Materials - Jigs and Fixtures

• Variety of materials are used

Jigs and Fixtures - Materials • Some materials hardened to resist wear
• Phosphor bronze used to reduce wear of
Dr.B.CHOKKALINGAM ME, Ph.D
Associate Professor
mating parts (steel)
Department of Mechanical Engineering
Sri Ramakrishna Institute of Technology • Use of nylon fibre to prevent damage to
Coimbatore-641010
the workpiece

1 2

Materials - Jigs and Fixtures Materials - Jigs and Fixtures

• Carbon steels • Alloy steels 40Ni2Cr1Mo28(EN24)
• Used to manufacture bushes and locators • Alloy steels used for press rams
• C-0.85-1.18%, Oil hardened to RC 62-63
• Mild Steels
• Spring Steels(Collet Steels)
• Tempered to RC47 hardness
• Carbon< 0.3%
• C-1%, Mn-0.5% • Cheap
• High Tensile Steels • Widely used
• Medium Carbon steels(C-0.45% -0.60%),EN 8-9
• Medium carbon steels used for fasteners & • Suitable for parts that are not subjected to
Structural work wear and high stresses
3 4
 Materials - Jigs and Fixtures
• Cast Iron
• Absorb vibration
• Widely used in milling fixtures
• Easier to cast
• Saving in machining time
• Variety of grades are available
• SG Iron- as strong as mild steel
Materials - Jigs and Fixtures
• Case hardening steels
• 17Mn1Cr95 steel (with 1%Mn ,95%Cr)
• Widely used
• 15Ni2Cr1Mo25 ( Ni 2% reduces thermal
expansion up to 100 degree C
• Suitable for parts which require only local
hardness on small wearing surfaces

5 6

Materials - Jigs and Fixtures Materials - Jigs and Fixtures

• Steel Castings
• Combines the strength of steel and
shaping of casting
• Nylon and Fibre
• Used as soft lining for clamps
• Avoid denting or damage to the workpiece
• Reduces the weight of jigs and fixture
• Phosphor bronze
• Used for nuts, screws and clamping
system
• Screw-Steel( harder)
• Nut- Phosphor bronze ( softer)
• Softer nut wears quickly-replaced
• Longer life for screw rod

7 8
 Materials - Jigs and Fixtures Materials - Jigs and Fixtures
PARTS MATERIAL PAGE NO.(PSG
PARTS MATERIAL PSG DDB
DDB)
( Page No.)
Swing clamps Toughened steel 5.91
Set collars(heavy 5.95
End locating Case hardening 5.91
series)
plugs steel
Case hardening Set collars(light Structural steel 5.95
Round locating 5.92
steel series)
pins
V-Block CI (Gr. 20) 5.97
Diamond Case hardening 5.92 V-Locator C 45 Case 5.97
locating pins steel hardened
Round locating Case hardening 5.93 Jig button C 45 5.98
studs steel Jig feet Free cutting steel 5.98
Strap clamps Steel 5.94 Fixed bush 5.100
Swing C washer Rolled steel 5.94 9 Liner bush 5.100 10

Materials - Jigs and Fixtures Materials - Jigs and Fixtures

PARTS MATERIAL PSG DDB
PARTS MATERIAL PSG DDB
( Page No.)
( Page No.)
Slip bushes and C 45 5.101 Thrust pads Surface hardening 5.105
locking screws steel
Tommy nut C 45 5.102 Locking dogs C 14 5.105
Knurled thumb nut C 45 5.102 Double cam lever 5.106
Spherical cam 5.106
Thumb nut C 45 5.102
clamping
Hand nut C 45 5.102
Spherical washer Rolled steel 5.107
Handle grip 5.103
and conical seat
screws
Ball grip 5.108
Pressure pads 5.104
Operating lever 5.108
Pressure disc 5.104
11 rod 12
 Summary- Jigs
Open Jigs Closed Jigs Other Jigs

TYPES OF JIG Template Jigs

Boxed Jigs or ‰ Indexing Jigs
Plate Jigs Tumble Jigs ‰ Pump Jigs
Dr.B.CHOKKALINGAM ME, Ph.D ‰ Multi-station
Associate Professor Jigs
‰ Table jigs
Department of Mechanical Engineering ‰ Sandwich Jigs ‰ Channel Jigs
Sri Ramkrishna Institute of Technology ‰ Leaf Jigs
(Latch jigs)
Coimbatore-641010 Rotary Jigs
Angle plate jigs

Modified Angle plate Jigs Trunnion Jigs

TYPES OF JIG Post Jig

• Post Jig
• Turnover Jig
• Channel Jig
• Latch Jig
• Box Jig
• Pot Jig
• Angular Post Jig
• Indexing Jig

Post Jig Post Jig

1
 Post Jig Post Jig

Post Jig Turn Over Jig

• Also called table jig and open jig

Closed jigs
Channel Jigs „

Channel Jig
• Simplest form of box jig.
• The work is held between two sides and machined from the
third side (Permit drilling into more than one surface of a workpiece; usually 2
or 3 sides),
• In some cases, where jig feet are used, the work can be
machined on three sides.

part

„ U-shape channel (can be cast or welded structure), press fit drill

bushings, locators, and clamping details.

11

2
Channel Jig Channel Jig

Latch Jig Latch Jig

Latch Jig Leaf Jig (Latch Jigs)

3
 „ Closed jigs
Leaf Jig (Latch Jigs) Leaf Jigs (Latch Jigs)
• Small box jigs
• Have hinged leaf to allow for easier loading and unloading (It
incorporates a hinged leaf that carries the bushings; through which
clamping pressure is applied)
„ Leaf jigs are smaller
than box jigs and are
sometimes made so
that they do not
completely surround
the part.
„ Equipped with a
handle for easier
movement.

„ In SME book: Leaf jigs with additional feet are called tumble jigs, which permits operation
from more than one side.
20

Leaf Jig (Latch Jigs) Leaf Jig (Latch Jigs)

Latch Jig Box Jigs or Tumble Jigs Closed jigs „

• Totally surround the part

• Allows the part to be completely machined on every surface (all 6 sides)
without the need to reposition the work in the jig
• Greater accuracy with less handling. So they are more expensive.
Quarter-turn
screw

Solid locators
Box or tumble jig
with leaf
The one here is shown
with the hinged top
open to permit loading
and unloading.

Thumb screw
Drill bushing

24

4
Box or Tumble Jig Box or Tumble Jig

Box or Tumble Jig Box-Type Drill Jigs

Total No. of feet

= 16

Pot Jig Pot Jig

5
 Angular Post Jig
INDEXING JIGS AND FIXTURES
One drill
bush is
required.
Three drill
bushes are
required.
Basic Features of an Indexing
Jig or Fixture
• The jig or fixture must include:
• 1- Component location and clamps
mounted on the movable member.
• 2- A slide or a bearing system to control
the movement of the movable member.
• 3- An indexing device to position the
member and a locking device to secure it
in position during the machining.
INDEXING JIGS AND FIXTURES
* Indexing is a process of quick,
accurate location of w.p. or fixture in a
number of specific positions.
* Indexing involves periodic linear or
rotary movement of the indexed part
to the next position.
Used when holes have to Four slots are to be milled
be drilled on a large pitch in the periphery of a
circle. One drilling station circular w.p.
is used, and the
component is rotated
about the axis of the pitch
circle to position it for
drilling each hole in turn.
Basic Features of an Indexing
Jig or Fixture
• It must be emphasized that the locking device
for the movable member must be separate from
the w.p. clamp; it must be convenient to operate
because it must be operated each time the w.p.
is indexed.
• For example, in the example shown in Fig. 8.6
the w.p. is clamped once during the milling
operation, but the movable member must be
clamped four times during the operation.
6
 Indexing Devices
The indexing device is usually mounted in the fixed part of the jig or fixture,
and it engages in slots or holes that are suitably spaced in the moving
member.

The end of the plunger

can be coned and the
Useful for light work locating holes in the
movable member can be
coned or vee shaped, so
that wear can be
compensated for.
As a refinement When the plunger is in an
awkward position it may be
operated by a rack and
pinion system.
Plunger gives positive location
(used for heavy work)

Typical Indexing Jigs and

Fixtures
Indexing Jig
BURR GROOV E

Indexing Jig Indexing Jig

• Used to drill holes in a pattern, usually radial.
• Used to accurately spaced holes or other
machined areas around a part.
• Uses either the part itself or a reference plate
and a plunger
• Larger ones are called rotary jigs

7
 Indexing Jig Indexing Jig
• Base is made from a standard angle iron • A drill bushing is press fit into the bushing
section plate.
• a location stud has been placed on the • The hex nut is loosened after the first hole
base is drilled,
• Location stud position a bored cylindrical • the part is revolved,
part • the index pin, which is held in place with a
• Cylindrical part is clamped on the stud with flat spring, is pushed into the hole,
a C-washer and a hex nut.

Indexing Jig Trunnion Jigs

• Form of rotary jig
• the second of four holes 90 degree apart,
• Used for very large or odd-shape parts
is drilled after the nut is tightened. • Used for large and heavy parts that must be machined
with several separate plate-type jigs
• Part is first put into a box-type carrier and then loaded
• Indexing is repeated until all four holes on the trunnion
Indexing lock pin
have been drilled.
Trunnion jig

Hoffman-Fig 2-14

46

Open jigs
Multi-station Jigs Template Jigs „

• Are made in any of the forms already discussed • Used for accuracy rather than speed.
• While one part is drilled, another can be reamed and a third • Fits over, on, or into the work and is not usually
counter-bored clamped.
• The final station is used for unloading the finished parts and • Cheapest and simplest type of jig.
loading fresh parts • May or may not have bushings (when bushings are not
• Used on multi-spindle machines as well as single-spindle used, the whole jig plate is normally hardened).
Check Hoffman-Fig 2-4
Ream Indexing holes
models

Drill Counter bore

Indexing lock plunger

Hoffman-Fig 2-16
Flat-plate template jig
Load-unload Nesting template jig
47 48

8
 Open jigs
Template Jigs „
Test yourself!
„ Explain the procedure of using this jig.
• What type of jig is this?

An angle plate jig

49 50

Test yourself! Test yourself!

• What type of jig is this?
• What type of jig is this?

An angle plate jig A table plate jig

51 52

Test yourself! Test yourself!

• What type of jig is this?
„ What type of jig is this?

A channel jig.
This is in fact a drill jig & milling fixture „ This is a box jig which is used to drill holes in an engine link.

53 54

9
 Test yourself! Test yourself
• What type of jig is this?
• What type of jig is this?

Box jig or tumble jig

(The top is removed)

A channel jig (can be considered as template)

55 56

In-class Project In-class Project

In-class Project In-class Project

10
In-class Project Case Study I

Plate drill jig for

drilling holes in
flange

Case Study II Case Study III

Case Study III Case Study IV

11
 Case Study V Discussion Case I

Discussion Case II Discussion Case III

12
 Advantages of Jigs and Fixtures
• Productivity
Advantages and
Disadvantages of Jigs and • Interchangeability
Fixtures
Dr.B.CHOKKALINGAM ME, Ph.D
Associate Professor • Skill Reduction
Department of Mechanical Engineering
Sri Ramakrishna Institute of Technology
Coimbatore-641010
• Cost Reduction

Advantages of Jigs and Fixtures Advantages of Jigs and Fixtures

• Productivity • Skill Reduction
– Elimination of marking, punching, positioning, – No need foe skillful setting of the workpiece or
alignment and frequent checking tool
– Use of unskilled labour saves labour cost
• Interchangeability • Cost Reduction
– Uniform quality in manufacture – Reduce measurement and its cost
– No need for selective assembly – Higher production, Reduced scrap
– All similar components are interchangeable – Easier assembly

1
 Disadvantages of Jigs and Disadvantages of Jigs and
Fixtures Fixtures
• Suitable for high volume production only • Skillful design engineers are required for
• Application is limited to specific the design of jigs and fixtures.
components only • More workholders for the same workpiece
• If standard parts are not used production with different locations increases errors.
will be stopped until their replacement
• Periodic maintenance is required
• Missing of parts in storage affects
production

2

DESIGN OF JIGS AND FIXTURES
Dr.B.CHOKKALINGAM ME, Ph.D
Associate Professor
Department of Mechanical Engineering
Sri Ramakrishna Institute of
Technology
Coimbatore-641010
1 2
Tool Design
z Process of developing tools, methods and
techniques to improve productivity
z Gives industry the machines and special
tooling needed for high volume production
z Ensures Quality
z Reduces the cost of manufacturing
z Growing process of creative problem solving

Types of Tools Objectives of Tool Design

z Material Cutting Tools z Provide simple, easy to operate tools for

z Work Holding Devices maximum efficiency
z Press Working Tools z Reduce the manufacturing cost
z Bending, Forming and Drawing Dies z Design tools that consistently produce parts
z Tool Design for Inspection and Gauging of high quality
z Tool Design for Joining Processes z Increase the rate of production with existing
machine tools
z Tooling for Casting

3 4

1
 Objectives of Tool Design Workholding Devices

z Design the tool to make it foolproof and to
prevent improper use
z Select materials that will give adequate tool
life
z Design the tools for maximum safety of the
operator.
z All devices that hold, grip, or chuck a
workpiece in a prescribed manner of
firmness and location, to perform on it a
manufacturing operation

5 6

Jig
Jig

z Hold, support and accurately position a

workpiece

z Provides some means for guiding the

cutting tool

7 8

2
 Fixture Fixture

z Hold and accurately position a

workpiece

z Does not guides the cutting tool.

z References the cutting tool

9 10

Drill Jig Drill Jig

11 12

3
 Drill Jig Drill Jig

13 14

Drill Jig Drill Jig

15 16

4
 Drill Jig Drill Jig

17 18

Drill Jig Drill Jig

19 20

5
 Milling Fixture Showing Method of
Milling Fixture Setting Cutter

21 22

Indexing Milling Fixture Face Milling Fixture

23 24

6
 Milling Fixture

25 26

Tenon Location between Fixture and

Machine Table Planer Fixture

27 28

7
 Function of Jig Function of Fixture

Jig Fixture
z Hold, support and accurately position a z Hold and accurately position a workpiece but
workpiece does not guide or locate the cutting tool
z Provides some means for guiding the cutting z Used for milling, grinding, shaping, turning,
tool planning, honing, lapping, broaching, boring
z Used on drilling, reaming, tapping and assembly and welding operations
counterboring operations

29 30

Jig Fixture

Jigs use drill bushings to Fixtures, use set blocks and

support and guide the tool. thickness gages (feeler gages) to
locate the tool relative to the
workpiece.

31 32

8
 What is the difference between a jig and
Jigs and Fixtures a fixture?
Fixtures, use set blocks and
jigs use drill bushings to thickness gages (feeler gages) to
Jig Fixture
support and guide the tool. locate the tool relative to the hold, support, and locate hold, support, and locate the
workpiece.
the workpiece workpiece
guides the cutting tool. Does not guides the cutting
tool. references the cutting
tool)
Not fixed to the machine Bolted or clamped to the
table machine table
Usually lighter in Usually heavier in
construction construction
33 33 34

What is the difference between a jig

and a fixture? Advantages of Jigs & Fixtures

Jig Fixture 1.COST REDUCTION

Used on drilling, reaming, Used for milling, grinding, z Higher Production
tapping and counterboring shaping, turning, planning,
operations honing, lapping, broaching, z Reduced Scrap
boring, assembly and
welding operations z Easier for Assembly
z Saving in Labour Cost
z Overall Reduction of Cost

35 36

9
 Advantages of Jigs & Fixtures Advantages of Jigs & Fixtures

2. PRODUCTIVITY 3.SKILL REDUCTION

z Elimination of Marking, Punching, Positioning,
z Elimination of Alignment
z Elimination of Frequent Checking
z Improve Safety of the Machine
z Improve Accuracy
z Duplication of Parts
z No need for Skillful Setting of the Workpiece
or Tool
z An Average Person can be Trained to Use
Jigs and Fixtures
z Use of Unskilled Labour saves Labour Cost
z Minimize the Possibility of Human Error

37 38

Advantages of Jigs & Fixtures Disadvantages of Jigs & Fixtures

4.INTERCHANGEABILITY

z Uniform Quality in Manufacture

z No Need for Selective Assembly

z All Similar Components are Interchangeable

39 40

10
41 42

Jig Feet

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

43 44

11
 Locating Devices

45 46

47 48

12
 Workpiece Stops Workpiece Supports

49 50

Workpiece Clamping

51 52

13
53 54

55 56

14
57 58

Drill jig components

z Jig body
– Holds the various parts of a jig assembly.
z Cap screws and dowel pins
– Hold fabricated parts together

59 60

15
 Drill jig component-Locating devices

– Pins, pads, and recesses used to

locate the workpiece on the jig.

61 62

Drill jig components-Clamping devices Drill jig components

z Locking pins
– Inserted after the first
hole is drilled to lock or
hold the workpiece
securely to the jig plate
while subsequent holes
are being drilled.

63 64

16
65

17
 PNEUMATIC CLAMPING

Pneumatic and Hydraulic

Actuation
Dr.B.CHOKKALINGAM ME, Ph.D
Associate Professor
Department of Mechanical Engineering
Sri Ramakrishna Institute of Technology
Coimbatore-641010

1 2

HYDRAULIC CLAMPING Hand Pump

3 4
 Air-Hydraulic Booster Principle

5 6

Air-Hydraulic Booster Circuit

7
 CLAMPING DEVICES
1. Mechanical Actuating Clamps
2. Power Clamps
CLAMPING DEVICES • a) Fluid power Clamping
» (i) Pneumatic Clamping
Dr.B.CHOKKALINGAM ME, Ph.D, » (ii) Hydraulic Clamping
Associate Professor, • b) Vacuum Clamping
Department of Mechanical Engineering,
Sri Ramakrishna Institute of Technology, • c) Magnetic Clamping
Coimbatore-641010.
• d) Electrostatic Clamping

Mechanical Actuating Clamps Mechanical Actuating Clamps

• Strap Clamp • Bayonet Clamp
• Heel Clamp • Toggle Clamp
• Bridge Clamp
• Edge Clamp
• Quick Acting nut/screw
• Latch Clamp • Double Clamping
• Hinged Clamp • Equaliser
• Wedge Clamp • Stacking
• Cams
3 4

1
 Mechanical Actuating Clamps Strap Clamp
• Strap Clamp • Equal Pressure at both the ends of the
clamp

5 6

Strap Clamp Strap Clamp

• Fastener at the center-Clamping two parts • Clamping a single part- Better placement
side by side of the fastener

7 8

2
 Types of Strap Clamp Strap Clamp

9 10

Strap Clamp Hinged Clamp

• Strap clamp with wedge action

11 12

3
 Heel Clamp Bridge Clamp

13 14

Edge or Side Clamp Edge Clamp

15 16

4
Swinging Leaf Clamp Swinging Leaf Clamp

17 18

Swinging Leaf Clamp Screw Clamp and Hook Clamp

19 20

5
 Multiple Clamping Multiple Clamping
• Double Clamping • Equaliser

21 22

Multiple Clamping Multiple Clamping

• Stacking

23 24

6
 Quick Action Clamps Cam Clamp
• Cams
• Bayonet Clamp
• Toggle Clamp
• Quarter Turn Screw

25 26

Cam Clamp Bayonet Clamp

• Cylindrical cam

27 28

7
Bayonet Clamp Bayonet Clamp

29 30

Toggle Clamp Toggle Clamp

31 32

8
 Quarter Turn Screw Fluid Power Clamping
• Quik acting nut for rapid clamping

33 34

Fluid Power Clamping Fluid Power Clamping

35 36

9
Fluid Power - Multiple Clamping Fluid Power Clamping

37 38

Fluid Power Clamping Fluid Power Clamping

39 40

10
Fluid Power Clamping HYDRAULIC CLAMPING

41 42

HYDRAULIC CLAMPING Hydraulic Clamping

43 44

11
 Hydraulic Clamping PNEUMATIC CLAMPING

• Hydraulic clamp for larger clamping force

• Swing clamp
45 46

Air-Hydraulic Booster Circuit

47

12

PRINCIPLES OF CLAMPING
Dr.B.CHOKKALINGAM ME, Ph.D
Associate Professor
Department of Mechanical Engineering
Sri Ramakrishna Institute of Technology
Coimbatore-641010
PRINCIPLES OF CLAMPING
• clamping and unclamping movement
should be limited
• clamping operation should be very simple
and quick acting
• Avoid complicated clamping and locating
arrangements
• Clamp should be designed to perform as
many operations as possible in one setting
3 4
PRINCIPLES OF CLAMPING
• Clamping need to be strong and rigid
enough to hold the blank firmly during
machining
• Clamping should be easy, quick and
consistently adequate
• clamping should be such that it is not
affected by vibration, chatter or heavy
pressure
PRINCIPLES OF CLAMPING
• clamping system should comprise of less
number of parts
for ease of design, operation and maintenance
• wearing parts should be hard or hardened
and also be easily replaceable
• clamping force should act on heavy parts
and against supporting and locating
surfaces
1
 PRINCIPLES OF CLAMPING
• Clamping force should be away from the
machining thrust forces
• Clamping method should be fool proof and
safe
• Clamping must be reliable but also
inexpensive
• If possible make all clamps integral parts
of the jig and avoid the use of loose parts
5 6
PRINCIPLES OF CLAMPING
• Clamp and clamping force must not
damage or deform the workpiece
• Clamps should be positioned above the
points supporting the component (to avoid
distortion and bending)

PRINCIPLES OF CLAMPING PRINCIPLES OF CLAMPING

• Clamping pressure should be directed
towards the points of support, otherwise
work will tend to rise from its support

7 8

2
 PRINCIPLES OF CLAMPING
• A properly designed jig or fixture can use
the cutting forces to hold the work
9 10
PRINCIPLES OF CLAMPING
• Bend of the part is avoided
11
PRINCIPLES OF CLAMPING
• Clamping pressure should only be enough
to hold the part against the locators.
• Part can bend
PRINCIPLES OF CLAMPING
• Any force imparted by a cutting action
should be directly opposed by a fixed
location and not by a clamp
• Component should be located and
clamped on a previously machined surface
12
3
 PRINCIPLES OF CLAMPING PRINCIPLES OF CLAMPING

13 14

PRINCIPLES OF CLAMPING PRINCIPLES OF CLAMPING

• Clamping process should be as simple as • Distribution of clamping force to more
possible than one point equally from one point of
application

15 16

4
 PRINCIPLES OF CLAMPING
• Clamps should keep the workpiece firmly
in contact with locating pins on surface
• For soft and fragile workpieces, fibre pads
are to be provided in the clamping face to
avoid damage to the workpiece

17

5
 LOCATING DEVICES
• Locating Pins and Buttons
• Adjustable Pins and Locators
LOCATING DEVICES • Screw type
• Spring type
Dr.B.CHOKKALINGAM ME, Ph.D • Edge Locators
Associate Professor
Department of Mechanical Engineering • Stops
Sri Ramakrishna Institute of Technology
Coimbatore-641010 • Fixed Stops
• Spring Stops
1 2

Locating Pins and Buttons Locating Pins and Buttons

• Generally Pins are longer than Buttons
• Pins are used in horizontal direction
• Buttons are used in vertical position
• Selection of head shape depends on the
type of surface to be located
• Flat heads are used to locate flat surfaces
• Curved heads are used to locate circular
and irregular surfaces
3 4
 Workpiece Locating using Pins Adjustable Supports and
and Buttons Locators
• Pins and locators adjusted to locate and
support irregular surfaces

• TWO TYPES
• Screw Type
• Spring Type

5 6

Screw-type Supports and Spring Type Adjustable

Locators Supports
• One or Two screws are used to adjust the • Spring is used to set the location and a set
locating position screw is used to lock the locator

7 8
 Edge Locators Edge Locators
• Edges of the machine work table used as • Two edge locators are used on each side
the reference surface for locating the of the machine table
workpiece • Pallet pushed against the four edge
• Ideal locators for pallet type fixtures locators

9 10

Stops - Fixed Stops Stops - Spring Stops

• Positive location was not provided due to
• Used as positive locators in a horizontal spring action
direction
• Normally used to exert a force on the
workpiece against positive locators or fixed
stops

11 12
Locating Pins-Shape: Diamond Locating Pins
• For positioning and clamping of 2" x 2"
grids and universal fixture elements on
grid bases, hardened and ground
precision locating pins are used.
• 4140 steel, Rc 50-55
• Precision diameter
•

13 14

Locating Pins- Shape: Round

15 16
17
 LOCATING METHODS
• Locating from a Flat Surface
– three primary methods of locating work
LOCATING METHODS • from a flat surface:
• solid supports,
Dr.B.CHOKKALINGAM ME, Ph.D
Associate Professor
• adjustable supports and
Department of Mechanical Engineering
Sri Ramakrishna Institute of Technology
• equalizing supports.
Coimbatore-641010

1 2

Locating from a Flat Surface Locating from a Flat Surface

• These locators set the vertical position of • Solid supports are the easiest to use.
the part, support the part and • normally used when a machined surface
• prevent distortion during the machining acts as a locating point
operation.

3 4

1
 Locating from a Flat Surface Locating from a Flat Surface
• Adjustable supports • Adjustable supports
• Used where surfaces are uneven
(casting,forging..)
• Threaded style is the easiest and more
economical.
• Adjustable locators are normally used with
one or more solid locators to allow any
adjustment needed to level the work.

5 6

• Adjustable supports • Adjustable supports

7 8

2
 Locating from a Flat Surface Equalizing supports
• Equalizing supports are also a form of
adjustable support
• provide equal support through two
connected contact points.
• As one point is depressed, the other raises
and maintains contact with the part.
• Used for uneven cast surfaces.

9 10

Locating from an Internal

Diameter
• With shank-type locators, it is a good • Qq
practice to
• use the press-fit locator rather than the
threaded locator
• for accuracy. Threaded locators are useful
in areas
• where the construction of the tool will not
permit the
• other type to be pressed out.
11 12

3
• Pin-type locators are used for smaller holes and for • Pin
• aligning members of the tool (Figure 3–17). When the
• pins are used for alignment, special bushings should
• also be used so that they can be replaced when they
• wear. Pins used for part location are made with either
• tapered ends or rounded ends, allowing the parts to be
• installed and removed easily (Figure 3–18).

13 14

• Ee • Ww

15 16

4
• Qq • Locating from an External Profile
• Nesting locators

17 18

• ww • eee

19 20

5
• ww • ee

21 22

• ee • Rr

23 24

6
• Ee • Sight Location

25 26

• Sight Location • ee

27 28

7
• Ee • Locating by two holes

29 30

Locating by a pin and Vee block.

• LOo • Vee block and cones should be used for
self-locating solid and hollow cylindrical
jobs

31 32

8
 PRINCIPLES OF LOCATION
Dr.B.CHOKKALINGAM ME, Ph.D
Associate Professor
Department of Mechanical Engineering
Sri Ramakrishna Institute of Technology
Coimbatore-641010

Operations common to a drill jig PRINCIPLES OF LOCATION

• Locating
• Refers to the dimensional and positional
relationship between the work piece and
the cutting tool
• Locator
• A device used to establish and maintain
the position of a part in jig or fixture to
ensure the repeatability of the
workholders.
4
 PRINCIPLES OF LOCATION PRINCIPLES OF LOCATION
• 3-2-1 method of location • Swarf clearance
• Principle of least point • Fool proofing
• Principle of extreme position • Redundant location
• Principle of mutually perpendicular planes • Make all the location points visible to the
• Location of accurate work operator from his working position
• Small locating surfaces • Make the location progressive( ie. Locate
• Replacement a necessity on one locator and then on to the other)
• Motion economy
5 6

PRINCIPLES OF LOCATION 3-2-1 Location

• 3-2-1 Location • Any part which has to be fixed during
• 3-2-1 principle is used to locate the job . welding or during machining process has to
• What 3 means ? be fixed with this principle.
• What 2 mean ? • Workpiece must be constrained in at least
three direction- mutually perpendicular
• What 1 mean?
• Three directions require three location
• Simple they represent the directions. surfaces
• Locating surface, Line up surface and
Positioning Surface
7 8
 3-2-1 Location 3-2-1 Location

• Locating surface requires 3 pins

• Line up surface requires 2 pins

• Positioning Surface requires 1 pin

3-2-1 Location 3-2-1 Location

 3-2-1 Location 3-2-1 Location

• Every object is having 6 degrees of freedom. • 4) Rotational movement along X -axis

1) Translational movement along X -axis 5) Rotational movement along Y-axis

6) Rotational movement along Z-Axis
2) Translational movement along Y-axis

3) Translational movement along Z-Axis

13

3-2-1 Location 3-2-1 Location

• Restriction of movement by Six-pin
method(3-2-1 method):
• Motion is restricted using clamps and
locators.
• A three pin base can restrict five motions.
>Rotation about X,Y axes.(4 motions)
>Translation along -ve z-axis (1 motion)
15 16
 3-2-1 Location 3-2-1 Location
• Directions nine, ten and eleven are
restricted by a clamping device. (3 motions)

17 18

3-2-1 Location 3-2-1 Location

• This is the most common locating method

employed for square or rectangular parts.
• Flat bases may also be used, but
• these should be installed rather than
machining into the base.

19 20
 3-2-1 Location Principle of Least Point
• But pin/button type locators offers more • Points more than necessary should not be
accuracy as the area of contact is less.
used to secure location

• If more are such as for the finished

• Moreover, they raise the work above the
surface, extra ones should only be
base so that chips wont interrupt the
operation. inserted

21 22

Principle of extreme position Principle of extreme position

• Locating points should be chosen as far

apart as possible on any one workpiece
surface

23 24
 Principle of mutually perpendicular
Principle of extreme position planes
• Locating points are to be provided in the
mutually perpendicular planes
• If not perpendicular
• Wedging action between the two locating
surfaces lifts the workpiece.
• A large error in the movement of the
workpiece due to displacement of locating
point or chip adhering to it
25 26

Principle of mutually perpendicular

planes Locating Surfaces-Raised above
the surrounding surfaces of
jig/fixture
 Location of accurate work
• Location should be done on the most
accurate surface of the workpiece
• A machined surface is preferable to the
unmachined surface
• When more than one machined surface
are available, locate from the most
accurate surface
29
Location of accurate work
• Located fro outside diameters 80mm or
110mm (or)
• Centre 40mm diameter bore
31
Location of accurate work
30
Small locating surfaces
• Use of small locating surfaces such as rest
buttons, supporting pins or cylindrical
locators.
• Benefits:
• Less time for cleaning
• Reduced chances of adhering particles
• Saving in material & labour
32
Small locating surfaces Small locating surfaces

Small locating surfaces Small locating surfaces

 Replacement a Necessity Swarf clearance
• All locating points require replacement due • All corners that collect small chips and
to wear and tear
• Easily replaceable swarf must be avoided by relieving them
• Easily repairable • Corners of locators should be provided
• VEE locator- easily built up & replaceable
with undercut(or) recesses.
• Rest buttons and cylindrical locators
– Easily pressed through the holes

37 38

Swarf clearance Swarf clearance

40
Swarf clearance Swarf clearance

Swarf clearance Fool Proofing

• Foolproofing ensures that the part will fit

into the jig/fixture only in its correct
position.

• Prevents the part from being loaded

incorrectly.
Fool Proofing Fool proofing

45 46

Fool proofing Redundant location

47 48
 Redundant location Redundant location

49 50

PRINCIPLES OF LOCATION Motion Economy

• Make all the location points visible to the • It involves use of easy, quick and
operator from his working position economic loading of work pieces.
• Make the location progressive( ie. Locate
on one locator and then on to the other)

51
 Motion Economy Motion Economy
• Machined Bore ‘A’ • I) Drilling of Hole ‘C’ (First)
• Either drill holes ‘B’ or ‘C’ first
• Locate on the drilled hole to drill the other • Locator A – First – Fixed
hole • Locator C – Second – Removal Locator

• Drilling of the hole ‘B’

Motion economy Motion Economy

• II) Drilling of Hole ‘B’ (First)
• Locator A – First – Fixed
• Locator B– Second – Fixed
• Workpiece is loaded on both the locators
‘A’ &’B’ in one motion
• ‘A’ & ‘B’ locators are parallel
• Parallel locators are preferable to right
angled locators
55
Motion Economy Golden Rule of Workholding
• “Grab the workpiece one time and don’t
turn it loose until you finished with all
operations”
• Goal :
• To prevent inaccuracy
• Change of workholders increases more
errors
• Best practice is to do all operations in
one set up
57
 Redundant or Duplicate Location
• The use of duplicate locators should
always be avoided
Redundant Location or
• duplication not only costs more but also
Duplicate Location
• could cause inaccuracies.
Dr.B.CHOKKALINGAM ME, Ph.D
Associate Professor
Department of Mechanical Engineering
Sri Ramakrishna Institute of Technology
Coimbatore-641010

1 2

Redundant or Duplicate Location Redundant or Duplicate Location

• Flange is located on both the underside • If the reference surface is the flange, hub
and the bottom of the hub. locator is not necessary.
• Both are parallel surfaces,
• only one is needed and
• the other should be eliminated.

3 4

1
 Redundant or Duplicate Location Redundant or Duplicate Location
• If the hub is the reference surface,, the • Locating the part from both its outside
flange locator is unnecessary. edge and the holes can create problems.
• Ww

5 6

Redundant or Duplicate Location

• location of the pins in the tool is fixed and
cannot be changed to suit each part.
• location of the holes in the part is variable
within limits.

2
 STANDARD PARTS
• Commercially available standard
components
STANDARD PARTS-Jigs and
• Locators, Supports
Fixtures
• Springs
Dr.B.CHOKKALINGAM ME, Ph.D
Associate Professor
• Bolts, Screws, Pins
Department of Mechanical Engineering • Washers, Drill Bushings
Sri Ramakrishna Institute of Technology
Coimbatore-641010 • Clamp Assemblies

STANDARD PARTS STANDARD PARTS

• Advantages • V Block
• V Locator
• Standard Parts improve tooling quality
• Jig Button
• Savings in Labour
• Feet Nuts
• Savings in Materials
• Jig Feet Button
• Interchangeable components • Locating Pin
• Cost is less • Bushes
• Locking Screws
3 4

1
 STANDARD PARTS
• Locking Screws
• Handle Grip Screws
• Wing or Fly Screws
• Pressure Pads
• Pressure Disc
• Double Cam Lever
• Clamps

5 6

Drill jig components Drill jig components

• Jig body
– Holds the various parts of a jig assembly. • Locking pins
• Cap screws and dowel pins – Inserted after the
– Hold fabricated parts together first hole is drilled to
lock or hold the
workpiece securely
to the jig plate while
subsequent holes
are being drilled.
7 8

2
 Drill Jig Drill Bush

9 10

Drill Bush II Drill Bush III

11 12

3
Typical Jig Feet Locating Devices

13 14

Workpiece Stops Workpiece Supports

15 16

4
Workpiece Clamping

17

5
 Error Analysis
Dr.B.CHOKKALINGAM ME, Ph.D
Associate Professor
Department of Mechanical Engineering
Sri Ramakrishna Institute of Technology
Coimbatore-641010
 Datum Selection
• A datum is a specific surface, line, plane, or
other feature
• that is assumed to be perfect and
• is used as a reference point for dimensions or
features.
• A workpiece datum: can be defined as point,
line , surface, or cylinder from which
dimensions are referenced.

2
 Datum Selection
• Guidelines for selecting datum surfaces:
• Important surfaces to the function of the
workpiece or the assembly.
• Reference planes for mating parts of an
assembly.

3
 Datum Selection
• Guidelines for selecting datum surfaces:
• Previously machined surfaces.
• Surfaces that are easy to establish at the
machine tool.
• Surfaces that are parallel to machine
movements.

4
 Datum Selection
• A datum can be explicitly or implicitly
indicated in the part drawing.
• A datum is normally called out by an
identification symbol such as:

-A-

5
Datum Selection

6
Feature Control Frame
 How do you read this feature control frame?
“The specified feature must lie perpendicular within a tolerance zone of 0.05
diameter at the maximum material condition, with respect to datum axis C.”

In other words, this places a limit on the amount of variation in perpendicularity between the
feature axis and the datum axis. In a drawing, this feature control frame would accompany
dimensional tolerances that control the feature size and position.

7
 Reference Frame
A reference frame is defined by three
perpendicular datum planes.
The left-to-right sequence of datum planes
defines their order of precedence.

8
Location-Accuracy

9
 LOCATION
• From the point of view of location, most
engineered parts can be placed in one of the
following categories:
• Prismatic parts
• Long cylindrical parts
• Short cylindrical parts

10
 LOCATION
• Parts with through hole
• Parts with flat base and two predrilled holes
• Parts with center holes at the end faces

11
 Error Analysis
• Main purpose of a jig/fixture is to provide
higher accuracy,
• Design should be based on a comprehensive
error analysis

12
 Error Analysis
• Errors can in general be classified as
• a) Errors of form and size and
• b) Errors of relative location of a feature with
respect to another
• 1

13
 Error Analysis
• Errors of form and size
• This error is practically independent of the
jig/fixture used,
• Errors of relative location of a feature with
respect to another
• Error strongly depends on the rigor of the
error analysis that serves as the platform of
the jig/fixture design.

14
 Error Analysis
• The total error consists of a large number of
error components:
• (a) Error of machine tool in idle condition.
• (b) Error of locating the jig/fixture on the
machine tool.
• (c) Error of the locating surfaces of the jig/fixture
with respect to the mounting surfaces.
• (d) Error of locating the component on the
fixture.
15
 Error Analysis
• (e) Error caused by clamping.
• (f) Error of tool setting and guidance.
• (g) Error caused by deformation due to
insufficient rigidity of the machine tool,
workpiece, fixture, or cutting tool.
• (h) Error caused by wear of the cutting tool.

16
 Error Analysis
• Not all the errors listed above occur in every
machining operation.
• Errors that occur in an operation on one machine
(say making of hole on lathe)
• May significantly differ from the errors in the
same operation carried out on another machine
(say making a hole on drilling machine)
• Reason- Due to the differences in the locating
surfaces adopted in the two cases.
17
 Error Analysis
• Analysis of locating errors in various locating
methods
• Used in practice for components of various
geometrical shape is the foundation of
jig/fixture design.

18
 Error Analysis-Prismatic Parts
• Prismatic parts are located by the 3-2-1
principle
• largest flat surface of the part is selected as
the main setting datum for removing three
degrees of freedom.

19
3-2-1 Principle

20
3-2-1 Principle

21
 Error Analysis-Prismatic Parts
• Largest flat surface of the part is selected as -
the main setting datum for removing three
degrees of freedom.
• No locating error - when the setting and
measuring datum coincide with the design
datum.

22
 Error Analysis-Prismatic Parts
• If the design or measuring datum does not
coincide with the setting datum, then a
location error is introduced.
• The magnitude of this error is equal to the
machining tolerance of the design/measuring
datum surface.

23
 Error Analysis-Prismatic Parts
• locating elements used for prismatic parts are
rest buttons (Figure a) and pads (Figure b).

24
 Error Analysis-Prismatic Parts
• Flat-headed rest buttons (Figure a) are used
for locating flat machined surfaces and
• spherical or knurled head buttons for
unmachined surfaces to restrict the area of
contact

25
 Analysis of locating error
• Machining of a flat seat on a shaft located on
the V-block.

26
 Analysis of locating error
• Based on the tolerance δd on the shaft
diameter, its size may vary between Dmin and
Dmax

27
 Analysis of locating error
• Accordingly, the locating error will be Δh1,
Δh2 and Δh3
• Locating errors for different values of angle a
of the V-block

28
 Minimizing the locating error
• Feature to be machined in horizontal
orientation on cylindrical shafts should be
specified from the bottom point of the shaft.
• Feature to be machined in vertical orientation
on cylindrical shafts should be specified from
the center line of the shaft.

29
Error Analysis, and Elements for
Parts with Through Hole

30
 Error Analysis, and Elements for
Parts with Through Hole
• The maximum clearance between the
• hole and the locating element is expressed as
follows:
• Smax = Smin + δh + δl
• where Smin is the minimum clearance
required to mount the workpiece hole on the
locating element,

31
 Error Analysis, and Elements for
Parts with Through Hole
• δh is the tolerance on hole diameter and
• δl is the tolerance on diameter of the locating
element.

32
 Error Analysis, and Elements for
Parts with Through Hole
• This misalignment is defined by angle α that is
found from the following relation:

33
 Error Analysis, and Elements for
Parts with Through Hole
• where l is the length of pin/mandrel

34
Limits, Fits and Tolerances
Dr.B.CHOKKALINGAM ME, Ph.D
Associate Professor
Department of Mechanical Engineering
Sri Ramakrishna Institute of Technology
Coimbatore-641010
 Introduction to Tolerances
• Can more than one or multiple parts be
produced with exactly same dimensions?

• Why?

2
 Tolerance
• “the allowable deviation from a standard,
eg: the range of variation permitted in
maintaining a specified dimension in a
machined piece.”
• Webster
•
•

3
Why is it necessary?

4
Consequences

5
Specification

6
 Limits and Fits
When parts are assembled together, engineers
have to decide how they will fit together and
the economics associated with it.
• How they will fit together?
– Clearance fit
– Transition fit Standards
– Interference fit BIS
ANSI B4.1
• Economics?
– Interchangability
7
Types of jig bushes

8
  Open jigs
Template Jigs
 Explain the procedure of using this jig.

9
9
Pot Jig

10
 Limits and Fits - Definitions

• Basic size /nominal size

• The reference size of hole/shaft to
which the limit of size are fixed, the
basic size is the same for both
members of a fit.

11
 Limits and Fits - Definitions
• Limits of size - the maximum and
minimum sizes permitted for a
feature.
• Maximum limit of size - the
greater of the 2 limits of size.
• Minimum limit of size - the
smaller of the 2 limits of size.

12
 Limits and Fits - Definitions
• Tolerance is the difference
between the maximum limit of
size and the minimum limit of
size.

13
 Limits and Fits - Definitions
• Allowance: It is the difference between the
basic dimensions of the mating parts.
• When the shaft size is less than the hole
size, then the allowance is positive and
when the shaft size is greater than the hole
size, then the allowance is negative

14
 Limits and Fits - Definitions
• Fit
• expresses the relationship between
a mating parts with respect to the
amount of clearance or interference
which exists when they are
assembled together.

15
 Limits and Fits - Definitions
• Hole - designate all INTERNAL features of
a part, including parts which are not
cylindrical.

• Shaft - designate all EXTFRNAL features

of a part, including parts which are not
cylindrical.

16
 Limits and Fits - Definit
• Upper deviation - difference between
the maximum limit of size and the
corresponding basic size. This is
designated ‘ES' for a hole and 'es' for a
shaft.
• Lower deviation - difference between
the minimum limit of size and the
corresponding basic size. This is
designated ‘EI' for a hole and 'ei' for a
shaft. 17
 Limits and Fits - Definitions
• Grade of Tolerance - Group of tolerances
with the same level of accuracy for all
basic sizes.
• Clearance - difference between the size of
the hole and shaft (positive)
• Clearance - difference between the size of
the hole and shaft (negative)

18
Limits and Fits - Definitions

19
 Unilateral Tolerance
The upper and lower deviations are all positive or
all negative. hole  30 0
0.033
shaft  30 0.092
0.040

20
 Bilateral Tolerance
The tolerance is split above and below the
basic size hole  30 0.006
 0.015 shaft  30 0.013
 0.008

21
Specification of DT

22
Specification of DT

23
 Exercise

Q1. Type?

Q2. Tolerance?

24
 Exercise
• Q1. Type?
• Bilateral, Unilateral, Unilateral.

Q2. Tolerance?
0.015, 0.005, 0.004

25
Fundamental Deviations (BS4500)

• The 27 deviations for HOLES are:

• A B C CD D E.EF F G H JS J K M N P
R S T U V X Y Z ZA ZB ZC
• The 27 deviations for SHAFTS are:
• a b c cd d e ef f g h js j k m n p r s t u v
x y z za zb zc
26
Fundamental Deviations (BS4500)
• The 27 deviations for HOLES are:
– A B C CD D E EF F G H JS J K M N P R S
T U V X Y Z ZA ZB ZC
• The 27 deviations for SHAFTS are:
– a b c cd d e ef f g h js j k m n p r s t u v x y
z za zb zc

27
 Fundamental Deviations

holes
Grade 7 tolerance
zone for the diameter
range 6-10 mm
DDB 3.3
shafts

28
 Grades of Tolerances
• There are 18 grades of tolerances IT01, IT0,
and IT1 to IT16. (IT - ISO series Tolerances)
• IT01 and IT0 are very fine grades
• IT16 is the most coarse grade reflecting the
precision of the process.
• The degree of error increases with:
– the precision of the process (IT grade), and
– the size of the component.
– (DDB 3.3)
29
Grades of Tolerances

30
 Limits and Fits Designation
• A hole tolerance with deviation 'H' and
tolerance grade IT7 is designated 'H7'.
• A shaft tolerance with deviation 'p' and
tolerance grade IT6 is designated 'p6'.
• Appropriate tolerance designation for a
feature of 45 mm, e.g. 45H7 or 45p6.

31
 Limits and Fits Designation

• A fit combines the basic size of both

features and their designations.
• The designation of hole limits should
always be quoted first.
• E.g. Ø50H8d9.
• Ø45H7p6.

32
 Three Classes of Fit
• Clearance fit

• Transition fit

• Interference fit

33
 Three Classes of Fit
• Clearance fit
• A fit provides a clearance.
• The tolerance zone of the hole is
entirely above that of the shaft.

34
 Three Classes of Fit
Interference fit
• A fit provides an interference.
• The tolerance zone of the hole is
entirely below that of the shaft.

35
 Three Classes of Fit
• Transition fit
• A fit provides either a clearance or
an interference.
• The tolerance zones of the hole and
the shaft overlaps.

36
 Hole Basis System of Fit
• Associating various shafts with a single hole
• ISO - the lower deviation of the hole is zero

37
 Hole Basis System of Fit
• More commonly used
• It is easier to manufacture shaft to the
tolerance values and measure those values

38
 Shaft Basis System of Fit
• Associating holes with a single shaft
• ISO - upper deviation of shaft is zero

39
 Shaft Basis System of Fit
• Less commonly used
• Preferable when a shaft may have to
accommodate a variety of accessories such
as couplings, bearings, collars, gears, etc. -
constant shaft diameter with varying bores
of accessories to obtain different types of
fits.

40
 Find the type of fit

• 1) Ø30H11c11

• 2) Ø30H7k6

• 3) Ø30H7p6

41
 Find the type of fit

• 1) Ø30H11c11

42
 TYPE OF FIT
Combination HOLE SHAFT Clearance/ Type
of Hole and of
Shaft
mm mm Interference Fit
mm
Max Min Max Min Max Min

DDB DDB 3.-- DDB 3.-- +VE / +VE/-

3.--
-VE VE
43
 TYPE OF FIT
Com HOLE SHAFT Clearance/ Type
binat of
ion
mm mm Interference Fit
of mm
Hole Max Min Max Min Max Min
and
Shaft
Ø30H 30.130 30.000 29.890 29.760 +0.370 +0.110 Clea
11c11
ranc
e
DDB DDB 3.9 DDB 3.7 +VE +VE
3.4
44
Example - Clearance Fit

45
 Find the type of fit

• 2) Ø30H7k6

46
 TYPE OF FIT
Combi HOLE SHAFT Clearance/ Type
nation of
of
mm mm Interference Fit
Hole mm
and Max Min Max Min Max Min
Shaft
Ø30H7k 30.021 30.000 30.015 30.002 +0.019 -0.015 Tra
6
nsiti
on
DDB DDB 3.9 DDB 3.8 +VE -VE
3.5

47
Example - Transition Fit

48
 Find the type of fit

• 3) Ø30H7p6

49
 TYPE OF FIT
Com HOLE SHAFT Clearance/ Type
binat of
ion
mm mm Interference Fit
of mm
Hole Max Min Max Min Max Min
and
Shaft
Ø30H 30.021 30.000 30.035 30.022 -0.001 -0.005 Inte
7p6
rfer
ence
DDB DDB 3.9 DDB 3.8 -VE -VE
3.6
50
Example - Interference Fit

51
 Find the type of fit
• 1) Ø30H7c11
• 2) Ø50H7g6
• 3) Ø100H6r5
• 4) Ø95H7k6
• 5) Ø50H7g6
• 6) Ø80H9c9
52
Drawing

53
 ISO Fit (size 6-180 mm)
• Easy running - H7/e8
• Normal running - H7/f7 Shafts and
• Slide - H7/g6 exposed
• Location - H7/h6 bores
• Push - H7/k6 should
have
• Light press - H7/p6 chamfers
• Heavy press - H7/s6

54
ISO Fit (size 6-180 mm)

55
56
57