JIGS & FIXTURE CONSTRUCTION

Chapter 4
Jig and Fixture Handbook
TOOL BODIES

Provides the mounting area for locators, clamps

and other devices that position and hold the
workpiece.

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TOOL BODIES

There are three general categories.

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CAST TOOL BODIES

Cast materials, iron ,aluminum and magnesium.

Can have complex and detailed shapes.
Require fewer secondary machining operations.
Dampen vibrations.

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CAST TOOL BODIES

Three draw backs

• Fabrication cost high.
• Not easily modified.
• Lengthy lead time.

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WELDED TOOL BODIES
Most common material steel and aluminum.
Inexpensive to build.
Easily modified.
Minimal lead time.
Durable and ridgid.
Excellent strength to strength to weight ratio.
Heat distortion a problem requiring secondary machining.

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BUILT UP TOOL BODIES

Most common tool body today.

Least amount of lead time.
Easily modified.
Durable and ridgid.
Good strength to weight ratio.
Depending on complexity may be least expensive.
Usually screwed and doweled together.
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TOOLING PLATES

Tooling plates are standard commercially available base's

used to construct different workholders.

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TOOLING PLATES

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PRECISION CAST SECTIONS

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PRECISION CAST SECTIONS

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PRECISION CAST SECTIONS

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PRECISION CAST SECTIONS

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PRECISION ANGLE PLATES

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THREADED INSERTS

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FIXTURE KEYS

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JIG CONSTRUCTION

Jigs are made to meet requirements of each

workpiece. These Jigs fall into categories

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TEMPLATE JIGS

• Simplest
• Least expensive
• Do not have a self-contained clamp

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PLATE JIGS

• Variation to Template
• But have a have a self-contained clamp

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TABLE JIGS

• Similar to Template or Plate jig with legs

• Used where surface to be machine also locates

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SANDWICH JIGS
• Is a modified plate jig
• Constructed with two plates
• Designed for thin, delicate workpieces

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BOX JIGS

• Box / Tumble Jigs

• Are the most detailed and complex
• Constructed allows all sides to be machined without
removing workpiece

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INDEXING JIGS

• Used for holes pattern around a center axis

• Ether by indexing ring holding bushings or by indexing
workpiece itself

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INDEXING JIGS

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TRUNNION JIGS

• Used for large, heavy or odd shaped workpieces

• Jig rotates workpiece on a bearing

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FIXTURE CONSTRUCTION

• Fixtures are made to meet requirements of each

workpiece. These Fixtures fall into categories
• Most often by the construction of the Fixture
• Or by the machine fixture is used on

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PLATE FIXTURES
•Most basic and most common
•Locators, supports and clamps are mounted directly to
plate

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ANGLE-PLATE FIXTURES
•Are a variation of a plate fixture
•Constructed ether as a right-angle or modified-angle

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WELDING FIXTURES

• Same basic workholding principles

• Major difference is locational tolerance and clamping
• Toggle clamps are most common
• Locators and supports should be position so that any
distortion doesn’t cause binding
• Provision for heat to dissipate

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INSPECTION FIXTURES
• Are subject to different requirements whether inspection
is done on a CMM or with manual gauges
• Workpiece must be oriented to expose all features to be
inspected
• Machined surface are often not used for locating, but
remaining exposed
• Quick-acting clamps, such as toggle clamps
• Light clamping force required
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