Aditya College of Engineering .

Madanapalle

MACHINE TOOLS - Part 1

(Jigs and Fixtures)

By:
Amar Gandhi
Faculty ,Dept. of Mechanical Enginering
 JIGS AND FIXTURES

 Jigs and fixtures are manufacturing tools that are

employed to produce interchangeable and identical
components.
 They are unique tool-guiding and work-holding
devices designed specifically for machining and
assembling large number of parts.
Applications of Jigs and Fixtures :

 Applications of jigs are:

1. Drilling
2. Reaming
3. Tapping
 Applications of fixtures are:
1. Milling
2. Grinding
3. Planning
4. Turning
 Jig :
 Jig is a work-holding device that supports, holds, locates a
work-piece and also guides the cutting tool for the desired
machining operations.
 Its main objective is to ensure high degree of precision,
interchangeability, and duplication in products
’manufacturing,
 It is also applied to manipulate the location and movement
of other tools.
Types of Drill Jigs :
1. Open Jigs 2. Closed or Box Jig
Types of Jigs :
Following are the seven different types of jigs :-
1. Template jig
2. Plate jig
3. channel jig
4. Diameter jig
5. Leaf jig
6. Ring jig
7. Box jig , etc.
Fixture:
 A fixture is a work-holding or support device used in
the manufacturing industry.
 Fixtures are used to securely locate and support the
work, ensuring that all parts produced using the
fixture will maintain conformity and
interchangeability.
 Using a fixture improves the economy of production
by allowing smooth operation and quick transition
from part to part.
 Types of Fixtures :
 Fixtures are usually named after the type of machining
operation for which they are designed and employed.
 Following are the different types of fixtures:
1. Turning fixtures.
2. Milling fixtures.
3. Broaching fixtures.
4. Grinding fixtures.
5. Boring fixtures.
6. Indexing fixtures.
7. Tapping fixtures.
8. Welding fixtures.
9. Assembly fixtures, etc
Uses of Jigs and Fixtures :
The uses of jigs and fixtures
1. Reduction of production cost,
2. Increase of production rate,
3. High accuracy of products without any
manufacturing defects,
4. Provision of interchangeability,
5. Easy machining of complex shaped parts,
6. Reduction of quality control costs, etc.
7. Less skill labour
8. Improves the safety – less accidents.
 Advantages of Jigs and Fixtures
The advantages of jigs and fixtures include but not limited
to the following:
 • Production increase;
 • Low variability in dimension, thereby leading to
consistent quality of manufactured products;
 • Cost reduction;
 • Ensures interchangeability and high accuracy of parts;
 • Reduces the need for inspection and quality control
expenses;
 • Reduces accident, as safety is improved;
 • Semi-skilled machine operators can easily use them
thereby saving the cost of manpower;
 Difference Between Jig and Fixture :
 1. Jig is primarily used to guide the movement of cutter
repeatedly at predefined locations on the work, and
support and locate the part as well.
 Fixture is mainly used to secure, support and locate the
work piece and maintain predetermined orientation, not
guide the cutter.
 2. Jigs are generally easier to use, while fixtures is kind of
complicated and may need some skills and accessories for
the operation.
 3. Jigs are often lighter in weight for quicker handling,
while fixtures are usually heavier and required to
withstand cutting force and vibration
-
 4. Jigs are commonly used in drilling, boring,
reaming and tapping, while fixtures are adopted
for milling, slotting, shaping, turning and planning.
 5. Jigs are usually more expensive than fixtures.
 6. The construction of the jig is often designed more
complex while the fixture designs are simpler.
 7. Fixtures are usually made from gray cast iron or
steel parts by welding or bolting,
jigs generally uses standard parts like bushes and
screws.
Elements of Jigs and Fixtures

 The Elements of Jigs and Fixtures are:

1. Body,
2. Clamping devices,
3. Locating devices, and
4. Tool guide/bushes
 1. Body:
 As the most outstanding element of jigs and fixtures, the
body is constructed by welding of different slabs and
metals usually mild steel or by casting of cast iron.
 After the fabrication, it is often heat-treated for stress
reduction as its main objective is to accommodate and
support the job.
 The different types of jig bodies are as follows:
1. Channel body type
2. Box body type
3. Plane body type
4. Leaf body type
5. Built-up body type
2. Clamping Devices :
 The clamping devices must be very simple and easy to
operate.
 Apart from holding the work-piece securely in place, the
strong point of clamping devices is its ability to withhold
the strain of the cutting tool during operations.
The familiar clamping devices include:
1. Clamping screws
2. Hook bolt clamp
3. Latch clamp
4. C – clamp, the Bridge clamp,
5. Heel clamp
 3. Locating Devices :
 The pin is the most popular device applied for the
location of work-piece in jigs and fixtures.
 Made with hardened steel and with different designs.
 The pin’s shank is press-fitted or driven into a jig or
fixture.
 The locating width of the pin is made bigger than the
shank to stop it from being pressed into the jig or fixture
body because of the weight of the cutting tools or work-
piece.
 The pins are classified as follows:
1. Locating pins
2. Jack pins
3. Support Locating/Rest pins
 4. Jig Bushing or Tool Guide :
 Jig bushes are applied in drilling and boring, here for the
drill to pass through, a bush fits into the hole of the jig.
 Bushes are mainly made of reliable grade of tool steel in
order to ensure hardening at a low temperature.
 Guiding parts like jig bushings and templates which must
be wear resistant, interchangeable, and precise.
 Although, hardened steel bushes are preferred for guiding
reamers, drills, and taps, the guiding tool bushings can
also be made of cast iron.
The jig bushings are categorized into three:
1. Linear wearing bushes,
2. Press-fit wearing bushes,
3. Renewable wearing bushes.
 Design considerations:
 The factors below are to be reflected upon during design,
production, and assembly of jigs and fixtures:-
 • Guiding of tools for slim cutting tools like drills;
 • Type of operations;
 • Inspection requirements;
 • Provision of reliable, rigid, and robust reinforcement to
the blank;
 • Production of jigs and fixtures with minimum number of
parts;
 Fast and accurate location of the jig or fixture blank;
Contd….

 • Rapid mounting and un-mounting of the work-piece

from the jig or fixture;
 • Set up time reduction;
 • Standard and quality parts must be used;
 • Reduction of lead time;
 • Easy disposal of chips;
 3-2-1 Principle of Location

 The 3-2-1 principle of location (six point location

principle) is used to constrain the movement of work piece
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.
3-2-1 Principle of Location (Six Point Principle)
Degree Of Freedom Controlled By 3-2-1
Location Principle - With Image
Degree of freedom controlled by 3-2-1 location
principle :-
In this method, 9 degrees of
freedom is controlled.

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 5 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 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.
 Work holding devices :
 Fixtures and jigs are examples of customized work
holding devices.
 Work holding devices provide fundamental functions,
locating and clamping.
 Locating refers to orienting and positioning the part
relative to the cutting tool.
 Clamping refers to holding the part in its proper
orientation with enough force to resist the force of cutting
but not deform the part.
Types of Clamping Device:

 Lever of Strap Clamps:

 Screw Clamps: fixtures. ...
 Cam-Action Clamps: ...
 Hinged Clamps: ...
 Two-Way Clamps: ...
 Wedge Operated Clamps: ...
 Cam Operated Clamps: ...
 Toggle Action Clamps:
 Locating Devices :

 The typical locating devices used for jigs and fixtures

are:
1. Locating buttons.
2. Adjustable locators.
3. Locating pins.
4. Conical locators.
5. Diamond and pin locators.
6. Profile locators.