Jigs and Fixtures

14 Jigs and Fixtures
Objectives
Understand the need for jigs and fixtures
Know the different types of surfaces in parts
Understand the principles of location, support and clamping
To select various types of locators to cater to the range of
part geometries involved
Identify the clamping requirements for jigs and fixtures
Know the different varieties of jigs in practice
Design jigs for practical application
Understand the various principles for fixture design
(c) TMH New Delhi, Manufacturing

Technology Vol 2,Metal Cutting and
November 5, 2008 Machine Tools by P N Rao 2
Jigs and Fixtures
Jigs and fixtures are the production devices that
are used for the accurate production of repeated
parts essentially for mass production.
Location
Clamping
Support
Resistance to Cutting forces
Safety

Jigs
Jigs are commonly used for making parts
that contain holes.
The tools used for making holes are
generally slender and need to be
supported because of the long overhang
ratios.
The jig bush is employed for this purpose.
The most common application of jigs is for
drilling and boring.
Fixtures
Fixtures can be used for all other
machining applications with a large
variety depending upon the type of the
cutting tool used and the geometry of the
workpiece.
These will be provided with setting blocks
for the tool setting.
The fixtures are generally identified by the
machine tool in which they will be used.
Modular Fixtures
Modular fixturing is used for quickly
rigging up a fixture for a specific
component using the off the shelf
components.
Standard fixture bases, and a large
number of fixture elements such as angle
blocks, base elements, locators, and
clamping elements are available for
assembling a fixture.
Applications of Jigs and Fixtures
External machining Internal machining Non-
machining
Milling fixtures Drill jigs Assembly
Surface-grinding fixtures Boring jigs fixtures
Planing fixtures Electrical-discharge- Inspection
Shaping fixtures machining fixtures fixtures
Lathe fixtures Punching fixtures Finishing
Cylindrical-grinding Internal-broaching fixtures
fixtures fixtures
Band-sawing fixtures
External-broaching
fixtures (c) TMH New Delhi, Manufacturing
Functional Surfaces
Identification based on
Surface finish to be achieved
Basic geometry
Tolerance on the dimension or surface
Functional Surfaces
Location,
Support (if necessary), and
Clamping

Location Surfaces
Location surfaces are the most critical
surfaces in a component from the
machining point of view.
They can generally be identified easily
with the help of base lines in dimensioning
or high finish already achieved in the
previous operation.

Support Surfaces
Select a surface where there is maximum
likelihood for the part to deflect under the action
of clamping and cutting forces.
Support areas selected should not disturb the
location of the workpiece in any manner nor
displace the locators while providing the support.
Support areas selected should not interfere with
the loading and unloading of the component into
the work holding fixture.

Clamping surfaces
Generally the clamping surface should be
opposite to that of a location surface for
clamping to be effective.
However, normally the surface opposite to
location would be the surface to
machined.
Hence this choice would only be possible if
all of that surface is not to be machined or
a parallel surface to this is available.
February 7, 2008 Nageswara Rao Posinasetti 15

Clamping surfaces
If the surface opposite to location is not
available for clamping, alternate surfaces
should be chosen for clamping such that
resultant clamping force is acting against
the locators.
As far as possible already machined
surfaces should be avoided as clamping
surfaces as they are likely to be spoiled
under the clamping forces.

Clamping surfaces
Care has to be exercised to distribute this
large clamping force over a large area of
the workpiece surface.
Choose a surface with enough rigidity
such that no deformation of the
component takes place under the
clamping forces.

Clamping surfaces
Always choose the clamping surface area
large enough such that the clamping
forces are properly distributed and no
surface plastic deformation takes place on
the component.
The clamping force used should take care
of the cutting forces likely to come and
maintain the stability of the workpiece
within the fixture.

Location Principles
The choice of location is essentially to
control the equilibrium of the component
in the work holding fixture under all the
disturbing forces during the machining
operation.
3-2-1 Principle

Location Principles
When more than one locator is placed on
a surface (plane), they should be
distributed as far apart as possible on the
surface.
This would help in placing the workpiece
on locators without much skill.

Location Principles
Also the clamping forces would not be able to
shift the workpiece from such locators.
A blank with irregular surface (such as sand
casting) would be better located on such
distributed locators.
Machining forces would not be able to disturb the
equilibrium of the workpiece in the fixture with
properly distributed locators.
Wear of any locator contributes less to the
inaccuracy of location if the locators are placed
far apart.
Clamping Devices
Always use simple clamps since complicated ones
may lose effectiveness as they wear.
Rough work pieces call for a longer travel of the
clamp in the clamping range, but clamps may be
made to dig into rough surfaces to hold them
firmly.
The type of clamp required is determined by the
kind of operation to which it is applied. A clamp
suitable for holding a drill jig leaf may not be
strong enough for a milling fixture.

Clamping Devices
Clamps should not make loading and unloading
of the work difficult, nor should they interfere
with the use of hoists and lifting devices for
heavy work.
Clamps that are apt to move on tightening, such
as plain straps, should be avoided for production
work.
The anticipated frequency of setups may
influence the clamping means.

Clamping Devices
Strap Clamps
Screw Clamps
Cam Clamps
Toggle Clamps
Equalizers

Fig. 14-35 A toggle clamp of hold down action type with horizontal handle (Courtesy
Carr Lane)

Drill Jig Bushes
Jig bush is used to position and guide the
cutting tool for cutting operation.
Jig bushes are made of materials with
sufficient hardness to ensure long life.
Typical materials used are, hardened
steel, Carbide, Bronze and Stainless steel.

Recommended interference fits for Jig
bushes (Carr Lane company)
Press-fit bushing OD Recommended hole
Nominal, mm Actual, mm (s6) size, mm (H7)
10 10.032-10.023 10.000-10.015
12 12.039-12.028 12.000-12.018
15 15.039-15.028 15.000-15.018
18 18.039-18.028 18.000-18.018
22 22.048-22.035 22.000-22.021
26 26.048-26.035 26.000-26.021
30 30.048-30.035 30.000-30.021
35 35.059-35.043 35.000-35.025
Types of Jigs
Drill jigs as explained earlier would have
the following provisions:
Correctly locate the workpiece with respect to
the tool
Securely clamp and rigidly support the
workpiece during the operation
Guide the tool
Position and/or fasten the jig on a machine
(normally for small jigs)

Jig Components
Locators
Clamps
Jig plate with bushes
Jig body
Other elements as required
Supports
Jig feet

Types of Jigs
Template jigs
Plate jigs
Leaf jigs
Channel and tumble jigs
Indexing jigs

Template jigs
No clamping arrangement
Plates with bushing to guide the tool
Directly placed on the part
Simple
Least expensive

Template jigs
Disadvantages
Not as foolproof as other types
Orientation of the hole pattern to workpiece
datums may not be as accurate as other types
They are usually not practical when locating
datums are dimensioned

Plate jigs
A template jig with workpiece clamping
system

Leaf jigs
Small
Hinged leaf with bushes which also applies
the clamping force

Channel and tumble jigs
For drilling in more than one surface
Complicated and expensive

Indexing jigs
To drill holes in a pattern
Indexing arrangement

Designing a Jig
Method of locating the part – identify the
standard components required for locating
purpose.
Design the clamping method. Make a proper
choice of clamps – C-washer, swing washer, nut,
strap clamp, toggle clamp, etc.
Design any supports required
Design the jig bushes required.
Design the jig body.

Design Study – Drill Jig
1. Method of locating the part – The
central hole which helps in locating as well
as indexing for the hole.
2. Clamping can be done with a nut and a
C-washer
Indexing will have to be done with a
plunger type retracting.

For locating 5/8 in hole
For locating
in the jig
body

For locating 5/8 in hole
For locating
in the jig
body

Jig Design Guidelines
Drill Jigs should be as light as possible consistent
with rigidity to facilitate handling.
A jig, which is not bolted to the machine table,
should be provided with feet, preferably four,
opposite all surfaces containing jig bushes.
Make the jig fool-proof so that the component
cannot be loaded in the wrong way.
Clearance holes or burr slots should be provided
in the jig to allow for the burr formed when the
drill breaks through the component and for swarf
clearance, particularly from locating faces.

Make all component clamping devices as
quick acting as possible.
Locate clamps so that they will be in the
best position to resist the pressure of the
cutting tool when at work.
Avoid complicated clamping and locating
arrangements, which are liable to wear or
need constant attention.

Make all component clamping devices as
quick acting as possible.
Design the jig fool-proof by the use of foul
pins and similar devices, that is arrange it
so that the component, tools or bushes
cannot be inserted except in the correct
way.
Make some locating points adjustable
when the component is a rough casting
and may be out of alignment.
Make, if possible, all locating points visible
to the operator when placing the
component in position in the jig so that
the component can be seen to be correctly
located. The operator should also be able
to have an unobstructed view of the
clamps.

Clamps should be positioned above the
points supporting the component, in order
to avoid distortion and should be strong
enough to hold the component without
bending.
The process of inserting and withdrawing
the component from the jig should be as
easy as possible. Ample space should be
left between the jig body and the
component for hand movements.
Fixtures
As explained earlier the function of a
fixture is to securely fasten the part to the
machine tool table with accurate location
of the part during the machining
operation.
In addition to the function of holding the
work piece, the fixtures also provide for
setting the cutting tool for the actual
machining operation
Fixtures are named on the machine tool in
which it is being used
Assembly Boring
Broaching Grinding
Heat treating Honing
Inspection Lapping
Milling Turning
Welding
February 26, 2008 108
Milling Fixtures
Milling fixtures are the most common type
of fixture in general use today.
The simplest type of milling fixture is a
milling vise mounted on the machine
table.
However, as the work piece size, shape,
or complexity becomes more
sophisticated, so too must the fixture.
February 26, 2008 109

Milling Fixtures
The design should permit as many
surfaces of the part to be machined as
possible. without removing the part.
Whenever possible, the tool should be
changed to suit the part. Moving the part
to accommodate one cutter for several
operations is not as accurate or as
efficient as changing cutters.
February 26, 2008 110

Milling Fixtures
Locators must be designed to resist all
tool forces and thrusts. Clamps should not
be used to resist tool forces.
Clearance space or sufficient room must
be allotted to provide adequate space to
change cutters or to load and unload the
part.
Milling fixtures should be designed and
built with a low profile to prevent
unnecessary twisting or springing while in
operation.
February 26, 2008 111
Milling Fixtures
The entire workpiece must be located
within the area of support of the fixture.
In those cases where this is either
impossible or impractical, additional
supports, or jacks, must be provided.
Chip removal and coolant drainage must
be considered in the design of the fixture.
Sufficient space should be permitted to
allow the chips to be easily removed with
a brush.
February 26, 2008 112
Milling Fixtures
Set blocks or cutter setting gages must be
provided in the fixture design to aid the
operator in properly setting up the tool in
production.
February 26, 2008 113

Lathe Fixtures
Similar to the design of milling fixtures.
In milling, the workpiece is stationary and
the cutting tool revolves. In turning
operations, the workpiece revolves and
the cutting tool is stationary.
Tool designer must deal with-centrifugal
force. The complete fixture must be
designed and constructed to resist the
effects of the rotational, or centrifugal,
forces present in the turning.
February 26, 2008 114

Lathe Fixtures
Since lathe fixtures are designed to
rotate, they should be as lightweight as
possible.
Lathe fixtures must be balanced. While
perfect balance is not normally required
for slow-speed turning operations, high
rotational speeds require the fixture to be
well-balanced.
February 26, 2008 115

Lathe Fixtures
Projections and sharp corners should be
avoided since these areas will become
almost invisible as the tool rotates and
they could cause serious Injury.
Parts to be fixtured should, whenever
possible, be gripped by their largest
diameter, or cross section.
The part should be positioned in the
fixture so that most of the machine
operation can be performed in the first
fixturing.
February 26, 2008 117
Lathe Fixtures
Clamps should be positioned on surfaces,
or areas, which are rigid before and after
machining.
As with other fixtures, some means of
cutter setting should also be incorporated
into the design. However, since the work
holder will be rotating, this setting device
should be removed.
February 26, 2008 118

Lathe Fixtures
Whenever possible, standard lathe
accessories should be adapted in the
design of turning fixtures. Lathe
faceplates are an ideal method to mount
large fixtures. Likewise, a standard lathe
chuck, or collets, can and should be
modified for many fixturing applications.
February 26, 2008 119

Summary
Jigs and fixtures are used to improve the
productivity and quality of machined
components.
Depending upon the production requirements
either custom made jigs and fixtures or modular
fixtures are used.
Part surfaces can be divided into location,
support and clamping depending upon the
function they serve.

Summary
A maximum of six degrees of freedom need to be
arrested in order for the workpiece to be stable
during the machining operation. For this purpose
3-2-1 location principle is used.
Round locators are more commonly used. They
may need to be reduced for radial location in
which case they are called diamond pins.
Rest buttons could be used for supporting the
part or jig.

Summary
Clamping force is directed against the locator for
stability. A variety of clamps such as strap
clamps, cam clamps, and toggle clamps are used
in jigs and fixtures. Their selection depends on
the part geometry, machining process and the
production volume.
There are a number of types of jigs used in
practice such as template jig, plate jig, channel
jig, etc. The part geometry, accuracy required
and production volumes dictate their individual
choice.
Summary
Complete jig design process is like an
assembly operation. After making the
individual choice of elements that form
part of the jig, they are geometrically
integrated to form the jig.
Fixtures are more specialized and varied
based on the machining operation
involved. They tend to be heavier and
clamped to the machine table.

Jigs and Fixtures

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14 Jigs and Fixtures

(c) TMH New Delhi, Manufacturing

(c) TMH New Delhi, Manufacturing

(c) TMH New Delhi, Manufacturing

(c) TMH New Delhi, Manufacturing

(c) TMH New Delhi, Manufacturing

February 7, 2008 Nageswara Rao Posinasetti 15

February 7, 2008 Nageswara Rao Posinasetti 16

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February 7, 2008 Nageswara Rao Posinasetti 19

(c) TMH New Delhi, Manufacturing

(c) TMH New Delhi, Manufacturing

(c) TMH New Delhi, Manufacturing

(c) TMH New Delhi, Manufacturing

(c) TMH New Delhi, Manufacturing

(c) TMH New Delhi, Manufacturing

(c) TMH New Delhi, Manufacturing

(c) TMH New Delhi, Manufacturing

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(c) TMH New Delhi, Manufacturing

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February 12, 2008 Nageswara Rao Posinasetti 70

February 12, 2008 Nageswara Rao Posinasetti 72

February 12, 2008 Nageswara Rao Posinasetti 75

(c) TMH New Delhi, Manufacturing

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Heat treating Honing

February 26, 2008 109

February 26, 2008 110

February 26, 2008 113

February 26, 2008 114

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(c) TMH New Delhi, Manufacturing

(c) TMH New Delhi, Manufacturing

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