the profile of the Component is not regular or
when machining has to be done w.r.t. a reference face or bore, application of fixture will be
necessary.

A1.1c Gauges:
Modern manufacturing requires extensive uses of gauges for shop work, inspection
and reference.

A gauge can be defined as a device for investigating the dimensional fitness of a

part for a specified function.
IGTR-Ahmadabad Subject: Jigs, Fixture & Gauge Design

A1.1d Press Tools:

Press tools are special tools custom built to produce a particular component mainly
out of sheet metal.

The principle operations of sheet stampings include cutting operations (Shearing,

blanking, piercing etc.) and forming operations (bending, drawing etc.).

Sheet metal items such as automobile parts (roofs fenders, caps etc.) components
of aircraft, parts of business machines, household appliances, sheet metal parts of
electronic equipments, precision parts required for horoloqical industry etc. are
manufactured by press tools.
IGTR-Ahmadabad Subject: Jigs, Fixture & Gauge Design

A1.1e Moulds:
Plastics did not enter our lives with the fanfare of other revolutionary inventions, but
more by the process of infiltration.

Plastics being synthetic materials were at first considered to be cheap substitute for the better
known and more expensive materials.

Plastic articles are not only replacing wood, metal and other materials but because of their
particulars qualities they function better than other materials for specific purposes.

Through the years plastics have carved the right as materials themselves and not as
substitute for other materials.

Not only are plastics more useful, adaptable and practical than the materials they have
supplemented, but uses for plastics have been found for which no other material can be used.
IGTR-Ahmadabad Subject: Jigs, Fixture & Gauge Design

A1.1f Pressure Die Casting Tools:

Pressure die casting is a quick, reliable and cost-effective manufacturing process for production
of high volume, metal components that are net-shaped have tight tolerances.

Basically, the pressure die casting process consists of injecting under high pressure a molten
metal alloy (Mainly Non-Ferrous Material) into a steel mold (or tool). This gets solidified rapidly
(from milliseconds to a few seconds) to form a net shaped component. It is then automatically
extracted.

 Lower costs compared to other processes.

 Economical - typically production of any number of components from thousands to

millions before requiring replacement is possible.

 Castings with close dimensional control and good surface finish

 Castings with thin walls, and therefore are lighter in weight.