Principles of Jigs Design

Prepared By
B.K.Saravanan
AP/Mech, SNSCT
DJFP-Unit II-B.K.Saravanan,AP/Mech
 Jigs
• Jigs which can be manufactured by any of the following methods:
• Machining
• Forging
• Casting and
• Welding

• Normally jigs are made of hardened steel, which are wear resistant, corrosion
resistant and thermally in sensitive.
• Their dimensional accuracy directly influences the accuracy of performance
of the operations where these are used.

DJFP-Unit II-B.K.Saravanan,AP/Mech
 Requirement of a Jig
• Quick and accurate location of the workpiece
• Easyloading and unloading of theworkpiece
• Prevention of wrongloading
• Prevention of bending or movement of the workpiece during drilling operation
• Ample(enough) chipclearance
• Facility for swarf (fine chips) removal andcleaning
• Light weight to minimise operator fatigue
• Prevention of loss of parts by usingchains
• Clearance for overshoot of thedrill

DJFP-Unit II-B.K.Saravanan,AP/Mech
 General Considerations in the Designof Drill Jigs

Rigidity:
•Jig must be strong enough to withstand all forces applied to it.
•It must also resist deflections that may be the result of excessive
tightening of clamps that hold the w/p in place.
•The work must also be supported so that it does not bend under drilling
pressure.
•Cast iron is generally used because it absorb shocks and compressive
forces.

DJFP-Unit II-B.K.Saravanan,AP/Mech
 General Considerations in the Designof Drill Jigs

Chip Control:
•Types of chips: segmental and continuous.
•The segmental chip is preferred.
•Space should be kept between the w/p and bottom of drill bushings to allow
chips to pass between the work and busing plate (1 - 1/2 * dia. of drill).
•Three ways of chip removal: coolant, manually with brush or hook,
compressed air.

DJFP-Unit II-B.K.Saravanan,AP/Mech
 General Considerations in the Designof Drill Jigs

Jig feet and legs:

•A drill jig should stand on four feet (Or legs) rather than a flat surface.
•Jig feet may be built into the jig body or purchased as standard parts.
•They are usually placed on the extremities of the jig body.
•Feet should be ground so that they are all in one plane after they are mounted
on the jig base.

DJFP-Unit II-B.K.Saravanan,AP/Mech
 General Considerationsin the Designof Drill Jigs

Types of Standard Jig Feet:

 ELEMENTS OFJIGS
• Jigbody - i. Build upbody
ii. Weldedbody.
iii. cast body.

• Jigfeet
• Drill bush
• Jigplate
• Locators
• Clamps

DJFP-Unit II-B.K.Saravanan,AP/Mech
 General Considerations in the Designof Drill Jigs

Miscellaneous considerations:
•Sharp corners should be eliminated.
•Gripping surfaces should be knurled.
•The jig should be large enough to hold it against the torque of the drilling
machine.
•It must be easy to handle.

DJFP-Unit II-B.K.Saravanan,AP/Mech
 Jigbody

DJFP-Unit II-B.K.Saravanan,AP/Mech
Jig feet, Drill bush, Jig plate,
Locators, Clamps

DJFP-Unit II-B.K.Saravanan,AP/Mech