J I G A N D F I XT

DES IG N

A S
A T R E TI E C O E R I N G TH E PR I N CIPLE S O F
V
J I G AN D F I XT U R E D E S I GN TH E I M P O RTAN T ,

CO NSTR U C TI O NA L D E TAI L S AN D M AN Y DI F ,

F ER E N T TY P E S O F WO R K H O L D I NG D E VI C E S
—

U S E D I N I NTER C HANG E AB L E M AN U F A C TU RE

E D ITE D B Y

F RA N KL N D I ?
ON E SI
ASS OCI ATE E DITOR O F MA H IN ERY C
A UT H O R OF T U RNING A ND B ORING
!
P LA NING A ND M I LL ING
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,

M EC H A NI S M S A ND M EC H A NIC AL M O V E M ENT S
,

“
,

T H RE A D-C U TTING M ET H OD S
!
“
ET C , .

F I RS T E DI TI ON

N EW YO RK

TH E IN DU S TRI AL PR E S S
L O N DO N : TH E MA CH I N E RY P U B L I S H IN G C O .
, m
L
 C OP YR I G H T , 1 9 20

BY

TH E I ND USTRI AL P RES S
N E W Y O RK

C O O S IT ON A ND
MP I EL ECTROT ING
YP BY THE P L I MP I O N
’ ‘
P RE SS , R OOD
NO W , MA SS U S
. . A .
 PREF A CE

The d e ve lopm ent of machin e too l s has be en accompani ed

by a corresponding development of auxi lia ry equipment for in
creasing the quan t ity an d imp roving the quali ty of the products
of thes e machi n e s Wh en eve r dupli cate parts requi re som e
.

op e ratio n such as dri l ling planing or mill ing the s elect io n

, , ,

of a suitable typ e of machi ne i s oft en followed by th e d e sign

of wha tever speci al tools or attach me nt s are need e d to adap t
t h e machi ne to the operatio n requi red The tool gui di ng a n d .
-

w ork holdin g jigs and fix t ures whi ch are n ow used in prac

-

ti cally all machi n e sho p s r ep res en t t h e most imp ortan t class

of sp eci a l equipm ent an d thi s b o ok d e al s exclusively wi th
,

t h ei r d e sign a n d construc tion .

A s most j i gs are used for dri ll in g o p erat i o n s a book was ,

p r e vi ously publ i shed en tit led D ril li ng P racti ce a n d Jig D e

s i gn covering di fferent types of dri llin g machi n es a n d the ir
!
,

us e the d e sign of drill jigs and t o som e extent the desi gn o f

, , , ,

fix t ures such for example as are used o n m illing machi ne s

, , .

Wh il e the subjec t s of dri ll ing a n d j i g d e sign are closely allied ,

it i s no longer p ossible t o cove r t h e m both in a s ingle volume ,

owing to th e extensive cha n ges i n dri lling practi ce and the

increas ing use of jigs and fixtures of various types on different
c lasses of machi n e t ools Therefor e the book referred to has
.
,

b ee n r ep lace d b y two volum e s of which thi s is one The other

,
.

book M odern D rilli n g P racti ce i s already well known to

“
, ,
!

many designers s hop foremen and machini st s in terested in

, ,

the latest types of drilling mach ines an d their u se .

Thi s new book Jig and F ixture D e si gn contains that

,
!

p art of the volume o n D ri lling P ractice and fig D e sign which

“ !

dealt wi th j igs an d fixtures Thi s mate ri al was used because it

.

i s a trea ti se o n the princip l e s of j ig an d fix tur e des i gn which

contains informa ti o n that i s indi sp en sab l e in a book of thi s
 PRE F A CE
kind . Thes e original chapters whi ch explain the general pro
c e d ur e i n de s igni ng jigs and fixtures and how work s hould be

located clamp e d
, ,
have b e e n supplemented by a large
amoun t of n ew matter thus making the present book unu sually
,

compl e te A gr e a t variety of jig and fixture de signs hav e been

.

des cribed and illustrated in order to S how j u s t how the principle s

and important d e tail s referred to in the forepart of the book are
applied under many di fferent con di tion s a n d to j igs and fixtures
u s e d o n vari ou s type s of machine tools .

M os t of the designs illu s trated in thi s book have be e n sent

to M A CHINE R Y from men i n the machin e bui ldi ng field b e-
,

cause th e designs w e re considered unusual and worth p lacing

o n re cord While it would not b e po ssibl e to giv e credi t to
.

each indivi dual contributor we are indebted to all who have

,

assisted i ndi rectly in p reparing thi s treati s e and especially to

,

E inar M orin and A lbert A D owd recognized too l experts and

.
,

p roduct i on engine e rs who have supp li ed valuable material for

,

several o f the chapt e rs on jig des i gn .

TH E E DI TO R .

N e w Y ork , Oc to ber , 1 9 2 0.
 CO N T EN T S

C HAP TE R I
PAGES
P R IN C I P L E S I OF JI G D E S GN

O bj ect s of Jig and F i xtu e D iff e ence between Jigs

s r s r

and F ixture F undamental P rin iple of Jig D e ign

s c s s

Locating P oint C lamping D evic

s Weight of Jig es s

Jig provided with F eet Material fo Jigs Gene al

s s r r

R ema k on Jig D e ign

r s S umma y of P rinciple of Jig
s r s

D e ign
s Type of Jig Open Jig B x Jigs De
s s s o

tail of Jig D e ign

s s I
“
20

C HAP TE R II
D E S GN O FI JI GS O P E N D R I LL

Jig D a wingr D e igning O pen

s Jig Imp o v
s ing the s -
_
r

S imple F o m of Jig by Adding L ocating S c ew

r P r s ro

v id ing C lamp and F eet f the Jig Example of Open

s or s

D ill Jig
r s

CH AP TE R III

I C L O S E D O R B OX J I G
D E S GN O F

Gene al P ocedu e in the D e ign of C lo ed

r r r B Jig s s or ox s

Jig f Rapid P o d uction Special F eatu e of B x Jig

s or r r s o s

Example of C lo ed or B x Jig
s s o s

IV C H AP TE R

J I G B U S H I N G S
R emovable B u hing Mate ial f Jig B ushing
s s r or s

D imen ion of S tationa y Jig B u hing

s s Mi cellaneour s s s s

Typ e of Jig B u hing Mean f P eventing L oo e

s s s s or r s

B u hing f om Tu ning
s s r D imen ion of R emo vable B u h
r
— s s s

ing s S ew B u hing
cr S pe ial D e ign of Gui de B u h
s s c s s s

ing s Met hod of making Jig B u hing Ha dening Jig

s s s r

B u hings
s G ind ing and L apping
r
 CO N TE N T S

C HAP TER V
LO CATIN G P OI N T S AN D AD JU ST
A B L E STO PS P AGES

P ins
and S top u ed a L ocating Mean L ocating by
s s s s

Mean of V block s C up and C one L ocating P oint

- s s

S ew B u hing and S lidi ng B u hing u ed as L ocating

cr s s s s s

Mean Adj u table L ocating P oint

— s sSpecial Type of s s

Adj u table S top

s -L ocating f om F ini hed Hole — L
s r s s O

eat ing by K eyway in the Wo k C ommon D efect in s r s

i
Jg D e ign s
9 2 —
1 09

HAP TE R VI C

J I G C LA M P I N G D E V I C E S
Type s of C lamp H ook bolt S c ew tightening D e
s - s r -

vice S winging L eave

s Wedge Tape Gib E s or r s c

cent ic Clamping A angement

r Application to Jig rr s s

D e ign s I 10 —
1 50

HAPTE R VII C

E XA M P L E S O F D RILL J I G D E S I GN

D iff e ent Type of Indexing Jig

r —
Jig fo Dseep—hole s r

D illing - Jig of S imple D e ign for drilli ng S traight and

r s

Angula Hole D ill Jig equipped with Mill ing A ttach

r s r

ment Jig for C os d illing P i ton and F acing W i t

—
r s- r s s r s

pin B o e Unive al Jig

ss s Machine Vi es with D rill rs s s

Jig Attachment Miscellaneou D e ign s s s s 151

—
1 94

HAP TE R VIII C

B ORI N G JI G S

B oring Jig of S imple D e ign A dj ustable B o ing Jig s r s

B o ing Jig supported on Wo k

r — Jig de igned f S up r s s or

po ting B a on On S ide of Hole Only Jig f Multiple

r r
-
e s or

B oring C ombination D rill and B o ing Jig r 1 95

—
2 10
 CO NTE NT S
C HAP TER IX

MILLIN G AN D PLAN I N G F IXTURE S PAGES

F ixtu e fr milling to a Given L ength Duplex F ix ture

or

Adj u table F ix tu e for Angular Work F ixtu e a

s r r r

ranged fo Lateral and Angula Adj u tment Indexing

r r s

Milling F ixture Variou D e ign of Radial Milling

- s s s s

F ixtu e —
r s Example of P lane F ixtu e D e ign s r r s 211 —
24 1

C H AP TE R X

ADJU STA B LE IXTURE S F O R TURRET LATHE S

F
A N D VE RTI C A L B O RI N G MILL S

Impo tant P oint in the D e ign Adju table F ixtu e

r s s
—
s r

f
or Holdi ng C a ting of D iffe ent Diamete
s sAdj u table r rs s

F ixture for S pecial B evel Gea B lank P ovi ion f r s r s or

maintaining Accu acy in Adj u table F ixtu e Va iou

r s r r s

D e ign of Adj u table F ixture fo V e tical B oring Mill s

s s s s r r . 242 —2
5 6

H A TE R XI C P

TH E F L O ATIN G P R IN C IP L E A S APP LI E D
TO F IXTUR E WO R K

Impo tant P oint in the Application of F loating P in iple

r s r c

— P i ton D ill Jig with F loating C lamp

s r
— D ill Jig f s r or

Rough C olla D ill Jig with F loating B u hing and

r r s s

Locating V ee Milling F i tu e with F loating Clamp

s x r s

and L ocato Va iou othe D e ign of L o ating D evi e

r r s r s s c c s

illu t ating the Application of the F loating P inciple

s r r 257 —2
75

HA P TE R XI I C

APP LI C ATION O F TH E TH RE E P OIN T P RIN C I —

P LE I N F IXTU R E S

Three point L ocating and Clamping e ice T ree

- D v h s

point S uppo t for F lywheel F ixtu e Th ee point F ixtu e

r r r - r

S upport on a Hub Ca ting F i tu e having Th ee C lamp s x r r

ing Jaw and Three L ocating P ad Double Th ee point

s s r -

—
2 76 287
L ocating D evice
X CO NTE NT S
HAP TER XIII C

SP E CIAL J I G AN D F IXTU RE M E CHAN I S M S

E qualiz ing the P e u e of C lamping D v e
r ss r C lamp s e 1c s

that d aw the Wo k down F irmly on t h L ocating

r r e

Mean Multiple-Clamping D evice

s C lamping D evice
s s

f
or F ixtu e t hat do not inte fe e wi t h the Tool u ed
r s r r s s

Three-point Clamping D evice s 2 88 —

30 5

HAP TE R XIVC

P ROVI DIN G F O R U P KE E P I N DE S I GN IN G JI GS
A N D F IXTU RE S

P oints P ertaining to Upkeep D ill Jig f a R eceive r or r

F o ging
r D illing and R eaming Jig
r Inde ing F i tu e x x r

f
or a Clutch Gear F i tu e with In e ted J aw B evel
x r s r s

Gea F i tu e wi t h A dj u stable F eatu e s

r x r F ixtu e for a r r

Hub Ca sting 3 0 6 -
315
'
 J I G AN D F I XT U R E DES I G N

C HAP TE R I
PRIN CIPLE S OF J I G D E S IG N

Jigs and fix tures may be defined as devices used in the manu

facture of duplicate parts of machines and intended to mak e
pos sible interchangeable work at a reduced co s t as compared ,

wi th the co s t of producing each machine detail individually .

Jigs and fixtures serve the purpo s e of holding and properly locat
ing a piece of work whi le machined and are pro vided with ne ce s
,

s ary appliances for gui di ng supporting setting and gaging the

, , , ,

tool s in such a manner that all the work produced in the s ame
i
jig or fixture will be al ke i n all re spects e ven with the employ ,

ment of un ski lled labor When u sing the expre s ion ali ke
. s
“
,

it implies of cour e simply that the pieces wi ll be near enough

,
s ,

alike for the purpo s e s for which the work being machined i s
intended Thu s for certain cla s ses of work wider limits of
.
, ,

variation will be permi ssible without affecting the proper u se

of the piece machined while in other cas e s the limits of varia
,

tion wi ll be s o small as to make the expre ssion perfectly alike

“ !

li terally true .

O b j e ct s of Jig s and F ixt ur e s The main ob j ect of using J gS

. l

an d fix ture s i s the reducti on of the cost of machines or machine

detail s made in great numbers Thi reduction of co s t i s ob
. s

t ai n e d in con sequence of the increased rapidity with which the

machines may be built and the employment of cheap er labor ,

which i s po ssible when using tools for interchangeable manu

fa c t u ri ng
. A nother object not le s s important i the accuracy
, ,
s

with which the work can be produced making it po ssible to ,

as s emble the piece s produced in jigs wi thout any great amount of

fitting in the a ss embling dep artment thu s also eff ecting a great ,

saving in this respect The u se of j igs and fixture s practically

.

doe s away wi th th e fitting as th i s expre s si on was unders tood in

,

the old -tim e shop ; i t elimi nates c u t and try methods and do e s
- -
,
 JI G D E SI GN
away wi th call e d patch work in the p roducti on of machin
so- -

ery It mak e s i t possible to have all the machines built in the

.

S hop accordi ng to the drawings a thi ng which is rather d i fficult

,

to do if each individual machi ne i n a large lot i s built without

reference to the other machine s in the same lot .

The interchangeability obtain e d by the use of j gs an d fix tures l

makes it als o an easy matter to quickly replace broken or worn

out parts withou t great additional cost and trouble When .

machi ne s are built on the individual plan it i s nece ss ary to fit ,

the part replacing the broken or worn out piece in place involv -
, ,

ing considerable extra expen s e not to mention the delay and the
,

di fficultie s occasi oned thereby .

A s mentioned jigs and fixtures permit the employment of

,

practi cally unskilled labor There are many operations in the

.

building of a machine whi ch if each machi ne were built in di

, ,

vi dually without the u s e of special tool s would require the work

, ,

of expert machini s ts and toolmakers S pecial tools in the form .

,

of jigs and fixture s permit equally good or in s ome ca s e s e ve n

, , , ,

better re sults to be O btained by a much cheap er class of labor ,

p ro vi ded the jigs and fixture s are prop erly de signed and cor
re c t ly made A no ther po ssibili ty for s aving particularly in the
.
,

ca s e of drill and boring jigs pro vided with guide bushings in th e

same plane i s met wi th in the fact that such j igs are adapted to
,

be used in multiple spindle drills thereby s till more increasing

-
,

the rapidity wi th whi ch the work may be produced In shops .

where a great many duplicate parts are made containi ng a ,

number of drilled hole s multiple spindle drills of complicated

,
-

design which may be rather expensiv e as regards firs t cost are

, ,

really cheaper by far than ordinary simple drill pre ss e s

, ,
.

A nother advantage which has been gained by the u s e of J l gS

an d fixtures and which should not be lo s t S ight of i n the enu
,

me ra ti on of the points i n favor of building machinery by the use

of special tool s is that the details O PE machine that h as be en
,

provided wi th a complete equipment of accurate and durable

j igs and fixture s can all b e fini shed simultaneou sly in differen t
dep artments of a large factory wi thout inconve me nce thu s mak
, ,

in g it po s sible to as semble the machine a t once after r e ce iving

 J IG D E SI GN 3

the par ts from the di ff erent departm ents ; an d there is n o n eed

of waiting for the comp letion of one part into which another is
required to fit before making thi s latter part Thi s gain i n
, .

time mea n s a great deal in manufacturi ng and was en tirely ,

imp ossible under the O ld ti me sy s tem of machi ne bu i lding whe n

-
,

each p art had t o b e made in th e order in which it we nt to

the fin i sh e d mach ine and e ach consecuti ve par t had to b e l ined
,

up wi th each one of the p revi ously made an d assembled de t ails .

B rackets bearings etc had to be drill e d i n place often wi th

, ,
.
, ,

ratchet dri lls which is a slow and always inconveni en t Operation

, .

D e e ce b e t w e e n Jig s and F ix t ur e s
ifi r n — To exactly define
the word j ig as consid e red ap ar t from the word fix ture
“
,
! “
,
!

i s di fficul t as the di ff erence between a jig and a fixture is ofte n

,

time s not very eas y t o decide The word jig is frequently al .

,

though incorrectly applied to any kind of a work holdi ng app li

,
-

ance us e d i n the buildi ng of machi nery the same as in s ome , ,

S ho p s
,
the word fixture i s appli ed to all kinds of sp eci al tools .

As a g eneral rule however a jig i s a special tool which whi le it

, , , ,

holds th e work or i s held o n to the work also contains guides

, ,

for the resp ecti v e too l s to be used ; whereas a fixture is only

holdi ng the work while the cutting tools are p erforming the op er
ation on the p i ece without contain ing any special arrangements
,

for gu i di ng these t ools The fix ture therefore mu s t its elf b e

.
, , , ,

securely held or fixed to the machine on which the operation i s

performed ; hence the name A fixture however may s ometimes .
, ,

be provi ded with a number of gages and s tops although it does ,

n ot con t ai n any sp ec i al de vices for the guiding of the tools .

Th e defini ti on given in a general way would therefore Cla s

, ,

s ify j i gs as s pec i al tools u s ed particularly in dri ll i ng and boring

operations whi le fixture s in particular would be tho s e special

, , ,

tools used on milli ng machi ne s and i n some cases on planers , , , ,

s hap ers and s lotting machine s

,
S pec i al tool s used on the lathe
.

may b e either of the nature of J gS or fixtures and sometimes the l ,

speci al t ool is actually a combination of both in which case the ,

term drilling fixture boring fixture etc is s uitable

, ,
.
,
.

F u nd am e n t al P ri n c iple s of J i g D e s ign B efore enteri ng .

upon a discussion o f the minor details of the de sign of j igs and

4 J IG D E SI GN
fix tures the fu n damen t al p r in cip les of j i g and fix tur e design
,

wi ll be briefly outlined When ever a jig is mad e f or a compo

.

n ent part of a machine i t i s almost always required that a corre

,

sp Ond ing jig be made up for the place on the machine or other ,

part where the fi st mentioned detail i s to be attached It is

,
r -
.
,

of course absolutely necessary that the s e two jigs be p erfectly

,

alike as to the location of guides and gage p oints In order to .

‘

have the hole s and guides in the two j igs in alignment it is ad vi s ,

able and almo s t always Ch e aper and qu i cker to transfer the

, ,

holes or the gage points from the first j ig made to the other In .

many in s tances it is p ossible to use the same jig for both part s
,
.

C a s es where the one or th e oth e r o f these pr i nciples i s applicable

will be shown in the followi ng chap ters i n the d et ai l e d d e scrip
tion s of drill and boring jigs .

There are s ome cases where i t i s not advi sable t o make two
J g
l S
,
one for each of th e two p arts which are to fit together It .

may be impo s sible to properly locate the j i g on on e of the parts

to be dr i lled or i f the jig were made i t may be so compli cated
, , ,

that i t would not be economical U nder such con di tions the.

comp onent part itself may be use d as a jig and the respe ct ive ,

holes in thi s part used as guides for the tools when machi ning
the machine detai ls in to whi ch it fits Gu i de bu shi ngs for the
.

drills and boring bars may th e n be p laced in the holes in the

comp onent part itself In many ca s e s drilling and boring opera
.
,

ti ons are al s o done to great advantage by u sing the brackets

, ,

and bear ings al r eady asse mb le d and fastene d to the machi n e

body as guide s .

One of the most i mp orta n t quest i o n s t o be dec i ded before mak

i ng a jig i s the amount of money whi ch can be exp ended on a
special tool for the O perati on requ i re d In many cases it i s
m
.
,

po ssible to get a h i ghly effici ent tool by aki ng it more compli

cat e d and more expen s i v e whereas a le s s e ffi cient tool may be
,

produced at very small expense To decide whi ch of the s e two

.

types of jigs and fixtures s hould be de signed i n each in di vi dual

ca se depends enti rely upo n the ci rcumstances There S hould be .

a careful comparison of the present co s t of carryi ng out a certain

operation the expe ct e d cost of carrying out the sam e operati o n
,
 J IG D E S I GN 5

wi th an efficien t tool an d th e cost of bu i l di n g tha t tool it se lf

, .

U nl e s s thi s i s don e it i s likely that the sho p i s burde n ed wi th a

,

gr e at numb e r of special tool s and fixtures which while they ,

may b e ve ry useful for the production of the parts for whi ch the y
ar e intended a ctually involv e a loss It i s readily s ee n how
m
, .

uneconom i cal it would be to ake an expen si ve jig and fixtur e

for a machine or a part of a machine that would only have to
be duplicated a few time s In s ome cases of course there may
.
, ,

be a gain in using special device s in order to get extremel y g ood

and accurate re sults .

L o cati n g P oin t s The mos t imp or t ant requ i rements in the

.

design of jigs ar e that good facili ti es be p rovi ded for locatin g th e

work and that th e piece to b e machined may be easily i ns e rted
,

and qu i ckly taken out of the jig so that no time is wasted in ,

placi ng the work in position on the machi ne performing the work .

In s ome cases a longer time is required for locating and d amp

,

ing the p i ece to be worked u p on t han is requ i red for the actual
machi ne O p eration i tself In all such cases the machi ne p er
.

forming the work i s actually i dle th e greater part of the time and , ,

added to th e loss of the operator s time i s the increa s ed expens e

’
,

for machi n e cost i ncurred by such a condition F or thi s reason .

,

the locating and clamping of the work in place quickly and

accurately should be carefully s tudied by the designer befor e
any attempt i s made to de sign the tool In choosing the lo cat .

ing surface or poi nts of the pi ece or part consideration must b e ,

g i ve n to the facili ti es for locati ng the corresponding p art of th e

machine i n a simi lar manner It i s hi ghly impor t an t tha t thi s
.

be done as otherwise although the j i gs may be alike as f ar as

, , ,

thei r guiding app liances are concerned there may be no faci li ty ,

for locatin g th e corresponding p art in the same mann e r as th e

one already dri lled and whi le the holes drilled may coi nci de
, ,

oth e r surfaces also required to co i ncide may be con siderably

, ,

out of line O ne of the main pri nciple s of locati on therefor e

.
, ,

i s that two comp onen t p arts of th e machi n e should b e locat e d

from correspondi ng poi nts a n d surfac e s .

If possible sp e ci al arrangements should be made i n the d e sign

,

o f th e j i g so that it i s i mpo ssible to ins e rt th e pie ce in any bu t

6 JI G D E SI GN
t h e corr e c t w ay M i s t ak e s are ofte n mad e o n t h i s account
.

in S hops wh e re a great deal of ch e ap help is us e d p i eces being ,

p laced in jigs upside down or i n some way other than the cor ,

rect one and work that has been previ ously machi n e d at the
,

expendi ture of a great deal of time i s entirely spoiled There .

f ore whenever p ossi ble a j i g should be made fool-proof

, , .

When the work to b e machi ned var i es i n S hape and s ize as , ,

for in stance i n th e cas e of rou gh castings it i s necessary t o hav e

, ,

at least some of the locating points adj ustable and placed so

that they can be ea sily reached for adjustment but at the same , ,

time S O fa s tened that they are to a certain extent po si tive In

, , ,
.

the following chapters different kinds o f adjus t able locati n g

points will be described in detail .

Cl am ping D e vi c e s The strapp i ng

. or clam pi ng arra n g e me nt s
should b e as simple as po ssible without sacrificing effectivenes s , ,

and the strength of the clamp s should be such as to not only hold
the pi ece fi rmly i n place but also to take the strain of th e cutting
,

t ools without springing or givi ng “

When de signi n g the jig .
!
,

th e di rec ti on in which the strai n of the tool or cutters acts upon

the work should always be con si dered and th e clamps so placed ,

t ha t they wi ll have the hi gh e st degr ee of str e ngth t o resi st th e

p ressure of the cu t .

The mai n principles i n the applicati on of clamps t o a j g or l

fixture are that they S hould be conveni ent for the operator ,

quickly op erated and when detached from the work still con
, , ,

n e c t e d w i th the j I g or fixture i tse lf so as to p reven t the o p er ,

ator from losi ng them M any a time looki ng for lost strap s
.
, ,

Clamp s screws etc cau s es more delay in S hops than the extra
, ,
.
,

cost incurred in designi ng a jig or fixtur e somewhat more com

p li cat e d i n order to make the bin di ng arrangement an i ntegral
,

p art of the fix ture i tself G reat complication i n the clamping.

arrang em ents how eve r i s not advi s able U sually clamping

, ,
.

arran gements of thi s ki nd work well when th e fixture i s new but , ,

as the v arious par t s become worn compli cated arrangements ,

are more likely to get out of order and the extra cost incurred in ,

rep ai ri ng often outwe i ghs the tem p orary gain i n qu i ckn ess o f

operation .
 J IG D E SI GN 7

The judgmen t of the d e signer is in every cas e th e m o s t im , ,

portant po i nt in th e desi gn of jig s and fixtures D e finite rules .

for all cases cannot be given General principles can b e s tudi ed

.
,

but th e efficie ncy of the i ndivi dual tool wi ll dep end entirely up on
the judgmen t of the tool designer i n app lyi ng the genera l p rin
c ip le s of tool de s ign to t h e case i n ha n d .

When designing th e jig or fix tur e the l ocati ng and b e ari ng ,

p o in ts for the work a n d the loca ti o n of the clamp s must also be

so s e l e cted that there is as li ttle li abi lity as po s sible of sp ringi n g
th e p i ece or jig or both out of shape when app lyin g th e Clamp s
, , ,
.

Th e sp ri nging of ei ther the o n e or the other part wi ll cause in

corr e ct results as th e work surfac e s wi ll b e ou t of align men t wi th
,

the hol e s drilled or the faces mi ll e d Th e clamps or s t rap s .

should therefore as far as po s sible be so placed that t hey ar e

, ,

exactly o pp osite some bearin g po i nt or surface on the work .

W e igh t of Jig s The designer must use hi s judgment i n re

.

gard to the amoun t of metal p ut into the jig or fixture It i s .

des i rable to make these tools as li ght as pos sible i n order that ,

they may b e eas i ly handled be of smaller S ize and cos t less i n

, ,

regard to the amount of materi al used for the i r making but at , ,

the same t ime i t is p oor economy to sacrifice an y of the ri gi di ty

,

and stiff ne s s of the t ool as thi s i s o n e of the main consi derati ons
,

in obtainin g efficient results On large s ized j igs and fixtures .

-
,

i t i s possible t o cor e out the m et al in a number of places withou t ,

decreas in g i n th e least the s treng th of the j ig itself Th e

, ,
.

corners of j IgS and fix tures should a lways b e we ll round e d and ,

all burrs and S harp edge s fil e d off so as to make th em co nveni en t ,

and pl e asan t for handlin g Smalle r j igs shou l d also b e mad e

.

with handles in prop er places so tha t they may be held i n posi ,

tion while working as in the case o f dri lling j igs and also for
, ,

conveni en c e in moving the jig abou t .

Jig s P r ovi d e d wi t h F e e t O rd i nary dri l l j Igs should al ways

.

be p rovi d e d wi th fe e t or legs o n all S i des which are oppo site the

holes for the bushing s so that the jig can be p laced level on th e
,

t able of th e machine Th e se feet also grea t ly faci li ta t e th e

.

making of th e j i g making it e asi er t o lay ou t and plane the differ

,

en t fi ni sh e d sur fac e s O n t h e s i des of th e j ig wh e r e n o feet are

.

U
g J I G DE SI GN

r e qui r e d if the body i s made from a cas ti ng it i s of advantage

, ,

to have small p rojec ti ng lugs for bearin g surfaces when laying

ou t and p laning Whi le jigs are mo s t commonly p rovi d e d wi th
.

four feet on each si de i n some cases it is su fficie n t to provide the

,

tool wi th only three f e e t bu t care S hould b e tak en in either case

,

tha t all bu shi ngs an d p laces wher e p res sure will be appli ed t o the
tool ar e p laced i nsid e of the g eom et ri cal figure obtai n e d by con
n e c t ing by lin es the p o in ts O f loca ti o n for t he fee t
, , .

While it may seem that three f eet are p referab l e t o us e b e caus e ,

the jig will the n alway s obtain a bearing on all th e three feet ,

whi ch i t would n o t wi th four feet if the tabl e of the machin e ,

were no t absolutely p lane i t i s not qu i te saf e t o us e the smal le r

,

number of supp orts because a chi p or some other obj e c t i s li able

,

to come under one foot and thr ow the jig and th e p iece ou t of
line wi thout thi s bein g noti c e d by th e opera tor I f the same
,
.

thi n g happens to a jig wi th four fee t it will rock and invari ab l y ,

cause the op erator to n o ti ce th e defect If th e tabl e i s out of .

true th i s defect too wi ll be n oti ced for the same reaso n

, , ,
.

Ji g feet are generally cast sol i d w i th the jig frame W he n t h e .

j g
I frame is made from machine st e el and somet i m e s in the case
,

of cast i ro n Jl gS detachable feet are used

-
,
.

M at e ri al s for Ji gs O pinion s di ffer as to th e relat i ve meri ts

.

o f cast i ron and s t e e l as materials from whi ch to cons truct the

j g
I and fixture bodies The d e c i sion o
. n thi s poin t sh o uld depend
t o a great exte n t upon the usage to which the fixture i s t o b e put
an d the character o f the work whi ch i t i s to han dle F or small .

and m e dium sized work s uch as typ ewri ter se wing machi ne , , ,

gu n add ing machi ne cash re gi ster p honograp h a n d similar

, , , ,

p arts t h e st e el jig offers deci d e d advan t ag e s but for larger work

, , ,

such as tha t encoun t ered in automobile engine an d machi n e tool , ,

fixture s the cast i ron jig is undoubtedly the cheaper and more
,
-

advi sable to use The steel jig should be left so f t in order that
.

a t any fu ture ti me addi ti onal hol es may be added or the exi s ti n g ,

bushi ngs ch ange d as r e qui red Wi t h a cast i ron j ig thi s addi ng

‘

- .

of bushi n gs i s a di fficul t mat te r as th e fram e i s usually bossed ,

and
“
spot fini shed at the point wh e r e the bushi ngs ar e located
!
,

an d i t is very di fficult to build up o n the jig fram e i n ord e r to

IO JI G D E S I GN
P lai n lugs proj e c ting ou t i n the sam e p lane as the bo ttom of
,

the jig or lugs with a slot in them to fit the body of T-bol ts are
, ,

the common means for Clamping fixtures to the table F or .

bori ng jigs it is u nn ece ss ary to p rovi de more than thre e such

,

Clamping points as a greater number is likely to cause some

,

springing action in the fixture A slight springing eff ect is almos t

.

unavoidable no matter how strong an d heavy the jig i s but by

, , ,

properly applying the clamp s it is p ossi bl e to confine thi s sp ring

,

ing within commercial li mits .

Jigs should always be tested before th e y ar e us e d so as t o ,

make sure that the gu i di ng provi sion s are placed in the right
relati on to the locating p oin ts and in proper relatio n t o e ach
other .

S um mary of P rin c ipl e s of Jig D e s ign S ummariz i ng th e

.

principles referred to the following rules may be given as the main

,

po i nts to be consi dered in the desi gni n g of jigs and fixtures

1 .B efore plann i ng the de sign o f a tool compare the cost of ,

p roducti on o f the work wi th p r e sent tools wi th the exp ected cost

of producti on usi ng th e tool to be made an d see that the cost o f
, ,

bu i ldi ng i s not i n excess of expected ga in .

2 .B efore laying out t h e j i g or fixtur e d e c i d e u p o n th e lo ca t

,

ing po in ts a n d outli ne a clamp in g arran gemen t .

3 .M ak e a ll d am pi n g and b i nd i ng dev i c e s as qu i ck - act i n g

as p ossi bl e .

4 In s e lecti ng locati ng po ints s ee t hat two compon en t par t s

.
,

of a machin e can be loca ted from correspondi ng points and sur

faces .

5 .M ake the j g
r fool proof that
- i s arrange i t so,
that th e
work cann ot be inserted except in the correct way .

6 F o r rough castings make some of the locati ng p o i nts

.
,

adjustable .

7 .L ocate clamps S O that they w i ll be i n t he be s t p osit i o n to

re sist the pre s sure of th e cutti ng tool when at work .

8 M ake i f possi ble all clamp s i ntegral p arts of t he j l g or

.
, ,

fix ture .

9 .A void compl i cated clam pi n g arra n gemen ts w hi ch are ,

liable to w e ar or get ou t O f o rd e r .
 J G
I D E S I GN 1 1

IO . lace all clamps as ne arly as po ssible opp osit e some

P
bearing poin t of the work to avoid springin g , .

11 C ore out all u nn ecessary m e tal makin g the t ools as l ight

.
,

as possible consisten t wi th rigidity an d stiffness

, .

1 2 R ound all corners

. .

1 3 P
. rovi de handles wher ever thes e will make th e handl in g
of the j ig more conveni ent .

1 4 P
. rovi de feet preferably four opp osite all surfac e s con
, ,

taining guide bushings in drilling and boring j i g s .

1 5 P
. lace all bush i ngs inside of the geometrical fi gure form e d
by connectin g the points of location of the feet .

1 6 P rovi d e abu n dant clearanc e

. particularly for rough ,

castings .

1 7 . M ake if possible all locati ng points vi sible to th e op erator

, ,

when pl acing the work in position .

1 8 P rovi de hole s or escap e s for the chips

. .

1
9 . P ro vide clamping lugs located so as to preven t sp ring
,

i n g of the fixture on all tool s which mu s t be held to the ta ble

,

of the machine while in u se and tongues for the slots in th e ,

t abl e s i n all mi l ling and planing fixtures .

20 . B efore using in the shop for commerc i al purp oses te st , ,

all j igs as soon as mad e .

Typ e s of Jig s . Th e two principa l class e s of J l gS are drill

—

j g
I S a n d bori n g l
j g s F ix t ures
. may be grou p ed as m i lling ,

pla n ing and sp lining fixtures although there are a number of

, ,

special fixtur e s whi ch could n ot be classifi e d under any special

h ead .

D rill j i gs ar e i n t ended exclusi vely for drilling r e aming tap , ,

pin g a n d facing Whene ver the s e four operations are re quired

,
.

o n a piece of work it is as a rule p ossible to pro vide the ne ce s

, , ,

sary arrangements for performin g all th e se op e rations in one

an d t he same jig S ometimes separat e j igs are made for each
.

one o f these operation s but i t is doub tless more conveni e n t

,

and cheaper to have o n e jig do for all as the de sign of the j ig ,

will not be much more complicated Although it may be p os .

sible to make a di s tinction between a number of di fferen t type s

of drill j ig s it is almost impossible to defin e and to get proper
,
1 2 J G
I DE S I GN
n ames for t h e vari ous class e s owin g t o th e gr e at vari ety of
,

shap e s of the work to b e drilled There are however two general

.
, ,

typ e s that are most commo nly us e d the di fferen ce between ,

them being very marked The s e types may be classified as

.

ope n j i gs and close d j i gs or box j i gs S omet im e s the open j i gs

,
.

are call e d clampi ng j i gs The open jigs usually have all the drill
.

bu shings in the same plane p aralle l wi t h o ne another and are

, ,

n ot provi ded wi th loose or r emo vable walls or leave s thereby ,

making it possible to ins e rt the piece to be drilled without any

mani pulation of the parts of the jig The s e jigs are often of .

such a con s truction that they are applied to the work to be

dri ll e d the jig bein g plac e d on th e work rather than the work
, ,

b eing placed in the jig The j ig may be held to the work by

.

straps bolts or clamps but in many cases the j ig fit s into or

, , ,

over som e fini shed part of the work a n d in thi s way the jig is
locat e d a n d h eld i n posi ti on .

Th e cl osed drill jigs or box j i gs fr e qu entl y resemble s ome

, ,

form of a box an d are in tend e d for pieces where the holes are
to be dri ll e d at vari ous angles to one anoth e r A s a rule the .
,

p ie ce t o b e drilled can be in s ert e d in th e jig only aft e r one or

more l e aves or covers have be en swung out of the way S ome .

t im e s it is n e c e ssary to r emov e a loose wall whi ch is held by ,

bolts a n d dowel p in s in order to locate the piece in the j ig

,
.

The work in the clo s e d drill jig may be held in place by s e t

scr ews scr ew bushings straps or hook bolts
, ,
-
,
.

The combin atio n dril lin g and boring j ig i s another typ e of

cl osed jig designed to s e rve both for dril ling and boring opera
ti ons B efor e designing a combination drill and boring jig
.
,

the re l atio n between and numb e r of the drill ed an d bor e d

, ,

holes must be tak en in to con sideration and also th e s ize of the ,

piece to be machi n ed In case there i s a great number of hole s

.
,

it may be of advantage to have two or e ven more jigs for the

same p ie c e b e caus e it mak e s it easier to d e si gn an d make the
,

jig and very likely wil l give a bett e r result The hole s drille d
,
.

or bore d in the first j ig may b e used as a mean s for locating the

piece in the jigs used lat e r o n C ombin ation drill an d boring
.

j igs ar e not very w e ll adapted for pieces of larg e siz e .

 J I G D E S I GN 1
3

O pe nJigs Op e n j l gs of the S imp l e r forms are S imp ly

.

plate s pro vided with bush e d holes w hi ch are located t o cor

respond with the r e quired locations for th e drilled hol e s While .

holes are sometim e s drilled by firs t laying out the hol e s d irectly
upon th e work it is qui te evident that thi s method of dr illin g
,

would not be effici ent i f a large number of duplicate p arts had

to be drill e d accurately as there is likely to b e more or l e ss
,

variat ion i n t h e locat i o n of the ho l es and cons i derable l oss of

a
,

time In the firs t place a cer t ai n amount of t ime is requ i red

.
,

for laying ou t t h e se hol e s prep aratory to drill ing Th e op e rator .

,

Fi g 1
. .
J i g for C ylind e r Flange and H e ad , and it s Appli c ati on

whe n start ing the drill must also be careful to mak e it cut
,

concen tric with th e scrib e d circle whi ch requi re s extra tim e

, ,

and there will n e cessarily be more or l ess vari ati on To over .

come these obj e ctions jigs are almost u niversally used for hold
,

in g the work a n d gui ding the drill when dril ling dup l i cate p arts
, ,

e specially when qui te a large numb e r of duplicate piec e s mu s t

be drilled .

Th e rin g-shap e d j i g shown at A in F ig i s used for drilling . I

th e s tud bolt holes in a cylinder flange an d also for dril lin g the
cylinder head whi ch is bolted to the cylin der The positi on of
,
.
I 4 J IG D E S I GN
th e J g
l wh en the cyl inder flange is being drilled is shown at
B . An an nular projection on the j g fits clo s ely in the cylinder I

coun terbore as the illu s tration shows to locate the jig concentric
, ,

with the bor e A S the holes in the cylinder ar e to be tapped or

.

threaded for s t uds a tap drill which i s smaller in diameter

,
“
,
!

than th e bol t body i s used and th e drill is gui ded by a r e mov

,

abl e bushing b O f t he pro p er size Ji gs of th i s typ e are oft en .

held in po sit io n by insert ing an accurate l y fitt ing plug through

the j g and into th e firs t hol e drilled whi ch p revents the jig
i
,

from turn in g wi th relat i o n t o th e cylinder whe n dril ling the ,

other hol e s Wh e n th e jig i s used for drilling the head the

.
,

opp osi t e side i s p laced

n ext to the work as ,

S ho wn at C Thi s side .

has a ci rcular reces s or

coun terbore which fits ,

the p rojectio n on the

head to p ro p erly locate
the j ig A s the holes i n .

th e h e ad must be slightly
l arger in diameter than
the studs another sized ,

drill an d a guide bushing

of corresp onding size are
F ig 2
. .D i ll J ig f th B Typ
r o e
us
ox
e d The e
cyl i nder is of .
,

course bored and the ,

h e ad turned b e for e the dr ill ing i s done .

Ji g s of the o p en class as well as thos e of othe r type s are

, ,

made i n a gr e at vari ety of S hape s an d when in use they are , , ,

e i th e r appl i ed to the work or the latter is p lac e d in the jig .

When t h e work i s qui te large the ji g i s frequently p laced on it

, ,

whereas smal l parts ar e more O ft en held in th e j i g which is so ,

design e d that the work can be clamp ed in the p rop e r position .

The form of an y jig depends to a great extent on the shape of

, ,

the work for whi ch i t is intended and also on the location of

the hole s to be dri lled A S the number of di ff er ently shaped
.

pieces whi ch go to make up e ve n a single machine is often very

 JIG D E S I GN 1 5

great a n d as most parts require more or less drilling j Igs are

, ,

made in an ahn os t endles s variety of sizes and forms When all .

the holes to be dril led in a certain part are parallel and e s ,

p e c i ally if they are all in the same plane a v ery simple form of ,

jig can ordinarily be used .

B ox Jig s. A great many mach i ne parts must be drilled on

—

different side s and frequently ca s tings or forgings are very

irregular in shape so that a j Ig which is made som ewhat in
,

F ig 3 . . B ox J i g for D illi g B
r n all s h wno l
e n ar ge d at A
th e form of a box and e nclos e s the work is very ess ential as
, , ,

i t en abl e s the guide bu shin gs to be placed on all sides and also

makes i t comparat ively easy to locate and securely clamp the
part i n th e pro p er p osi tion for dri l li ng Thi s typ e of jig whi ch .
, ,

becaus e of its form i s kn own as a close d or box j i g i s us ed

,
“
,
!

very exte n sive ly .

m
'

A box ji g of s i p l e d e s i gn i s shown i n F i g 2 Thi s p ar t i c u . .

lar j ig is used for drilling four small holes i n a part !not shown)
whi ch i s located with referenc e to th e gu i d e bushings B by a
c en tral pi n A attached to the jig body Th i s p in e nt e rs a hol e .

in the work which is finished i n another mac hi n e in co nne ct i o n

,
1 6 J G
I D E S I GN
wi th a previous o pe ration A fter the work is inserted in the
.

jig it i s clamped by clo sing the cover C which i s hinged at one

, ,

end and h as a cam S haped Clampin g latch D at the other that

-
,

engages a pin E i n the jig body Th e four holes are drilled by .

pa s sing the drill through the gui de bushi ngs B in the cover .

A nother jig of the same k ind but d e signed for drilling a ,

hole having two di am e t e rs through the center of a steel ball ,

F ig 4
. . B ox Jigs for D ri lling P art s h s wn
o by H yD
e av ot - d h Line s
and - as

is shown in F ig 3 The work which is shown enlarged at A

. .
, ,

is inser t ed while the co ver is thrown back as indicated by the

dotted lin e s The cover is then closed and tightened by the
.

cam latch D and th e large part of the hole is drilled wi th

-
,

the jig in the po sition shown The j ig is th e n turned over and

.

a smaller drill of the correct siz e is fed through guid e bu shi ng

B on th e O ppo site sid e The depth of the large hole could be
.

gaged for each ball drilled by feeding the drill spindle down to
,

a certain position as shown by graduation or oth e r marks bu t ,

1 8 J G
I D E S I GN
ings s hould vary the posi ti o n of the clamping bushing could
,

ea sily be Changed .

The work is properly lo ca te d by th e i n ner en ds of th e thre e

guide bu shi ngs a b and e and al s o by th e locating screws l
l , 1, l,

against which th e castin g is held by knurled thumb scr ews m -

an d n Wh en th e holes a a n d b ar e b e ing drilled th e jig is

.
,

plac e d wi th th e cove r sid e down as shown at A in F ig 5 and , .

,

the drill is guid e d by r emovabl e bushings o n e of which is shown ,

at 7 Wh en th e dri lling is completed th e drill bushi ngs are

.
,

replac e d by reamer bushings and each hole is finish e d by ream

ing Th e small hol e 0 F ig 4 is drill e d i n the en d of the cast
.
,
.
,

ing by simply p laci ng the jig o n e nd as shown at B F ig 5 ,

. .

B ox jigs whi ch have to be plac e d in more tha n o n e positio n

for drilling the diff erent hol e s are usually pro vi d e d with feet
or exte n sions as S hown whi ch are accurat ely fini sh e d to a li gn
, ,

the guide bu shings prop e rly wi th th e drill Th e s e fe e t exten d .

b eyond a ny clamping screws bolts or bushings whi ch may , ,

p rotrude from th e si de s of th e J l gS and p rovi d e a solid su ppo r t , .

Wh e n in s e rtin g work in a j i g car e should b e t ak en t o r e m o v e ,

all chips whi ch might have fall en u p o n thos e surfac e s a ga in s t

which th e work i s clamp e d and which de t ermin e its loca tion .

S ti ll a n oth e r jig of the box t yp e which is quit e s im i lar t o ,

th e one shown at A F ig 4 but is arran ge d diff e r ently o win g

,
.
, ,

to the shape of th e work an d locati o n of the hol e s i s sh own ,

at B in th e sam e i llustration Th e work has thr e e hol e s in .

th e base It a n d a hole at i whi ch is at a n an gl e of 5 d egr ee s

,

wi th th e base The three holes are drill e d with th e j ig s tand

.

ing on the opposi t e en d y an d the angular hole is drill e d whi le

,

th e jig r e sts o n the four fe e t k the en ds of whi ch are at such an ,

angl e with th e jig body that the gui de bushi n g for hole i is prop
e rly al i gn e d wi th th e drill Th e cast in g is located in thi s j ig
.

by the inner ends of the two guide bushings w an d the bushi ng

o and also by two locat in g s crews p a n d a s ide locatin g screw q .

A djustabl e s crews t and h in the co ver hold th e casting down ,

and it is held laterally by the two knurled thumb screws u —

and I) If an attempt were made to drill thi s particular par t

.

wi thout a jig !as would be done if only a few castings w e r e

 J G
I DE S I GN 19

n eed e d) i t would have to be set wi th con siderable care pro vided ,

the an gle betw e en hol e i and those in the base had to be at

al l accurat e a n d it would be rather diffi cult to drill a n umber
,

of th e s e cast in g s and have th em a ll dupl i cates B y the u e of . s

a jig , how eve r designed for drilli n g thi s particular casting

, ,

t h e relat ive p os i ti ons of th e ho l es in any number of par t s ar e

p ract i cally the sam e an d th e work can be done much mor e
qui ckly than would be p ossib l e if i t were held to th e dri ll p ress -

table by ordin ary clamping appli an ces Various desi gns of j i gs .

wi ll be d e scri b e d in Chapte r VII .

D e tails of J ig D e s ign The general prin cipl e s o f th e d e sign

.

a n d us e o f jig s have b een exp lai n e d Th e details o f j ig design

.

will now b e con si de r e d Generally sp eaking the most im

.
,

port ant p ar t s o f a j ig are th e gui de bushi ng s for the dr ills an d

oth e r too l s the clamp in g d e vi ces and the l ocating p o in ts
, , ,

against whi ch th e work i s pl ac e d t o in sur e a n accurate p osi

t ion in the j ig Th e gui des for th e cutting tools in a drill jig
.

tak e the form o f concen tri c st eel bushing s whi ch ar e pl aced i n ,

t h e ji g body in p ro p er p osi ti o n s .

The dril l bushings ar e gen e ra lly mad e o f t oo l ste el hard en ed ,

and l appe d a nd where convenien t shoul d b e groun d insi de

, , ,

a n d out Th ey shou l d also b e long enough t o support the

.

dril l o n each si d e r egardless o f the flut ing and they shoul d be ,

so located tha t th e l ower e n d o f th e bushi ngs will s top about

th e sam e di stanc e above th e work as th e di am e t e r of the drill ,

S O t h a t Chi p s w ill cl e ar t h e bushi ng s readi l y Wh e r e ho l e s are .

dr ill e d o n t he s i de o f a co nv ex or a co n cave sur f ace th e e n d of ,

t h e bushi ng mus t be cu t o n a b eve l an d come closer t o the p art

be ing drill ed to in sure t h e drill having adequate supp or t whi le
,

s tar ting int o th e work The bushings should have heads o f

.

sufficient diamet e r Lon g bushi ngs should b e reli eve d by in

.

cr e asing t he ho l e d iam e t e r a t the upp er end Th e lowe r end .

o f the bushi ng S houl d have i ts e dg e s roun ded in order to p ermi t ,

some of th e chi p s be ing shed from the dril l easil y ins te ad of ,

all o f them be ing forced up throu gh the bushi ng It i s also .

good practi ce to cu t a groove under the head for clearan ce for

t h e wheel when gr i n di ng the bu s h ing on the out s ide A c o m .
20 J G
I D E S I GN
p le t e treat i se covering dimensions and d e si gn i s gi ven in th e '

chapter on Jig B u shings

“
.
!

In order to hold the Work ri gi dly in the fig so that it may ,

be held a g ain s t th e locat in g points whil e th e cutting tools

o p erate up on th e work j ig s an d fixtures are p rovi ded wi th
,

clamping devi ces S ometi m e s a cl amping devi ce serves the

.

p urp o s e Of holding t h e j ig t o the work in a cas e where the ,

work i s a very large pi ece an d the j ig i s attached to the work

in som e sui tabl e w a y Th e p urp o s e of t h e clamp ing de vice
.
,

however remains the same n ame ly that of prevent ing any

, , ,

sh ifting of the gui ding bu shi ngs whi l e t h e op erat i o n on the

work is p erfo rmed The clamping devi c e S hould always be a n
.

in t egral part of th e j i g body in order to p revent i ts g ett ing lost .

D iff erent typ es o f clamping de vi ces are shown a n d descr i bed

in the Chap ter o n Ji g C lamp ing D evi ces
“
.
!

Th e locat in g po ints may consi st of scr ews pin s fin ished , ,

p ads bosses ends of bushin gs seats or lug s cast s olid with

, , , ,

t h e fig body e t c Th e vari ous t ype s used are de s cribed i n

,
.

detail in th e ch apter on Lo cati ng P o in ts an d A dju s table

“

S tops
!
.
 CHAP TER II
DE S IG N O F O PEN D RILL J IG S

To giv e any rational rules or methods for the design of drill

j i gs would be almo s t impo sible as almost e very jig must be
s ,

designed i n a somewhat di fferent way from every other jig to ,

sui t and conform to the requirements of the work All that can .

be do ne i s to lay down the p rinciple s The main principle s for .

jigs as well as fixture s were treated at l ength in C hapter I .

It is p rop osed i n the p resent Chapter to dwell more i n detail o n

the carrying out of the actual work of des igni ng ji g s .

J g rawings
i D B e for e maki n g any attemp t to p u t the lay
.

out o f the ji g on p ap er th e design e r should carefully consi der

,

what the jig will be requ ired to do th e limits of accuracy etc , ,

.
,

and to form in hi s i magination a certain idea of the kind of a

, ,

ji g tha t would be sui table for the purp o se In doing so if a .

,

mode l or samp le o f the work to be made i s at hand it wi ll be ,

found to be a great help t o study the actual model If the draw .

ing as i s most often the case is the on ly thing that i s at hand

, , ,

then th e outli n e of the work should be drawn in red !or other

colored) i nk on the drawi ng paper on whi ch the j ig is sub se ,

quently to be laid out and the jig built up so to speak around

, , ,

thi s ou tlin e The designi n g o f the jig wi ll be greatly simp lified

.

by doi ng thi s as the relation between the work and the jig wi ll
,

always be p lainly before the designer and i t wi ll be more easily ,

deci ded wher e th e locating points and clampin g arrangements

may b e p roperly p lac e d Whe n drawi ng and p rojecting the
.

diff e r ent vi ews of the ji g on the p ap er the red outline of t h e work

,

will not in any way i n t erfer e and when the jig is made from the
,

drawi ng the red li nes ar e simply ignored except to the extent

, ,

to which the outline of the pieces may help the toolmaker to

unders tand the drawi n g and the purp o s e of certain locating points
and d amp i ng d evic e s .
22 JI G D E SI GN
I f po ssib l e the fig S hould b e drawn fu ll size as it i s a great
, ,

d e al easie r t o ob t ain the correct p rop ortion s wh en so doing .

O f co urse i n many cases it wi ll b e i mp ossible t o d raw the jigs

, ,

full size In such cases th e only thing to do i s to draw them to

.

t h e largest po ssible r egular scal e E v e ry j i g draftsman should .

be supp lied with a se t of bluep rints containi n g di m e nsio ns of

standard screws bolts nuts thumb -screws washers wi n g-nu t s
, , , , , ,

slidi ng p oints drills count e rbor e s ream e rs bushings e t c ; i n

, , , , ,
.

short with blueprints givin g di mensions of all parts that ar e us e d

,

in the construction of jigs and which are or can be standardiz ed, , ,

.

It should be required of every d e si gn e r and draftsman that he use

the s e standard s to the larges t p ossibl e ex tent so as to brin g the ,
'

cost of jigs down to as low a figure as p ossible .

It is highly desi rable for the obtai ni n g of best resu l t s tha t

, , ,

before s tarting on the drawin g the draft sman who is to lay out ,

the jig should consult the foreman who i s actually going to use
the j ig Oftentimes t hi s man wi ll b e able to supp ly the be s t id e a
.

for the makin g o f the j ig or to o l Th e comb i ned exp erienc e of .

the drafts man an d th e for e man wi l l gen e rally p roduc e a much

be t ter tool than could e i ther o f them alon e .

As a ji g drawing i n most cas e s is only used onc e or a t most

, , ,

only a very f ew times it is not advi s able to make a tracing or

,

bluep rint from the drawin g but as a rule the p encil drawing its elf , , ,

may be used to advantage If however it i s give n ou t in the .

, ,

shop directly as it come s from the drawing board it is likely -

,

to b e come soi led so that after a whi le i t would be impo s sible

, , ,

to make out the meaning of the views shown on it F or this .

rea s on j ig drawings S hould b e made on heavy paper preferably ,

of brown color whi ch is not as quickly soiled as whi te pap er ;

,

and in order to p revent the drawing from being torn it S hould ,

be mounted on strawboard and held down along the edges by ,

thin wooden strips nailed t o the board It is al s o de sirable t o

,
.

cover the drawings with a thi n coat of shellac before they are
sent out into the shop When thi s i s done dirt and black spots
.
,

may be washed Off directly ; and the shellac itself may be wa shed
O ff by wood alcohol when the drawing i s returned to the draft
,

in g r oo m Th e drawi ng aft e r havi ng b e e n cl e an e d is th en

- .
, ,
 O E P N D RI LL J I GS 23

detached from the s t rawboard whi ch may be us e d o ver an d o ver ,

again The drawin g is of course filed away according to the

.
, ,

drafting room system The mos t advantageous sizes for jig

- .

drawin gs for from medi um to heavy work ar e about as follows :

I . F ull size sh e et 4 0 X 2 7 % in ch e s
-
, .

2 . H alf size she e t 2 7 % X 0 in ches

-
, 2 .

3 Quarter size she e t 2 0 X 3 % in ch e s

-
.
,
I .

4 . E ighth siz e sh eet 1 3 X 1 0 inches

-
,
2
7 .

Of course the s e sizes will vary in di ff eren t shop s and in many

, ,

cases p arti cularly when the tool de signing dep artment and the
,
-

re gular draftin g room are comb i ned as one draftin g dep artment
-
,

t he j ig drawings s hould be of the same re gular si zes as the ordi

n ary machine drawings .

It is common practice in a grea t many shops t o m ake n o d e

t ai l ed drawi ngs oi ji g s but simp ly to draw a su fficient number o f
,

views and sections and to di me n si on th e diff erent p arts dir e ctly

,

on the assembly drawing s In cases wher e the ji g drawing s ar e .

complicated and wher e th ey are cover e d wi th a larg e number

,

of dimensions which m ake i t hard to read the drawin g and to se e

the outlines of the ji g body itself i t h as p roved a gr e a t help to ,

trace the ou tlines of the ji g body and of such p orti on s as are ,

made o f cast i ron o n t racing p ap er omitting all loos e p ar ts and

, , ,

simply p u t ti n g o n the necessary di mensions for m aki ng the p at

te rns A blueprint i s then made from thi s pap er trac in g and i s
.
,

sent to th e p a tte rnmaker who will fin d the drawin g less o f a

i
,

puzzle and who wi ll need to spen d far l e ss tim e t o un ders t and

,

how the p a ttern actually looks I t i s however go od policy to .

, ,

detai l j ig drawi ng s comp l etely the same as o the r machine de ,

tails .

Wh en j Igs are mad e for pi ec e s o f w o rk whi ch r e qui re a g rea t

many op erations to be carried ou t wi th the sam e j ig an d wher e ,

a great numb e r of di ffere n t bu shings differen t S iz e s o f dri lls , ,

reamers counterbores etc are u s ed a sp ecial ope ra ti o n sh e e t

, ,
.
, ,

should be provided wh ich should be delivered t o the man u sin g

,

the jig together with the jig its elf Thi s enable s him to use the
,
.

jig to be s t advantage O n thi s sheet should be marked the order

.

i n which the v ariou s operation s are to be performed and th e

u
JIG D E SI GN
26 J IG D E SIGN
with p roper cl e aran c e for the cut ting t ools If th e size a n d l oca .

tion of the holes to b e dri lled are not very imp ortant as regards
accuracy i t is suffici ent to simp ly drill through the work with a
,

full-S iz e d drill guided by the jig plate but when a nice smooth -
, , ,

standard sized hole i s requi red the hol e s i n the work mu s t be

-
,

reamed The hole i s fi rst sp otted by a sp otting dri ll which is

.
,

of exactly the same siz e as the reamer used for fini shi ng and ,

whi ch ni cely fits the hole i n the ji g p lat e or bushing Then a - .

s o called reamer dr i ll
- whi ch is i nch or les s smaller in
, , ,

diameter than th e r e am e r i s p u t throu gh leaving only a slight

, ,

amount of stock for the reamer to remove thereby O btaining a ,

very sati sfactory hol e S ometim e s a sep arat e loose bushi ng is used
.

f or each one of these op erati on s but this is exp ensiv e and also ,

unnecessary as the method described gives equally good results

,
.

B y usin g th e rose reami ng method very good results wi ll al s o

be ob t aine d In thi s case two loose bushi ng s besides the li ni n g
.

bushing wi ll b e use d Th e s e bu shi ngs are d e scribed a n d tabu

.

l a ted in a f ollo wi ng chap ter Th e drill preced ing th e rose .

chucki n g reamer i s T 3 i nch small e r than the s ize of the hole

1
.

Thi s dri ll i s fir s t p ut through the work a loose dri ll bu shing ,

made of st e el bein g used for gui di ng the drill Then the rose .

chucking r e amer is emp loyed u sing i f the hol e in th e jig b e , ,

large a loose bushi ng made of cast iron

,
.

Wh e n di m e nsi o ni n g the fig on th e drawi n g di m e nsi o n s should ,

always be given from two fini shed surfaces of the jig to the
center of the holes or at leas t t o the more important ones In
,
.

re g ard t o th e holes i t i s n o t suffici ent t o give o nly the ri ght

,

an gl e di mensi ons a b c and d e t c F ig 2 bu t the radii between

, , , , ,
. .
,

the v ari ous holes must also be given If there are more than .

two holes th e radi i should always be given between the nearest

,

holes and also betw een th e holes that bear a certain relation
to one anoth e r as for i nstance be tween cent e rs of shafts carry
, , ,

i n g meshi ng gears sp rock e ts e t c Thi s will p ro ve a grea t help

, ,
.

to the toolmaker In the case under consi deration the di me n

.
,

s io ns ought to be i v en from two fini hed side of the work to

g s s

the centers of the hole s and als o the di men sion between the
,

centers of the holes t o be dri lled .

 P N D RI LL JI GS
O E 27

Wh en using a simp l e made as ou t line d in F igs 2 an d 3

j g,
i .
,

this jig is simply laid down flat o n the work and held agains t i t
by a C clamp a wooden clamp or if con veni ent held right o n
-
, , , ,

the drill press table by mean s of a strap or clamp as shown in

-
,

F ig 4
. H e re two pieces of the work are shown beneath the j Ig
.

plate both being drilled at one time

,
.

Impr ovin g t h e S impl e F ormof Jig Th e first imp rovemen t .

that could be made on the jig shown in F ig 3 would be the plac .

i ng of locating poi n ts in the jig plate i n the form of pins as shown

-
,

in F ig 5 in which the dotted li ne s represent the outline of the

.
,

work The p lat e n e ed n ot nece s sarily have the shape shown in

.

F ig 7 Si mpl e J ig wi t h L c ting S c w H l ding

o a re s o th e
W k in P l c
. .

or a e

F ig 5 ,
.
but may hav e the appearance shown i n F ig 6 according .
,

to the conditions .

The adding of the locating poi nts will of course i ncrease the , ,

cost of the jig but the amount of time saved in u sing the jig
,

wi ll undoub t edly make up for the added expense of the jig ,

provided a fair number of piece s is to be drilled ; be side s a great

advantage is gained in that the holes will always be located in
the same relation to the two side s resting agains t the locating
pins on all the piece s drilled The locating pin s are flattened .

o ff to a depth of TH,
inch from the out s ide circumference and ,

dime n sions should be given from the flat to the center O f the pi n
28 J IG D E SI GN
hol e s and to th e c ente r of th e n e arest or t h e most i mp or t ant o f
the holes to b e drilled in the ji g The same s trapping or d amp .

i ng arrangements for the jig and work as mention e d for the ,

simpler form of jig may be employed ,

.

Improving t h e Jig b y Ad d ing Lo cati n g S cr e ws Th e n ext .

step toward imp roving the ji g under consideration would be to

p rovi de the j Ig with locati n g screws as shown in F ig 7 B y ,
. .

the addition of these the locating arrangements of the jig be

,

come complete and the piece of work will be prev ented from
,

S hifting or mo ving sideways These locating screws are placed

.

so that the clamping point s come as nearly Opposite to some

bearing points on the work as po ssible In order to p rovide for .

locating set screws in our pre s ent jig three lugs or projections
-
,

A are added which hold the set s crews If po s sible the s e t s crew
-
.
-

lugs should not reach abov e the su face of the work which r ,

s hould rest on the drill pre ss table when drilling the hole s
- .

The pre s ent case illu s trates the difficulty of giving exact rules
for jig de sign Two s e t s crews are u s ed on the long side of the
.
-

work but in a ca s e like thi s where the piece i s comparatively

, ,

short and s tiff one lug and set s crew as indicated by the dotted
,
-
,

line s at B in F ig 7 would be fully su fficient The s train of the

.
,
.

set s crew placed right between the two locati ng pin s will not be
-

great enough to spring the p i ece out of shape When the work .

i s long and narrow two se t screw s are required on the long s ide
,
—
,

but in the cas e illu s trated two lug s would be con sidered a waste
, ,

ful de sign .

Pr ovi d in g Cl amps an d F e e t for th e Jig Th e means by which .

the work has been clamped or strapped to the j Ig when drilli ng

in the drill pre ss !se e F ig 4 ) have not been in tegral part s of the
.

jig in the S imp le typ es shown If clamping arrangements that .

are integral parts of the jig are to be added the next improv e ,

ment would be to add four leg s in order to rai e the j g plate s i -

enough above the surface of the drill pre ss table to get the r e -

quired space for such clamping arrangements The completed .

jig of the be s t de sign for rapid mani pulation and duplicate work
would then hav e the appearance shown in F ig 8 The j ig here . .

i s provi ded with a handle cast integral with the J l g body and ,
 P N D RI LL JI GS
O E 29

with a cl ampin g strap whi ch can be pulled back for r emovin g

and inserting the work Instead of having the leg s soli d W l t h
.

the jig as shown in F ig 8 loose legs scr ewed i n p lace ar e some

, .
, , ,

time s used as shown in F ig 9

, . .

The s e legs are round an d p rovi ded wi th a S houlder A p r event ,

ing them from screwi ng i nto the j ig p late A headless screw or

-
.

pin through the edge of the ci rcumference of the thr e ads at the
top prevent s the s tuds from becoming loo s e Thes e loose legs .

are usually made of machine s teel or tool steel the bottom end ,

S t and ar d J ig F e et

S c re w s for J ig F e e t

being hardened and then ground and lapp ed so that all four ,

le gs are of the same length It is the practice o f many tool

.

makers n o t t o thread the le g s i nto the jig body bu t S imply to ,

p rov i de a p l ain surface on the end of the le g whi ch enters i nto

,

the ji g p lat e and is driv en into p lace Thi s i s much ea sier, and
—
,
.

there i s n o reason why for almost all kin ds of work j i gs p rovi ded
, ,

wi th l egs attached in this manner should n o t be equally durable .

Ji g fee t are al s o made of the form s hown in the accompanyin g

table where a sep arate s crew is u s ed for hold ing the jig feet to
,

the j ig body .

When j ig s are made of machine or tool steel and feet are ,

JI G D E SI GN
 O E P N D RI LL JI GS 31

required th e only way t o p rovid e them i s to in s e rt loos e fee t

, .

In the case of cast i ron jig s however s olid legs cast i n p lace are
-
, ,

preferable The s oli d legs ca s t in place generally hav e the appear

.

ance shown in the u pper right-hand corner of F ig 8 The two . .

webs of the leg form a ri ght angle which for all practical pur , ,

p oses makes the le g fully as s tron g as i f i t were solid

, The .

leg is t ap ered 5 degrees as a rule as shown i n the engraving

1
, , ,

but thi s may b e varied accordin g to conditions The thickne s s .

of the leg v arie s according to the size of the jig the weight of the ,

work and the pre s su e of the cutting tool s and depend s al s o

,
r
,

upon the length of the le g The length b on top is g enerally .

made one and one half times a A s an indication of the size

- .

of the legs required it may be sai d that for smaller jigs up to

, ,

jig s with a face area of 6 square inches the dimension a may be ,

made from T% to g inch ; for medi um sized jig s to 2 inch ; for

‘
— -
,

larger-sized jig s to % i nch ; but of cour s e these dimen sions

,
1 , ,

are simply i ndications of the required dimen sion s A s to the .

length of the legs the gov ernin g condition e vidently i s that

, , ,

they mu s t be long enough to reach below the lowe s t part of the

work and the clamping arrangement as clearly indicated in the ,

design in F ig 8 . .

If a jig i s to be used i n a mul tip le spindle dri ll i t S hould be -

,

de si gned a great deal s tronger than it is ord inarily desi gned when ‘

used for drilling one hole at a tim e Thi s i s e sp ecially true i f .

there is a large number of holes to dri ll simultaneou sly It i s .

e vide n t that the p ressur e up on the jig in a multip le spindle drill

-

is as many t i me s grea te r than the pressure in a common drill

p ress as the number of drills in operation at once .

R eferr i ng aga i n to F ig 8 a t tention should be called t o the

.
,

small lugs A on the S ides of the jig body which are cast in place
for layin g ou t and p laning p urp oses The h andle should be .

made about 4 i nche s long which p ermits a fairly good grip by ,

the hand The de sign of the jig shown i simple and fills all
.
s ,

requirement s neces s ary for producing work quickly and accu

r at e ly ; at the same time it i s s trongly and rigidly de signed,
.

Locating points of a di fferent kind from tho s e shown can of ,

course be u s ed ; and the requirement s may be such that adj ust

,
3 2 J G
I D E S I GN
able locating point s as d e scribed i n a followi ng chapter may b e
, ,

requi red A more quick -acting but at the s ame time a far more
.
, , ,

complicated clamping arrangement might be used bu t th e ,

que s tion is whether the added increa s e in th e rap idi ty of manip u

lation offsets the expens e thu s incurred .

A question whi ch the designer should always ask h i m s elf i s

C an more than o n e piece be drilled at one time ? In the present
ca se the locating p in s can be made longer or i f there i s a locat
, , ,

ing wall it can be made higher the leg s of the jig can be made
, ,

longer and the screw holding the clamp can al s o be i ncreas ed in

,

length If th e p iec e s of work are thi ck enou gh se t-screws for

.
,

F ig 9
. . L e gs S c ew
r ed int o J i g B od y

holdi ng th e work agai nst the locating p i n s can be placed in a

vertical line or i f the p i eces are narrow they can be placed
, ,

diagonally so as to gain space If the p i eces are v ery thi n

,
.
,

the locating m i ght be a more difficult proposition If they are .

made of a uniform width they may simply be put i n the slot ,

i n the bottom of the jig as shown in the lower ri ght hand corner
,
-

of F ig 8 or if a j ig on the p rinciples of th e one shown to the left

.
,

i u s ed they might be located sideways by a wedge as shown in

s , ,

F ig 0 . A couple of lugs A would then be added t o hold the

1 .

wedge in place and take the thrust In both cases the p i ece s .

mu s t be pu shed up in place endways by hand If the pieces are .

not of exactly uniform size and it is desired to drill a numb e r

34 J IG D E S I GN
Thi s s i d e i s also p rovided with feet and has a fini s hed p ad agains t ,

which the work i s held The locati ng pi ns extend clear through

.

the central p ortion of the j i g body a n d consequently wi ll l ocate , , ,

t he compon e nt part of the work i n exactly the same p osi ti on as

the pi ece of work dri lled on t he f ron t S i de o f the j ig The s ame .

clamping strap s ar e used the screws be ing simply put i n from ,

t he oppos i te s i de i n t o th e sam e t app ed holes as are used when

clampin g on the front s i de of th e j ig The four holes D are .

gu i de ho les f or drilli n g t h e scr ew h ole s i n the work these being ,

dri ll e d th e body size of th e bolt in on e p art an d t h e t ap dri ll siz e ,

F ig . 1 1. Exa m pl e of O p en D ill
r J ig . Vi e w sh o wi ng F r ont S i de
i n t hecomponent part The li ni ng bushing i n the holes D serves
.

as a drill bu shi ng for drilli ng the body size holes The loo s e .

bu shi ng E F ig is u s ed when drilling the tap holes i n the

,
. 11 ,

component p art the in side di ameter of thi s bushi ng bein g the

,

tap drill size and the out ide diam eter a good fi t in the li ning
,
s

bushi ng The two hole s F F ig

. are provi ded wi th dri ll ,
. 12,

bu hi ngs and s erve as guides when drilling the dowel pin hole s
s ,

whi ch are drilled below s ize leavin g about i nch and are , ,

reamed out after the two component parts of the work are p ut
together The two holes shown in the middl e of the ji g i n F ig
. .

1 1, whi ch are provided with lining bu shi ngs and al s o with ,

l oo se bushings as S hown inserted in F ig

,
may be used for . 12,
 P N D RILL J I GS
O E
35

t ogether .

The larg e b ushi n gs shown be si de th e j Ig i n F ig are the . 11

loose bushings shown in p l ac e i n F ig 1 2 It will be no ted tha t . .

the bushi ngs are p rovi ded with dogs for easy removal as ex ,

p la ine d i n a foll ow i ng chap ter A s the central p orti on o f the

.

F ig . 12. R e ar V ie w of D ill
r J ig s h o wn i n F ig . 11

J g
l body i s rather thi n it wi l l be se e n from F ig 1 2 th a t th e boss e s
,
.

for t he central holes p rojec t outsi de o f the ji g body i n order to

gi v e a long enough beari n g to the bushi ng s Thi s of cours e .
, ,

can be don e o n ly when such a projection doe s no t i nterfere wi th

the work The bos s e s i n thi s p articular cas e also s erve another
.
, ,

purpo s e They make the ji g fool p roof becau e the pieces

.
“ -
,
!
s

drilled on th e si de of the j ig shown in F ig canno t be put o n . 11

the si de shown in F ig the bo ss e s pre venting the piece from

. 12,

being placed in p o sition in the jig .

A ttention s hould be called to the s i mplicity of the de sign of

thi s jig It simply consi s t s of a ca s t iron plate with fini shed
.
-
,

seats and feet projecting far enough to reach below the work
,
3 6 JI G D E SI GN
whe n dri lli ng thre e dowel pins set-scr ews for bri ngi ng the work
, ,

up a gainst the dowel pins three clamp s and the n e ce ss ary , ,

bush in gs The heads of all the set screws and bolts should if
.
-
,

possible be made the same siz e so t h a t th e same wrench may be

, ,

u sed for ti ghtenin g and un s crewing all of them It can al s o be .

p lainly seen from the halftones that there are no unnecessarily

fini shed surfaces on th e j ig a mat t er which i s highly imp ortan t,

i n e conomical production o f tools .

Anoth e r example of an Open dri ll J g s i mi l ar i n des i gn to th e l ,

o n e jus t described i s shown i n F i The work to be dr i lled

g 3 ,
. I .

F ig . 13 . D ill
r J i g U s e d for D illi
r ng W or k s h o wn t o ih
th e R g t

i n thi s j i g is
sho wn at A and B at t he right hand si de of the Jl g — .

In thi s cas e the work is located from th e half circular ends

,
-
.

T he pi ece s A and B are comp onen t p arts and when fini shed ar e , ,

s cr e wed together The p iece A is located again s t three dowe l

.

pin s and pu s hed against them by s e t -s crews C and held in p osi

, ,

ti on by three clamp in g strap s as shown i n F ig I 4 In thi s case ,

. .
,

t he s t rap s are p rovi ded wi th oblo ng s l ots as i ndi ca t ed and whe n ,

the clamp s crews are l oo s ened the clamps ar e simply p ulled

backward permittin g the in s erti on and remo val of the work
,

Without i nterference It would improve thi s clamping arrang e

.

ment to place a s ti ff heli cal spr i ng around the screws under each
s trap so that the straps would be p reve n ted from falling down t o
,
 O EP N D RILL JI GS
the bo tt om of th e Jl g when the work was removed At th e sam e .

time this would p revent th e strap s from swi veli ng around th e

screws when not clamp ed .

In F ig 1 5 t h e p art B i n F ig 3 i s sh own clamp ed i n posi ti o n

.
,
. I

f or dri lli ng t h e opp os it e s i de of the jig being u s ed for thi s p ur

,

p ose In j i g desig n of thi s ki nd it is nece ss ary to provide som e

.

mean s so t hat the p ar t s A and B wi ll be p laced each on th e

corr e c t si de of the jig or as menti oned the jig should be mad e
, , ,

f ool -p roof .I n th e p resen t cas e the p ar ts cannot be exchanged ,

and p lac e d o n t h e w ro ng s i d e b e caus e the cov e r or guard B can

,

n o t b e h e l d by th e thr ee strap s shown i n F ig 1 4 as th e screws .

,

F ig . 14 . D i ll
r J ig s h o wn in F ig . 13 wit h Wor k in Pl c a e

f or th e s t rap s ar e n o t l o ng en ou g h O n th e other han d th e . ,

pi ec e A could n o t b e p laced o n t h e s i d e shown in g 5F i I becau s e .

,

t he l o ng bolt a n d s t rap us e d for clampi ng on t hi s s i de would

inte rf er e wi th t h e work .

It may app ear t o be a fault in d e sign t hat th ree strap s are used
t o fas ten th e pie c e A in p lace a n d only one is emp loyed for hold ,

ing pi ece B Thi s differ e nce i n Clampin g arrangement however

.
, ,

i s due to the d iff e ren t number and the di fferent s izes of holes t o
b e drilled in the di fferent pieces The holes i n the piece A are .

lar ge r and t he n umber of holes i s greater and a hea vier clampin g

,

a
rra nge m ent i s therefore ,
requ i red i na s much as the thru s t o n
, ,
3 8 JIG D E SI GN
the former i s corresp ondingly greater the mul tip l e spindl e dri ll ,
-

being used for drilling the hole s If each hole were drilled and .

reamed individually th e design of the ji g could hav e b een com

,

ar a t ive ly li ghter
p .

In the de sign shown the locating of each pie ce ind ivi d ually
,

i n any bu t the right way is al s o taken care of The p iece A .

,

whi ch i s S hown in p lace in the j ig F ig 4 cou l d n ot be swung ,

. 1 ,

around into ano ther p o siti on because th e s trap and scr ew at E ,

would interf ere F or the same reason th e cov e r or guard B

.
,

coul d no t be located except i n the right way A s shown in F ig . .

F ig 15. D i ll J i g h w i F i g 3 wi th C
R e ar Vi w e of r s o n n 1 ove r
b D i ll d in Pl c
.
. ,

t o e r e a e

1 5 t h e s t rap and scr e w would have to be de t ached f rom the j 1g

,

i n order to g e t the cov e r i n place if i t w e r e turned around The ,

.

locating p in s for the work pa ss clear through the body of the jig ,

and are used for locating both p ieces The piece s are located .

di agonally in the jig becau s e by doing so it i s po ssible to make

, , ,

the outside di m ensions O f the ji g small e r In thi s particular .

case the p arts are located on the machine t o which they belong ,

i n a di ag onal direction so that the ad di ti onal adv antage i s gai ned

,

of being able to use the same di mensions for locating the jig
holes as ar e u s ed on the drawing for the machine details them
selves Thi s also tends to eliminate mistakes in making the jigs
. .

S o me t imes wh en m o r e o r less c o mplicated mechani sm s ar e

,
 P N D RILL JI GS
O E
39

comp osed of s everal par ts fitted together and worki ng in relati o n

to each other as for in s tance f iction clutche s one jig may be
, , ,
r
,

made to s erve for drilling all the individual parts by the addi tio n ,

of a few extra part s applied to the jig when diff erent details of
the work are being drilled In F igs 6 7 and 8 such a case . . 1 ,
I ,
1 ,

i s illu s trated The p ieces A B and C in F ig 6 ar e comp onent

.
, , , . 1 ,

p art s of a fri c ti on Clutch and the jig in which these p arts are
,

being drilled is sho wn in the same figure to the left S uppo s e , .

n ow that the friction expansion ring A is to be drill e d The jig .

i s bor e d ou t to fit the ri ng b e fore it is spl i t an d whe n it i s only

F ig . 1 6. D ill J i g f P
r or ar t s of c
F ri ti on C lut ch e s s h own at th e Ri gh t

rou gh turn ed l e avi ng a c e rta in number Of thousandths o f an

-
,

i nch for fini shin g The p 1e ce 18 located as S hown in F ig 7

.
,
. 1 ,

against the steel block D entering into the groove i n the ring and ,

i s then held by three hook -bolts whi ch S imply ar e swung around ,

when the ring i s inserted or removed Th e hook bolts are - .

t ightened by nuts on the back si de of the jig Three holes .

marked E in F ig 7 are dri lled simultaneou s ly in the multiple

. 1

spindle dri ll and the fourth hole F !se e F ig 6) i s drilled by

,
. 1

turni ng the j g on the side The steel block D F ig 7 i s hard

i .
,
. 1 ,

ened and has a hole to guide the drill when pas sing through into
,

the other side of the slot in the ring The block is held in p lac e .

by two screws and two dowel pins .

3 1
40 JI G D E SI GN
Wh e n dri lli n g t h e holes in the lugs in the friction sleev e B,
F ig . the block and the hook bolts are removed It may
1 6, D -
.

be menti oned here althou gh it is a small mat t er that these

, ,

parts s hould be ti ed tog e ther when remov ed and th ere should ,

be a sp ecified p lace wher e all th e p arts belon gin g to a p art i cular

jig should be kept wh en not in use The fricti o n sl e ev e B fits .

over the collar G F ig 1 8 Thi s collar is an ex tra pi ece belong

,
. .
,

i n g to the jig and used on l y when drillin g the fricti on sl e ev e ;

,

it should be marked Wi th instructi ons for wha t purp ose i t is

us e d Th e coll ar G fi t s over the projec ti ng fini shed p ar t H in
.

D ill J i g h w i F ig 6 wi th O f th Pi c i P l c
F ig . 17. r s o n n . 1 , ne o e e es n a e

the center of the j i g an d i s l ocated in i ts right p o siti on by the

,

keyways shown Th e keyw ay in the fri c ti on sl e ev e B wh ich

.
,

must be cut and p lac e d in t h e ri ght rela ti on t o the p rojec ting

lugs before the pi ece can b e dri lled l oca t es the sleeve o n th e ,

collar G whi ch i s p rovi ded with a corresp onding keyway A

,
.

flange on the collar G as shown mor e p lai nly at L in F ig 8 ,

. 1 ,

locates the friction sleev e at the right di stance from the botto m
of the jig so that the holes wi ll hav e a proper location si deways
,
.

Two collars G and L are used f or the same pi ece B thi s b ei n g

, , ,

n ecessary because the ho l es M and M in the p rojectin g l ugs

shown in F ig 6 are n ot p laced i n the same relation to the side s
. 1

of the fri ction sleeve The co llars are marked to avo i d mi s .

takes and corresponding marks on the jig provided so as t o

,
42 J IG D E SI GN
It may be well t o add that loose bushings ough t to b e marked
wi th the size and kind of cutti ng tool for which they are intended ;
and the corre sp on di n g p lace in the jig body where they are to b e
used should be marked so tha t the ri ght bushi ng can e asi ly b e
p laced i n the ri ght p o si ti o n .

A few more examples of o p e n dri ll j Ig de sig ns o f vari ous typ es

may prove i nstructive In F ig 9 are shown two views of a jig
. . 1

for drilli n g two holes through the ri m of a handwheel To th e .

l eft i s shown th e j ig it self and t o t h e ri gh t t h e j Ig with th e hand

F ig . 19. D ill
r J i g for H ol e s in Ri m of H and wh e e l

wh e e l mounted i n place ready for dril ling As shown th e han d

,
.
,

wheel i s locat ed on a s tud through i ts bore and clamp ed to the ,

ji g by passin g a bolt through the stud thi s bolt bei ng p rovi ded ,

with a spli t wash e r o n the end The spli t washer p ermits th e

.

easy remov al of the handwheel when drilled and the p uttin g i n ,

p lace o f an o ther handwheel wi thout l o s s o f time Th e hand .

wheel i s loca t ed by two set screws B passing through two lugs

-

p rojecting on each side of a spoke in the handwheel the s e t ,

screws B holding the handwhe e l i n p o si ti on whi le bei n g dri lled , ,

by clampin g agai n s t th e si d e s of the spok e The jig i s f astened .

on the edge of the dri ll press table i n a manner simi lar t o tha t
-
,

in di cated i n the i llustration so that the table does not i nterfer e

,
 O E P N D RILL JI GS 43

wi th the wheel The vertical hole with the drill guided by

.
,

bu shi ng G is now dri lled i n all the handwheel s thi s hole being
, ,

drilled i nto a lug in the sp oke held by the two set screws B - .

When thi s hole i s drilled th e jig i s mov ed over to a h orizontal

,

drillin g machine and the hole D i s drilled i n all the handwheel s

, ,

the jig being clamp ed to th e t abl e of thi s machi n e i n a manner

s i mi lar t o tha t o n t h e dri ll p r e ss .

F ig . 2 0. e D ill J g
M i s c ll ane u s o E xa mp l e s of O pe n r i s

I n F ig 2 0 a t A an op en dri ll p g of a typ e si mi lar to tho s e

.
, ,

shown in F ig s 1 1 and I 3 i s sh own Thi s j ig howev er i s pro

.
,
.
, ,

vi d e d w i th a V b l ock locatin-g arrangement A n objectionable .

f ea ture of this j i g i s that the one clamping strap i s placed in the

cen ter o f the piece to be drilled S hould thi s piece be slender . ,

it may caus e it t o be nd as there i s no bear i ng surface under the

,
44 J IG D E SI GN
work at the p lace where the clamp i s located for taking the
, ,

thrust of the clamping pre sure s .

A t B and C in the same illu s tration are S hown the front and
back vi ews of a dri ll jig where the front side B is u s ed for dri ll
,

ing a small p iece located and held in the jig as u sual ; and the
back side C whi ch is not provi ded wi th f eet i s located and app li ed
, ,

d irectly on the work i tself i n the place where the loose p i ece i s
to be fastened the work i n thi s ca s e bein g s o large that i t sup
,

p ort s th e ji g instead of the j ig supp orti ng the work

,
.

A t D i n the same illu s tration is s hown a jig for locatin g work

by means of a ton gue E Thi s tongue fits into a corresp ondin g
.

slot in the work Thi s mean s for locating the work was referred
.

to more completely in connec t i on with locating devi ces F inally .

,

at F is s hown a jig where the work i s located by a s lot G i n the

,

jig body i nto whi ch a corre sponding tongue i n the work fits
, .
 C H AP TE R II I

D E S IG N O F L
C O S ED O R B o x J IG S

In the preceding chapter the s ubject of the de si gn of o pen

,

drill jigs h as been dealt with In the pre s ent Chapter i t is p ro

.

posed to outli ne the develop ment of the design of clo s ed or box

jigs.

A ss ume that the holes i n a p iece o f work as shown i n F ig ,

. 1,

are to be drilled H oles A are drilled straight through th e work

.
,

while hole s B and C are so call e d blind hole s drilled in to the

-
,

work from the opp osite sides AS thes e hole s mu s t no t be drilled

.

t h rou gh it is e vident that the work must be drilled from two

,

si des and the guiding bushing s for the two b lind ho l es mu s t

,

be p ut i n O pposite sides of the j ig The simple s t form of jig .

for thi s work is shown in F ig 2 Th e pi ece of work D i s located

. .

be tween the two p lates E whi ch form the jig and whi ch if the
, , ,

jig i s small are made of machine steel and ca s ehardened If

,
,
.

the jig is large these p lates ar e made of ca s t iron The work D .

i s si mp ly located by the outline s of the p lates which are made ,

t o t he same dimensions as r eg ards wi dth as the work it s elf

, ,
.

The p lates are held in posi ti on in relati on to each other by the

gui di ng dowel pins F The s e pins are dri ven into the lower
.

p la te and ha ve a sliding fit in the up per one In some ca s es .

,

blocks o r lu g s on one p late would be used t o fit i n to a s lot i n the

other p late instead of p i ns These minor chang es of course
.
, ,

d ep end u p on the nature of the work the princip le i nvolved being,

tha t some means mu s t be p rovi ded to p revent the two plates

from shifting in relation to each other whi le drilling The .

whol e de vi ce is finally held tog e t her by clamp s of suitable form .

The hole s A may be drilled from either s i de of the jig as they ,

p as s Clear through the work and the guide s for the drill s for
,

the s e holes may therefore be placed i n either plate Oppo site

, ,
.

the bu shings in either plate a hole i s drilled i n the other p lat e

45
46 JIG D E SI GN
for Cl e aranc e for the dril l whe n p assing throu gh an d for th e ,

e s cape of the chi ps .

The two plates should be marked with neces s ary general in

formation regarding the tool to be u s ed the po sition of the platess , ,

etc to prev ent mi s take s by the op erator It i s al s o an ad van

.
,
.

tage not to say a nece ssity to use some kind of connection b e

, ,

tween the plates in order to avoid such mistakes as for instance , ,

the placing of the upper plate in a revers ed po sition the wr ong ,

pins entering into the dowel pin holes This of course would .
, ,

locat e the hole s in a faulty po sition B e sides if the upper plate .

,

be entirely loo s e from the lower it is likely to drop off when the ,

jig is stor e d and get lost S ome means of holdi ng the two p arts
,
.

F ig . I . W or k to be D ill d
r e

t ogether e ven when not in u se or when not cl amped down on

, ,

the work should therefore be provided S uch a means i s em

,
.

ploye d in F ig 2 where the screw G enters into the guiding dowel

.
,

pin at the left and holds the upper plate in place A p in H .

,

fitting into an elonga t ed slot i n the dowel pin as shown at the ,

left could also be u s ed in s tead of the screw The design shown

,
.

pre s e nts the v ery simplest form of box j ig consi s ting as it does , , ,

of only two plate s for holding the neces s ary guiding arrange
ments and two pin s or oth e r means for locating the p lates in
,

r elation to each other .

In manufacturing wher e a gr e a t number of duplica t e parts

,

would be encountered a j ig designed in the simpl e man ne r shown

,

in F ig would how ev e r b e wholly i n ad e qua t e T h e simple st

'

. 2 , ,
.
 B ox JI GS 47

form o f a j 1g t ha t would be used in such a case would be one in

which some ki nd of locating mean s is employed as in di cated in ,

F i g 3 where three pin s are pro vided two along the s ide of the
.
, ,

work and one for the end of the work again s t which the work ,

S i mpl e F or m of Cl d
os e J i g for D illi
r ng W or k
s h o wn in F ig . I

may be pushed prior to the clamping together of the two j g i

plates In thi s illustration the jig bu shings are not shown in

.
,

the el evation and end view i n order to avoid confusion of line s

,
.

Th e next improvement to which thi s j g would be subjected would I

F ig .
3 . Lc o ati ng P ins ad d d e to J ig

b e the addin g of walls at the end of the j g and the screwing

- i

together of the upp e r and lower plate the result being a j ig as ,

shown in F ig 4 Thi s design presents a more advanced s tyle of

. .

clos e d j 1g a typ e which could be recommended for manufac

turin g purp oses Whi le the same fundamental principle s ar e
.
4g J IG D E SI GN
still i n evi denc e t hi s j g embodies most of th e requ i r e me nt s
,
I

nece ssary for rapid work This de sign provide s for integral .

clamp ing means within the jig it s elf provided in this cas e by , , ,

the s crews J The upp er plate K i s fa s tened to the walls of the

.

lower plate L by four or more screws M and two dowel pins N .

The cover K could also be p ut on as shown in F ig 5 by making ,

.
,

the two part s a good fit at 0 one piece being tongued into the ,

other Thi s giv e s greater rigi di ty to the J g In this jig also

. l .
, ,

solid locating lugs F are u s ed in s tead of p in s .

R eferring again to F i g 4 by p ro vi di ng a swi nging arm P wi th

.
,

a set screw Q the work can be taken out and can be i n s e rted
-
,

F ig .
4 .
J i g S u i t ab l e for M nu f c t u
a a r in g P up
r os e s

from the s i de O f the j i g which will save making any provi si ons
,

for taking off or putting on the top cov er for every piece being
drilled If there i s enough clearance between the top cover and
.

the piece being drilled the screw Q could of cour s e be moun t e d

, , ,

in a s oli d lug but it would not be advantageous to have so large

,

a space between the top plate and the work as the drill would ,

hav e to extend unguided for some di s tance before i t would reach

the work The set screws Q and U hold the work against the
.
-

locating points and the set screws J on the top of the j g pre
,
— I ,

vi o u sly referred to hold the work down on the fini s hed pad R
,

on the bottom plate The s e s crews al s o tak e the thrust when

.

the hole C i s drilled from the bottom side It i s immaterial on .

which side the bushings for guiding the drills for the two holes
A are p laced but by p laci ng them in the cover rath e r than in
,
5 0
J IG D E SI GN
of cours e dep en ds enti rely up on the si z e o f th e work an d the
,

size of the hole s to be drilled S ometimes one set s crew i s quite .

-

suffici ent whi ch in thi s ca s e would be placed in the ce n ter as

, , , ,

i ndicated by the dotted line s in F i g 4 . .

The type of jig s hown in F ig 7 now po s sesses all the features .

F ig 6 . .
J ig in F ig .
4 u s d i n Comb i n
e ati on wi t h Tw o P ar all e ls
generally required for a good j i g and pre s ents a type which i s ,

largely u s ed in manufacturing plant s particularly for medi um ,

and heavy work The jig s hown in F ig 8 howev er repre sents

. .
, ,

another typ e s omewhat different from th e ji g i n F ig 7 The

,
. .

Fi g 7 J i g i m pr ove d b y Ad di g F n e et o pp i t
os e Fa c es
i i D ill B u hi
. .

c ont a n ng r s ng s

j Ig in composed
F ig 7
. is
of two large s eparate piece s wh i ch for , ,

large jigs means two s eparate cas tings inv olving s ome extra
, ,

exp en s e i n the pat t ern shop and foundry The reas on for mak
- .

ing the j ig in two parts i n s tead O f ca s ting it in one i s becau s e it

, ,

makes it more conv enient when machining the jig The loc at .
 B OX JI GS 5 I

ing p o int s how e v e r are som ewha t hi dde n from view when the
, ,

p iece is in s erted The jig shown in F i g 8 consi s ts of only on e

. .

casting L p rovided with feet and resemble s an open dri ll ji g

, , .

The work is located i n a manner similar to that already d e scribed ,

and the leaf D wi de enough t o take in all t h e bu s hings except

,

t he one for the hole that must be drilled from the op po site side ,

is fitted acro ss the jig and gi ven a good bearing between the
lugs in the jig wall It swings around the pi n E and is held down
.

by the eye bolt F wi th a nut and washe r S ometimes a wing

- .

n u t i s handi er than a hexa g on nut C ar e should be taken tha t .

Fi g 8 . . Alt e rnati ve D e s i gn of J ig in F i g 7
.

the feet reach below the top of the nut and screw The se t .

screw G holds the work down and takes the thru s t when the ,

hole from the bot t om side is drilled The three holes A A and .
,

B are drilled from the top so that the t hru s t of the drilling of
these three holes will be taken by the bottom of the J g body L l .

If one s e t screw G is not suffici ent for holding the work in place
m
- ,

the leaf may b e made wider so as to accommodate ore binding

screws .

It i s howev er an objectionable feature to place the Clamping

, ,

screws in t h e b u shing plate If the leaf has not a perfect fit in

.

its s ea ts and on the swiv e ling pin the screw s will t i lt the l eaf ,
5 2 J G
I D E SI GN
one way or another an d thus caus e the bus hin gs to stan d at an
,

angle with the work p roduci ng faulty results I n order to avoid

,
.

thi s O bjectionable feature a further improvement on the jig

, ,

i ndi cated i n F ig 9 is p rop osed I n the jig body the loca ting
.
,
.
,

points and the set-screws which hold the work against the loc at
i ng pin s are p laced so that they wi l l not i nterfere with two straps
G which are provi ded with elongated s lo t s and hold the work
, ,

securely in place al s o su s taining the thrust from the cutting

,

tools The s e strap s should be heavily de signed in order to be

.
,

able to take the thru s t o f the multiple sp indle drill becau s e in -

,

thi s ca s e all the bushin g s excep t the one for hol e B are placed
, ,

Fi g 9 J i g in whi c h Thr u s t of D illi

r ng O p i
e r at o n s
k mp
. .

i s ta en b y Cl a s

i n the bottom o f th e j Ig body The l ea f i s made n arrower an d

.

i s not as heavy as the one S hown in F ig 8 because it does not .

, ,

i n thi s ca s e take any thru s t when drilling and simply serve s the
, , ,

p urp ose of holding the bu shing for hole B The leaves and loose .

bu shing plates for jigs of this kin d are generally made of machine
steel but for larger sized jigs they may be made of cas t i ron
, .

The l e af i n F ig 9 is s imp ly held down b y the thumb -s crew H

. .

I f the hole B comes near to one wall of the jig it may not ,

be nece ss ary to hav e a l eaf but the ji g casting may be made with
,

a projecting lug D as shown in F ig 0 the jig otherwise being

,
. 1 ,

of the same type as the one illus trated in F ig 9 Th e proj ecting . .

 B OX JI GS 53

p ar t D F ig 1 0 i s s t r en gthened wh e n n e cessary by a rib E as

,
.
, , , ,

indi ca te d C ar e must b e tak e n that th e r e i s suffici ent clearance

.

for t h e pi ece to b e ins erted and removed O nce in a whil e it .

happ ens eve n wi th fai rly good jig de signers that an otherwi s e
, ,

well designed jig wi th good locating clampin g a n d guiding

-
, ,

arrangements i s render e d useless for the S imple r e aso n that there

, ,

i s not enough Clearance t o allow the in s ertion of the work .

F ig 1 1 shows the same jig as before but with the addi ti o n al

.
,

feature of p ermi tting a hole in the work to be drilled from the

end a n d si de as indi cated th e bushi ngs E an d F being added
,

F ig . I o. M o dific ati on of J ig S h wno in F ig .

9

for this purp ose The bu shi n gs i n this case extend through the
.
, ,

jig wall for some di stan c e in order to guide the drill closely to
,

t he work B osses may also b e cas t o n the jig body as in di cated

.
,

by the do t t e d lin es to gi v e a longer bearing for the bu shi ngs

,
.

F eet or lu g s are cast a n d fi ni sh e d o n t he S i d e s of the ji g o pp osite

the bushi ngs so tha t the j ig can b e p laced co nveniently o n the
,

drill-p ress table for dril li n g i n any di rection When drilling .

the holes from th e bushin g s E an d F the thru s t i s taken by the ,

stati on ary locati ng pin s I t i s obj e cti onable to use set screws
.
-

to take the thrust although in some cases it i s necessary to do

,

so W h en de igni ng a j i g o f thi s typ e care must be taken that

. s ,

strapping arran gem en t s and loca t i ng points are placed so tha t

54 JI G D E SI GN
they i n no way will i nterfere with the cuttin g too l s or guidi n g
, ,

means In this case the strap H is moved over to one side in

.

order to giv e room for the bu shings F and the s e t -screw K .

S trap G should then be mo v ed al s o because mo ving the two ,

strap s in oppo site direction s still gives them a balanced clamping

acti on on the work If the s trap G had been left in p lace with
.
,

the strap H moved sideway s ther e would have b een some t en ,

d e ncy to tilt the work .

S ometime s one hole i n t h e work comes at an angle with th e

face s of the work I n such a cas e the ji g mu s t be made alon g
.

Fi g . 11. J i g for D illi

r ng H ol e s f m
ro T wo D i ct i
re on s

the line s i ndi ca t ed in F ig 1 2 the fee t on the si des op posi t e t o

.
,

where the drill bushi ngs are placed being planed so that their
face s will b e perp endi cular to the axis through the hole A Thi s .

will in no way interfere with the drilling of hole s whi ch are

, ,

p erpen di cular to the faces of t he work as these can be dr illed ,

from the opp osite side o f the work th e ji g then resting on the ,

feet B S hould i t however be necessary to drill one hole at an

.
, ,

angle and oth e r holes perp endi cular to the face of the work
from the same si de an arrangement as shown in F ig 3 would
,
. 1

be used The jig here i s made i n the sam e manner as the jig
.

S hown in F i g wi th the diff erence that a bu s hing A is placed

. 11,

at the required angle It wi ll be seen how ever that as th e

.
, ,
 B ox JI GS 55

o ther holes drilled from the same side mu s t be drilled p e rp e ndi cu

la ly to the face s of the work it would not b e of advantage to
r ,

p lane the feet so that the hole A could be dri lled i n the manner
previou s ly hown in F ig
s Therefore the feet are left to sui t
. 12 .

the perpen d i cular hole s and the s eparate ba s e bracket B F ig

, ,
.

1
3 ,
i s used to hold the i
j g n the de s i red incl i nIe d pos i t i on when
the hole A i drilled
s .

S tand B in F ig 3 i s v ery uitable for thi s special work

. 1 s It .

i made u p as li ght as possible being cored a t the center so as

s , ,

to remov e superfluou s metal The s e stands are sometimes p ro .

F ig . D ill i g H l t A gl
12 .
J i g f or r n o es a an n e

vi d e d wi th a clamp ing dev i ce for holdin g t h e fig t o th e stand .

S p e ci al stands are not only used for d illing hole at an g le s with r s

th e r e mai n in g holes to be drilled but s ometi m e s such stands ,

ar e made t o su i t the jig i n cases where i t would be inconvenient

t o p rovi de the ji g wi th feet fini shed bo ss e s or lug s f or resting
, , ,

di rectly on th e drill p ress table -

.

Wh en a j ig of larg e dimen sion s i s to be turned ov er either for ,

the in s e rtio n or removal of the work or for drilling hole s from ,

opp osi te s i de s i t is i n case s where the use of a crane or hoi s t

, ,

can be obtained very sati factory to have a special devi ce at

,
s

t a h e d to the jig for tur ni ng it over

c F ig 4 s how s s uch an . . 1

arrangemen t In thi s i llu s trati on A repre s ent s the jig wh ich is

.
,

4:
5 6 JI G D E SI GN
to be turne d ove r The two studs B ar e dri ve n in to th e Jl g in
.

convenient places as nearly as p ossible in line with a gravity axi s

,
.

These stud s then re s t i n the yoke C whi ch i s lifted by th e crane ,

h ook placed at D The jig when li fted off the table can then
.
, ,

ea sily be swun g aroun d T h e yoke i s made simply of round

.

machi ne s teel .

Fi g. 13. Jig an d S t and for D illi

r ng H ole s at an A ngl e

F ig 14. D icev e for T u

r ni n g ove r an d H an d ling
H y Ji g
.

e av s

Exampl e s of Cl o s e d or B ox Jig s T he d e ve l op men t o f a .

—

clo s ed or box jig has now been treated In the following pages .

a numb e r of example s of closed jig desi gn s will b e shown and

de s cri bed There i s however no di stinct di vi sio n li ne between
.
, ,

op en and clo s ed drill jigs s o that in many ca s e s it 15 rat her in

,

con si stent to attempt to make any such di s ti ncti on .

5 8 J IG D E SI GN
The swingin g strap I wh ich really is the only thi n g tha t makes
,

thi s j ig a clo s ed jig s erv e s the s ole purp ose of taking th e thrust
,

of the heav y cutting tool s when drilling the hole E and of steady
ing the work when facing off the two ends of the hub The two .

collar head screws K hold the strap t o the ji g body and the se t
-

F ig . Pl
1 6. d El
an an ti f J ig S h w i
e va on o Fig
o n5 n . 1

screw L bears again s t the work This strap is easily swu n g out
.

of the way by looseni ng one of the bollar-head screws a s lot be ing ,

mi ll e d at one end of the strap to permi t this S tati onary bu sh

.

i ngs are u s ed for the s crew hole and dowel holes but for the bear
,

i ng hole E three loo s e bu shing s and a lining bu shi n g are e mploy e d .

 B ox J I GS 59

The hole E i s first O pen ed up by a small twist drill whi ch make s ,

the work con siderably easier for the s -ca lled ro s e bit drill The o - .

latter drill leaves T g inch of stock for the ro s e reamer to remov e

l '

whi ch p roduces a very smooth s traight and concentric hole , , .

The la s t operation is the facing of the h ole s The holes ju s t .

drilled are now use d to guide the pilot s of the facing tools and , ,

as the operatio n is p erformed whi le the work i s held in the jig ,

it i s imp ortant that th e l ocati n g or s t rappin g arrangement s

should not be in the way .

In connection with the openi ng up of a hole with a smallc r

drill it may be mentioned that it is not only for la ge hole s that
,
r

t his method of procedure wi ll save time but the method is ,

often a time saving one al s o for smaller holes down t o i i nch i n

-
,

di ameter when drilled i n steel

,
.

The u se of lubrication in jigs is a v ery i mportant i tem the mo s t ,

common lubricant being Oil or va s eline but soap solution is al s o ,

used The objection to the latter i s that unle ss the machi ne

.

and tools are carefully cleaned i t i likely to cause ru s ting U si ng s .

a lubri cant freely wi ll s av e the guiding arrangements such as the ,

drill bu shi ngs th e p ilot s on counterbore s etc to a great extent

, ,
. .

The jig in F ig 5 is shown in F ig 6 and a clear idea of the

. 1 . 1

design of the jig will b e had by s tudying this line engraving .

The bracket B in F ig 5 could hav e been drilled in a di ff erent

,
. I ,

way than de s cribed whi ch would s ometime s be advantageous

,
.

It could be held in a chuck and the hole E reamed and faced in a ,

lathe whi ch would in sure that t h e hole would be perfectlycentral

,

wi th the outside o f the bo ss Then a jig could be de signed .

,

locatin g the work by a s tud enterin g i n hole E as indi cated in ,

F ig
.
7 add1i tional
,
dowel pin s and s t screws being used for e -

locating the piece sidewi e The whole arrangement could be s .

held down to the table by a strap and bolt a jack scr ew supp ort ,
-

i ng i t at the o v erhan ging end .

F ig 8 s how s another jig of the closed t yp e wi th the work

. 1 ,

i n serted The piece A i s a ca sing and the hole s to be drilled

.
,

vary greatly in size The casing re s ts on the flat fini hed bottom
.
,
s

surface of the jig and i brought up s quarely again s t a fini hed

s s

p ad at B It further locate s again s t the fini shed lug C in order

.
,
60 J G
I D E SI GN
to in sur e g e t ting th e prop er amou n t of m et al arou n d th e hole D .

A t the bottom it i s located against the s liding point E the latter ,

being adju s table because the location of the work is determined

,

by the other locating points and surface s The work i s held .

again s t the locating point s by the long e t s crew s hown to the s -

left Thi s clamping arrangement howev er is not to be r e com

.
, ,

mended becau s e thi s screw mu s t be s crewed back a considerable

,

di s tance in order to permit in s ertion and remov al of the work .

W OR K

DRI LL RE SS TA LE
-P B

F ig 17. S i m pl P l t
e a e J i g for D ill ing B ck t h wn
r ra e s o in F ig 15,
ft H l d in t h L th
. .

a er o e E h as b e e n B or e e a e

An eye bolt u s ed in the manner de s cribed in a precedi ng chapter

-

would have giv en better service The three s trap s G hold the .

work again s t the bottom s urface and the two s trap s H hold it ,

against the fini shed surface at B There i s not a long finished .

hole through the ca s ting as would be a ssumed f oni i t s appear

,
r

ance but simply a short bearing at each end the remaining part
, ,

of the hole being cored out F o thi ea s on the hole i s drilled

. r s r ,

and reamed in tead of being bored out

s the latter operation ,
as
 B OX JI GS 61

wou l d b e a s l ow e r o ne A lthough th e two short bearin gs ar e

.

som ewha t far ap ar t th e gu i di n g bushi ngs come so clo s e to thes e

,

beari n g s that the ali gnmen t can be made very good The screw .

holes an d dowel p in holes at the bottom of the ca si ng are no t

shown i n the i llustrati on as the inserted casing i s n ot ye t dri lled
, .

The hole dri ll ed from bushing I i s a rath e r imp or t ant hole and ,

the bushi ng r e quire s a long beari n g i n order to guide the drills

s traight wh en drilling W hen thi s j i g was made the p rojectin g
.
,

lug which was p rovi ded s olid with the j ig body to gi v e a bearing ,

Fig . 1 8. B ox J i g for C as i ng d ill d f om F i v

r e r e D i cti
re ons

to th e j i g bu s hing came so much ou t of th e way in th e rough

,

castin g for the ji g that ha lf of the li ni n g bushi n g would have bee n

exp osed It was therefore planed off and a bushi ng o f the type
.

shown in F ig 5 in the Chap ter on J ig B ush ings i nsert e d

.
,
“
,
!

i n s t ead i n order to p rovi d e for a l ong beari ng

,
.

L eaf K wh i ch c ar ri e s the bushi ng s for drilling the hole D

,
'

fits in to a s lot planed out in the jig body and is h e ld down by

the eye -bolt L Two lugs M are provided on the main ca tin g
. s

for hold ing th e pin on whi ch the leaf s wi vels A rou n d the hole .
62 J G
I D E SI GN
D th er e are thr ee small t ap ho le s 0 whi ch ar e dri ll e d b y th e
guidi ng aff orded by t h e bushing P which is mad e of cast i ron ,

and provided wi th s mall steel bu shing s placed in side as illustrat ed

i n F ig 4 in the Chapter o n J ig B u hi ng s
. 1 ,
In the bu shing P
“
s .

i s another hole Q which fits o ver a p i n located in the top of the

leaf and which in sure s tha t the three screw hole s will come in
t h e right po sition It should be n oted that larg e p orti ons of th e
.

Fi g . 19. B ox J i g for D illi

r ng W or k s h wn
o by D h-d
as ott e d Li ne s

J g
l body ar e c or e d o u t a t t op an d bo tt om in ord e r t o mak e it
light and easy to handle O f cour s e some metal i s al s o s aved
.

by the con s truction of j gs in thi s manner but comparing the

I ,

p ic e of cast iron with th e total price of a finished jig of thi s typ e

r ,

the saving in this re spect is o in significant that it i s not worth

s

whil e mentioning The leaf K i s al o made of cast i ron being o f

. s ,
 B OX JI GS 63

p articularly l ar ge size and i t , is planed at the places where it has

a bearing on the ji g body .

F ig
. hows a Closed j g about which there can be no doub t
20 s l

but that it should be cla ssified as a box j i g The p i e c e of work .

drilled the foot trip A has two holes B and C whi ch ar e drilled
, ,

i n thi s jig Th e cyli ndri cal hub of the work i s l o ca te d agains t

.

V blocks and h e l d in p l ace by a swi n gi n g strap D

- Th e work i s .

further located again t a stop p i n placed opposi t e the set-screw

s -

E . The trip i s located si dewi s e by being brought again s t anoth e r

F ig
. 2 0. J i g sh own i n D e t ai l in F ig . 1 53

s top b y th e s et scr ew F One -quar te r o f a turn o f the collar-he ad

- .

scr ew o n the top o f the jig releases the swinging strap -which is
then turned out of the way ; thi s permit s the trip to be removed
and another to be in s e r t ed H alf a turn or less of the s.e t -s crews

i s e nou gh to rel e as e and clamp the work agains t the stop s men
t i one d A l i ne engrav i ng o f t his jig i s shown in F ig 9 which
. . 1

gives a b e tter i dea of some of the detail s of the con truction s .

In F igs and 2 are shown two views of another type of

. 21 2

c lo s ed drill j g The work A to be drilled is shown at the left

i .
, ,
64 JIG D E SI GN
in both illu s trations and consi t s of a special lathe apron with
,
s

large bearing hole s screw hole s and dowel pin holes to be drilled
, , .

The apron i s located in the ji g body in the s ame mann er as i t is

located on the lathe carriage in this case by a ton gu e whi ch may
,

be seen at B in F i g 2 2 Thi s t on gu e fits into the s lot C i n the jig

. .
,

Fi g
. 2 1. J ig of T ypi c l D
a e s i gn, an d W or k for wh i c h it i s U s e d

F ig . 22 . An t h
o er Vi we of th e J ig in F ig . 21

care being taken in the con s truction of the j i g that the s lot i s
made dee p enough to p revent the tongue from bearing in th e
bottom of the slo t A good s oli d bearin g should be provided
.
,

however for the finished surface on both side s of the tongue

,
.

The s urface D should al so hav e a solid bearing on the surface E

i n t h e jig the difference in heigh t between the two beari ng sur
,

faces in the jig being exactly the s ame as between the two bear
i ng surfaces on the lathe carriage where the lathe apro n i s to b e
fi tted The work i s brought up against and further located by
.
, ,
66 J IG D E SI GN
t o make i t as l i ght as p ossi bl e to handl e Lu g s p roject wher ev er .

n ecessary to gi v e amp le beari n gs t o t he lini n g bushi ngs and in ,

turn to the loo se guidi n g bu shing s

,
.

F ig 2 3 s hows two clo s ed jig s made u p o f t wo ma i n parts wh i ch

.

are planed and as embled by s crews and dowels as indicated the

s
'

rea son for making the j igs in this way bein g the ea s e of planing
the bottom s ection The work drilled i n the s e jigs some special
.
,

slide s i s located by the dov etail and held up agains t one dov e
,

t ail S ide by set screws A as s hown in the illu s tration In th e jig

-
, .

F ig. 2 4. J i g for D illi

r ng Hl
o es at ot h er t h an 9 0 d
- e gr e e Angl es

to the left th e work is located endwi se agai nst a dowel pi n and i s

,

held up against thi s stop by a set-screw through the block shown

to the left Thi s bloc k mu s t be taken out when the slide i s in
.

se t e d
r th is being the reas on why a lu g ca s t directly in place
, ,

through which the set s crew could pass i s not u s ed The top
-
,
.

p late D i s held down on the mai n body by S ix fillis t e head s crews r -

E and two do wel pin s F pre vent it from shi fting

,
N o clamp ing .

arrangements except the set screws A are nece s s ary The

,
-
,
.

holes bei n g drilled from the top the main body of the jig takes ,

the thrust The s e j igs are als o u s ed in multiple spindle drills

.
- .

O ne ob j ectionable feature of the j ig to the right in F i g 2 3 i s .

t hat set s cre ws A are diffi cult of acces s

- There are th erefore .
, ,
 B ox JI GS 67

ho l es p ie rci n g the h e ads of th e set screws i n two di recti ons in ord e r

-

to allow a pin to be u s e d when tightening the s crews A better .

idea however is to have the screw heads extend out through

, ,
-

the wall and if thi s i s s olid to hav e cored or dri lled holes through
, ,

which th e h e ads of the s crews may pass .

In F ig 2 4 i s another Closed dri ll j ig in whi ch the work 8 loca t ed

.
1

F ig 25. J i g in F i g 2 4 in P o s i ti o n fo r D illi
r ng H l
o es at an
O bl i q u e Angl wi t h
. .

e J ig B as e

in the usua l man n er the j Ig stan di n g on its own feet bu t when

, ,

dri lling the hole s C whi ch come on an angle the sp ecial stand
, ,

D is employed which br i ngs the holes i n the right p osition for

,

drilli ng as i llu s trated i n F ig 5 If only the hole s C were to

,
. 2 .

be drill e d the feet on the side opposite the guiding bushings for
,

these holes could hav e been planed off S O that they would have ,

been in a p lane perpendicular to the axi s of the hole s Thi s last .

j i g has a peculiar appearance on account of the end wall s coming

,

up square as shown i n the illustrations but thi s design was

, ,

adopted only to simplify matters for the patternmaker i t bein g ,

easi er to make th e p attern this w ay .

 C H A P TE R I V

J IG B US HIN G S

Th e drill s counterbore s reamers etc us e d in Conn e c ti on

, , ,
.

wi th drill j i gs are guided by st e el bushi ng s whi ch are hardened ,

and ground and p laced i n the jig body in their p roper locati on
,
.

These bu shings may be of two kind s : s tationary and removable ,

the latter usually being known as loo s e bu shings The mo s t “ !

.

common and the preferable form for the stationary bu shing is

shown i n F ig . This bushing is straight both on the in side
I .

and on the outside excep t that the upp er corners A on the in

,

side are given a liberal radiu s so as to allow the drill to ent e r

,

the hole ea sily while the corners B at the lower end of t he out
'

side are slightly rounded for the p urpose of making i t ea sier t o

drive the bu shing into the hole when maki ng the jig and al s o , ,

to prevent the sharp corner on the bu shing from cuttin g the

metal i n the hole i nto whi ch the bu s hi ng i s driven .

R e movab l e B u s h i n gs When remo vable bu shi ngs ar e used

.
—
,

they S hould never be placed directly in the jig body excep t i f ,

the j i g be used only a few time s but the hole should always be ,

p rovi ded with a li ni ng bushin g Thi s li ni ng bu s hing i s always

.

mad e of the form shown i n F i g If the hol e bored i n the j ig

. 1 .

body rece ives the loo se or removable bu shi ng directly the in ,

sertin g and removi n g of the bu shi ng i f the jig i s frequently ,

used would soon wear the wall s of the hole i n the jig body and
, ,

after a whi le the j i g would have to be rep laced or at lea s t the ,

hole would have to be bored out and a new removable bu shi ng ,

made to fit the larger ized hole In order to o vercome thi s

-
s .
,

the hole i n the j ig body i s bored out large enough to recei ve the
lini ng bushi ng referred to whi ch i s dr iven in place Thi s lini ng
,
.

bushing then in turn receiv es the loo s e bushi ng the outsi de

, , ,

diameter of which clo s ely fit s the in side di ameter of the li ni ng

bushing as shown in F ig 2 i n whi ch A i s the ji g body B the
, .
, ,

68
 BU S H I NGS 69

li ni n gbushi ng and C the loo s e bu shi ng B oth of thes e bush

, .

ing s are hardened and ground so that th ey wi ll stand cons t ant

u se and wear for som e len g th of t i m e When no r e movabl e .

bushi ngs are requ i red th e li ni n g bushin g i ts el f becomes th e

,

drill bushi n g or ream e r bushi n g and the i nsi de di ame te r o f the

,

lini n g bushi n g will th en fit the cutt ing tool us e d Th e bushi ng .

s ho wn i n F i g i s cheaper to make and wi ll work fully as well

. 1 , ,

whe n dri ve n i n place in the hol e r e ce i vi n g i t as do bush in gs ,

havi ng a S houlder at the uppe r en d such as the loo s e bushi ng ,

s hown in F i g 2 It was th e p racti ce some years ago to mak e

. .

all bu shi ngs wi th a shoulder bu t t hi s i s unnecessary and simp ly

, ,

i ncrea s es the cost of making the bu shing .

M at e ri al for J ig B u s hi ngs B u sh ing s are gen e rall y made o f

.

a good grad e of tool steel to i nsure hardening at a fai r l y low

te m pe ra tur e an d t o l e ss en th e dange r o f fi r e cracki n g T hey .

F ig . 2. F ig .
3 .

c an al so b e made from machi ne st e el whi ch wi l l a nswer al l ,

p ractical purp oses pro vided the bushing s are p ro p erly case
,

hardened to a depth of about fi i nch S ometi mes bushi ng s for r .

gui ding tools may be made of cast iron bu t only when the cut ,

ting t ool is of such a design that no cutti n g ed ge s come wi thin

t h e bushi n g it s e l f F o r examp l e bushin g s us e d s i mp ly t o su p
.
,

p or t th e smo o th sur f ace of a boring bar or the shank of a r e amer

-

mi gh t in som e in s t an c e s be made o f cast iron but harde ned

, , ,

ste e l bushi ngs should always b e us e d for gu i di ng drill s re amers , ,

tap s e t c wh e n th e cutting e dges Come i n di rect contact with

,
.
,

the guidi ng sur f aces I f the out side diameter of the bushing is
.

very large as comp ar e d wi th the di ameter of the cutti ng tool

, ,

the co s t of th e bushing can som e times be reduced by usin g an

out e r cast-i ro n body and inse rting a hardened tool s tee l bush
7 0 JI G D E S I GN
ing O ccasi onally
. a bushi n g having a larg e outsid e d i ameter
i s requ i red as for example when a large counterbore must be
, ,

used in a smal l hole whi ch make s i t n e c e ssary t o h ave a larg e

,

O p eni ng i n the jig body .

D im e n s io ns of Stat io n ary Jig B u s h i n g s S ta n dard d ime n .

sion s for jig bushings app li cable under all Ci rcumstan c e s can
, ,

not be given as the s e depend in mo s t cases on the d ifferent

, , ,

conditions of th e various class e s of jigs in whi ch th e bushi ngs

are ins e rted The common practice i s to make th e length of
.

th e bushing twi ce the in side diameter of the hole in the bushin g

for stationary drill bu shing s On v ery small bushi ngs howeve r .
, ,

say 3; i nch di ameter hole and le ss the length of th e bushin g will

1
,

hav e to be made longer than twi ce the di amet e r whi l e on very ,

large bushi ngs the length may be made som ewha t l ess than
twi c e the diameter Table I give s p rop orti ons o f sta tio nary
.

dri ll bushi ngs The di mensi ons as her e gi ven wi l l be found

.
, ,

su i table i n all cases where no speci al condi ti ons d emand devi a

ti o n f rom ordi nary p ract i ce If the j ig wal l i s thi n the bush i n g
.
,

may p roject out as shown in F ig 3 so as to g ive the cu ttin g t oo l .

,

th e prope r guiding and support as Close to the work as p o s sibl e .

In Table II are given di men sions for lini ng bushi ngs not in ,

t en d e d to di rec tly guide the drill but to hold removable bush ,

i n g s whi ch i n t urn gui d e the cu t ti n g tools Th e dim e nsi ons

, , ,
.

given i n Tabl es I and II are for bushi ngs made from ei th e r t ool
s teel or machi n e st ee l .

Whi le i t i s difficu l t i n some cases to draw a di sti nct line b e

, ,

twee n s tati onary dri ll bu shings and li ning bushi ngs i t may b e ,

sai d in gene ral that the bushings i n Table I are used for gui d
, ,

i ng th e dri lls when drilling holes directly eith e r with a full ,

S ized dr i ll whe n th e hole is not required to be very smooth or

,

accurate o r i f greater accuracy is requi red f or guiding a sp ot

, , ,

tin g drill whi ch fit s the bushings exac tly afte r whi ch the hole i s ,

drill ed ou t wi th a s o called reamer dri ll whi ch i s

- inch
“ -
,
!

or l ess under th e size of the fini shed hol e and fin ally reamed ,

out with a re am e r exactly fitting the hole in the bush ing Th e se .

bu shings are thus in general u sed when no tapping or counter

, ,

borin g would be r e qu i red The li ni ng bu sh i n g in Table II

.
,
 B U SH I NGS 7 1

a gain may gu i d e on e of th e tools for the hol e s to b e fini shed

,

directly and then remo vable bushi ngs are i nserte d t o gui de th e
,

other tool s used .

Mi sc e ll an o
e u s Typ e s of D rill us hing s
B -
As m enti oned i t .
,

was s ome year s ago general practi ce to provi de e ve n stati on

, ,

ary bushi ngs wi th a shoulder or head as S hown i n bushing ,

C F ig
, Thi s will p revent the bushi ng f rom b eing pushed
.

through th e j i g by the cutting tool but thi s s e ldom happ ens if ,

th e bu shi ngs are made to fit the tool corr e ctly S ometime s the .

should e r i s us e d to t ak e the thrus t o f a stop collar which i s -

,

Tab l e I . D im n i e s ons of S t ati onary D i ll B u

r s h ings

clamp e d on the drill to allow it to go down to a certai n depth

, ,

as shown i n F ig 4 in whi ch C i s the s top collar D t he wall of

.
,
-
,

the jig and E the stationary bushing ; F i s the work In such

,
.

a case a shoulder on the bu shing should be pro vided

,
.

If the work to be drilled is located again s t a finished seat or

bos s on the wall of the jig and the wall is not thi ck enough to
,

take a bushi ng of standard length then i t is common practice ,

to make a bushing having a long head as shown i n F i g 5 ,

. .

The length A of the head can be extended as far as necessary

to get th e prope r beari n g As th e bushing i s driven in p lac e
.

5 1
7 2 JI G D E S I GN
and the shoulder of the head bears again s t the fin i shed surface
of a bo ss on the j g it will give the cutting tool almo s t as rigid
1 ,

a be aring as if the jig metal surrounded the bu shing all the way
up
R e mo v ab le bush i ng s are frequently used for work whi ch mu s t
be drilled reamed and tapped there then being one bu shing
, , ,

for each of the cutting tool s They are al s o used wh en di fferent

.

pa ts of the same hole a e to be drilled out to di ff erent diam

r r

e te s or when the upper portion of the hole i s counterbored

r , ,

Ta bl e II . Dim e n s i on s of Lini ng Bu s h in gs

or when a lug h as to be faced o f In thi s ca s e each tool of .

, ,

cour s e h s i t s own guide bu s hi ng The commo n de si gn of

,
a .

remo vable bu shing s i s s hown in F i g 6 The outside i s made . .

to fit the in ide of the lining bu shing with a nice sliding

s

fit so that it can be g ently p re ss ed into the lining bu shi ng by

,

the hand The di s tance A under the head of the bu shing

.

S hould be the s ame length as or longer than the guide bu s hing , ,

.

The thickne ss B of the head varie s of cour s e according to the , ,

size of the bushi ng The diameter C of the head should be

.
74 JIG D ESI GN
but i t do e s n ot add th e co nvenient m e an s fo r r emovi ng th e
bushing as do e s the dog To m ake such a bu shing more easily
.

removable the arrangement shown in F i g 8 i s probably the

,
.

most common A step A is turned down on the head whi ch

.
, ,

in thi s case will have to be a trifle larger i n di ameter This

,
.

step permit s some kind of a tool a s crew driver for i nstance , ,

to be put un derneath and with a jerk the bushi ng may be

,

lifted enough t o get a good hold on it The half round slot at B .

-

i s milled or filed in t h e periphery of the head and fits over a pin ,

or screw whi ch is fastened i n the ji g body as m e nti on e d b e for e , .

F ig . 1 1. M e th od s us ed for P r e ve nti ng J ig B u his ng s f m

ro Tur ni ng

I n F ig .are shown three method s of holdi ng bushi ngs to

11

p revent them from turni ng the methods all being on the pri n,

c ip le described : A shows a bu s hi ng ha vi n g a p i n i n s erted wh i ch

slip s in a slot cut i n the lining bushi ng ; B show s a bu shi ng h av

ing a slot mi lled thr ough the collar a pi n being loca ted i n the ,

ji g to engage thi s slot ; and C i llustrates a more elaborate device

that i s someti mes used The stop button which i s fas tened to
.

the j Ig p revents the bushi ng from being drawn out of the liner
while wi thdrawin g dri ll s or reamer s as well as p r eventi n g i t ,

from turni ng .

The following method for holding slip j I g bu shi ngs i n p lac e

 B U SHI NGS 75

h as been found to be a very good one : D ri ll and tap a i or

- inch hole i n the si de of the j ig bu shi ng as indi cated in F i g ,
. 12 .

A fter the bu shing i s hardened and ground screw in a pin and cut ,

it off so that it projects about { inch outside of the bu shing as 3

6 ,

at B C hip out a S lot in each hole in the jig as indicated at A

.
,

the hole bein g chi pped in the di recti on of a spi ral B y engagi ng .

the projecti n g p in in thi s slot the bush ing i s pr evented from ,

turning and from ri sing out of the hole A t the s ame time i t .

c an ea sily be remo v ed when requi red and there is no pro j ection ,

on the j ig of any ki nd that can be broken off whi le handling .

It i s not always necessary to tap a hole for the pin i n the jig
bu shi ng A p lai n drilled hole i s suffi cient when the bu hing
. s

is at least 3 inch thick If the wall of the bu shing i s th inner

—
.

than thi s the pi n cann ot b e driven i n ti ghtly enou gh to stay in

,

place s ecure ly .

F ig . 12 . An t h
o erD ill Bu hi g f m Tu ni g
M th d f
e o or P r e ve nt i n g r s n s ro r n

D i me n s ion s of R e movab le B u s hings In Table III are give n .

di men sions for removable bushing s of the type shown in F i g 8 . .

Table I V giv es di men ions for bu shings for holes which are
s

reamed with a ro s e chucking reamer after havi ng first been ,

drilled wi th a dri ll 1 6 i nch smaller than the di ameter o f the

3

reamer wi th which the hole is finally reamed out The bu sh ing .

to the extreme right o ver the table i the lining bushing which
, ,
s ,

is made of machine steel cas ehardened and gr ound The ,

.

bushi ng to the extreme left is the bu sh ing for the rose chucking
reamer It is made of cast iron and ground The bushing in
. .

the center is the drill bu shing whi ch i s made from tool s teel ,

hardened and ground or in case s where it doe s not seem war

, ,

ranted to make the bushing of tool steel of machine s teel ca se , ,

hardened and ground .

The tapered removabl e bushing shown in F i g 9 is ob j ection .

7 6 J IG D E SI GN
Ta bl e III . D im n ie s ons of Re m ovabl e D ill B u
r s h ing s

Wh e n u si ng d og s as illu st t d i
ra e n F ig 7 t h e d
. , im si s i th s
en on n l mns
e e co u are o mitte d .

able on account of be i ng expen sive to make an d also on a ccount ,

of being likely to be thrown out of true by chips etc forced in ,

.
,

between the outside of the bu s hing and the hole .

 B U S HI NGS 77

S cre w i S ometimes removable

B us h ngs . bushi ngs are
threaded on the out side and made to fit a tapped hole in the
jig as shown in F ig
,
The lower part of the bu shi ng i usu
. 10 . s

ally turned straight ,and ground in order to center the bu shing ,

perfectly in the hole in the jig The head of the bushi ng is .

either knurled or milled hexagon for a wrench When the s e .

bushings are u s ed they are as a rule not u sed for the single
, , ,

purpo s e of guidi ng the cutting tool but they combine with this ,

the p urposes of locating and d ampin g th e work F o such . r

Tab le IV . Bu s h i ng s for H ol e s me d
Re a w i th R o s e Ch uc king Re a me r s
7 8 J IG D E S I GN
purposes they are q uite frequently used Thes e bushings ar e .

not commonly u s ed as removable bushings as it would take ,

considerable time to un s crew and to again in sert a bu sh ing of

, ,

thi s type into the j ig body .

S p e c i al D e s i gn s of G ui d e B u s h i ngs Whe n the gui de bu sh

.

i ng s are very long and con s equently would cause u nnece s sary
,

friction in their contact with the cutting tools they may be ,

rec e ssed as shown in F ig 3 The distance A of the hole in

,
. 1 .

the bu shing is reces s ed enough wi der than the diamet e r of the

tool so as not to bear onit Th e length B being about twice
.
,

the diameter of the hole gives su ffi ciently long guiding su

, r

faces for the cutting tool to p r event its fu nning out If the
,
.

ou t si de diameter of the bush ing is very large comp are d with

F ig . 14. F ig . I 5 .

the di ameter of the cutting tool as indicated in F ig 4 the

,
. 1 ,

exp ense of making the bush ings may be reduced by making the
outside bushing of ca s t i ron in s erting into thi s a hardened
,

tool steel bu shing driven in place The steel bu shi ng is then

-
,
.

given di men sion s accordin g to Table I for s tationary bu shings .

The rea s on why there may be a nece ssi ty of a bushi ng having

s o large an outsid e diameter and so small a hole may be that

the bu shing is requ i red to be remo ved for counterboring part

of the small hole being drilled by a counterbore of large diam
eter in whi ch cas e the hole in the jig body has to be large enough
,

to accommodate the large counterbore .

If a loose or remo vable bushing is longer than the lining bush

ing as illustrated i n F ig 5 it wi ll prove advantageous to have
,
. I ,

the diameter of the pro j ecting portion of the bu shing about 5 7 1

i nch smaller in diameter than the part of the loo s e bushing which
 B U SH INGS 79

fits th e li ni ng bushing Thi s le ss ens the amoun t of surface .

whi ch has to be ground and at the s ame time makes it ea sier , , ,

to in sert th e bu shing giving it so to s ay a point which will , , , ,

first e nter the lining bus hi ng and it interfere s in no way with ,

the proper quali ties of the bu shing as a gu i de for the cuttin g

tool .

In some case s the holes i n the pi ece to be dri lled are so close
,

to one another that it i s impo ssible to find space for lini ng

bushing s in the jig If thi s happen s i t i s neces sary to make a
.
,

leaf or a loose wall or the whole j ig of machi ne steel or tool

, , ,

s teel hardening a port i on or the whole jig thus made

,
.

T bl V All w nc f G ind ing nd L pping B u h i g

a e . o a es or r a a s n s

D ia me t e r of s s
B u h i n g i n I nc h e s
O pe ra ti on

A — Gi r nd o ut s id e ; B — Lap o u t s id e f
a ter g ri nd in g; C —
G r in d insid e ; D— Lap
insid e a f t e r g rind ing .

M eth o d s of M aki ng Jig B u s h ings There are se veral method s .

followed in turning jig bushings S ome toolmaker s p refer to .

“
chuck out the hole to the desired size and then fini sh the
outsi de of the bushing b y placi ng it on an arbor ; others prefer
to turn up the bushi n g s two at a time end to end cut them , ,

ap art and then bore as the final O peration Thi s i s an excellent

,
.

method to follow when maki ng large bu shings Th e most rapid .

method howe ver i s t o chuck out the hole and fini sh the out side
, ,

a t one s e tt i ng using bar s tock held in the chuck of a rigid e m

,

gine lathe Thi s method is not always practicable on large

.

bu shi ngs .

In maki ng allowances for grinding and lapping many tool ,

makers u se too s mall limit s whi ch is the cau se of many bu sh ,

“
ings having to be made over again on account of not finishing
out .On the other hand many toolmaker s lea v e too liberal ,

an allowance for finishing thereby cau sing unnecessary troubl e ,

80 J IG D E S I GN
and labor The allowance s gl ve n I n Table V can be safely
.

u sed when the bushi ngs are made som ewhere near the propor
tion s indicated in Tables I to IV but for extra lon g bushin gs ,

more liberal allowanc e s should be made .

B efore harde ni ng the bu shi ng s should be p lainly s t amp ed

,

with the size and purpose for which they are intend e d ,

drill ,
!
é ream etc They should be stamped with a set of
“
,
!
.

plain S harp figures reserved solely for thi s purpose It i s p oor

,
.

practi ce t o try to stamp the words drill ream e t c in a “

,
! “
,
.
,

straight li ne as this is di ffi cult to do If however th e words

,
.
, ,

are lai d out on a slight curve the results are more satisfactory ,

as s light irregularitie s of alignment are not then so noticeable .

S harp clean figure s and letter s neatly laid out not only improve , ,

the appearance of the toolmaker s work but al s o s av e the

’
,

drilling operator s time as sharp clean cu t figures can be read

’
,
-

at a glance .

H ar d eni n g Jig B u s h ing s Wh en hardeni ng bushi ngs mad e .

—

o f tool s teel they should be brought to an eve n red heat in a

Cl ean fire ; the heating S hould never b e hurrie d When bush .

i n gs are heated quickly they are apt to h e a t une ve n ly whi ch , ,

r e su l ts in warping or di s t orti on that mak e s i t impos sible to fini sh

them to the required size G as furnaces are excellent for h eat .

ing but a Clean charcoal fire will answer the purpo s e A s soon
,
.

as the bushing has been brought to an e v en red heat it should ,

be dipped in water ju s t warm enough to take off the Chill The .

bu shing should then be heated to a sizzling heat after whi ch !

,

i t i s left i n th e ai r to cool S ome toolmakers draw bushings to .

a medi um straw color Thi s i s a m i stake as it onl y tends to

.

shorten their life .

G rin d ing and Lapping There are four method s i n common

.

u se for fini shi ng holes in j I g bushi ng s : L apping wi th a l e ad I .

lap . L apping wi th a lead lap followed by a cast i ron or

2 .
-

copper lap 3 Internal gri ndi ng 4 Internal grinding fol

. . . .

lowed by a cast i ron or Copper lap for removi ng the last

-

inch The firs t method is erroneous as it invariably results in

.
,

bell mouthed hole s e specially when the toolmaker Charge s th e

-
,

lap whi le in use whi ch i s an unsatisfactory but very commo n

,
82 J IG D E S I GN
si ve s , p roducts o f
th e el e c tr i c furnace ar e di sp l acing em e ry as , ,

they cut faster producing excellent results in a comparatively

,

short time as compared to emery N os 90 to 5 are used in . . I 0

connection wi th lead lap s for rou ghin g o p erations F or the .

final fini shing with cast i ron lap s flour abra sive i s us e d When
-
,
.

not in use any abrasive used for lapping should be kept in a

,

co vered box to protect i t from di rt and other foreign sub s tance s .

'
A small Chip or p iece o f gr i t will often cu t a dee p score i n a piece
of work .

Lap s should always be run at a fairly l ow sp eed F ifteen to .

twenty feet surface speed for a l e ad lap used for roughi ng and

F ig . 17 . Us u l
a F or m of C as t -ir on Lap

twen ty to twenty five feet surface spe ed for a ca s t i ron l ap u sed

.
- -

for fini shing are about right A hi gh surface speed cau se s the .

lap to wear out wi thout cutting as rapidly as i t should M any .

toolmaker s make the mistake of runn ing laps t oo fast often ,

cau sing unsati sfactory work F or light lapp in g the work can .
,

be held by hand but for a heavy roughing cut it i s be s t to hold

,

the work with an ordinary lathe dog care being t aken to see ,

that the dog is not clamped so tightly as to spring the wo k r

out of shap e L ead lap s should be split to compen s ate for wear
.
,

and the spindles S hould have a groo ve cu t alon g the i r entire

length to p reven t the lap from turning .

B efore te s ting wi th a s i ze plug the work shou l d be washed ,

wi th benzine or ga s oli ne to remove all traces O f the abra si ve

material a few grains of whi ch wi ll wear th e size p lu g b e low
,

s tandard S i ze i n a surpri s ingly s hort t i me .

M any toolmakers look on the fini s hing of j I g bushi ngs by

internal grinding as a rather uncertain method wherea s it is a ,

comparatively simple process when the followi ng important

factor s are ca efully con sidered F irst proper selection of grind
r .
,

ing wheels ; s econd correct wheel speed s or at lea s t as n early

,
 B U SHI NGS 83

corr e ct as th e d e si gn o f th e machine wi ll pe rmit ; thi rd correct ,

alignment of the h e adstock i n regard to the travel of the p laten ;

and fourth pro p er tr ui ng of wheel s
, .

Wheels for internal grinding should be of a m e di um gri t ,

soft grad e and o p en bond A s a rule the gri t should never be .

finer than 6 grit ; i n fact a coar s er grit can often be used to

0 ,

adv antage Wheel s with fine grit cut slowly and fill up readily
.
, ,

glazing and i nvari ably heatin g the work an d causing chattering ,

and other troubles In f act th e only argument in favor of a

.
,

fine gri t wheel i s that i t leaves a smooth surface H owever no .

,

matter how smooth the surface appears e ven under a p owerful ,

gla s s i t must be lapped to remove the wheel marks

,
.

F or the internal grinding of j g bu shing s aloxite whe e ls 1 % i , ,

i nch i n diameter i nch face 60 grit P grade D 4 9 5 bond may

,
- —
, , , ,

be used wi th g ood results the wheel speed bei ng ,

R P M . . .

F or bu sh i ngs averagi ng 2 % i nche s long % i nch h ole the holes ,

I -
,

rough-bored ,
inch bei ng left for grinding the grinding ,

time p er bushi ng including chuckin g and truing up would b e

, ,

about twelve minutes each and the fini sh left good , ,

in ch b e ing su fficient to lap out the wheel marks R efere nce i s .

made to the hole s being rough bored ; thi s is good p racti ce as —

,

th e rather rough surfac e tends to wear the wheel just a li ttl e

W hi le remo vi ng the fire scale thus p reventing the whe e l from ,

glazing O nce the scale i s removed from the hole the wheel
.
,

should not glaze r e adi ly p rovi ded i t is of the p rop er gri t and
,

g rade .

Wheels f or i nt e rnal gr i nd i ng should be run at a surface speed

o f 5 000 feet p er m i nut e Thi s h ow ever is a general rule O p en
.
, ,

t o excep tions A safe p racti ca l ru l e to follow i s to sp eed up the

.

wheel i f i t wears away too readi ly and to reduce th e S peed wh e re ,

the wheel shows a t enden cy t o glaze A ttenti on to thi s rule .

wi ll often s ave much trouble The toolmaker should bear in .

mi nd the fact that it i s ea si er to adju s t the speed to suit the wheel

than it is to try to k e e p on hand a large variety of wheels to su i t
all speed co n di ti ons .

A ssumi ng that the work i n question i s to be done on an ordi

n ary u ni versal grin d e r the headstock mu s t be s e t p arall e l wi th
,
84 J IG D E SI GN
th e t ravel o f the p lat e n to produc e s trai gh t h ol e s A p racti cal .

way to determine p aralleli sm is to clamp a pi ece of round

stock in the headstock chuck l e tting it projec t from the jaw s a
,

littl e farther than the length of the holes to b e grou n d Thi s .

piece should have a groove turned in it for the wheel to dwell

in during reversal This test p iece i s then ground in th e regular
.

way wi th the wheel u s ed for cylindrical work the headstock ,

b eing adjuste d by means of i t s swi vel bas e unti l the t e st pi ece

i s ground p arallel B efore cali p er i ng the wheel should be al
.
,

lowed to grind until very few spark s ar e vi sible Wh en once .

thi s test piece has been ground straight the setting c an be de

pended upon to produce straight holes provi ded of course , , ,

that the swivel adju s tm e nt of the head s tock and th e ang ular
adjus tm ent of the p laten ar e not disturbed To try t o align .

the headstock by calipering th e work while the i nternal g rin di n g

i s in proces s is at best di ffi cult and the o p erat or i s nev e r sure
, , ,

of accurate re s ults .

It is common p racti ce to true wheels for i nternal grindi n g

with a di amond fed by hand u sing the eye as a guide This,
.

i s p oor pract i ce as the wheel i s seldom turned p arallel on e

, ,

edge being left to do all the cutting whi ch glazes it readily A ,

.

more p ractical way to true these comparativ ely soft wheel s i s

to fe e d them p as t the end of a carborundum rub in 2 0 grit H , ,

grade The rub can be held in a s uitable holder strapped to

.

the platen of the grinder or held firmly by hand agai nst the end
of the work A carborundum rub shows high e fli ci e ncy whe n
.

used for thi s purpose .

In holdi ng work in the Chuck for internal gri nding i t i s well to ,

exerci se due care to see that the work i s not clamped hard
enough to spring it out of shap e A s a rule it does not requir e .

much pre ss ure to hold work of this nature as the grindi ng cut ,

i s comp arativ ely light A s it i s general practice to grind internal

.

work dry a certain amount of exp ansi on from frictional heat i s

,

always p re s en t F or this reason considerable care has to b e

.

u s ed in cali perin g the work with the sizing plug A s th e p lug i s .

many degree s cooler than the work it i s liable o n being in serted , , ,

t o contract the bu shing suddenly causing bushi ng and p lug to ,

 B U SHI NGS 85

freeze together firmly This can b e avoi d e d by co oli ng the .

work with a plug that i s kn own to be u n d e rsi ze befor e calip er

in g wi th a plug of the de sired size .

When a wheel of 60 grit i s u s ed a hole o ne i nch or under in ,

di am e ter should be left app roximately inch undersize .

Thi s amount is sufficient to lap out the wheel mark s and leave
a dead smooth mi rror fini h to the hole T hi is a general
!
s . s

rule ba sed on the fact that a certain amount !in thi s case
inch) i s enough allowance to lap out the mark s left on a surface
by a grinding wheel and that S hould suffi ce for all holes regard
‘ ,

le s s of size With comparativ ely large holes one an d one half

.
,
-

inch di ameter or over it i s better however to make allowance

, , ,

for finishin g owing t o the fact that the area of contac t of whe e l
,

F ig . 18. A r b or H l di g B u hi g
f or o n s n s

and w ork is generally not so great and the ground surfac e is no t

quit e so smooth .

In regard to the external grindi n g of bu shi ngs th ere ar e two ,

i mp ortant points that s hould be giv en con siderati on : the selec

ti on of wh ee ls and the method of holding the work The .

whe e l should be fas t cutting and at the same time it s hou ld hold
i t s shape and leave a good fini sh F o r thi s work good results .

may be O btained wi th an alox i te wheel of 2 inches diameter 3 1

1
, ;

i nch face 5 i nch hole 4 0 5 grit N grade D 4 9 7 bond the wheel

,
-
, , ,
-
,

being run at a sp eed of 8 00 R P M 1 .

When a number of bushi ng s arc to be ground one after ano ther

i t is be s t to mount them on arbors of the s ame len gth wh en ,

practicable to do so thus saving considerable time generally

,

sp en t i n re setting th e p laten whi ch has to be done whene ver

-
,

the tailstock i s moved to accommodate arbors of diff erent

l engths A n arbor for holding bu shings should be made as
.

S ho wn in F i g 8 The s traight p art should be a good fit in th e

. 1 .
86 JI G D E SI GN
bushi ng a sli gh t t ape r o n t h e remain der o f th e arbor b eing
,

suffi ci ent to pr even t the bushing from turnin g o n th e arbor .

Wh e n bu s hings are hel d on an ordi nary arbor or man drel the

O perator is never qui te sure that the hole and the ou t s i d e O f the

bushin g are concentric as one end of the arbor owi ng to i t s

, ,

taper does not quite fill the hole Thi s i s i llustrated in F ig 9

,
. . 1 .

B oth F igs . 8 and 9 are somewha t exaggerated t o i llustrate

1 1

the p rinciple
In grindi ng lini ng an d solid bushi ngs due allowanc e must be ,

mad e for a driving fit i n th e body of the jig Th e r e are three .

methods in common use for making driving fits o n thi s Class of

work : F irs t gri nding the bu shi ng unti l the lower end just
,

en ters the hole the bu shing being slightly tapered to bri ng i t

,

t o a s nu g fi t wh en p r e ss e d into p lac e ; s e cond g rin ding th e ,

F ig . 19 . I mp p
ro er F it of B u s hing on Or d in yar Ab r or

bushi n g straight for i t s entire length leav ing i t jus t en ough ,

overs ize to make a good d iving fit ; and third grin di ng the r ,

bu shing for nearly its entire length ju s t enough oversize to

make a good driving fit and grinding about one eighth its l ength
,
-

ju s t enough un der size to enter the hole .

Th e firs t method i s not con sidered very good p racti c e as the ,

bushing contract s more at the top t h anelsewhere owing to the ,

taper which leav es the hole i n the bu shing tapered Th e se c

,
.

ond m e t hod i s v e ry p oor practice as the bu shi n g is li able to ,

cramp whi le b eing forced in place whi ch re sults in an unsat is ,

factory job as the hole i n the jig i s generally s heared b y the

,

S harp e nd o f t he bushi n g The third method i s correct as the

.
,

p ar t tha t is g roun d to fit the hole act s as a pilot thus in suring ,

the p rop er starting of th e bu shin g and th e body being s traight , , ,

i nsures even contracti on .

I n making allowances for drivi ng fits in ch f or e ac h ,

 B U S H I NGS 87

i nch diam e ter of the bushing is con sidered practical wh e re th e

holes are on e inch or over a n d where the holes in the jig ar e ,

bore d smooth If the holes are rough bored a more lib e ral
.
-
,

allowance i s requir e d A fter the lining bushings are dr i ve n In

.

place they requi re re lapping as they always contract a little

,
-
, .

The outs ide of the removable bu shing s should be finished

by lapping to a dead smooth finish as otherwise they will !
,

soon wear loos e Thi s should never under any Circumstan c e s

.
, ,

be done wi th em e ry cloth but with a cast iron lap as illustrated

,
-

in F ig 2 0 Th e abras iv e used in thi s ca s e should b e of flour

. .

gri t wi th lard o il as a lubri cant the abrasive and oil b eing ,

appl ie d through a hole in th e t op of the lap The w ork should .

be lapp ed wi th a reg ul ar e ve n mo ti o n to in sur e i ts b eing

F i g 20 Lap for F ini s hi ng O t s d e

. . u i of S il p Bu s hi ngs
straight and s hould b e b ou gh t to the temperature of the room
, §
r

by b ein g cooled in benzine or gasol ine b e for e t e sting for a fit .

Th e lapping should be carri ed to a p oint where the bushing is

a wrin gin g fit in its lin er but n ot tight enough to st i ck wh en
,

l eft for a mome n t .

A fter the grin di ng and lappin g of the remo vable bushi n gs ,

the i r tops can b e fini shed by lapping on a carborundum ston e ,

in med i um grit wet with gasoline A regular motio n should

,
.

be used across the face of the stone without turning or altering .

the r elat iv e p osi tio n of the bushing This lapping gives th e .

bushin gs a good appe aran ce and as the dimension s stampe d , ,

are left black from the actio n of th e fire in hardenin g they ,

can be r e ad a t a gla n ce .

Dr iving F it All owanc e s for J ig B u s h ings S tandard d ime n .

sions for driving fit allowance s for j ig bushings arranged ac ,

cordi ng to th e outside diameter of the bushing are give n in

'

6 ]
88 J G
I D E S I GN
Table VI O ftentime s d ifli cult y i s experienced in a s sembl ing
.

the bu shings on account of n ot havi ng allowed the proper

amount of s tock for fitting .

P lat e B ushing H ol d e r s for Multi pl e D rilli ng Wh e n a .

—

number of holes are to be drilled and reamed on a multiple

spindle machine the mo s t S imple method i s to place the piece
,

in a suitable j ig and use individual S lip bushing s s o that after ,

the hole s are drilled the bushi ngs can be replaced with reamer
Tab le VI . All o w anc e s for D ri vi ng F i t for D ill B u
r s h in gs

size bu shings the j g mo ved und e r the reamers and the hol e s
m
,
i ,

achi ned The lo ss of time in ha ndling the s e slip bushings

.

i s so great that the p roduction costs increase v ery rapidly ,

e sp e cially wh e n the op erator has to stop to p ry up bushi ngs

with a screwdri ver or s ome other t ool as is ofte n th e ca s e , .

Thi s style of bushi n g will freque n tly catch the drilling or r e am

ing tool and turn with i t thu s weari ng the bushi ng plat e To
,
.

preve nt i ts turni ng the groove cu t bushing is sometimes u sed

,
- .

This consists of an ordin ary slip bushing in which a slot is cut

spirally aroun d on e quarter of the outer periphery Thi s slot
— .

engage s a pi n i n the bu shing plate so that when th e bushing , ,

starts to slip the pin preve nts i t s maki ng a full turn A mo di

,
.

ficat i on of thi s method was described in connection wi th F ig 2 . 1 .

One s ource of trouble from indi vidual s lip bushings i s the

‘

accumulati on of chip s Which mu s t be carefully remo ve d befor e

,

the bu shin g s are changed ; another i s the pos sibility of int e r

9 0 J I G D E S I GN
or two slots The r emo vable bushing p lates us e d wi th thi s
.

frame have holes or hinged b in ders to corr e spond with these

pin s or slots and so are correctly locat e d .

G ui d e B u s h ing s att ac he d t o Drill s Wh e n se veral small .

hole s nece ssitat ing two or more operations are to be mach ined ,

the following plan work s we ll from a production s tandpoint .

Gu i de bu shings of the same diameter are fastened to the dri lls ,

reamers and other tool s to locate them in the bu shings in the

plate whi ch are uniform in diameter Thus when drilling or
,
.
,

reaming the tools will be guided from the bushing A F ig

, l ,
. 21 .

This method i s n ot recommended for holes o v er one inch deep ,

a s there is a tendency for the dri ll s to sp ring out of alignment ,

especi ally i f the drilling is done against a rough s urface since ,

the end of the dri lling tool wi ll be some di s tance from the aux
iliary bu shi ng gui di ng i t Thi s arrangement is e ff ective for
.

drill in g s teel as the space between the jig plate and the work
,

allows room for the curled chips The di ameter of the guid e .

bu shi ng however mu s t be kept as small as po ssible sinc e thi s

, , ,

pi ece has a tendency to heat and stick owing to t h e peripheral

speed Thi s sticking and the wear o n the bu s hing plate may
.

be a vo i ded by u sing a stationary p ilot S imilar to that shown in

F ig 2 2
. A Z shaped ca s t ing wi th a bore equal to the tool size
.
-

and a nose equal to the jig bu shi ng di ameter is secured to the

arm of the multiple sp indle drilling machi ne by a bolt that
-

ext ends through the slot in th e arm as S hown in the illustration ,

.

G e n e r al N o t e s on B ushings When accurate work is ne ce s

.

sary the bushings S hould s upport the cutting tool to within

,

one d iameter of the too l from the work If a inch drill is

i
.
j g
—

used th e end of the bu sh ing s hould not be more tha n

,
in ch s
Tz
;

from the work and it may be carried to within in ch of the work

,
.

B u shings should not be loca ted clo s e to the work with the object
of carryin g the chip s u p through the bushing It is much better .

to p rovide other means in the jig for the removal of th e chips .

The s hape O f th e work frequ e ntly requires bu shings of con

s id e r able length in order to carry the cuttin g tool close to the

work W hen the length exceeds four diam e ters of th e tool to

.

be guided the bushing presents con siderable friction surface

,
.
 B U S H I NGS 9 1

A l ength equal to two diameters of th e cutt in g tool is usually

suffi cient for a bearin g surface in the bushing The r e mainder .

of the length of the hole in t h e bu shing may be coun t e rbored

or reliev ed Th e end that should be re lieved is of cours e tha t
.
, ,

which is farthest from th e work in to whi ch the t oo l is to be

guided .

S crew bu s h ings are generally avo i ded whe n accurate work i s

required Ther e must be a certain amo un t of clearance in the
.

ordina ry tapped hole and a threaded bu shin g i s likely to be

,

out of true on that accoun t S ometime s however it happ en s , ,

that no other typ e of bu shing can be u s ed for the work in ha nd .

The headed or flanged bushing is preferred by many too l

designers as a lining bushin g W heneve r i t i s p ossibl e to ut il ize
,

it If it is de s ired to have the h e ad of the bu shi ng flush w i th

.

the surface of the jig the jig is counterbored to receive the h e ad

, .

A s pre viously me n tioned slip bu s hings ar e employed wh en

,

s e v eral o p erations ar e to be p erformed through the same l inin g

bu shing F or examp l e when it is desired to drill and ream a

.
,

hole and to finish a boss or sp ot around the hole while th e work

is still in the jig a lining bushing is selected that will guide a
,

count e rbore T E inch larger than the boss to be fini shed A slip
I
.

bushing is then made to guide the drill the body of which is ,

a slidin g fit in the lin ing bushin g An other slip bu s hing i s mad e

.

for the r e amer which is al s o a s liding fit in the lining bushi n g .

The slip bu shing walls may have an y thickness p roviding they ,

are n ot too thin S hould the conditions require bushings wi th

.

too th in walls the counterboring operation in the j i g must

,

b e abando n ed an d som e different method of procedur e adopt ed .

 C H A P TE R V

LO CATIN G P O I NT S AN D AD JUS TAB LE S TOP S

The locating points in a j i g u sually con si s t of fini sh e d pads ,

bo s se s seat s or lug s ca s t solid with the jig as illustrated i n

, , ,

F ig . I In thi s engraving the surface s marked f are the locat

.

ing p oint s which bring the piece to be machined in Correct e

,
r

latio n to the bushings guiding t h e drill s or to the gages to which ,

other cutting tool s may be se t Thi s method of locating the .

work is satisfactory when the work done is finished i n a uniform

way and wh e r e there is very little variation in the p arts inserted
in the jig .

P i n s and S t u d s u s e d as Loc ati n g M e an s A n other c om .

—

monly u s ed method for locating the work in jigs is by mean s of

dowel pin s as shown at A and B in F ig,
The S ides of the . 2 .

dowel pins which re s t against the work are u sually flattened

‘

as indicated so as to give more bearing than a me re lin e con

,

tact with the pins could give and at the same time pr event , , ,

too rapid wear on the locating pin s as would be the ca s e if the ,

work bear again s t the p in s along a line only .

S ometime s pins or stud s are in s erted in jigs to act as locating

p oints instead of havin g lug s cast directly on the jig as shown
,

in F i g .A case where a pin i s used for t hi s purpo s e i s shown

1 .

in F ig 3 where B i s the body of the jig A the pin in s erted t o

.
, ,

act as a locating and resting p oint and C the work located ,

again s t this point L ocating p ins of thi s character S hould

.

always be provided with a shoulder or collar so that they wi ll ,

firmly re sist the pressure of th e work they support without ,

possibility of moving in the hole in whi ch they are in erted s .

i n
Locat g b y M e a n s of V -bl ocks A common method of .
—

locating cylindrical pieces or surfaces is that of placing the

cylindrical surface in a V -block as shown in F ig 4 Thi s ,
. .

V block as a rule is stationary and is held in p lace by screws

-
, , ,

92
94 JIG D E SI GN
in mak ing thes e b l ocks of cast iron as mos t of th e sur f ac e s ,

have to be machined and the difference in the cost of material

,

on such a comparativ ely small piece i s v ery slight .

C up and C one L o catin g P o int s W hen it i s e s sential tha t a .

cylindrical p art of the work be located centrally either with the

outsid e of a cylindrical surface or wi th the cent e r of a hol e

Fig .
5 . Ad ju L c ti g P p
s t ab e l V-b l o ck use d for o a n ur o s e s

p assing through the work good locating means ar e p rovi d e d

,

by the de sign s shown in F igs 6 and 7 In F ig 6 the stud A . . .

,

i s countersunk conically to recei v e the work The stud A i s .

made of machi ne or tool steel and may in many cases serve , , ,

as a bu shing for guiding the tool In F ig 7 the s tud is turned . .

,

coni cally in order to enter into a hole in the work Th e s e two .

Fi g 6 Re c e sse d u u d
St d se Fi g 7 C ic
on l S t ud u s e d
a
L c ti R L und W k o c a t i n g W or k i n R e
. . . .

for o a ng f o or or
in a J i wi t h R l ti
g t l ti t th
e a C t f
on o a on o e en er o
th e C t en er Hl a o e

locating appliances are always made s tationary and ar e on ly ,

used for locating the work never for binding or Clamping ,

.

S c r e w B u s hi ng s an d S li d in g B u s h ing s u s e d a s Loc ati ng

M e ans . S crew bushi ngs may be used for locating and clamp
i ng purposes by making t h e m long en ough to project through
t he walls of the ji g and by turning a co nical p o int on them as ,
 LO C AT I NG PO I NT S 95

shown in F ig 8 or by count e rsi nkin g them as shown in F ig 9

.
, ,
. .

In all ca s e s wh e r e long guide bu hi ngs ar e u sed the hole in the s ,

bu shing ought to be counterbored or recessed for a certain d i s

tance of its length .

A nother type of bushing whi ch serve s the same purpose as a

screw bu shing is illu s trated in F ig 0 Thi s bu shing together . 1 .
,

with the forked lever D and d amp ing bolt and wing nut s hown -
,

will s erve not only to locate but al s o to Clamp the work in p lace .

This sliding bu s hing g ives very good re sult s and i s p referable

t o th e scr e w bu shi n g in cases where accurate work i s requi red ;
but as a rule where extrem e accuracy would be required thi s
, , ,

kind of locating means i s not used .

In F ig
. 10 the slidin g bu shing A has a close sl i di ng fi t i n the
l inin g bu shin g B In the head of the bushing A there are two
.

i
F gs . 8 an d 9 . S c w Bu hin g
re s s

screws with hardened heads which fit i nto elongated slots i n ,

the forked lever or yoke D which in turn swiv els around pi n

, , ,

E . The eye bolt F fit s into a slot G in the yoke and the win g
-
,

n u t t igh te ns down the bu shi ng a g ai nst the work as c l early i ndi

cat e d in the engraving A comparativ ely long b e aring for the
.

bu shi n g i s required in order to produce good re sults On work .

tha t vari es consi derably in size this arrangement works s ome ,

what quicker than does a screw bushing but it i s clearly e viden t ,

that i t is a rather expensive ap pli ance and that th e constructi on

o f th e j ig does n o t always p ermi t of i ts app lication .

In som e i nstanc e s i t is nece s sary to have the scr ew bushi n g

movab le sideways for i n s tance when the p iece of work to be
, ,

made i s located by some finished urface s and a cylindrica l s ,

p art is to be provided with a hole drilled exactly in the center

9 6 J IG D E SI GN
of a lu g o r p rojecti on th e relation of this hol e to th e finished
,

surfaces used for l ocating b eing imma t eri al The p i ece of work .
,

being a cas ting would naturally be liable to v ariation s between

,

the fini shed surface s and the center of the lu g particularly if ,

there are other surface s and lug s to whi ch the already fini shed
s urfaces must correspond and in s uch a ca s e the fixed bu sh ing
, ,

for drillin g a hole that ought to come in the center of the lug ,

mi ght not always su i t the ca s ting In such a case so called .

,
-

“
floating bushings as shown in F ig ,
are u s ed The screw . 1 1, .

Fig . 10
. Sl i di L c ti g d C l mpi g W k
ng B u hings f or o a n an a n or

bu shi n g A i s conically rece s s ed and locate s from the projecti o n

on the casting It is fitted into another cyli ndrical piece B
.
,

provi ded wi th a flange on one side The p iece B ag ain set s .

, ,

into the hole C i n the jig body D this hole being large enou gh ,

to permi t the nece s sary adju tment of the jig bushi n g s .

When the bu shi ng h as been lo c at e d c once nt ic wi th the lu g r

E on the work the nut F ha ving a wa sher G under it i s tightened

, , ,
.

The flange on piece B and the washer G mu s t be large enough

t o co ver the hole C e v en if B i s b ought o ver again s t the sid e r
9 8 JI G D E SI GN
p o ints o f thi s
ki nd ar e often mi s taken for bindi ng or clamping
devices and the set screws are tightened up an d loo s en e d to
,
-

hold and release the work when the intention i s tha t these ,

screws should be fix ed when once adju s ted It is not even .

po ssible to depend upon the Check nut s topping the operator -

from u sing the screw as a binding s crew A headle s s scr ew .

,

therefore is p referable as i t is le ss apt to be tampered wi th

, ,
.

The sliding point as illu s trated in F ig s 3 and 4 i s another

,
. 1 1 ,

adju s table locating point which is u ed to a great extent in j ig s

work A flat piece of work or a plate whi ch i s not perfectly

.

level will always rock if put down on four s tationary locating

F ig .L c ti g W k
14. Sl i di ng Po i nt u se d for o a n or

points but the di fficulty thu s enco untered i s v ery easi ly ov er

,

come by making one of the locating p oints adjustable and as a , ,

rule the S liding point i s u s ed for th i s purpo s e

,
.

One de s ign is shown i n F ig 3 where A represents the work . 1 ,

to be located B t h e sliding point i tself and C the set screw

, ,
-
,

bindi ng i t i n place when adjusted The sliding p oint B fit s a .

hole i n the j g wall and i s p rovided with a milled flat s lightly

i

tap ered as shown to p revent its s li di ng back under the p re ssure

, ,

of the work or the tool operating upon the work Thi s de sign .

of slidi ng p oint i s frequently us e d but it i s not as e fficient as ,

the one i llustrated in F ig 4 In thi de sign the s lidin g point . 1 . s

A con i s ts of a sp lit cylindri cal piece with a hole drilled through

s ,

it as illustrated in the engrav ing and a we dge or shoe B tap e red

, ,

on the end to fit the sides of the groov e or s plit i n the sliding

point itself This wedge B is forced in by a set screw C for the
.
-
,
 LO CATI NG POI NTS 99

p urp os e o f b in ding th e slidi ng p o in t in p lac e E vi d e ntly wh en .

,

the screw and wedge are forced in the sli di n g p oint is exp anded , ,

and the friction again s t the jig wall D i s s o great that it can
wi thstand a very heavy pressure without moving P in E p re .

v e n ts the sli ding point from s lipping through the hole and into

the jig when loo s ened and also makes it mor e convenient to
, ,

get hold of In the accompan ying table are given the d ime n
.

sions most commonly used for sliding p o ints and bindin g shoes
and wedges .

S pe c i al Typ e s of A d j u s t ab l e S t ops A dju s table s tops are .

—

us e d to a greater extent i n milling fixtures than in drill ji g s bu t ,

D im n i e s ons of S l i d ing P o int s and S h oe s or B i nd e rs

S c re w s

the prin cip l e s emp loyed are the same Th e examp les shown i n .

connection with the following de s cripti on of adjustable stops

hav e bee n applied to milling fixture s and i n some cases to drill , , ,

jigs In F ig 5 is shown the simplest type of adjustable s top

. . 1 ,

provi ded with a helical spring beneath the plunger to p ress i t ,

agai nst th e work The O bjection to thi s type of stop is tha t

.

the plunger A will slip back under the pres sure of the clamps or
cuttin g tools up o n the work There is al s o danger of the milled
.

flat on -the plunger clogging wi th dirt so that th e stop will not ,

work prop erly C onsiderable time i s therefore lo s t in u sin g

.
, ,

j igs or fix ture s wi th this typ e of stop The method of clamping .

th e plunger i s al s o slow as i t i s nec e ssary to use a wrench in

,

tightening or loosening the set screw B In F ig 6 i s shown an

- . . 1

adjustable s top which is an improv emen t over that shown i n

F ig 5
. I .The flat on the side of plunger A is milled at a sligh t
1 00 J IG D E SI GN
angl e ins t ead of p arall e l with the c e n t er line as in F ig 1 5 -
,
. .

Thi s prev ents the plunger from slippi ng after being clamped .

A piece of harden e d drill rod B which i s kept from turning by a ,

small pin C engaging a flat milled in piece B is u s ed between

, ,

the p lunger A and t h e clamp A wi ng nut D i s fa s tened to the .

-

Fig 15 S i m pl e T yp e F ig 1 6. I mp r ov e m e nt on S to p
Ad ju p h wn
. . .

s ta b e l S to s o i n F ig . 15

end of the screw as s hown in order to elimina t e the u s e of a ,

W rench.

I n F ig 1 7 is S hown another adju s table stop which presents a

.

further impro vement ov er that s hown i n F i g 6 A bronz e . 1 .

bu shing B is driven i nto the base of the j ig and allowed to pro

F ig 17 A F urt h e r I mp r ove m e nt up on th e Ad j u s t ab e l S to p s
h wn i
. .

s o i n F gs . 15 an d 16

j
e ctabo v e the base as indicated P lunger A ,
is a s liding fit i n .

the bu shing A cap C i driv en onto the end of the plunger

. s

and extends down o v er the out side of the bu shi ng as indicated , ,

making the s top dirt proof Thi s s top however as well s that
- .
, ,
a

shown in F ig 6 i not entirely sati sfactory b e cause it will

. 1 ,
s ,
102 J IG D E SI GN
In order to overcome thi s diffi culty an adjustable stop as , ,

shown inF ig h as been de signed

. 2 0, The fla t style of wedge i s .

abandoned and the wedge A i s made of drill rod and slides in

,

a hole drilled in the ba s e of the fixture The stud at the back .

e nd of the wedge is s crewed into it instead of being riv eted a ,

s

in the p reviou s example B ushi n g C is p rovi ded wi th a shoulder

.

and a headle ss s e t s crew D is added to p rev ent plunger E from

-

dropping out when the fixture i s not in use The wedge A i s .

subjected to consi derable fri cti on and the fixture i s therefore , ,

n ot S O sen sitiv e to the touch of the operator a would be de ir s s

Fig 1 9. I mp r ove m e nt u p n t h Adju

o e s tab e l W e dge S to p
h wn in F i g 8
.

s o . 1

able It is di fficult for th e op erator to feel when the stop i s

.

against the work when tighteni ng t h e wedge in po sition

,
.

F ig .s how s a modi fication of the de sign s ho wn in F i g 2 0

21 .
,

the only Change made being in bu shi ng A which has been ,

lengthened so that it will act as a support for the end of wedge B .

The bu shing i s made of cold rolled steel and ca s ehardened - .

The bottom part of the ba s e i s cut away in order to reduce the

friction between the base and the wedge Thi s design i s better .

than that shown i n F ig 2 0 . .

In F ig 2 2 i s s hown a somewhat compli cated and expensiv e

.

adjustable s top whi ch howev er h as the adv antage s of almo s t

, ,

p erfect operating condition s B u shi ng A i s lengthen e d and h as .

 L O CATI NG P O I NT S 1 03

a much larger shoulder in order to take the thrust t o whi ch it

will be s ub j ected when the device i s operated A small pin B .

replaces the headles s set screw used in the de signs in F igs 2 0

-
.

and 21 The arrangements for clamping the wedge hav e bee n

.

con iderably changed and bronz e casting C is added A hole

s , .

i s cut in the ba e into which the ca s ting i s ins e rted clearance

s ,

F ig 2 0. A F u th
r er I mp r ove m e nt up on th e Ad ju s t ab e l W e dg e
p h wn i
.

S to s s o in F gs . 18 an d 19

being permi tted all around s o tha t the casting can be a li gn e d

easily with the wedge The casting is held in place by two
.

filli s t e r head s crews and two dowel s ; a hole i s drilled through

-

the lower p art of it which act s as a s upport for the back end of
the wedge as indicated The front end is supported in the
,
.

bushi ng A i n such a manner that the friction i s reduced to a

F ig 21 A m or e f ct y F m f Adj u
S at i s a or or o l
s t ab e W e d ge Sto p
th n th t h w n in F i g
. .

a a s o . 20

mini mum C asting C al s o supports the shoe D and rai ses it

.

from the ba s e of the fixture A ton gue i s cut on the lower side .

of s hoe D which fit s into a groov e i n casting C thereby prevent ,

ing the shoe from turning when the nut i s tightened or loosened .

S tud E is screwed into the side of the knurled nut and a small
pin F is dri ven into the s hoe Thi s pin act s as a stop for th e .

7 1
I 04
J IG D E SI GN
s tud prev enting the operator from turning the nut more than
,

i s necessary in tightening or loo s en i ng .

The adjustable s top shown in F ig meets practically all . 22

requirements p laced on an adjustable s top It will not S lip .

back under the pre s sure of the s top ; it will not slip in tighten
ing ; it is dirt proof ; all the parts form integral part s of the j ig ;
-

and it will not become loo s e due to v ibration of the machine , ,

or spring down under the pressure of the cut due to unevenne s s ,

of the table s of the machine s on which the fixture i s u s ed It .

c an be rapidly operated and i s so s en iti v e that the operator s

fe els instantly when plunger G i s in contact with the work .

F ig 22 Pr incipl e of t h e F i nal I mp r o ve m e nt in th e Adju l

s t ab e
p
. .

W e d ge S to

The only objecti on to this de sign is that s o much of the metal

of the base has been cut away that it is s eri ou s ly weakened ,

and the desi gn shown in F ig 3 i s sup eri or i n thi s respect In . 2 .

the mak ing o f the fixture difficulti es were also encountered in

,

alignin g the hole s in bu shi ng A wi th the hol es in ca s ting C ,

F ig 2 . This was remedied by making the bushi ng an easy

2 .

fit and addi ng a small pin D and the round head s rew C F ig - c ,

.

23 to keep the bushi ng from turning or working loose The

,
.

wedge was also jointed and made in two parts as indicated in , ,

order to take care of the v ari ation s that migh t occur i n drilli ng
1 06 JIG D E SI GN
of expansion s o that when the s tud B which i s turn e d to fit
, ,

the tapered hol e i n the bushi ng is screwed down the bu shi ng , ,

i s exp anded .

Locat ing b y K e yway s i n t h e W or k S ometi mes the work t o .

be finished in the jig i provided wi th a keyway or a slot or with

s ,

s ome other kind of a s eat by mean s of which it is located on its

,

component part on the machi ne for whi ch i t i s ultimately in

F ig . 24. F ig . 25. F ig . 26 .

tended and it is alway s e ss ential that the work be located i n

,

the s ame way in the jig as it i s to be located on the machine

on which it i s to go ; thu s if the work has a keyway suitable ,

for locating a corre spondi ng keyway ought to be put into the

,

ji g and the work located by mean s of a key as s hown in F igs

, ,
.

F ig . 2 7 . W or k whi c h is M ill d e as dc
In i at e d at E

25 and 2 6 Instead of a loo s e key a tongue may be p laned or

.
,

mi lled so li d wi th the ji g but as a rule i t is more satisfactory

, , ,

t o have the loose key as if it should happ e n to wear i t i s pos

, , ,

sible to replace i t ; and if the wi dth of the keyway S hould v ary

i n diff erent lots of the p arts made it is po ssible with little ex , ,

p ens e to make a new k e y to fi t the variation whereas if th e

, ,

key is made solid with the jig and found to be e i ther too large or ,

too small the trouble of fixing this would be considerably greater

,
.
 LO C ATI NG PO I NT S I O 7

Co mmon De fe ct s i n J ig D e s ign The fir t co n sideratio n o f . s

the jig designer should be to determi ne what degree of accuracy

is essential in the part that i to be produced and al o whether s ,
s

absolute interchangeability i nece sary Thi information will s s . s

be a guide for the economical production of the jig The de .

signer mu t also con ider any operation whi ch are to be per

s s s

forme d on the work prior to the one for whi ch the jig under
con iderati on i intended ; for whi le thi preli minary machining
s s s

may not need to be accurately done inaccuracy or uniformity ,

may re ult in improperly locating the work in the next jig

s ,

F ig 2 8. D f c ti
e e ve D e s i gn of i u
F xt r e for H l di
o ng P ic
e e
h w
.

s o n in F i g 2 7
.

should be so desi gned as to l ocate the p ar t wi th the re

qui red accuracy .

Th e locatin g p o ints of an y j i g should b e such as to allow as

wi de a range of inaccuracy on any preceding operation as i s
compatible in the part F or example if the part h as to be
.
,

turn e d to say a li mi t of
, ,
inch it will require more skill and ,

time than i f a li mit of i nch i s allowable A gai n as far .

,

as pract i cable the p ortion of the work that requires to be the

,

most accurate should be used in locating it in the j i g for the

succ ee di ng Operation O ften a surface i s s elected to locate
.

from which in cons equence mu s t be machi ned to an accurate

, , ,

li mi t wh e n accuracy otherwi e would be unnece s sary

,
Thi s of
s .
,
1 08 J IG D E SI GN
course only adds to the co s t of produc ti on A f te r co n si deri ng
,
.

the p oints mentioned the best method of arranging th e detail s

,

of the j i g so that i t h as as few dimensi on s as p ossible requiring

,

absolute accuracy s hould al s o receive attention ; that i s the

, ,

ji g should be as simple as p o ssible and still be so desi gned as ,

to accurately locate the p art s to be machined .

In F igs 8 and 9 are shown two jig de s igns whi ch wi ll serve

. 2 2

to illu s trate the s e point s The part for which a j ig is required.

i s hown in F i g 2 7
s In the preliminary machining operation
. .

the work is turned to diameters A and B and to lengths C and

D . The limit of accuracy required on end A is 1 or any 5
1
,

diameter from % % inch as a minimum to % inch F o r end B a

I 1 .

F ig it
29 F x ur e whi ch wi ll h l d o a N umb f Pi c
er o e e s, F ig 27
p p ly n wh n D i m t f L c t in g P a t y
.
. .
,

ro er , e ve e a e e rs o o a r s var

finer li mit of i s necessary s o that thi s end s hould be u s ed ,

as the locati ng p art for the next operation ; vi a the milling out ,

of the S lot E which must be central wi th the p art B A de sign .

such as s hown in F i g 2 8 i s not uncommon for thi s op erati on

.
,

and with it fairly accurate re sult will be s ecured ; but if the s

loca t ing diameter on the work i s slightly small say inch , ,

then the forcing of the piece over to one side by the locking
s crew A will re s ult in an inaccuracy in the milling operat i on .

The locating hole s B mu s t be the exact size of the locating part

of the work and unle s e very piece is a pu sh fit !which i s u n
,
s
 C H AP T E R VI

J IG CLA M P IN G D EVICE S

The clamping d evi ces used in connectio n with j i gs and fix

tures may either Clamp the work to the jig or the jig to t he work ,

but very frequently the clamps simply hold in place a loose or

movab l e p ar t i n the jig which can be swun g out of th e way to ,

facilitate removing the work from and inserti ng i t in the jig , ,

.

The work itself is in turn clamped by a se t screw or other mean s -

pa ssing through the loo s e part commonly called the leaf ,

.

Type s of Clam p s T he s i m p lest

. form of
—
clamp i ng devi ce is
the so called clamp of whi ch a number of di fferent form s are
-
,

commonly us e d P erhap s the mo s t co mmon of all clamp s is

.

the one S hown i n F ig Thi s kind of d amp is al so commonly

. I .

termed a s trap It is simp le cheap to make and for mo t

.
, , ,
s

purpose s i t gives satisfactory s e rvice The clamp shown in

,
.

F i g 2 is made on practically the s ame principle as the one

.

shown in F ig but several improv ement s hav e been intro

. 1,

d u ce d. The clamp is reces s ed at the bottom for a di s tance b ,

to a dep th equal to a so as to giv e a bearing only on the two

,

extreme end s of the clamp E ven i f the strap should bend .

somewhat on account of the p re ssure of the s crew it would be

, ,

certain to bear at the ends and exert the required pre ssure on
the objec t being clamp ed This strap i s also p rovi ded with a .

ridge at D located centrally wi th the hol e for the s crew This

,
.

insures an even bearin g of the screw head on the clamp ev en -

,

if th e two beari ng p o in t s a t each e nd of the clamp s hould v ary

in hei ght as illustrated in F i g 3 The clamp in F ig would
,
. . . I

not bind very s ecurely un der such circum s tance s and the col , ,

lar of the s crew would be liable to break off as the whole s train , ,

when tightening the s crew would be put on one side ,

.

A further imp rov ement in the construction of thi s clamp

may be had b y roun di ng the under si de of the clamping points
1 10
 C LAM P ING D EV I C E S I I I

A, as shown in F ig 4 When a clamp with such roun ded Clamp

. .

ing p oint i s placed in a po sition like that indi cated in F ig 3

s .
,

i t will bind the object to be held fully as firmly as i f the two

clamping surfaces were in the s ame plane .

The hole in the s e straps is very often elongated as indicated ,

by the dotted line s i n F ig and T hi s allows the strap to

s . 1 2 .

be pulled back far enough so as to Clear the work makin g it ,

eas ier to in ert and remov e the p iece to be held in the ji g In

s .

some cas e s it is neces s ary to extend the elongated hole as shown

, ,

i n F ig 5 s o that i t becomes a S lot going Clear through to th e end

.
, ,

of the Clamp instead of being simply an O blon g hole A si de

,
.

f rom thi s di fference t he clamp i n F ig 5 work s on exactly the

,
.

same principle as the clamps prev i ou sly shown .

F ig .
3 . F ig .
4 .

The clamp s described may be given a number of differen t

shapes to suit different condition s Instead of having the strap .

or clamp bear o n only two p oints it is sometimes nece ss ary ,

to have it bear on three points in which cas e it may be designed ,

similar t o the strap shown in F ig 6 In order to get an equal . .

pressure on all the three points a special screw with a half , ,

spherical head like the one shown may be u s ed to adv antage ,

.

The half sph e ri cal head of this scr ew fits into a concave rece s s o f
-
I I 2 J IG D E SI GN
the same S hap e in the strap When th e bearing for the s crew
.

head i s made i n thi s mann e r th e hole through the clampmu s t

,

have plenty of clearance for the body p art of t h e bolt .

When de signing clamp s or s traps of the typ e s shown o ne of ,

t he most i mportant con siderations i s to p rovide enough metal

around the hole s so that the strap will stand the pre ssure of
,

the s crew without breaking at the weake s t place which naturally ,

i s in a lin e throu gh the center of the hole A s a rule the s e

.
,

st ap s are made of machi ne s teel although large clamps may

r ,

sometimes be made from ca s t iron .

Fi gs 7 and 8 S how Clamps bent to meet the requirements

.
,

and also i n di cate the appli cati on of thi s type of clamp the ,

p art s hown in cro s s section being the work The s e clamps are
- .

commonly used for clamp ing work i n the p laner and milling
machi ne but are als o frequently used i n jig and fixture de sign
,
.

The screws used for clamping these strap s are either s tandard
hexagonal screws or standard collar head s crews W hen it i s
- .

n ot n ecessary to tighten the screws v ery firmly thumb s crews ,

-

ar e fre qu en tly used espe cially o n small jigs

,
.

S ome time s th e s t rap or clamp is arranged as shown in F i g 9 .

,

t h e screw pa s sing through it at t he center and bearing upon

the work eith e r di rectly as indi cated or through the medium
, , ,

of a collar fitted to the end of the clamping screw as shown in ,

I I 4 JI G D E SI GN
which are v ery much alik e but tha t of F ig 1 4 i s simp ler
,
.

and more rapidly operated when the work i s t o b e remov e d .

When the Clamp i s slotted as s hown in th e p lan Vi ew of F i g 1 4 .

,

fixed studs may be u s ed instead of the swinging bolts .

F ig . 1 1. T yp es of Cl a m p i ng S trap s

The type shown in F ig 5 is often found in machi ne shops

. 1 ,

o n milling fix tures dri ll j i gs lathe fixture s etc The clamp

, , ,
.

and bolts can be removed by loo s ening the n ut s and pulli ng out
the sli p washers whi ch allow the nuts to pass through the large

F ig C l mp Ad pt d t B Ji g
. 12 . a a e o ox s

holes F ig 6 i llustrates a method whi ch i s commonly used

. . 1

on mi lli n g fixtures when li gh t mi lling is to b e don e The design .

of clamp shown in F ig 7 i s not frequently seen in use as it i s

. 1 ,

a method whi ch a mech ani c wi ll not u s e if he can se e another

way out of i t ; bu t at times it i s found almo s t imp o s sible to us e
a clamp of a different type .
 C LA M P I NG D E VI C E S 1 1 5

A styl e of clamp that is som ewhat similar to the one illustrat e d

i n F i g 2 i s shown in F i g 8 In thi s ca s e howev er two
. 1 . 1 .
, ,

clamp ing bolts are u sed and the clamp i s removed from the end
of the ji g Thi s is a good as well as a quick method of clamp
.

i ng work i n op en end drill jig s F i g 9 illustrate s the u se of

- . . 1

bolts only for holdi ng down work The i llu s tration is s elf
,
.

C l mp wit h S wi gi g B lt
F ig . 13. a n n o s

explanatory F ig 2 0 shows a good de sign of clamp for holdi ng

. .

work in a milling fixture It bind s the work both horizontally.

and v ertically and i s the v ery best type for its purpo s e wh en
it can be used .

F ig C l mp
. 14. Eas il y Re m ovab e l a

H ook-b olt s The hook bolt shown in F ig 2 i s better

.
- . 1

adap ted for some classes of work than any other clamp in g de
vi ce
. A t the sam e tim e i t i s very cheap t o make and e asi ly
,

applied Th e bolt A p asses through a hole in the j ig having a

.
,

good S li di ng fit in thi s hole and is pu shed up until the hook or

,
1 1 6 JIG D E SI GN
Dim e ns i ons of Co ll ar-h e ad Sc re ws use d on Jig s

k —D —> E
j

D im
e n s i ons of Sh ul d
o er Th umb -s c r e w s u s e d on Jig s
C

D im e n s i ons of W in g or Th umb -nu t s for Ji g s

I 1 8 JIG D E SI GN
suited to i t s purpose becau s e the bearing point on the work is
,

clo s er to the bolt body .

S c r e w Tigh t e ni ng D e vi c e s In a box j g or a j g where the

. i ,
i

work is entirely or almo s t entirely surrounded by the jig the

, , ,

work i s ea ily held in place by set screws which are us e d when

s -

F ig . 18. S i mpl C l m pin g M t h d

e a e o

F ig . 19. C l mpi a ng b y S e t -s c ws
re in O p e n-e nd J ig

F ig . C l mp t h t h l d th W k F i ml y i pl c
2 0. a s a o e or r n a e

ever great clamp ing p ressure is required the square head allow ,

in g the use of the wrench S ometimes s crew s of thi s kind may

.

be tightened enough for the purpose by hand if a pin i s put

through the head of the s crew as s hown in F igs and 3 ,
. 22 2 .

This mean s i s u sed not only when great pres sure is not necessary ,

but also when the work i s liable to spring if the screws ar e

 CLAM P I N G D EV I C E S I I O

tightene d to o hard I n such a cas e if a pin is in s e r te d it i s

.
, ,

obvi ous that th e scr ew head i s n ot inten d e d fo r a wr ench bu t

-
,

that th e pin i s in t en d e d for g et tin g a g o o d grip by the h an d

for t ight enin g the screw wi thou t r e sor ting t o any addition al
,

mean s U sually i t i s n o t p ossib l e t o us e an o rdinary machi ne

.

wr en ch o n such a screw Wing-nuts ar e gene rally mos t.

sa t i sfac tory fo r j ig s whe r e only a ligh t b in ding p r e ssur e i s

r e qui r e d
.

Wing nuts are us e d o n h ook -b o l t s or swiveling eye-bo l t s

-
,

wh en a comp arativ ely ligh t p ressur e i s requir e d Th e thumb .

F ig . 2 1. F ig
. 22. Fi g . 23.

F ig . 25. H ok-b ol t M e th od
o of l amping
C

o r wing-nut i s p r e f e rab l e to a knur l e d n u t as it giv e s a b ett er ,

grip a n d mak e s it p oss i b l e t o tigh ten the b o l t m o re fi rmly Th e .

di men si on s o f a n exc e l len t d e sign of h an dwh ee l for use on j ig s , e t c .

ar e given in a n accomp a nying tabl e Thes e whee ls h ave a ra ther

.

l ong st em o r hub whi ch p rovi d e s a g ood l en gth o f th r e ad and

brin gs th e grip or h an dl e f ar en o ugh f romth e jig body t o p r event
t h e fin g e rs o r knuck l e s f ro m s t rik in g i t The star d e si gn o f
“
.
!

han dl e also p e rmi t s a good grip B y having th e casting sol id

.
,

th e s e handwheel s can be tapp e d out for any siz e thread or a ,

1 20 J I G D E S I GN
l

plai n hol e can be d rilled when i t is desired to at t ach t h e han dl e s

t o round s tock .

If screws are t o b e fi rmly ti ghte ned wi thou t t he us e o f a

.

wrench the me t hod o f using a pin throu gh the screw h e ad

,
-

shoul d b e use d o nly on l arge fix tur e s wher e the pin i s 5 i nch ,

F ig . 2 6. B i di g S c w
Pin use d as H andl e for n n re

in di ame t er and requi r e s th e use of both hands an app li cati o n

‘

of whi ch is shown i n F ig 2 6 On smaller sizes of fix tures wh e r e

. .

t h e pin is abou t 3
; in ch in di ameter by 4 inches long a n d must ,

be us e d wi th on e hand th e p r e ssure is concentrated across th e

,

F ig . 2 7 Bi di g S c w
. H an d Knob for n n re

p alm of the h an d a n d i f t h e fix t ur e i s us e d f r e qu ently it i s

,

lik e ly to develop a sor e sp o t .

In t h e case of the hand kn ob shown i n F ig 2 7 however it

!

.
, ,

i s evi d e nt tha t t h e p ressure i s di stributed o ver the p alm of the

h an d and therefor e t h e like lihood of producing a sore i s much
,

l e ss Tables of s izes o f two diff eren t typ es of kn obs for differ

.

e n t c l ass e s o f fix t ur e s are g i ven her e wit h .

1 22 J IG D E SI GN
Di me nsi ons of -
J g s cre w Latch e s
i

D im e n s i ons of R e gu l ar mb-s cre w s

Th u

D im n i
e s ons of Th u mb -s cre w s w ith Wi d e G rip

Th e qu e s ti on s n aturally arise how much p re ssur e can a man

,

e x e rt wi th hi s finge rs in op erati n g a kn urled-head scr e w how ,

much p res sure can h e d evelop wi th a scr ew and han d knob ,

and how much p re s sure can h e exert in op erating a screw wi th a

p in through i t ? It i s qu i te safe t o say that for co n tin uous
ope ra ti o n o n jigs or fix tur e s al l that c an b e d epen d e d up o n wi th
a knurl ed -h e ad screw i s to b rin g th e scr ew up t o s te ady the
work but wi th a scr ew and p in through it i t is not u n commo n
, , ,
 C LAM PI NG D EVI CE S 1 2
3

to b en d t he pin With a hand kno b th e amoun t of p r e ssur e i s

.

doubtful and depen ds largely up o n the p o sition of th e scr ew ,

wh ich gov e rn s th e grip obtainabl e o n th e knob .

S wingi ng Le ave s Th e eleme n tary p rinciples invo lve d in

.

the swinging leaf Clamp ing construction are s hown in t h e ir sim

’

p le s t form in F i g 2 8 L oose lea

. v es w hi ch.swin g out in order ,

F i g: 2 8. P ri n i c pl e of C mm l y u d C l m pi
o on se a ng M e th o d

F ig . 2 9. A not h er C mm o on D e s i gn of J ig L e af

F ig .
30 . C l m p in g
a D ic ev e for D il l
r J ig L f ea

to p ermi t the work to be i ns e r te d an d removed are usual ly ,

constructed in some manner S i milar to tha t sho wn in F ig 2 9 .

,

in which A repr e s ent s t h e leaf bei ng p iv o te d a t B an d h e ld b y

,

a p in at C which go e s through th e two lugs on the ji g wall and

,

pas es through the leaf thus binding the leaf and allo wing the
s
,
1 24 J IG D E SI GN
ti ghtening of th e set screw D whi ch bears again s t the work
-
,
.

The holes in the lug s of the casting s are lined wi th steel bu sh

ing s in order to prevent the ca s t iron holes from b ein g worn -

out too soon by the constant p ulling out and p uttin g in of the
p in Thi s ki nd of leaf when fitted in nicely i s rather expensive
.
, , ,

but is used not only for binding purpose s but also for gui di n g ,

purp oses makin g a conveni ent seat for the bu shings If leaves
,
.

are fitted well in place the bushi ng s i n the leaves will gu i d e the
,

cutting tools in a sati s factory manner .

A nother method of Clamping down the leaf i s shown in F i g 3 . 0,

i n which A is a thumb s crew screwed directly into the wall B of

-
,

the jig and holding the leaf C down as indi cated To swing the
, ,
.

F ig .
3C l mpi g D ill J i g L f
1. E y e -b ol t u d
se f or a n r ea

lea f out the thumb s crew i s turned back about a quarter of the
,
-

turn so that the head of the thumb screw s tand s in line with
,
-

the s lot in the leaf thi s slot being made wide and long enough to
,

permit the leaf to clear the head of the thumb s crew T hi s i s a - .

v e ry rap i d way of clamp ing and is frequently u s ed The lower

,
.

side of the head of the screw will wear a long time before th e head
finally comes i n line with the slot when binding It can then .

easily be fixed for binding the leaf again when standi ng in a

po ition where the head of the thumb -screw i s at right angles to
s

the slot by turni ng off a portion of the head on the under si d e

,
.
1 26 J IG D E SI GN
to b e dri ll e d can b e p ut i n p lac e in t he j i g This r e qu i r e s a .

l o cking dev i c e whi ch can b e depen ded upon to hold the bushin g
p l a te exactly in p lace whil e dri lli ng Th e locking d evic e shown .

i n F ig 3 3 an d also shown app lied to a j ig in F ig 3 4 answers

.
,
.
,

this purp ose ad mirab ly To op e n the jig so as to put in the

.

pi e c e to b e drilled all that is nece s sary to do i s to push the

,

A J i g L c ki g T i gg
F ig .
33 . o n r er

butto n on the e n d of t h e lock trigg e r and li ft th e leaf u p When .

the p ie c e i s i n place in the j i g the l e af is again p resse d down

,

into place Th e pr e ssure springs the locking device and the

.
,

trigge r grip s the pin shown The p art of th e trigger which

.

F ig . L c ki g D i c i F i g 3 3 ppli d t J ig
34 . o n ev e n . a e o

fi t s agains t the pin should tape r sligh t ly This mak e s i t hold .

much more ti ghtly and also takes up what little w e ar th e re

,

may b e o n i t Th e device can be fitted to a great v ariety of

.

ji g s an d fixtures It i s v ery simple and in exp en sive to make

.
,

i s qui ck an d si mp l e to O p e rat e an d i s p o sitive in its ac ti on

,
.

A hi n ged jig cover may also be co nv e ni e n tly held i n p lac e by

m e ans of a spring latch of the form shown in F ig 3 5 whi ch i s .
,
 CL A M PING D E VI CE S 12 7

s emi automatic in its action In th i s i llustrati on th e b o dy of

- .
,

th e j i g is sho wn at A and the hinged cover a t B Th i s cov e r .

swings o n th e pivo t C and drop s on to th e latch D which tak e s

th e p lac e of th e l ocking scr ew arrangem e n t shown in F i g 3 6 .
,

an d whi ch shows an app li ca tion of th e p rin cip l e i llus trat e d in

F ig 3 0
. . I n cas e s wh e r e the c ov e r i s m e r ely us e d t o carry bush
ings a la t ch o f thi s kin d i s en ti rely satisfac t ory al though it
, ,

is n ot r e comm en d e d f or us e on jigs wh e r e screws f or holdin g

down the work ar e carri ed by th e cover The me thod of u sin g .

i s e vi den t f rom the illustratio n To swing th e cove r clear of

.

F ig 3 5
. . L t ch
J i g wi th Cove r h e l d b y S p ring a

th e work in t h e j i g th e latch D i s p ushed back in th e di r e c ti o n

,

o f th e arrow A ft e r the cover has been rai s e d th e l a t ch sp rings

.
,

back in to p lac e ready t o ca t ch over th e t op of the cove r wh en ,

i t i s droppe d back onto th e j ig When the cover is droppe d

.
,

th e l a t ch catch e s it au to mati cally requ i rin g n o atten ti o n from

,

th e O p e ra to r
.

A n umber o f app l i cati o n s tha t vary in d e tai ls only ar e shown

in F ig s 3 7 t o 4 0 F ig 3 7 S hows th e styl e o f clamp that is used in
. . .

conn ecti o n wi th b ox dri ll ji g s wh e n it is desired to supp ort a p art

to b e dri ll e d on two point s As wi ll b e s e en th e s e two bearing
.
,

poi nts are s el f-adjus tin g Th e d e sign of F ig 3 8 is g e ne rally

. .

u s e d when it is desir e d to supp or t the work in two place s i n

1 28 J IG D E SI GN
an open en d dri ll j i g F igs 3 9 an d 4 0 show type s which ar e
- . .

quit e similar but there are many cases where one type can be
,

u sed to advantage and not the other F or in s tance th e Clamp .

, ,

F ig 3 9 is i nt e nd e d for box ji g s b ut the type sho wn in F i g

‘

.
, .
,

4 0 could n ot be used f or s uch a j i g because the lat te r i s alto ,

gether too slow H owever its advantag es over F ig 3 9 in ca s e

.
,
.
,

F ig .
36 .
J ig C ove r L ck d o e by Qu u
ar t e r -
t rn S c w re

F ig .
37 .
J i g C ove r wi th Two-point S e l -a f dj u s t ing Cl a mp
it desired t o hav e an op en e nd j i g ar e apparent The r e lati on
is -
,
.

of th e firs t cost o f a ji g to th e quan ti ty of work to b e done is a

factor whi ch som e ti mes makes a ji g whi ch i s not p erf e c t from a ,

purely mechani cal standp oin t mor e de si rable than one which ,

rep resent s bett e r de si gn but greatly i ncreased co s t ,

.

The ordinary jack-screw is employed quite commonly as a

clamping device in drill jigs but the obj e cti on to i ts us e is that , ,
130 J IG D E SI GN
t h e r e by p r o vi ding a c l amping d e vi c e whi ch may b e sai d to
p oss e ss doubl e adjus tm ent Thi s d e vi c e mak e s a v e ry con
.

v e ni e nt clamping arra nge m ent It w orks sa tisfac torily an d has

.

the advan t ag e of being easi ly swun g ou t o f th e way .

W e d ge or Tape r G ib Th e p rin cip l e o f clampin g work i n th e

.

j g
i by m e a n s of a w e dg e or tap e r gi b is show n i n F i g 4 2 a n d .

two applicati on s are illustra t ed in F igs 4 3 and 44 I n F ig 4 3 . . .

,

F ig 41. C l m pi a ng D ic
ev es W or kin g on th e Jack -s c e w
r
P r i nc ipl e
.

F ig . Appli c ti f W d g Cl mp
42 . Si mpl e s t a on o e e a

the work is l o ca te d b etween th e wedg e A an d the wa l l B o f the

j ig and pressed agai ns t the w all by th e wedge which c an be ,

drive n in by a hammer or screwed i n place wh en th e j i g i s

,

con s truc te d as shown I t i s p r efe rab l e t o hav e the we dg e scr e wed

.

in p lac e as it i s the n l e ss lik e ly t o l oos en by th e c on sta nt vibra

,

ti ons to which i t is subj e c te d and at th e sam e tim e the wedge ,

 C LA M P I NG D E V I CE S 1
3 1

i s l e ss li k e ly to get l o s t b eing a n integ ra l p ar t of t h e j i g T he

, .

e ar fo r t h e scr e w may b e p l ac e d in a ny di r e c tion in r e gard t o

th e gi b as i n d i ca te d by th e do t t e d lin e s in th e en d v i ew o f
,

F ig 4 3
. . T hi s tightening d evice is i n particular adapte d t o , ,

work of dove t ai l shape as shown in F ig 44 I n this cas e the

,
. .

we dg e i s mad e s i mi lar to th e co mmo n t ape r gi b us e d f or t aking

up th e w e ar in dov et ai l s li d e s I t i s som eti m e s o f advantage
.

to r eliev e th e bearin g surface opp osi t e th e w e dg e as shown in ,

F ig .
43 . W e d ge or p
Ta er G ib u d
se for C l m pi
a ng

F ig .
44 . W e d ge for C l mping
a D ove t ail e d W or k

do tte d line s in F ig 4 3 in ord e r t o p r ovi d e two di s tin c t b e ar ing

.
,

p oint s whi ch p r eve nt t h e work f rom r o cking T he ho l e in th e

,
.

e ar o f th e gi b t hrough whi ch the scr ew p ass e s mus t be oblo ng

, , ,

so that when th e scr ew i s adjus te d an d th e gi b move d in or ,

out th e re i s ampl e allowan ce for th e sid ewi s e mov em en t of the

,

e ar du e to t h e tap er o f th e gi b
,
.

If it i s r e qu i r e d to get a b e arin g on two point s of a surf ac e

th at i s lik e ly to va ry in it s d i m en si o n s a yok e can b e us e d , ,

de si gne d on th e prin cip l e o f th a t sh own in F ig 4 5 In th e . .

I 32 ,
J IG D E SI GN
engravi n g A i s th e work t o b e clampe d a n d B i s th e yok e whi ch
, ,

fits into a slot in t h e c e nt e r of the s trap or clamp C Th e yoke

'
.

i s h e ld by a pin D around which it can swivel to adjust it s elf

,

to the work It is evident that the amount of p re s sure at the

.

t W O p O lnt S E and F will be equal or at leas t near enough so

‘

for all practical purposes even though th e scr ews at the end s
,

of the strap may not be equally tightened In thi s device the .

F ig .
45 . E qu ali zi ng Clam p

Fi g 4 6 . . E cc e ntri c Cl m ping
a B lt o

pi n t akes th e full Clamping strain and shou l d there f ore be

D ,

designed s trong enough and th e strap which is weakened by the

, ,

slot and the hole i n the center should be reinforced as indi , ,

cat e d a t thi s p lace It is preferable to have spi ral springs at

,
.

each end of th e strap t o prevent the strap from slipping down

whe n the work is take n out The strap may be made either of .

ca s t i ro n or machine steel the yoke being mad e O f machi ne

;

steel .
1 34 J IG D ES I GN
in g p urp os e s ne c e ssary guid e s mus t b e p r ov i d e d for the s t rap
, ,

so as to hold it in the r e quired p osi ti on Th e s e gu i din g arrang e .

m en ts may consi st of rigid rods grou n d and fi t te d into dr ill e d ,

and reamed holes in the strap or square bar s held firmly in the ,

ji g and fitted into square slots at the end s of the strap The
,
.

bars may also b e round an d th e slo t s at the e n ds of th e s trap

,

half round the p rincip le in all cases remaini ng the same ; but
,

the more ri gid the gu i di n g arrangem e nt i s th e mor e may the ,

accuracy of the locating be d epended upo n .

The ordinary eccentric l ever works on the same p rin cip l e as

the eccentric rods just de s cribed There are a great v ariety of .

eccentric Clamping device s but they ar e not as commonly u s ed

,

F i gs .
48 and 49 . Ca m C l m pi g
s or E cc e ntr i c u d
s se for a n

i n p resent day j i g d e si gn as th e y wer e a few y e ars a g o The

- .

eccentri c clamp ing levers however p rov i de good and rap id

, ,

clamp ing acti o n I n F ig 4 8 i s shown o n e espe ci ally i nten ded

. .

for clamping fini shed work It i s not advi sab l e t o us e this kind
.

of l ever on rough casting s for the reason that the latter may
,

v ary so much tha t the cam or eccentr i c w ou l d r e qu i re too g r e at

a throw for rigid clampi ng to suit th e rough castin gs The .

extr em e throw of th e e cce ntri c lever should in g eneral n ot , ,

exc ee d o ne S ixth of th e leng th o f the radius o f th e ecce nt ri c

-

arc ,
if th e ri s e tak e s p lac e during o ne -quart e r of a comp lete
turn of the leve r Thi s wo uld gi ve a n extrem e t hro w of say
.
, ,

3 i n ch for a le ver having 3 inch radius of the camor ecc e ntric

, 1 .

It i s plain that as the eccentric cam wi vels about the center A s ,

 CLAM PI N G D EV I C E S 13 5

the lev e r being conne c te d t o th e j i g with a s tud o r pin th e f ac e ,

B o f th e cam which is struck wi th the radi us R f rom th e ce nte r

,

C rec e des or approach e s the s i d e of the work t her e by rel e asi n g

, ,

it from or clamping i t again st the bottom or wall of th e j i g

,
.

,
.

T h e l e ver f or the e ccentri c may be placed in a n y di r e c tion as ,

F ig .
50 . A ppli cati on of C l am ping Ca m
i n di ca te d b y t h e full and dotted lines in F ig 4 8 I n F ig 4 9 i s
,
. . .

S h own a not her e cc en tric l ev er which i s us e d f re q u en tly o n small

,

work fo r holdi ng down strap s or leave s or for pulling togeth e r

'

two sli di ng pi e c e s or on e sli di ng and one s tationary part which

, ,

i n th eir turn hold the work These s li din g p iec e s may b e .

F ig.
51 . Th e “ C l mpi g
G ri pping Dog M e th od of a n

V blocks or some k i nd o f jaws

-
Th e cam lev e r i s a tt ach e d t o
.

the jig body the l e af or the jaw by a pin through hol e A

, , ,
.

The hook B en g ag e s th e s tud or pin C wh i ch i s faste ne d in th e

opp osite jaw or p art whi ch i s t o b e c l amp ed to the p ar t into
,

w hi ch th e pin through hol e A i s fast ene d Th e var iety of .

design of e cc ent ri c cam l ev e rs i s So grea t tha t i t i s impo ss i b l e

to S how more than the principles but the examp les s hown ,

9!
13 6 J IG D E S I GN
embody th e u n derlyi ng actio n of all the diffe r ent d e sign s A n .

elementary app lication is shown in F ig 5 0 . .

Irregular shaped cas tings which must b e machi ned ofte n

p re s e nt no appar e ntly good mean s of holdi ng by ordinary grip
ping appliances for drilling shap ing or milling In such ca s es
, ,
.

a gripp ing dog as i llustrated in detail in F ig 5 may be used

,
. 1 ,
.

The bas e block C of the dog is slotted to receive jaw D which ,

i s fulcrumed on a cross —pin In the tail of the dog i s threaded

.

a set-screw E and by turning in thi s set-scr ew the jaw is caused

,

to bite inward and downward at the same time firmly

“ !
,

F ig
.
5 2. Wor k H e ld b y V- cl amps
p ing the cas ting and forcing it down on the tabl e A backstop .

F i s bolted behi n d each do g so that th e re is no cha n c e for slip

,

p ing away from the work .

Appli cati ons t o J ig De s i gn The p recedi ng d e s cri pti on an d

.

illu s trations i n dicate the p rin ciples embodi ed i n jig clamping

devices The followi ng typical illu s tration s s how a number of
.

applica ti ons that are merely modifi cation s of the v arious methods
already revi ewed M o s t of the devi ces de s cribed may be
.

quickly opera t ed the purpose being to show a col l ection of

,

effici ent designs that will hold the work s ecurely They posse ss .

th e further advantage of being relati vely simple so that the ,

jigs can be made at a mod e rat e cost in all cas e s where th er e are
138 J IG D E S I GN
A p ilot on the end of the adjus tin g scr ew e n t e rs a hole in th e
V block the two members being held together by a p in which
-
,

fits i n a g roove i n the p ilot The movable V block i s held to

-
.
'

th e body of th e jig by two s t eel strap s F ig 5 3 i llustrates i n . .

,

th e upp er View another method of attachi ng a s crew to a s li d

,

i ng clamp m e mb e r In thi s ca s e the sli di n g p iece is used for

.
,

f orci ng th e work down i nto p lace T hi s screw run s i n a tapp ed

.

hole in a stationary part of the fixture whi le the collar at the ,

end of the screw fits into the movable wedge to pu sh it forward

or draw it back The lower View hows a mov able c l amp
. s

ECCEN RIC IN
T B DER

R
WO K

F ig .
55 . Hi nge d Cove r wi th Fl oat i ng S tu d
member that has a tapp ed hole to receiv e the adju s ting s crew .

H ere two collars on t h e screw are located at each side of a boss

on the fixture and t h e adjustment i s Obtai n e d b y the screw
turni ng in th e tapp ed hole .

Two example s of hi nged covers ar e sh own in F igs 5 4 and 5 5 . .

Th e cover show n i n F ig 5 4 !s ame p rin ciple as i n F igs 3 0 and 3 6)

. .

is h e l d in p lace by a lockin g screw whi le the work is secured by,

a s et screw carri ed by the co v e r

- Th e hi nged cove r i llustrated
.

in F ig 5 5 is provided wi th a floati ng s tud that secures th e

.

work the cover whi ch carries the stud being held in place by
,

a n e ccentric binder wi th a hook which slide s under the p in A .

 C L AMPI NG D EV I CE S 13 9

Thi s p rovi d e s a v e ry qu i ck acting j i g Th e lu g B a t th e opp o

- .

sit e e nd of the cover p r ev e nts it from s wi n gi ng back too far

and br e aki ng the hi ng e .

F i g 5 6 shows the app li cation of a bell mouthed bushing

.
-
,

which is screwed down o nt o t h e hub of a l ev e r ther eby lo cating ,

F ig .
56 . B e ll -m ou t h e d S c e w B u hi ng
r s

F ig .
57 . l
S i p-
on Knob for Cla mping
th e work and at the sam e tim e p rovidin g a guide for the drill
whi ch i s to op erate up on it The objectio n to thi s type of
.

bushi ng i s that i t requi res an ex t ra lon g drill an d if made with ,

two S izes of holes as shown particular care wil l have to b e take n

, ,

in using sma l l dri lls t o prev en t br e ak in g a n um

,
ber of th em .
1 40 J IG D E SI GN
An other obj e c ti o n able feature of this clamping d evi c e i s tha t
chi p s work into the threads and prevent turning the bushing
easily whi ch also shorten s the life of the thread Thi s diffi culty .

c an be overcome howev er by not tapping the hole all of the way

, ,

through as indicated at A ; by counterboring the hole at the

,

top marked B ; an d then grinding the p ilot C an d shoulder D

on the bu shing to a snug i unning fit The bushing i s then held .

true and chip s are excluded from the thread Th e av erage .

tool desi gner n ever theless avoids screw bushi ng s wh eneve r p os

, ,

F ig .
58 . mprove m e nt
An I on th e S cr e w B u hing
s

sible but such bu shi ng s are frequently selected after carefu l

,

consideration because of their neat ap pea rance an d eff ective .

op eration .

F i g 5 8 shows a clamp i ng devi ce whi ch although a l i ttle more

.
,

expen siv e than a screw bu shi ng would probably pay for i ts elf
,

i n saving the breaking of drills as the bushing o n thi s jig can be

,

made shorter an d with a one size hole The s crew A swings

- .

the lever B abou t pin C an d pu she s down the bushing D whi ch

is a s lip fit i n the body of the jig .

A rather unusual method of d am p ing is illu s trated in F ig 5 7 .

,
1 42 J IG D ESI GN
b e tigh tene d in th e fixtur e wi th gr e at rap i di ty F ig 60 shows a . .

spe ci al nu t fo r a box wr en ch the p urp os e of whi ch is to permit

,

li f tin g the wren ch off the h ex an d moving i t back f or a new

“
,
!

grip The round p ar t of t he n ut serves to k eep th e wr en ch in

.

p lac e t o b e slippe d back o nt o t he hexa go n nut whi l e th e pin a t ,

t h e top of the n u t makes th e wre n ch a n integral p art of th e

fix tur e so tha t it cann o t g e t lost
,
.

Two unusual examples of jig and fixture de sign are illu s trated
in F i g s 6 1 and 6 2 Th e di stanc e that the clamp had to b e
. .

F ig
. 62 .
Q ui A gm t
c k - l
r e e a s i ng Cl a mping r ran e en

raise d i n removi ng the work from betwe en the V s of th e s e ’

fix tur e s made i t de sirable to provide some method of releasing

the clamp more quickly than by turni ng the screw back through
‘

the ne c e ssary distance The way in which thi s was a e com

.

p li s h e d i s clearly show n in th e illustrat i o n s a n d will be seen t o ,

con si s t o f loose nin g th e scr ew and then swinging th e block

whi ch carri e s the screw o n th e pivot A the dir e ctio n being indi ,

c at e d by the arrow Thi s moves the s crew off its bearing o n

.
 C LAM PI NG D EVI C ES 143

th e casting in th e cas e o f th e jig shown in F ig 6 1 whi l e i n F ig .

, .

6 2 th e b in ding screw is r e mov e d from th e clamp The clamp .

shown in F ig 6 2 h as been c ut away at B to permit the point of

.

th e scr e w t o cl e ar it ; a sp ring-p in holds the clamp against th e

scr ew a t all times .

F ig 6 3 shows a hing e d cov e r wi th the clamp at t ached to i t

. .

Thi s is a conveni e n t arran geme n t to r emember when consi der

ing th e d e sign Of ji g s a n d fix tur e s Th e clamp an d c ov e r are
. x

F ig . 63 . Hi ng ed C ove r wit h Att ch

a ed Cl a mp

h e ld by the S ame p in a n d bo th parts are swung out of the way

a t the sam e time by means of the corner of the clamp which ,

ca t ch e s o n th e hing e d cov e r at B The design is such that the

.

fix ture has su ffici e n t clamping ran ge whe n the cover i s held i n

p lac e by th e scr e w C The clamp in g is e ff ected by m e ans of
.

th e s cre w in th e cov e r whi ch f orc e s the Clamp do wn on th e

work F ig 64 shows a cl amp b eveled a t th e en d to p ul l the
. .

work down flush and p ush it i nt o th e V at th e sam e tim e Th e .

clamp is tigh t e n ed by a scr ew an d a sp ring forces it open wh e n

1 44 J IG D E SI GN
th e scr ew i s loosen e d Thi s type i s oft en us e d whe n it i s d e si r
.

able to keep th e clamp out of th e way of the cutter .

Two examp le s of the us e tha t can b e mad e of cams ar e shown

F ig . 64 . V-b l c k Cl am p
o

Fi g . 65 . Ca m Cl amping D ic
ev e

i n F igs 6 5 and 6 6 Th e d evi ce shown in F ig 6 5 i s simply an

. .

ecc en tri c stud op era te d by a handl e Thi s devi ce p ush e s the.

clamp agains t the work ; a hol e i s dri ll e d in th e clamp t o sli d e

14 6 J IG D E SI GN
by th e arrow th e work i s securely clampe d an d if ne ce s
cat e d ,

sary ordinary straps may be added for holding the work

,
.

When making tool for thin ca s ting of odd shapes it is oft en

s s ,

desirable to u se an adju s table clamp ing device that can be

B INDING S CREW

S I EL ST D
W V U OC ING S D
L K TU

F ig . 67 .
Q ui c k - c ti n
a g Cl a mp of S i mpl D ig
e es n

F ig . 68 . Si mp l e F or m of G an g M illi ng F ixt u re

easily mov ed out of th e way when reloading the fixture .

S uch a floating Clamp i s s hown in F ig 7 where the piece of . 0,

work to be drilled was properly located and clamped with the ,

excep tio n of one arm E for which no ordinary clamp could be

,

u sed B y p ushi n g the supp ort A down a g ainst th e work and

.
 C LAM PI N G D E V I C E S 1 47 ,

clampin g th e strap B the work is held ti g ht wit hou t springing

,

it ; an d by ti ghtening the nut C t he Clamp i s h e ld i n place by

the bun te r an d the work i s s e curely s upported Whe n reload .

in g th e fixture the clamp i s brou gh t out o f the way by m e ans of

,

m
the handle D .

In F ig 7 is shown a s mall cla ping devi ce u s ed when drill

. 1

ing the riv et hole s through the beadi ng A and the plate B The .

steel bracket C i s fa s tened by s crews to the s i d e of the fixture .

The front face of the clamp bracket is u s ed as a s top f or t he p late

F ig . C l mpi g D i c f H l di g L g W k
69 . a n ev e or o n ar e or

and the beading and th e Clam p D with a small h ole drill e d in

,

one end i s fitted loosely in the mi ll e d slot i n the bracket The .

s e t -screw i s located a l i ttle h ig her than th e hol e in th e clam p

and by a few turns o f the screw t he Clamp i s brought down

against th e work and f orc e s th e bea di n g up again s t the stop
ready to b e drilled .

S pr i ng bunter s are O ften used i n designi n g fixtures where

adjustable supports ar e n ecessary and the form of bunter sho wn ,

in F ig 7 2 has p roved very e ffi cie n t The bun t e r A and t he

. .

binder B fit freely in the hole s in the castin g The bunter i s .

148 J IG D E SI GN
1 5 0 J IG D E SI GN
j g,
i wi th th e r e su l t that th e work wi ll f r e qu en t ly be sp rung by
,
.

th e clampi n g devi c e an d dri lled in thi s p osition whi ch would

,

n a turally spo i l the accuracy of the location of the hole after the
work was released from the jig and had expanded back to its
normal shape .

It should b e furth e r born e in mind when clamp i ng rough cast

i n g s in a fix tur e that they can be supp ort e d only on three p o i nts
, ,

and adju s table s t ops should be p lac e d o n the fourth point of

the support and also under any weak p ortions of the p iece
through which holes are to be dri lled or machining op erati ons
are to be perform e d in ord e r to resist the springing action of
,

the cutter P o s t s in which d ampi ng an d locating screws op er

.

ate should be oi liberal p rop ortions an d should not p roject abov e

the fixture body an y furth e r than i s necessary i n order to kee p
down the tilting action to a minimum ; an d all handle s for
clamping devi ce s should b e so located that they will not be
awkward to ope ra te .
 CH A P T E R V I I

XAM PLE S O F D R ILL J IG DE S IG N

E

A s j i gs and fixtures are now us e d wh e rev e r machines and t ools

are constructed the number of d e signs in use is p ract i call y
,

e nd l e ss although a great many of the s im p ler jigs are con

,

structed on the same general p rin ciple and differ chi efly in
regard to form Th e r e are however many di st inct typ es which
.
, ,

have b ee n develop ed to handle different class e s of work to the

best ad vantage S in ce the jig or fixture is designe d around th e
.

part for whi ch it i s intended the form and size naturally va ry

,

accordi ngly ; but aside from such Changes th e re are many ,

details for in surin g accuracy of locat i on and rapidity of cl amp

ing or releasing which give the designer an opportuni ty for
,

the di sp lay of jud gment and ingenu i ty in producing a jig that

i s effect ive and at the same t ime not unnecessarily comp li cated
,

and exp en sive In order to i llu strate the relation between the
.

work to be don e and the de sign of the jig or fixture for that work ,

t hi s chapt er and tho s e which follow will be confined largely to

illustrat e d d e s cripti ons of de signs tak e n from practic e I n .

s electi ng th e se d e s i gns th e obj e ct has b een to show as man y

,

typ es of j ig s and fix tures as p os sible .

Dr ill Jig h avin g A u t o m at i c Lo cat in g D e vi c e s I n F ig 1 .

—
.

i s shown a combinat i on flywh e el and driving p inio n A wh i ch

i s to be drilled and tapp ed for four hollow p o int se t screws as
- -

shown All th e surfaces mark e d wi th do tte d lines as w e ll as

.
,

the bor e ar e fini sh e d before the wh e e l com e s t o the drilling

,

machi ne The p roblem was to construct a j i g by which any

.

u nskill ed laborer or boy could drill and tap these wh eel s qu i ckly
and correct ly wi thout any pre vi ous layi ng out of the holes .

The jig had to be constructed so that it would be p ract i cally

im p oss ible to make any m i stake in drillin g wh en th e w ork was
p roper l y cl amped .

10 J
1 5 2 jiG D E S I GN
The j i g shown in F ig 2 fulfill s all t h e s e co n diti o n s and gives
.

very good re s ults It con sists of a cast i ron angle p late base B
.
- -
,

which is fastened u p on the dril ling machin e table A bracket C .

is fastened to this base by countersu n k fil li s t e head screw s

r - .

This bracket wh i ch i s of U shap e is provi ded wi th a stud L

,
-
,

fitting into th e finish e d bore O f whee l A The two arms of the .

U sha p ed bracket serv e as su pp orts for t he dril l guides M

- .

A t one s i d e the pin P passes throu g h bracket C w h i le the oppo ,

site side of C i s p rovi ded wi th an indentat i on to r e ce ive the

pin N wh i ch con ne cts the drill gui des M P in N i s held in .

Fig 1
. . Co mbinati on Fl wy h ee l and Di r ving Pini on

plac e by he adless set screws S which also hold the dr ill gu id e s

-

to pin P as shown One end of pin N forms a handle by means

.

of wh i ch the guides may b e conveniently swung out about

pin P as a fulcrum B racket C fits tightly between dr ill guid e s
.

M a t both end s thus holdin g th e m firmly in p la ce A scr e w 0

,
.

having i ts c e nt e r located som ewha t above the center of p in N

pr eve nts this p in an d also th e drill gu i des from comi n g u p wi th
th e drill and breaki n g the l atter B racket C i s provi ded wi th
,
.

a slot in wh i ch sl i des a rack D a detail Vi ew of whi ch i s shown

,

at Y whi ch is provi ded with teeth of the s ame pitch as thos e

,

in pinion A that are cut before the wheel com e s to the drilling
I 54 J IG D E S I GN
hold the drill and tap Th e whe e l is now r evolved causing
.
,

the rack the t e eth of which m e sh wi th those of the p in ion to

, ,

move unti l the sto p pin E t erm in ates i ts motion at p oint G

-
.

The wheel will then have turned 3 5 degr e es an d i s ready for 1

the drilling and tapping of the other two holes A fter thes e .

are fin i shed the wheel is turned back u n ti l stop p in E Comes

,
-

agai n st po int F The operator cannot t ake the wheel off nor
.

F ig 3
. .
J i g for H l d ing C
o i
as t - r o n B l ck whi l d illin g
o s e r

p ut i t o n until th e rack is in the correct starting positi on b e ,

cause s af e ty latch H wil l be lift e d by rack D thus p r eve n t ing ,

the pinio n which just p asses i t wh en in th e l ow e st p osit i on from

bein g taken off or put on The operator must therefore start.
, ,

at the proper point for turning the full 1 3 5 degree s and can n ot ,

make the mi s take of n ot turning the wheel back far enough

to ach i eve tha t r e sult .

Cam -o e rat e d C l am in
p p g S li d e on Dr il l J g
i Two j i gs w e re .

re quir e d for drilling blocks of the S iz e shown at A in

F ig .
3 . The s e block s were of gray iron and when received , , ,
 D R I LL j i G s 1 55

were machined ll o ver and accurate wi thin

a inch i
.

Th e drilling was performed in two operati o n s ; the two % inCh ‘

holes a n d the i inch hole we re drilled simultan e ously in the

-

firs t operation the { inch hole b eing dri lled in the s econd
, B
r -

operation Thi s order of drill ing was nec e ssary as the g in ch

.
,
-

drills would have been deflected by cutt ing i nto th e lar ge r hol e ,

but the { inch drill having a large r di amet e r was not affec te d
B
r -

by cutting into the s maller holes .

The first problem was to design j i gs for holding the blocks

that would require the minimum amount of tim e in loadin g
and unloading A t B is shown the jig tha t was us e d successfully
.

for dril lin g the inch hole It i s similar in d e s i gn a n d ope ra

5 -
I g .

tio n to th e one that was used for drilling th e two g in ch hole s -

and the i inch hole The jig con si sts of the cast i ron body C
- .
-
,

whi ch is set on legs five inches hi gh in order to p ro vi de han d

room for using th e handle D an d also t o give a sharpe r angle ,

to th e dis charg e chu te E a n d at the same t im e to provi d e ,

cl e arance for t he receiving box a t the e nd O f th e Chute .

The s lide or movable jaw F i s made a clos e S l i ding fit in the

body C and i s held in p lace by p i eces G J aw F carri es at th e .

forward end th e hardened wearing p ie ce H a n d th e t emp let

K for gu i ding th e drill the t emp l e t K b eing attach e d to the
,

movabl e jaw in thi s cas e to allow great e r freedom in loadin g .

S li ding jaw F i s clos e d up on th e w ork by the mo vement of the

c am I which i s of such shap e as to gi v e a p owerful g ri p to the
,

jaws a wi de loadin g space a n d a qui ck moveme n t Ten s i on

, ,
.

sp rin g I holds the sli d e back l e avin g th e jaws always in a n ,

op en posi tion excep t wh e n forc e d to ge th e r by means of p res

,

s ur e exert ing o n the hand -l ev e r D A carbo n st e el locat i ng .

p i e ce L i s dowe l e d t o t h e body to r e c ei v e the blocks ; i t is aC

c ur at e ly lin e d u p wi th the hol e i n te m p l e t K Th e block when .

in place rests on a half floor extendi n g across and in front of

the o penin g in L Just in front of thi s i s the large o p ening into
.

whi ch the blocks fall and b eneath whi ch th e chut e E i s p lac e d

, .

A li ght s p rin g not shown kn ocks th e b lo cks O ff into th e o pen

, ,

in g when the slide F is wi thdrawn and th e y slide down the Chute ,

into the recei ving box It is only nece ss a y for th e O perator

. r
 J IG D E S I GN
to place th e block in the j i g an d f ee d the drill to the work .

B rushe s are unnec e ssary as the Chip s clear themsel ve s and

,

th e blocks are fr ee d from chi ps as they slide o ver the perfora t ed

section of chute E .

F or drilling the three holes in the sides a multiple dri ll head ,

is us e d and the piece i s held in a jig which is a duplicate of the

one S hown except that the templet whi ch gu i des the drills is
,

S ECTI N Y-Y
O S EC ION X X
T -

Ma c h i ner y

F ig 4
. .
J i g for H l di o ng R ing whil d illing
e r

attached to t h e stat i onary jaw an d is pro vided with thr ee hol e s

for gui ding the three dri lls
w
.

i
J g for D ri ll i n g Ri n g The.
j g sho n in F i g 4 at A iand B .

i s used for drilling the ring shown at C R eferring to the illus .

t rat i on at B i t wi ll be seen that there are three plung e r s D

,

held against the con i cal point of wing screw E by S prings F - '

In operat i on the wing s crew E i s turned back un til the plungers

,
-

D are just wi thin the body G at po in ts H The ri ng C is then .

s lipped on and the wing screw turned down until the plunger s D
-

are forced out and in to contact wi th the in side surface of th e

ring The ring i s then drilled on a sensiti ve drilling machine
. .

Ind e xi ng J ig op e r at e d by H and l eve r and F oot-t r e a d l e

- .

The drill j ig shown in F ig 5 was designed for drilling four

.

angular holes in a bras s time fu s e cap !S e e s ectional view of

-
.

cap at lower part of illu s tration ) The principle of thi s j g can

. i
1 5 8 j G
i D E S I GN
one end of whi ch is round e d and engag e s with th e n otches in
the index plat e B ack of th e pin and held in p lac e by a headless
.

set s crew K i s a co i l sp ring J whi ch ho l ds th e lockin g p i n

—
,

against th e in d ex p late The t en si o n of thi s S pring is just

.

enough to hold the work from turning whi l e be in g dri lled but ,

not enou gh t o p r e vent i ts b eing r e adi ly in d exed by a qu i ck

pull on the indexing lever .

The work is held in p o si t i o n aga ins t th e l ocat ing p l ate A by

the plunger L whi ch r e sts on a s ingl e in ch hardened ste e l
,
-

F ig 6
. .
J ig h avi ng L
e ve r and Sp i
r ng-
o p e r at e d Cl amping M mb e
e rs

ball that acts as a b e ar ing while the work i s bei ng index e d .

P lunger L is carr i ed in a second plunger M wh i ch i s held u p ,

by a powerful coil sp ri ng N This spring should be l onger and

.

stiffer than the o ne shown as an e normou s p r e s sure can b e

,

, ,

obtained with drills as small as the N o 3 0 used wi th thi s work . .

The outer plu nge r M i s op erated by a foot -t r e adle co nn ected

to the lever 0 I n operati on th e foot treadl e i s depressed
.
,
-

and a piece of work i s plac e d betwe en the plung e r L and th e

locating plat e A Wh e n the treadle is released the work i s
.
,

held by the tension of the spri ng N whi le th e i ndexing i s done

by t he lever E The locating plate A has slot s milled in it
.
 D R I LL J I GS 1 59

wi th a radi u s cutter of the sam e ra d ius as th e dril l t o be us e d .

Th i s fe a ture in co nn e ction wi th th e lip o n th e work a n swers

, ,

the sam e purp ose as a dril l bushi ng no other m e a n s of guiding ,

th e drill be in g n e c e ssary Th e p ro duct ion of thi s j ig was about

.

4 000 ca p s per day .

i
J g h a vi n g L e v e r a nd S p r i n -
g p
O e r at e d C l a m in
p g M e mb e r s .

— The jig shown i n F i 6 is us e d for dr i ll in g in ch hol e s -

g .
5 0

in th e motor truck steering arms shown in F ig 7 Owi ng to ,

. .

the means provi ded for securi ng work in thi s jig ready to be

F ig 7
. . yp
T e of S te e r ing A md ill d in J i g h wn in F ig
r r e s o . 6

dril led and for releas ing th e fini she d p ar t aft e r t he op erat ion
,

ha s b ee n p erformed t hi s i s kn own as a pum p j i g B ushin g

“ !
.
,

A i s be ll mouth e d on the low e r sid e a n d dro p s d own over t h e

-
,

top of the boss at the end of the steerin g arm The t hread e d .

en d of th e wo rk i s sup ported by m e an s of a s l otted block B

car ri ed a t th e e nd of bracket C .

Wh en it is d e sired to se t u p a pie c e of work in t he j i g ,

p ump ha ndl e D i s p ush e d down ; thi s handle swin g s o n

!

pivots E wi th the re sult tha t rods F ra i s e jig bushing A against

,

th e p r e ssure app lied by coil springs G The piece of work is th en .

S lip p e d in to place a n d handle D i s rel e as e d so t h a t s p r in gs G

apply sufficien t pressur e to enable bushi ng A t o hold th e work

in th e desired position to be drilled Thi s arrang ement wi ll be .
1 60 J I G D E S I GN
rea di ly understood by comp aring the j i g wi th the work After .

the drillin g o p eration has been completed it i s a simple matter ,

to relea s e the work from the j i g by pu shing down the handle D

and withdrawing the piece from under the bell mouthed bushi ng - .

D rill Jig for F or k L inks The drill j ig s hown in F ig 8 was

. .

de signed for drilling fork links The form of these link s i s

.

indicated by dot and da sh lines in both views The link h as a

- - .

round boss at one end and rounded forks at the other end It .

F ig 8. . D ill J ig f
r or F or k Link s

is accurately held between two V block s one being adjustable

-
,

and the other stat i onary The adjustable V block A is clamped

.
-

against the work by the star wheel and screw shown and it
-
,

travels between fini shed ways thus provi din g an accurate as well
,

as rap id method of clamping These V blocks have inserted

.
—

steel plates B and C The latter which is in the s tationary

.
,

V block car ie s a drill bushi ng for drilli ng the lower fork and
-
,
r
,

an upper shoulder on t hi s plate provi des a support for the

upper fork ; thus there are two bu shi ngs i n alignment for drill
ing the two end s The in s erted plate B in the ad j u s table block
.

supports the oppo s i te end of the fork link With thi s arrange .
1 62 J G
I D E S I GN
flat of the work and then tapping it lightly the j ig i held
, ,
s

s ecurely in place When drilling one of these half holes it i s

.

found that if an or di nary twist drill is u s ed there i s a tendency

for it to hog in which is likely to re sult in breaking the tool
“
,
!
.

F or thi s rea s on it i s de sirable to u se a s traight flu t e d or farmer s

’ -
,

drill although good result s may also be obtained by grinding

,

a twi s t drill i n such a way that i t h as no rake or hook re sult

ing from the spiral form of the flutes A drill which is ground .

in thi s way pre sent s a s quare or slightly obtu se cutting edge to

the work thu s doing away with the trouble experienced f om
,
r

d ill breaking when ground in the u sual way

r s .

F ig . 10 . D illr J ig p i d d wi t h R ck
r ov e o e rs to F a c ilit at e

Re v i g i t P it i n
e rs n s os o

Whendrilling t h e hole the work is set up on end on the drill ,

pre ss table and the drill is fed th ough the bu shing in t h e u sual r

way the bu hing ho ldi ng the drill in po sition until it s tart s to

,
s

cut A s the drill i s fed down there i s a tendency to force it

.
,

away from the work but thi s tendency is re sis ted by the ,

hardened stud A so that the half hole i s drilled parallel with

the axi s of the work Thi s jig a fford s a convenient mean s of
.

quickly accompli shing thi s work and having the two half hole s
match up accurately so that no di fficulty i experienced in as
,
s

sembling the work .

Jig havin g R o c kers u po n whi c h i t is t ur ne d o ve r The box .

drill j ig shown in F ig was u s ed for d illing three hole s in a

. 10 r

certain piece that was to be produce d in quantity The j g is . i

 DR I LL J I G S 1 63

made from a forging two stationary bushi ngs b ei ng i n serted in

,

the top and one in th e bottom A s the jig and work weighed .

about twelve pounds i t was hard for the workmen to be con

,

s t ant ly lifting the jig and turning it o ver for the o pe rat i on o n

the other side ; therefore two p iec e s of st ee l we r e mach ined to

,

a radiu s and attach e d to th e j ig be twe en the four fe et on the

s ide oppo s ite th e lea f With t he a i d of these rockers the jig
.
,

i s ea sily turned ove r f rom on e s i de t o the other They do not .

interfere in any way wi th the worki ng part s and when changing ,

F i g 11
. . D ill J i g d
r e s i gne d p
for Ra i d Ind e xing

work the j g i s supp orted by the rock e rs In thi s way the j g

,
i .
,
i

i s always on the dril l ing tab l e and there i s l e ss l ikelihood of

,

the op erator l ett ing i t fal l to the ground or throwin g i t down

and snappin g the bushi ng or le gs whi ch are harden e d to glas ,
s

hardn e ss I n addi tion th e op era t or does not have to work so

.
,

hard and the p roduction is consi derably increased .

D r i ll Jig d e s igne d for R api d In d e xin g The necess i ty for .

-

a drill jig of the indexi ng typ e was brought about by a cert a i n

desi gn of motorcycle dri ve pulley Thi s pull ey is of t he flat .

belt flanged type having co k in s ert ov e it entire periphery

, ,
r s r s .
1 64 J IG D E S I GN
To the ri ght in F ig i s shown a completed pulley wi th the
. 11

cork in sert s in place M ounted on the drill j ig i shown a pulley

. s

being drilled The pulley i 4 5 inches in diameter and has 4 2

. s

hole s 5 inch deep arranged in three rows of 4 equally spaced

, ,
1

around the p erip hery The drill j ig is built in such a manner

.

that it will take a large variety of sizes o f pulleys .

A t the left of the jig is s hown a larg e drum whi ch serves as

-

a means of indexin g the d ill j ig readily and has three annular r ,

groo ve s on its periphery spaced the s ame d i st ance ap ar t lon gi

,
'

t u d inally as it i s desired to ha v e the hole s drilled on the pulleys .

D irectly in the center of th e se groo ves and spaced equ i di s tantly

around the p eriphery are 4 tapered index pin holes A t th e 1 .

base of the dri ll jig is an index pin !not S hown) which i s tapered ,

on the end to fit the tapered index hole A t the back of thi s .

index pin is a light S p ring which holds it con s tantly in contact

with the index drum .

In operati on the firs t row of hole s i s drilled When enough

,
.

pre ssure is app lied to the drum to rotate it the index pin , ,

being correctly tape red will jump out and allow the drum to ,

r evolve to the next i ndex hole A fter the firs t row of hole s h as .

been drilled in thi s manner the s econd row is placed i n line ,

wi th the revolving drill by forcibly s li ding the index drum and

i t s shaft longitudinally until the index pin jump s into the mid
dle groove In thi s position the 4 central hole s are drilled as
. 1

before To drill the las t row of holes it is only n e cessary to

.

move the index drum over as in the second c ase .

Where i t is essential to drill holes accurately spaced around

th e p eriphery thi s form of index drum and pin might not b e
,
'

accurate enough H owe ver in t his case and in many other

.
,
’

cases i t i s sufficiently accurate It h as the advantage of being .

qui ckly index e d whi ch is not always true of the ordi nary index
,

pin that has to be grasped by one hand while the other hand is
employed in rotat ing the fix ture In thi s case the right hand .
,

i s n ever moved from the drill sp indle le ver .

In d e xing J ig pr ovi d e d wi th W or k lo c a ting D e vi c e

- The .

j g
i s hown in F i g 2 i s for drilling
. 1di fferential s pider arms .

B efore the drilling O peration the forging i s chucked and rough

1 66 J G
I D E S I GN
stud D In order to locate the spider c entrally in th e j i g tha t
.
,

is so that the arm s will come in average alignment with th e

,

four bu shin gs the centering device E is emp loyed B y mea n s

,
.

of a spring F the e nd of which i s attached to the bent end of

,

the part E the two aligning fingers are brought to b e ar S imul

,

F i g 13 Tr unni on yp
T e of d
In e xi ng J i g for Autom ob i e
l
Hui
. .

R e ar -a xl e o s ngs

again s t oppo site arms of th e spi der thus locating

t ane o u sly ,

the spider in a central po sition i n the jig A fter thi s i t is a .

s imple matter to drill and countersink the spider arms o n e

after another indexing the j g by hand for each arm

,
i .

A n idea of the facility with which thi s j ig i s operated can be

gat hered from the fact that 5 00 of the s e pider are drilled s s
 D RI LL J I GS ‘

1 67

and cou nt e rsunk i n a day of nin e hours maki ng a tota l of 2 000 ,

hol e s per d ay The most impo rta nt part how eve r i s th e fac t
.
, ,

that th e m et hod insure s that th e c enterin g is do ne wi th r e fer

e n c e to th e hard e ned sp ider arms thus in suring that th e amou nt
,

of m eta l r emoved in grinding will be p ract i ca lly e qual a t all

po in ts .

Ind e xing Jigs mount e d on Trunnions —

A box dri ll j i g for .

us e in drillin g r e am in g tapping chamf e ring a n d sp ot facing

, ,
-
, ,

hol e s in automobil e r e ar-axl e hous ings is i llustrat e d in F ig 1 3 . .

F ig 14
. . An t h
o er In d xing D ri ll
e J ig of u
t h e Tr nni on T yp e

It wi ll b e s ee n from the illustratio n that th e j i g swi ngs on tru n

nion s fitted in the cradl e or bas e a n d th a t t he base i s equipped
,

wi th i ndex pin s for locat ing t h e j ig in an y of five p ositions

- .

The r e i s a n in d ex pin at e ach s i de of th e base and th e s e pin s

-

are op erated s imultan e ously by a S ingl e ha n d l e ver

- .

The r e ar axle hous in g i s p ut in th e ji g through a n open ing

-

covered b y a h in ged an d latched l i d ; and the work is held in

plac e by m e an s of hardened steel plugs whi ch insure p ositive
locat io n All p arts of the j i g which ar e subject to w e ar are
.

hard ene d a n d grou n d to size thus gr e atly reducin g th e po s si

,

bilit y of i naccuracy o f th e work as a resu l t of wear The weight .

of the j i g is 0 pound
1 10 and it is equipp ed with rollers carried
s
11 J
1 68 J I G D E S I GN
by hardene d and ground steel pins These rollers run on tracks
.

whi ch carry the j ig under the machi ne and also enabl e it to be

ea sily run back to remove th e work .

It i s necessary to drill quit e a number of hol e s in the castin g

shown in place in t h e jig illustrated in F ig 4 an d the s e holes . 1 ,

F i g 15
. . D i ll J ig f Y k E d
Mul ti pl e r or o e n s

ar e locate d on different si de s and at various angles to one

anoth e r F or t hi s reason an i ndexing jig is employ e d Thi s
.
,
.

particu lar illustration shows the cover A of the j ig removed

in order to illustrate more clearly the position of th e ca st i ng ,

whi ch i s located in the j ig by it s trunni ons The ma in body of .

1 7 0 J G
I D E S I GN
A Vi s e Dr illi ng J ig F ig 1 6 show s a j i g for drilling and
.
—
.

milli ng an elon gated hole in a p iece of work wher e the limit of

accuracy r e qui re d is not less than in ch A flanged i .

mil ling machine Vi se was fitt e d wi th a spe ci al j aw havi ng a

V groo ve c u t lengt hwi s e as shown at B
- ,
P in C was put in to .

. Vi D ill J ig with S wi li g L f f F mi g O bl g H l
F i g 16 . se r ve n ea or or n an on o e

a soft jaw on the movable s lide of the vise and located so that
th e m il led surface of shaft A would rest on the upper surface
of the pin and hold the shaft level for drilling B ushing plate .

D was n ext p ut o n a n d h e ld in plac e by a cap s cr e w E B ushin g - .

plat e D was th en lai d out and dri lled a n d reamed i n positio n

for th e locat ing pin F an d the dri ll and cou nterbore bu s hings G .

The s top pin H was locat e d in the bu shing plate D to in ure

- s
 D R I LL J I GS 1 71

obtainin g the right locat i o n of the dri ll e d hol e from the e n d of

th e shaft A .
0

A fter th e ho l e was dri l l ed the locat ing pin F was p u ll ed out

,

a nd t he p late D swu ng arou n d from the first p os i t i on as sh own ,

by th e dotted line s to the s e co n d p osi t i o n a n d pin F was ih

, ,

se r t e d i n a n oth e r hol e E ach ho l e for pi n F was loca te d so as

.

to bring th e bushi ng p late D in to the p rope r p osi ti ons for dril l

in g a n d coun t e rbori ng A spe c i al count e rbor e or m i ll was t h e n
.

us e d through t h e bushi n g G to el o ng ate the ho l e t o the p rope r

s ize and d ep th Thi s counterbore was mad e from drill rod of
.

th e sam e diam e t e r as th e wi dth o f t he e l on g at e d slot in the

shaft F our t ee th we r e cut in the en d a n d i t was th en hard ene d
.

a n d t emp ere d .

A ft e r the shaft A was p r ope rl y dri ll ed a n d cou nte rbor e d i t ,

was rem o ved from th e vi se an d th e bushi n g p late D swung

,

back in to the dr il ling p os i t i o n ; t hi s also bring s th e stop pin -

H in to po s i t i o n for locat ing t he n e xt S ha ft An other sha f t i s

.

n ow p u t int o t h e vi s e a g a in st t h e sto p pin a n d the p revio us

-

o pe rat i ons are repe at e d .

Thi s d e vi ce has be en us e d wi th new bushing p late s to sui t

many di ffe r en t kinds of wo rk F or dr il ling a n d tapping when
.
,

using a r eve rs ib l e t appin g chuck o r a drill p r e ss tha t has a

r eve rsibl e spind l e i t wi ll b e foun d to b e a ve ry h andy t o ol
,
.

A ft e r th e ta p h ol e i s dri ll e d in th e w ork pin F i s p ul l e d out

,

a n d bushi ng p la te D can b e swung ou t o f th e w ay .

i
J g for D r illi ng D e e p H o l e s in S t u d s Th e
. j ig to
f b e
-
d e
s cri b e d was des ign ed for dr i l l in g brass studs whi ch w e r e
t urne d from a g in ch squar e bar w i th a S hort sect i o n of th e
-
,

origina l squar e bar left at th e c ent e r of th e fini sh e d stud Th e .

drilling o pe rati o n could n o t b e do n e c o nven i ently on the aut o

mat i c scr ew machin e as i t was n ecessary t o drill a 5 inch hol e
,
- 3

t o a d ep th of 2 2 in che s .

Th e machi ne us e d i s a spe ed la the w hi ch i s p rovi d e d wi th

bo t h wh ee l and leve r f e ed for the tai lstock F or thi s work .
,

th e ta il stock spin dl e was remove d an d rep lac e d by a spe cia l

s pin dle whi ch i s shown at A in th e cross-s e ct i onal View F ig 7 ,
. 1 .

In th e i llustrat i on i t wi l l be s ee n that th e sp in d le i s provid e d

1 7 2 J I G DE S I GN
with a threaded nose on whi ch the bracket B is screwed .

The spindle was bored out to such a size that the work holder
-

C is a sliding fit in the spindle the mo vement of the work ,

holder being accompli shed by means of the le ver D which is

pivoted to the bracket B The quadrant E is pro vided with
.

teeth for the purpose of locking the le ver i n the closed po sition .

One of the s tuds to be drilled is s hown in po s ition at F in

the work holder It is accurately centered between the tapered
- .

drill bu shing G at one end of the work holder and the tapered -

end of the rod H at the oppo site end of the holder The drill .

F i g 17
. . D illi g D p H l i S t u d
J i g for r n ee o es n s

bushing is pressed into the end of the work holder and the -
,

de sign of the work holder and the manner in which the rod H
-

i s thread e d into t h e tailstock screw are all clearly shown In .

setting up a piece of work in the jig the rod H i s held stationary

,

by it s threaded connect ion with the tail stock screw and a ,

movement of the lever D r e leas e s or re centers the work by -

sliding the work holder C in the spindle A the work holder

-
,
-

being prevented from turn ing by mean s of a clamp J which

engage s th e square which is left at the center of the stud .

The drills u s ed for thi s operation were of exceptional length

and made with an increase in the angle of twi st They were .

held in the lath e spindle and the work was fed up to the drill
by means of the tailstock le ver The u se of this lever feed
.

made pos sible the quick return of the work whi ch enabled ,
 D R I LL J I G S 1 75

th e work is such that i t must b e located in mor e than o ne dirc e

t i on a n d clampe d a t s eve ral p o in ts If th e ne c e ssary clamp s
.
,

could b e p osit i vely o p erated by a S ingl e le ver th e gr e atest ,

possible sp eed w ould be obta in e d but this i deal co n di t i on may

,

n o t b e p ract icabl e owing t o the fac t that the hol di n g p osi t i o n

,

of e ach clam p is l ikely to vary wi th th e siz e of the work t hus ,

making an y combine d p osit iv e moveme nt of th e clamp s ine f

fe ct ual Th e clamp s may b e r e l e as e d by a s in gl e l e ver bu t wh en
.
,

ho l d ing th e w ork thei r pos i t i o n is fixed by th e work i ts el f and ,

thi s con d it i o n coupl e d with vari atio n s in the size of th e work

, ,

F i g 20
. . W ork t o b e d ri ll d in J ig s h wn in F i g
e o . 19

mak e s th e o p eration of the clamp s by a single lev er a d iffi cu l t

mat te r .

If it w e r e always p ossible to reve rs e thi s condition maki n g ,

each clam p ind epen d e nt of th e o t hers in i ts closing moveme n t

an d thus com pen sat in g fo r varying s iz es of work a s ingl e l eve r ,

mi gh t b e arrange d to r el e as e all th e clam p s a t o n c e Thi s d e .

si rabl e r e sult has be en accomp l i sh e d i n the jig shown in F ig 9 . 1

by emp loyi ng sp rin g p r e s sure to clos e th e locatin g an d hold ing

m e chani sms The p o sit i on o f the work i s fix e d in two di re c
.

t i ons a n d the wo rk i s clampe d at two po in t s by a S ingl e move

,

m e nt of th e ope rat ing l e ver to the right whil e movi ng t hi s l ever ,

to th e l e ft re l e as e s th e work from the clam ping and l ocatin g

d evic e s Th e work !w hi ch i s shown o n a r e duced scal e in F ig
. .

2 0) lies on three harde ne d st ee l blocks A and is locate d b e ,

hi nd pins B moun t e d in th e se blocks an d to the left of the pin

C i n the base of the j i g .

Th e block D forms a s e at for th e cove r plat e and th e l a t ch -

whi ch holds t h e cove r-p lat e down i s pivot e d in thi s block Th e .

lat ch is he ld down by a sprin g p lu n ger The be llcrank le ver E .

,
1 7 6 J G
I D E S I GN
whi ch carri es the fourt h locating p in is pivoted to the base ,

of the fixture and pro vided with a lug which en ters an op ening
through the ba s e and receives the pre s sure of the spring
plunger F Th e bracket s G are attached to the bas e of the
.

fix ture and the cover plate is hinged to these brackets Th e

- .

brackets are al s o bored out to receive two sp ring plungers .

The ope rating le ver is fastened to a hub H and a link I is

pivoted on thi s hub th e oppo site end of th e link being att ached
,

to the hub J The screw s whi ch hold the op erating le ver to

.

the hub H and the link I to the hub J ar e exten ded to form
, ,

p in s which engage the l ever s K .

The jig is shown closed wi th all parts in th e p os itions th ey

would occup y when holding a piece of work To rais e th e .

cover p late the latch is p re s sed back when th e thrust of a

-
, ,

spring p lu nger rai s es i t su ffici e ntly to p re vent the latch r e

engaging the co ver plate Th e cover plate i s ra i sed to th e
—
.
-

l imit of its movement which is a few degrees beyond the p e r

p e n d i c u la r . The operat i ng le v e r i s then swung to the left until

it s trikes a limit pin Thi s mo vement of the lever turns the

.

hubs H and J bringing the pins again s t the tail ends of th e

,

leve rs K and compres sing the springs behi nd the plungers carried
in the bracket s G Thus the end s of the le vers K whi ch
.
,

engage the work are swung back relea sing the i r grip ,
.

The final movement of the left hand lever K brings the ad -

j u s t a b le stop screw—
L carried by thi s le v er aga i n s t a lug p ro
j e c t in g above the le v er E thus compres ,
s ing the spring F
and relea sing the work from the pre ssure of the p in carried .

by the lever E The s crew L limits the mo v ement of the lever

.

E to the m in imum amount nece ss ary to release the work and ,

the stop s crew may be adj u sted to accompli sh this after the
-

jig has been locked open A fter removin g the work from th e
.

jig an undrilled piece i s placed in po sition and the ope rating

,

lever thrown to the right T his cau se s the different holding

.

members to go through the i r sequence of movements in the

oppo site order to that described for relea s ing the work from
the jig The re sult is that the work i s clamped in place in a
.

minimum amount of time .

1 7 8 no DE S I GN
j g
i is in d ex e d to the p ositi on shown in F ig 2 2 Whi l e in thi s . .

position 2 2 hol e s are drilled in th e crankcas e a n d after th e s e

, ,

ar e compl eted the mil ling i s do ne The millin g attachm en t .

for this drill jig con sist s of two m emb e rs D and C P art C .

con si sts of a body member for the millin g at t achmen t I n th i s .

memb e r ar e cut ve rtical ways in whi ch th e cutter carryin g

m emb e r D trave l s u p an d down The movable m e mber D .

carrie s a horizo ntal cutt e r arbor having a gang of thr e e cutters J

-

an d G on each e nd In the center of this arbor is a bevel gear

.

whi ch m e shes with an oth e r b ev el g e ar carrie d by a vert i ca l

Fi g 22
. .
J i g in P o s iti on for D i lli
r ng and M illing O p e rat i ons

sha ft th e u ppe r e nd of which t e rminates in a M orse ta p er

,

shank E The movable m ember D is held normally in the upp er

.

p os i t i on by s p ring s .

I n o pe rat i o n the dri ll sp indle i s brought down in co n tact

,

wi th the t ap er shank E unt i l i t is seated i nto the ta p er dri ll

socket Th en th e drill spindle i s rotated and the mil l ing arbor
.
, ,

of course rotates also through the b evel g e ars The dr ill

, .

spin dle i s fe d down ward the sam e as f or drilling a n d i n so ,

do in g the en t i r e m e mber D is low e r e d unti l the ri gh t hand set

-

of cu t t e rs G i s brought in to con tact wi th th e boss to b e m il led

a t th e ri ght han d side of th e crankcase Th e cutt e rs continue
.
- .

t o b e low e r e d u n t i l they com e aga i nst a p r e vi ously s e t stop i n ,

wh i ch p osi ti on t h e m illing of the right han d bo s i complet e d - s s .

 D RI LL J I GS 1 79

To p roc e ed with the m il l ing of th e left -hand boss it i s ne ce s ,

sary to l o os e n the strap s that hold the milling fixture i n place ,

grasp the han dl e s H and li ft th e mill in g attachmen t o ver to

th e l e ft hand si d e of the dri ll j i g where there are dowel pi n s
-
,
-

whi ch accurately l ocate i t i n i ts corr e ct r e l ati ve p ositi o n The .

ope rat i on i s rep eat e d in th e same way as for the right han d -

boss exc ep t that cutters J are used in s te ad of cutt e rs G This

, .

milli ng at t ach m ent i s n eve r remo ved from th e drill ji g except ,

as exp la in ed for m illing th e right and left han d bosses The

,
-
.

movab l e member D is mo ve d up ou t of the way by sp ring p res

sure wh en a new cra nkcas e i s be ing p laced in the jig It would .

b e p ossi ble of course to equip thi s drill j i g with two m il ling

, ,

attachm en ts on e at e ach end so that i t would not be nece s sary

, ,

to mov e t he attachment from one S id e to the other but as the ,

ch anging of the fix t ure from one S i de to another was such a

S im p l e matter i t was not de e med ad visable to go to t h e extra
,

expen s e that thi s would invol v e .

i
J g fo r C r o s s -d rillin g P is t o n s The j g
i shown
.
—
in F ig 2 3 .

i s us e d succe ss fully in cro ss dri lling pistons Th e piston is

- .

drilled from both s i d e s and not all th e way through from one
s i d e which i s th e common p ractice e specially wh e n the work
, ,

i s done o n some k in d of lath e It i s n o t an easy matter to drill

.

a n d r e am a true hole by starting on one s ide of the pi s ton ,

dril ling through one bo s s and then advancing the tool acros s
,

th e o pening between the boss e s and exp ect ing the tool to secure
a true start i n the s e cond boss .

Thi s jig was made in the follow ing manner to insure accuracy .

A block of cast i ro n was milled squar e and the large hole rough
bored t o withi n T g inch of s iz e Thi s block was then milled
l
.

across one end to receive the stop -bar A A fter fitting the .

stop-bar i t was removed and th e seat for th e clamp bar B

,
-

was bored by using a fly cutter i n the milling machi ne This

- .

clamp bar was a p i ece of two inch cold rolled stock m illed
- - -
,

fla t to form a little more than a half rou n d D uring the suc .

c e e di ng bori ng and grinding operations th e clamp bar was held

-

to it s s e at by the two screw s C which had wash e rs under their

h e ad s in s tead of the springs S hown in the illu stration A p iece .
1 80 J G
I D E S I GN
of in ch stock was placed betwee n th e c l amp bar a n d
- -

s ea t whi le borin g and grinding ; t hi s s him was take n out la t e r

to allow for a little clearance A fter the clamp bar was fitted
.
-

and bored the holes for the hardened bushin g s D were bored
,

and the bu shing s fitted The s e bushings were long enough to

.

reach through the large bore so that they could be ground flush
with the in side of the jig .

The jig was next se t up on the table of a H e ald cylinder

grinder and the holes in the bushings ground in l ine and true

F i g 23
. .
J ig u dfse or C d
r o s s - ri lli ng P i s t on s

to s ize The j i g was then placed on one side with the bush
.

ings in a horizontal plane and the large hole fin i shed to s ize

by grinding To be sure that the hole s in the bu shings would
.

be perfectly central wi th the large bore an arbor was groun d ,

to a snug fit for the bu shin gs and the large hole was gaged
from it m e asurin g from the wall of t h e large hole to the arbor
,

until both side s were exactly the s ame The hole was then .

fini shed inch la ger than the pi ston to be worked on

r .

Two sli p bu s hings E were made to fit the bushings in the j g i ,

1 82 J G
I D E S I GN
a p air of jaws bored to the p roper s ize to fit the piston to be
worked on The sp rings o n the up right studs h o l d up the upp er
.

or clamping jaw whi le the work is being put in or take n out .

In op e ratio n a pis t on is slipp ed between the jaws th e fac in g

, ,

bar run down through the cro ss drilled holes the cutt e r fitted -
,

into the bar and the to p j aw set by a half turn of the lever
,

hand l ed nut A feature of the facing bar i s the mann er in

.

F i g 24 . .
J ig B
u dfse or c
F a ing t h e Pi st on os s e s

which the cutt e r is h e ld It will be s e en that the cutt e r h as a

.

half round notch in the c en te r of th e bottom e dge that r egisters

-

with a steel ball L in the center of th e cutter s lot A s t iff sp rin g .

holds th e ball to it s sea t in the bar The cutte r is also provided .

wi th two hole s near each end that are u s ed for pull ing i t out
of the bar with a s tout wire hook It i s double e dged so that .
,

both bo s ses can be faced wi thout rever sing i t or stopping th e

machi n e Thi s method of holding the cutter would n ot be
.

de sirable in the ca s e of a boring tool but for a facing tool i t ,

s e rv e v ery well O f course the cutter mu s t be a ni ce fit in the

s .
 D RI LL J I GS 1 83

bar Whe n t he facing j g is used it can be clamped to th e

. i

machine table while the cros s drilling jig is not clamp ed b e

,
-
,

cau s e it i s necessary to turn it over and over .

Unive rs al Jig s .While a large perc e ntage of th e j i gs in

common use are designed espe ci ally for some part a n d ar e used
exclu sively for that particular part occasionally j igs are so ,

constructed that they are adju stable and adapted for a variety
of work F o this reason they are often called un iv ers al
. r
“

jigs Jigs of this typ e may re s emble an ordinary j g som ewhat

. i

F ig 25
. . Tool m ak e rsD i ll J ig
’
U ni ve r s al r

and s imply b e arranged to locat e th e gui d e bush ing s !in the

case of a dr ill jig) in differe n t p os i t i o n s ; or th e j ig may b e in
the form of a sp eci al a t tach m e nt for th e dr illi n g mach in e .

An e xamp l e of un i v e rsal jig co n struct i o n i s shown i n F ig 5 . 2 .

This i s a very s im p le design and cons i sts of a p lat e conta ini ng

o ne or more dri ll bushi ngs and adjustabl e loca tin g rods It .

may be used for accurately locat ing and dr il lin g hol e s in j i gs ,

d i es and temp lets A hard en e d and ground block A i s pro

,
.

vi d e d w i th four sl i d i ng p in s B a s e t of removab l e bushi ngs C

, ,

and eigh t headl e ss s e t screws B us hi ngs C may be mad e u p

- .

with vari ous sized holes to provi de for gu i ding different sizes of
drill s S mall S lugs of brass or copper are used between the set
.

screws and the pins B so that ad j ust ing th e scr ews wil l n ot
tend to change the position of the p ins .

12 J
1 84 J I G D E S I GN
T0 il lustrate the us e of thi s j i g suppose t ha t a number of ,

holes must be accurately located drilled and reamed in a di e , ,

block A fter the block h as been p lan e d up p erfectly squar e

.
,

p arallels are clamp ed to the edges so tha t they overhan g in

the manner shown i n F ig 2 6 allow ing the pin s B t o enga ge
.
,

with these p arallel s when the jig is laid fla t again st the die
block The bushin g C is located at a known di stance from the
.

e dge s of the j ig a n d by s etting the p in s B in the required

,

po sition by means of a micrometer or m i crometer depth gage ,

F i g 26
. . M th d
e o of u ing U niv
s e r s al D ill J ig h w
r s o n in F i g 25
.

the bushi ng i s located in po sition for drillin g the hole in the di e

block F or thi s purpo s e the j g i s clamped to the die block wi th
.
,
i -

a pair of p arallel clamp s after whi ch the hole i s spotted dril led
, ,

and ream e d in the u sual way It will of course be evi dent.

, ,

that any number of holes that come within the range of the ji g
can be located on the di e block in the same way The useful
-
.

ne ss of thi s tool wil l be apparent to any toolmaker and many ,

uses wil l be found for it that may not be s een at the first glanc e .

A uni versal jig whi ch is in the form of an attachment whi ch

i s clamped to the table O f a drilling machine i s shown in F ig 7 . 2 .

The dri ll bushing is in l ine with the axi s of the machine spin dl e ,

so that holes may be dr illed as in the ca e of an ordinary jig s ,

and there is a compound table with slide s at right angle s which ,

1 86 J G
I D E S I GN
ment to l oca te an y n umber of ho l es in th e work in th e desired
relat i on to each oth e r as th e table sli des may b e mani p ulated
,

and fin al s e tt ing s ma d e wi th the mi crometer h e ads and d i s

tanc e bars so t ha t each ho l e i s l oca te d in the p ro pe r relati on
,

to th e p r e cedi n g ho l e C lamps are p rovi ded to l ock the t ab l e

.

in e ach p os it i o n befor e th e drilling operat i on i s starte d .

Th e di stanc e bars ar e supported by bushi n g s hel d in

!

V shaped s e ats whi ch su pp ort them at th e proper hei gh t to

-
,

line up properly b e twe en the micrometer spindles and stops o n

th e tab l e whi ch com e in contact with th e micromet e r spindl e s

F i g 28
. . Vi se wit h J i g Att chm a e nt

whe n the t ab l e i s se t in th e z ero p os iti on J ohan sson or oth e r .

gages may b e us e d in p lac e of the di stanc e bars i f so d e s ir e d , .

Jig A tt a c h me nt s fo r D r ill in g i n Vi s e s — T h e machi ne Vi ses.

s uch as ar e us e d f or m illin g or p l anin g o pe rat i ons ma y b e used

for drilling when th ey ar e p rovi d e d with at tachments for h old

ing dr ill bushings or l ocat ing st op s Th e r e ar e n ow o n th e
.

market Vi ses furni sh e d wi th j ig at t achments r e ady for us e .

O ne of the s e Vi ses i s il lus t ra te d in F ig 2 8 where it will b e see n

.
,

tha t a s t o p A may b e used t o l ocate th e work whil e the bracke t

B ho l ds th e bushin g whi ch gui des the dri ll .

A S a Simp l e i llustrat i on of th e p rin cip l e in vo l ve d in us in g

a jig of thi s type ref e rence is made to F ig 2 9 in whi ch the
,
.
,

part be ing machi n ed is a round collar Thi s collar A i s grippe d .

aga in st a ve e in th e s o li d j aw and the bracket conta in ing th e

,
 D R I LL J I GS 187

F i g 29 Vi se e qui pp ed wi th J i g Att chm

a e nt and V—
b lo ck s for G ri ppi ng
C ylind ic l P
. .

r a ar t

F ig 3 0
. . D illi
r ng S e ve ra lH l o es wi t h a Te m pl ch d t
e t att a e o Vi se
1 88 J G
I D E S I GN
bu shi ng B i s adjuste d to t h e correct p osition for guiding the
drill into the work It i s clamped in p lac e on the solid jaw by
.

means of bo lts C To op erate the jig the movable jaw is

.
,

open e d and a pi ece of work inserted in the V block ; then i t is -

only nece s sary to tighten the jaws and proc e ed to dr ill In thi s .

way duplicate parts are obtained without an elaborate j ig

,
.

B y using suitable plates in these jigs many odd shaped pieces ,

-

can be drilled of which F ig 3 0 is a typical examp le The method

,
. .

of u sing thi s plate is shown by the illu stration B ushings A are .

placed in the p late B at the proper locat i on to guide the drills

into the work The plate i s screwed on t op of t he vi se the stop
.
‘ '

C is adjusted to the p roper locat i on and the work D placed in

,

the vi se agains t the s top after whi ch the holes are drilled
,
.

This jig con struction adapted to drillin g holes on an angle

i s illustrated in F ig 3 In thi s case a swive l vi se is fitted
. 1 .
,

with a p late A set at the prop er angle in relat ion to the ba s e B .

Then by swing in g the vi se up to the p rop er angle the part s ,

may b e drilled in duplicate as in the previous case ci ted That .

there are infin ite p o ssib il it i e s in the fitt ing of vi ses wi th bu sh

ing plates when these are intelligently used wil l be readi ly
, ,

seen by con siderin g the methods of drilling il lustrated in F ig 3 2 . .

This i llu strates a swivel vise used as an index ing jig and where ,

extreme speed or accuracy is not requ ir ed it works out very

satis factorily The fir s t drilli n g i s done w ith the vi s e in the
.

po sit i on illustrated The subsequent drillin g i s accompli shed

.

by tilt in g the S wivel vise to the right an d left the de sired number
of degrees .

A noth e r exam p le of dri ll ing in a vi s e i s shown in F ig 3 3 .

,

a number of holes be ing drilled around a circl e The work .

i s gripped between the jaw s in the vi s e proper a n d a bushi ng

plate is located by pins A and B in the vi se B y sli d ing the vi s e .

to various posit i ons the hole s are dril led in the u sual manner .

This bushin g plate is removable for taki ng out the work .

The vi ses here illustrated are not always the most economical
means Of handl ing work but they are often the be s t that the
,

extent of the j ob will warrant They mu s t not be confused

.

with more elaborate j i gs and fixture s which although vi s es ,

1 90 J I G DE S I GN
in pri ncip le are sp eci al in construct i on N ot al l shop s can
,
.

a ff ord the costly design that the manufacture of guns or auto

mobile s will warrant They must comp rom i s e on the cheaper
.

and le s s effective equipment that can be adap ted qui ckl y to a

wide ran ge of work and the machi ne Vi se as S hown in the
, ,

foregoing can be made a universal fixture w ithin i ts l im it s

,
.

M ultiple D rilli ng Jig of R e ve r s ib l e Typ e The drill ing of .

the spok e holes in the hubs of motorcycl es i s illustrated in F ig 3 4 . .

Fi g 3 3 Vi p
se rovi d e d wi t h R m e ovab el Bu hing P l at e
s for D illi
r ng
C i cl
. .

H l
o e s on a r e

These hubs are made of low carbon ste el and the end flanges
through which the hol e s are drilled are 3 inch thick Through .

e ach fla n g e S ixteen N O 5 holes are drilled at a slight angle

,
. 2

s o that the directio n of the drilli ng i s a l ong the l in es of a cone .

The di stance b e tween the h ole s is about one half inch -

.

The spin dl es of the multiple spindle drillin g machi ne in -

whi ch th e work i s done are guided in their inclin ation by a

stee l ring support ed from the head of the machi ne The j g . i

i s of the swi veling type permitting the hole s in one end of

,

t h e hub to be drilled after whi ch the work hold in g part of

,
-
 DRI LL JI GS 1 91
‘

F i g 34
. . D ill J ig f M t cycl Hub
l
S wi ve ing r or o or e s

the j i g i s swi ve l ed 8 0 d e gr ee s a n d t he hol e s in the o pp os ite

1

en d are drill ed T he dr ill in g i s p e rform e d by running the h e ad

.

and dril ls down t o the work whi ch o n accou nt of th e in clin a

,

tion of the spindl e s i s the o n ly way poss i b l e .

1 92 J G
I D E S I GN
In order that the work may be quickly in s erted and removed ,

the j g is made in halve s A s the illu s tration shows these

i .
,

halve s are hi nged at the left and held together for the drilling
by a latch that appears at the right of the illustration The .

drill bushings are located in the faces of the halve s of the jig .

A fter the hole s in one flange of the hub hav e been drilled ,

the steel plate that takes the thru t i s remov ed from beneath s

D illi g H l i P w P D i l P l t
F ig 3 5
. .
J i g for r n o es n o er re ss a a es

the work Then by withdrawing the index pin at the left the
.
-
,

worki ng part of the jig can be turn e d 8 0 degrees to p re sent 1

the other face of the hub to the dri lls The heavy stud on .

which the jig swi vels is directly behind the work and there , ,

fore not vi ible in the illu stration The index p in is inserted

,
s .
-
,

the thrust plate is replaced and the drilling of the hub is com
,

p le t e d The hubs
. each hav i ng 3 hole
,
s 6 in each end 2 1

are drilled at the rate of 3 per ten hour day 00 - .

1 94 J IG D E S I GN
on the table of a drill p ress and th e center p un ch was s et in
the chuck in the drill spindle so that the prick—pun ch mark on
the dial could be lined up wi th the spindle The plate was then .

s trapped to the t able and stud C dr i ven i n t o the center hole .

The top of the s tud C i s mach ined to fi t the pi vot hole in the
arm D of the j i g .

The next step con si sted of l inin g u p the bu shin g A of t he

fixture wi th the center pun ch in the dr ill spindle It wi ll be .

noted that the bu shing i s made adju s table relat ive to the center
C about whi ch the arm s win gs so that i t may be se t i n the
,

required posi t i on before clamping the b indin g bolt Th e bu sh .

ing is locat ed i n the proper relat i on to the notches in the di al

plate by mean s of the lockin g pawl E and the eccentric s crew F
,

adjust s th e positi on of the p awl relat ive to the arm D of the

jig Th e p awl i s held i n the proper notch i n the d i al by the
.

spring G which i s moun ted on the pins H and I and stud J is

u s ed to hold the arm of the fix ture true wi th the fac e of the di al
plate It will be e vi dent that after thi s setting has been made
.
,

the bu s hi n g A i s located directly o v er the center punch mark

whi ch was mad e on the dial plate whil e the pri ck punch was —

mounted in the punch block of the power press The hole ca n

- .

now be drilled i n the dial p lat e after whi ch succe ssive holes
,

are drilled by simply swin ging the dial around the piv ot C
and locking it for drilling each hole by dropping the pawl E
into succes sive notches in the dial plate .

D u pl e x C lamping Ar r ang e m ent on D rill Jig The j g shown . i

in F ig 3 6 is u ed for drilling and tapping s tud A which is

. s ,

made from by i inch cold drawn steel The end of the s tud
- -
.

enters h ole B in the locat ing block and thi s hole i s mi lled to
'

provide clearance for the head of the s tud The work rest s on .

the drill bu hing which is sli ghtly counterbored to provi de clear

s

ance for the tap The most intere s ting feature of the jig is that
.

the cover and clamp ing mechani sm are both s ecured by the same
knob ; clamp C holds the stud s ecurely in place when the knob
is s crewed down and the same operation tighten s the co ver
,
It .

will be readily s een that thi s principle could be employed on

jigs and fix ture s u s ed for holding a great variety of part s .
 CH AP T E R V III

B O R IN G J GS
I

B oring j i gs are g ene rally us e d for machi n in g ho l es where

accuracy of alignmen t and Siz e ar e p art icularly essent i al and ,

al s o for holes of large S izes where dri lli ng woul d be ou t of the

que s tion Two or more ho l es in the same li n e ar e also as a
.
,

rule fin i sh e d wi th t he a i d of bori n g j i gs Th e boring o p erat i o n

,
.

i s pe rformed by bori ng bars havin g i ns e rt e d cu tte rs of vari ous

ki nds and bori ng j i gs ar e almost always used in connection
,

wi th thi s ki nd of borin g too l although bori n g o p erat i o n s may

,

be sat i sfactori ly accompl ished wi th thre e or four lip ped drills -

and reamers The reamers may b e made so li d althou gh most

.
,

frequently shell reamers mount e d o n a bar and gu i ded by bu sh

i ng s are used The majori ty of holes p roduced in bor in g jigs
.
,

whether dri lled or bor e d ou t are r e qu ir e d to be of such accuracy

,

that they are ream e d ou t in th e last o pe rat i on .

The boring bars are usually gui ded by two bushi ngs one on
-
,

each si de of the bored hole and l ocat e d as cl ose as p ossible to

,

each end o f t h e hol e be ing bored The bar i s rotated and

.

s imultan e ously fed through t h e work or the w ork wi th i ts j i g

,

i s fed over the rotat ing bar : B oring j i gs may b e used e i ther
in re gu la r boring lath e s in horiz o nta l borin g a n d dri l ling
,

machi nes or i n radi a l dri lls

,
.

The jig body is made e ither in o ne sol id p ie c e or com p osed

of several members the sam e as in drill jigs The stra in on
,
.

boring jigs i s usually heavy whi ch ne ce ssi ta te s a very ri gi dly

,

de signed body wi th ribb e d and braced walls a n d members so ,

as to allow the least pos s ible spring As bor ing j i gs wh e n i n

.

operat i o n must be securely fastened to the machin e table ,

means must also be provided in convenient and acce s sibl e

p lace s for clamp ing the jig wi thout appreci ably spri ng ing i t .

1 95
1
9 6 JI G D E S I GN
The p laces in th e j i g wh e re the bu shi ngs are located should
b e provi ded wi th p lenty of metal so as to give the bu shings a
s ubstant i a l b e arin g i n th e j i g body S maller jig s sh o uld be
.

provid e d with a ton gue or lip o n th e surfac e whi ch i s clamped

to the machin e table ; thi s permi ts th e o pe rator to quickly
locate th e ji g in t h e ri gh t position As an a l t e rnat ive fin i shed
.
,

lugs locatin g a gainst a p arallel or squar e may b e p rovided .

It is frequently advan tageou s to have small Size d bori ng jigs

provi ded with feet S O that they can be used on a regular drill

F ig 1. . u
G e n e ral O t li n e of Si m pl B
e ori ng J ig

pre ss table in ca s e s where hole s to be bored out are to be o p ened

up wi th a drill pierc ing the s olid m e tal It i s bo th e as ie r and .

Cheaper to do thi s rough drillin g in a drill p ress .

The gu ide bu shi ngs o f the same typ e as th e bushi ngs for
,

drill jigs are made e i ther of cast iron or stee l and groun d to
,

fit the boring bar which is also ground The bushin g s should

-
,
.

be made rather long to in sure good b e ari ng .

B oring Jig o f S impl e D e s i gn The most common type o f

.

boring jig for small and medium S ize work i s s hown i n F ig . I .

In thi s engravi ng A repre s ent s the work which i s held down

,

by straps or clamps In many in stance s when the work is

.
1 9 8 J I G D E S I GN
which case t h e fini sh e d bosses of cours e must stand in a ce r , ,

tain relation to the loca t ing poin t ; such boss e s are indi cated
at E from whi ch measurements B can be taken to surfaces G
,

on the work Th e thre e lugs H are p rovi ded for clamp in g pur
.

pos e s the jig being clampe d in three p lace s onl y to avo i d unne ce s
,

sary spr ingin g action If the jig i s in constant use i t would be

.
,

advisab l e to ha ve sp ecial clamping arran gem ents as comp onent

parts of t h e j ig for clamping it to the table ther e by avo i din g ,

loss of time in fin ding suitable clamps .

The walls or standards K of large j i gs of thi s type ar e fre

quently made i n loose p iec e s and secured and doweled in p lace .

In such a cas e the most important thi ng i s to fasten these

,

F ig 2. . S impl D ign
e es of Adju s t ab e l B oring J ig

memb e rs firmly to th e base preventing shift ing by t on gues , ,

keys or dowels It is evi dent that when the standards are

,
.
,

made loose i t i s e asi er t o fini sh the pad of th e base and t hi s

, ,

i s of importance part i cularly when diffi cu l t locat in g arrange

,

ments are p laned or m illed in the base ; t h e patternmaker s ’

an d the molder s work is also simpl ified A s a rule the standards

’
.

are screwed t o the bas e p ermanently and then the bu shi ng

holes are bor e d In some ca s es however i t may be easi er to
.
, ,

first bore th e h ol e in a l o os e p art an d th en a tt ach i t to th e main ,

body .

Ad j u s table B o ring Jig s When bori n g j i gs ar e desi gn ed for

.
—

machine p art s o f a S imilar design but of differen t dim ensi ons ,

arran g ements ar e oft en made to ma k e one j ig take vari ou s

size s In such a case one or both s tandards may have to be
.
,

move d an d ext ra pads are provided o n th e fac e Thi s shi ft ing

, .
 B O RI NG JI GS 1
99

of the standards wil l take care of di fferen t l en gths of work .

S hould th e work di ff er in height a blocking pi ece may be made

,
.

S ometimes sp ec i al loose brackets may be more sui table for

replacing the regul ar sta n dards for S horter work If there i s a .

long di stance between two bearings of the work a thi rd standard ,

may be placed in between the two out s i de ones i f the de sign ,

of the bored work permit s ; thi s may th e n be u s ed for shorter

work together with one of the e nd standard s In F ig 2 is . .

S hown an adju s table bor ing jig H ere the jig con s i s ts of two
.

part s A mounted on a common baseplate or large table pro

vi d e d with T slots
— The work B is located between the standard s
. .

A numb e r of di fferent s tandard s su i table for d i fferent pieces of

F ig 3
. .
J ig l c
o at e d o n and s upp ort e d by th e W or k
work may be u s ed on the s ame ba s eplate The jig s or stand .

ard s are held down on the ba s eplate by Screws or bolt s and gen ,

e ally located by a ton gue enterin g the upper p art of the T s lot s
r — .

B oring Jig s u ppor t e d o n W or k B orin g jigs are frequently.

made whi ch are located and supported on the work F ig 3 . .

shows such a j i g The work A whi ch in thi s case rep resent s

.
,

some kind of a machi n e bed has two holes bored through the
,

walls B and C Thi s j i g may gu i de the bar p ro p erly i f there

.

be but one gu i de bu shi ng at E but i t is bett e r if i t ca n b e ar

,

ranged to carry down the j ig member D as indi cated to give

support for the bar n e ar t h e wal l B It may somet imes be .

more conveni ent to have two separa t e j igs located from the
same surfaces on the top or si des In other ca s es i t may be .

better to have the members D and E s crewed in place instead

13 ]
2 00 J I G D E S I GN
of being solid wi th F and in some cas e s adjustabl e Of course
,
.
,

these vari ations in de sign dep end up on the conditions involved ,

but the p rinciples remain the sam e The ji g or jigs ar e held .

to the machine on whi ch they ar e used by clamping arrange

ment s of sui table type .

Jig s for S upporting B ar on O ne S i d e of H ol e O nly The .

type of boring jigs previously described supp orts the bar in

two or more p laces and the cutting tools are placed at certain
predeterm
,

i ned di s tance s from the e nd s of the bars depending ,

upon the shape and size of the work S omet ime s it may prove .

n ecessary however to have a cutting tool i nserted just at the

, ,

end of the bar F or example a boring jig may consi s t of

.
,

F ig 4
. . E xa m pl e s of Gu idi ng Arran ge m nt wh
e s e r e no S uppo t i
r s ob t ai nab e on l
O ne id
S e of Hl t b
o e o e b or e d
simply one bracket as shown at the left in F ig 4 A v e ry lon g . .

beari ng A i s then provi ded s o as to gui d e the bar tru e Th e .

arrangement shown at the ri ght in F ig 4 is som etimes used to .

in sure a long bearing for the bar A sp ecial bracket E i s moun t e d.

on the jig and bored out at th e sam e t ime as the jig p rop er i s
machi ned Thi s p rovi des in effect two b e ar ings In these
.
, ,
.

ca s e s bars wi th a cutti ng t ool at the end are u s e d There are .

several r e a s ons why a boring j ig of thi s kind may b e required .

F or i nstance there i s a wa ll B im
,
mediately back of th e wall C
in whi ch th e hole i s to b e bored O ther obstacle s may be in .

the way to p revent p lacing a bearin g on o n e si de of the hol e to

be finished In stead of havin g a sp ac e D betwe en the j ig an d
.

the work the jig can oftentime s b e brought up Cl os e to th e

,

work and clamped to it from the bu shing si d e .

E ach of the diff er e nt holes i n boring jig s has o f course i t s , ,

own outfit of boring -bars reamers and facing tools I n mak ing
, ,
.
2o 2 JIG D E S I GN
may not be n ecessary wh e n uni ve rsa l jo ints are us e d between
the spindle and the bar .

Jigs for M ultipl e B oring A s a rule but one hole is bored

.
—

out at a time owin g to the fact that machi n e s for boring

,

generally hav e bu t one sp indle S everal holes however could .

, ,

be bored out in a large size multiple spindle drill in whi ch

- —
,

ca se the jigs naturally ought to be de signed somewhat s tronger .

Another method of des i gn in g j i gs for boring two or more holes

F ig 7
. .
J i g for B ori ng H ol es t h ugh W k b
ro or ot h f m Sid
ro e s and End s

a t the s ame t ime i s illustrated in F ig 6 the outlines only b eing .

,

shown in thi s illustration The gear box A contains the main

.
-

driving gear whi ch is mounted on a shaft B which in turn is , ,

driven by the sp indle of the machi ne The gear on shaft B .

drives the gears and shaft s connected with the boring bars
pas sing through the bushi ngs C D E F G and H The gears , , , , , .

are proportioned according to the speed required for each bar ,

whi ch in turn i s determ ined by the sizes of the holes The .

housing or gear-box A slide s on a do vetail s lide K A p art i cu .

la ly good fit should b e provi ded and the gear-box c an be fed

r ,

along in relati on to the work either by table or spindle feed If .

 B O R I NG J I GS 2 03

boring operat i on s are to be p e rformed in two direct i ons a J l g ,

on the l ines indicated in F ig 7 is designe d Thi s jig may be . .

mo unted on a special revolving table perm i tt ing the work and

the j i g to be turned and indexed s o as to s ave r e sett ing and
readjusting th e work a n d j ig when once plac e d in p os i tion on
the machi ne .

The foregoing outl ine of boring j i g s i l lus t ra te s onl y t he funda

mental principles i nvolve d it bein g co n s id e red more im p ortant
,

to stat e the fundame ntal p rin cip l es in thi s co nn ecti on than to

describe comp l i cated d e signs of tools i n whi ch the ap pli cati o n
of such p rinciples may be m o re or less obscure or hidden .

F ig 8
. . E xa mp l e of Small B ri ng J ig wit h R m ov b l
o , e a e L e af for
H l di ng G ui d Bu hings
o e s

B or ing Jig D e sign s I n F ig 8 are shown two vi ews of a

.
—
.

small jig supported d i r e ct l y o n the work to be bored Thi s Jl g .

i s us e d for bori ng out a cross sl i de carr i a g e and is located on

-
,

the work b y the dove ta i l sl i de a n d h e ld in p lac e by the two

set screws A The two bushi n gs B ar e d riven into t he solid
- .

part of the jig a n d the two corre sp on di n g bushi ngs C ar e p laced

in the loo s e leaf D whi ch is r emoved when the jig i s p laced in
position on or removed from th e work The two set screws A
, ,
.
-

do not bear di rectly o n the s i de of the carri age but are p rovided ,

wi th brass or steel shoe s The leaf D ca nn ot be attached p erma

.

ne nt ly to the jig and s imply s wung out of the way when the

fig i s located on the work becau s e i t could n ot

,
be swung i n
place after the j g is applie d on accoun t of the small clearance
i
2 04 J I G D E S I GN
in the cross sli de carri ag e The leaf is therefore made loo s e
- .
,

which i s an objectionable feature but lugs hav e been carried ,

up on the casting o n both s ides of the leaf as shown to giv e ,

good support ; these lugs are carefully fini shed to fit the leaf ,

and the latter i s located and held in place b y ground p lugs .

In F ig 9 i s shown a borin g ji g which receives th e work A

.

between two up rights The work in thi s ca s e is the tailstock

.

of a lathe where two holes B and C are to be bored out The .

bottom surfac e of th e tailstock i s fini shed before borin g and ,

i s located on the fin i shed bottom of the jig by m e ans of a k e y

F ig 9
. . Co mm on yp
T e of M e di um- i z
s e B ori ng J ig

and keyway The keyway is cut in the J g and is a li ttle wi der

. l

than the key in the work and the s e t screws D brin g the key
'

,
—

against on e si de o f the keyway that si de being in accurate ,

relation to th e hol e B to be bor e d in the tailstock Longi

!

l
t udi nal y the work i s l ocated b y a sto p —pin aga inst whi ch i t i s ,

brought up by a set screw from the opp osi te s i de The tail

- .

s tock i s he l d t o the j ig b y bo l ts E exactly as i t i s h e ld on the

lathe bed .

The placin g of the set screws D at di fferent hei ghts i s one

-

of the feature s of the jig ; this make s i t po ssible for the jig to
take tailstocks of vari ous heights for different sizes of lathes ,

raising blocks be in g used for the smaller sizes The rai s ing .
2 06 J I G D E S I GN
to be bor e d and i t involves more or le s s work to get the J g in
,
l

order The jig in F ig

. doe s not need to be as heavy as would
. IO

be inferred from the illu stration becau s e a large portion of ,

the bottom can be cored out .

F our -par t B oring Jig The bor ing j g i llustrat e d i n F ig

. 1 . I I

con sis ts of four p arts ; the up right members A B and C and , , ,

the baseplate D whi ch l atter may b e used for all jig s of similar
,

construction Thi s typ e of borin g j ig i s used only for ve ry large

.

work In th e cas e il lustrated larg e l ath e heads are to b e bored

.
, .

The work i s located on the baseplate between the two m e mbers

A and C The member B is only used when the di s tanc e b e
.

F i g 11
. . B ori ng J ig c i i
ons s t ng o f B as ep l t nd S p
a e a e ar at e Re movab l e
U p i ght c
r s yi arr ng th e G ui d B u hi ng
e s s

tween A and C i s very long so that an auxiliary s upport for ,

the boring bar is required or when s ome ob s tacle prevent s the

-
,

bar from p ass ing through the work from one of the out side
members to t h e ot h e r AS a rule these members are located
~

on the basep late by a t on gue fitt ing into one of the S lots as
S hown a t E The members are brought as close as po ssible
.

to the work su ffici ent spac e of course being permitted for

, , ,

the cutting tools to be in s ert ed The s tandard s are cored out .

and ribbed and lugs provided so as to giv e the bearing bu shings

long and sub s tantial s upport G ood re ult s will be obtained . s
 B O RI NG J I GS 207

wi th this type of j i gs provi ded they are carefully set up on

the baseplate A t F in the member B i S hown a bo s s ; thi s
. s

i s pro vided with a tapped hol e for a hook or eye bolt to facili -

tate moving th e j g member by an overhead crane The other

i .

members have tapp ed hol e on th e t op for the same p urp ose .

Align me nt of Jig wh en H ol e s ar e at an Angl e I n F ig 2 .

—
. 1

i s S hown a bori ng j i g for bor i n g out th e to p fram e A f or a di al

drills Th e design of th e jig i s S imp le but e ffectiv e ; the hole
.
,

F i g 12
. .
J i g h avi ng W e d ge -s h ap e d Lc
o ati ng Pie c e for B ing H
or l
o es
at an Angl e

B i s p aral le l w ith the fini shed S i de C of t he j i g and i s bored out

after the ji g has been brought up squar e aga ins t a parallel and
strappe d to the machi n e t ab l e The hole D i s bored at an.

angle w i th the hole B and t h e s et t ing of the j ig for the boring

,

out o f thi s h ol e i s fac il ita t ed by provi din g a wedge shap ed p i ece -

E of such a n an g le that the jig wi ll be s et i n the p ro p er p o si t i on

wh en move d up again s t the wedg e If universal jo ints are .

used f or connect ing the boring bar wit h the driving spindl e -
,

the s e tt ing of the work a t an angle could be omitted although ,

i t i s p referable even when us ing un ive rsal joint s t o have the

boring -bars as nearly as p o ssible in line with the S pindle This .

elim inate s a great deal of the eccentric stress e specially when ,

taking a heavy cut with coarse feed .

2 08 J I G D E S I GN
Us ing Work t o G ui d e B oring-b ar B orin g o p erations are .

s omet imes carried out u s ing p art s of the machine itself as g uid

ing means for the boring bars and in s ome instances it is very
-
,

e ss ential that boring operation s be p erformed in this way i n

order to obtain perfect alignment In F ig 3 i s S hown a ma . . 1

chi ne bed with the headstock soli d wi th the bed In th e top .

view is shown a method for boring out a hole at B b y the use .

of two j igs C and D whi ch are located on the V s of the machi ne

’

and held down by hook bolts If the hole B only passes through
- .

the part E of the head this would be the p referabl e way of

F i g 13
. . m pl
Exa e i ll u s tr at ing Use of W or k as a G i ud e for t h e B oring-b ar

boring i t In some instance s however the hole B may be

.
, ,

requ ir e d to be in ali gnm ent wi th the holes in a carriage or in

a bracket as at F and G These hol e s of cours e can th en b e
.
, ,

u s ed t o great advanta ge as guid in g means S hould the ho le s .

be too large to fit the boring bar cas t i ron bushi ngs can b e -
,
-

mad e to fit the hol e s and the bar The front el evat i on in F ig 3 . . 1

shows how a cross sl ide carri age and ap ron I whi ch h as a hole J
-

i n l ine wi th the holes in bearings K L and M and travels , , ,

between K and L can be bored out by using the brackets

,

K L an d M to guide the boring bar B y k e ying the trave lin g

, ,
- .
21O JIG D E S I GN
locat in g th e work in a sep arate drill j i g I n oth e r case s i t may .

be better to do the drillin g first and l ocat e the work for the
borin g operations from the drill e d holes The designer should .

decide whi ch method would be preferable con sid ering the time ,

requi red and the accuracy of th e work It is impossible to gi ve .

any defini te rules for this work ; but i t may be s ai d that com
binat ion jigs S hould be used only when the drilled and bored
hole s have nearly the same di ameters As a general rule when .
,

the hole s are of wi dely different di ameters two jigs are pref e r ,

able F or examp le if a few holes of small diameter for holding

.
,

a collar or bracket w e re located around a large bored hole ,

and were drilled wi th the same jig used for the large hole the ,

jig when used on a small drill pre s s would be entirely too heavy
, ,

to manip ulate It is likely that in such a ca s e a small separate

.

drill j ig could be attached d irectly to the work In many other .

ca s es however it will prove a di s tinct s aving to combine the

, ,

boring and drilli ng jig in one .

In F i gs 4 and 5 i s S hown a comb inatio n drill and boring

. I 1

i
j g of large S ize The work con
. s i s t s of a headstock for a lathe
with a number of holes to be drilled The large hole B F ig 5
. s ,
. I ,

at both ends of the head s tock are cored as usual and allow the ,

boring bar to enter for takin g the roughing cut The holes .

at C and D are open e d up by dr ills p revi ou s to the boring opera

tion AS there i s considerable di stance between the end of the
.

headstock and the uprights of the jig long bushings are u s ed ,

to give the tool s a good bearing close to the work B oth the .

drilling and boring operations may b e p erformed o n a hori

zo nt a l boring and drilling mac hi n e A s the horizontal boring
.

and drilling machine s usually have adju stment i n all di e c s r

tion s the only moving of the j g nece ary i s to turn it around

,
i ss

for drilling the hole s on the oppo site side s .

 CH A P T E R I X

M ILLIN G AN D P LAN IN G F I TURE SX

M illin g machin es ar e n ow used for s o many diff erent p urp oses
that the fixtures us e d for holding p arts to be milled diff er con
s i d e r ab ly in form and s ize and there are several dist i nct types
,
.

The simp les t form of mi lling fixture i s r epresented by the type

whi ch s imp ly hol ds and l ocates a s in gle pi ece for a milling
op erat i on Then there are mult ip le or gan g fix tures for hold
.

i ng a row of dup licate cast i ngs or for gings Thi s type may be
.

intended either for machines having a strai ght line feed ing -

movemen t or a circular mot ion as in the case of mach ines

,

de signed for continuous m illing

“
O ther mi l ling fix tures
.
!
,

which often are more complicated i n de sign than the work

holding fixtures are arranged to hold the work in different
,

p osit i ons e i ther for milling su rfaces whi ch are at an angle or ,

for milling at vari ous po ints around a ci rcular p ar t The p ath .

followed by the mill ing cutter i s al s o controlled by som e fix

tures e specially i n connect i on wi th profile mill ing ; or the fixture
m ,

ay be con s tructed to gi v e th e work a rotary feed i ng mo v e

ment a s when milling a curved slot or groov e o n a cyli ndri cal

part S ome idea of the variation in diff e rent types may be
.

obtained from the de sign s illustrated i n thi s chapter .

C are S hould be taken to des i gn m il lin g and other fix t ur e s in

such a way tha t the p ar t s to be machin ed will be p rop erly
located and so tha t th e o pera t or who us e s the tools cann ot
,

get t h e work in wron g and thu s sp oil th e p arts The fix ture .

should b e e a sily loaded and un load e d a n d i t S hould b e as o p en

,

a s poss i ble to make cl eanin g easy a n d to p revent p ock e ts for

,

chi p s H ardened st e el sea t s should be ground p aralle l wi th

.

the base after ass embl ing to obtain the be s t results T 0 brin g
,
.

the cost as low as po s sible the tool parts should be standardized

,

wherever practi cable The bodies and ba s e s of fixture s S hould

.

2I I
212 J IG D E S I GN
be made of cas t i ro n a n d kept in stock in various s iz e s to m eet
the requi rements of the sho p whene ver thi s i s p racti cabl e .

C lamping cams dowel p i ns bolts and screws S hould be mad e

, , ,

up in large quantity and steel s eat blocks s traps a n d other

, ,

steel parts should be made of standard stock siz es i f p ossibl e , ,

to pr e vent unne cessary machi ni ng .

F ig 1
. . D t ch
e a ab e l Vi J w
se a s for U s e i n cutt ing ofi B ar S t oc k

F ig 2 . . S t ra ddl -milling
e F i xt ure
D e tach ab l e
Jaws for Vi s e The ch e ap est k in d o f mil li ng
.
—

fixture that can be bu ilt i s a p ai r of d e tachable vi se jaws as ,

S hown i n F ig Th e se jaws are mad e of cold rolled st ee l a nd

. I .
-

casehardened They can be r emoved from the vi se qui ckl y

.

an d rep laced by other jaws It i s advi sabl e howeve r to us e.

, ,

vi se jaws onl y where gr e at accuracy i s not r e quir e d such as ,

214 J G
I D E S I GN
Ad j us table ixtur e for Angular Work O ccasi onally in
F .

every line of manufacture th ere are p arts whi ch are S im p le in

appearance but di fficult to mach in e F ig 5 shows a p art of
,
. .

a belt shifter used on an automat i c machi ne the mak e rs of ,

whi ch u se eight diff erent S hap ed p ieces of thi s kind Th e stock .

is flat and one-half inch thi ck If the S i des of the slots wer e .

perpendicular the manufactur e of the s e piec e s would be ve ry

,

simple but the S id e s are not perpen di cular and the angle s
, ,

they form with the bottom differ wi th each different shaped

piece As a result these p i ece s are difii cult to manufactur e
.
,

without th e p rop e r form of fixtur e .

F ig 4. . F i tu
x re for M chi ning Tw
a o P art s in O ne O p e rati on

The fixture shown in F igs 6 to 8 con si s t s of two parts A .

and B whi ch are clamp ed tog e ther when in the proper posi
, ,

tion by bolts p a s s ing through holes in th e lower casting A

,

and S lots i n the upper ca sting B A tongue planed in the bottom .

of the base A fit s a s lot in the m illing machi ne table to which ,

the ba s e is bolted The upper part B is turned to fit the lower

.

part so that no gib i s r e qui red The part s to be milled are held .

in place by a set scr ew whi ch is not S hown E ach sh ape h as

-
,
.

i t s own number and thes e numbers are stamped upon the

,

top surface of the ba s e A The upper part of the fix tu e can. r

move in either direction from the cente s that by placing r, o

 MI LLI NG FI XTURE S

F ig 5
. . B lt S hift
e er P art s e d in hl Adj u t ab ls e F i xt u re s h o wn in
F i gs 6 t o 8 ,
. inclu sive

F ig 6 . . P t h w i F ig 5
M i lli ng S t e p s D and E of th e ar s o n n .

t h e l ocating pin C in the p ro pe r hole as shown by the number ,

the fixture can be qui ckly set for machining any shape F ig 6 . .

shows the diff e ren t S ize cutt e rs milling projectio n s D and E ,

F ig 5 ; in F i g 7 the central S lot F F ig 5 i s being cut

. .
,
F ig 8 ,
.
,
. .

14 ]
 JIG D E S I GN

F ig 7. . Milling Ce ntral Sl ot in B lt S hi ft P
e er ar t

F ig 8
. . P os i ti on of F ixt u re for C utt i g A gul
n n ar S id e of E nd S lot
21 8 J I G D E S I GN
J and pin F in th e ho l e 0 Thi s s e ts th e swive l p l at e A a t
.

the requi r e d angl e and a l so l ocates th e cross S li de C a t the -

requi red di st ance off center to enable th e work to b e mil l e d by

the ou t er e dg e o f th e cutter Aft e r thi s operat i on has b e e n com
.

p le t e d the sw i v el plate A i s swung o v er to enab l e the pin E t o

enter the hole K S imilarly the cro ss S l i de C is moved so tha t

.
-

the pin F w il l enter the hole M Thi s brings the work in po si.

F i g 10
. . P lan and c
S e ti onal Vi w
e s of M illing F ixt ur e for Pi c h
e e s o wn in F i g 9
.

tion to enabl e the angul ar side B to be mi lled by the outer edg e

of the other cutter on th e arbor .

L e ve r op er at e d F ixt ur e for M lling O il gr oove in B u s hing

- i - .

F igs . and 2 S how a sp e cial m i llin g fix tur e d e signed to hold

I I 1

the brass bushing A wh ile mil ling the oil-groove B The fix tur e .

wi th the bushing in place may be se en in F ig The deta il ed . I I .

constructi on of the fix ture however will b e more clearly , ,

 M I LLI NG FI XTUR E S 21
9

un d e rst oo d b y r eferr ing t o F ig 2 Th e fixtur e con s i sts of a

. 1 .

base C whi ch carri es a s li d e D se t a t an a ngl e of about 3 0 ,

de gre e s wi th th e bas e Th e V b l ock E supp or t s the work

— .
,

whi ch i s he l d b etwee n th e a n gl e p la t es F a n d G P la te F forms

- .

a s t o p for th e w ork whil e p la te G is mi ll e d t o mak e p rovi si on

,

f or the in ser ti o n o f th e we d g e H T h e ha n d l eve r J i s mor e .

-

clearl y s h own in F ig I I To o pe ra te t h i s fix t ur e whi ch may

. .
,

be used o n any m illing machi ne th e cu tte r K i s p l aced in th e ,

'

horizo nt a l spin dl e of the machine a n d t h e fix t ur e s e t up facing

,

i t Th e method o f ho l din g the bush ing durin g the machi n ing

.

of the groove i s ap p are n t from the i llustrat i ons wh i ch S how ,

i t s e ated in the V block and held firmly betw e en the a ngl e

—

F i g 11
. . F ixt u
re for H ld ing B u hings wh
o s en M illi ng O il -gr oove
p l ates b y th e wed ge Aft e r the wedge has b ee n dr i ven into
.

place the cu tte r i s f ed in t o the work to t h e requ i red dep th

, ,

and sli de D i s op era t ed by m e an s of h a n d-l e v e r J advan cing

the bushing unti l t h e p r ope r l ength o f groove h as b een m ill ed .

Thi s fix ture cou l d n o doub t b e gr e a t l y imp roved up o n b y

th e addi t i on o f bet te r m e ans of clampi n g t h e work a n d coul d ,

also be mad e to han dl e a wi d e r range of work by the addi ti o n

of sui tab l e s top s fo r c o n tro lling the l en gth o f th e cut H ow .

e ver for the p art i cular wo rk f or whi ch the fixtur e w as de si gned

, ,

thi s w as n o t tho ugh t ne cessary as t h e qua ntity o f pi ec e s to

,

be machined di d not w arra n t i t .

In d e xing M illing F ixt ur e for Roll e r S e par at or Th e bronz e .

roller sep arator s s een i n F ig 3 form part of the roller bear

. 1

i ng of a gun moun t upo n which the carriage turns when tra in

2 20 J IG D E S I GN
ing t he gun or adjustin g it horizontally Thes e sep ara t ors have .

twenty four hol e s and oppo si te holes must b e in a lignment

-
,

and in a radial position as otherwise th e re wi ll be a creep ing

,

acti on of the rollers relative to their bearing rin g s or tracks .

A m i l li ng mach in e equ ipp ed wi th a s im p le typ e of indexin g

fix ture i s u s ed for thi s work The base A of the fixture i s bolted
.

to the machin e table and the upper p art B i s free to revolve .

Thi s revol ving member has accurately spaced hol e s whi ch are
engaged by indexing plunger C A fter the hole s have been .

. D t i l Vi w f M illi g F i t u h w i F ig 11
F i g 12 . e a e o n x re s o n n .

drilled and reamed they are counterbored by the u se of su i t

,

able tool s The separator rin g s are located on the fixture by

.

mean s of the central bore .

In d e xing F ixt ure for M illing C lut ch e s The de sign and .

—

con s truction of a special form of fixture used for cutting the

clutche s on transmission drive p inion s and S liding gears i s
s hown in F i Th i fi x ture consi ts of a frame A into which
g 4. 1 . s s

the sp indle B is fitted The spindle i s de signed to s erve as

.

a collet chuck on the upper end and is arranged to carry the

large index plate C at its lower end The index plate h as a .

s eries of holes E dr illed in it at a con v eni ent angle to recei ve

222 J IG D E S I GN
fixture i t is customary to put a sheet metal washer between the -

lower face of the pinion and the top surface of the chuck ring I
in order to keep chips and oil from runn ing down into the
divi di ng head
- .

When milling the clutch gear J the sp l i t co ll et i s re p laced ,

by t he expan sion chuck K The body of thi s chuck fit s into

.

the spindle and is locked in posi tion by the chucking ring I .

The work is held on thi s chuck by expanding i t by mean s of

the taper headed screw L which is turned by a square key
-
,
.

F i g 14
. . c
Cros s -s e ti onal Vi w e of u fo M illi ng Cl ut ch
F ixt re r e s and
D t il f W e a s o or k-h l d ing Arb
o ors

The hard e ned ste e l collar M is fitted on the chuck to p ro vi de

a good beari ng s urfac e and re si st wear Th e clu t ch gear is .

shown in position on the chuck by dotted lin e s .

E ight cuts are required to com p l et e the m i ll in g o pe rat i ons

on one of these clutch gears and con s equently i t i s neces s ary
,

to us e an eight point index p late A fter sett in g to bring the

-
.

cutter to the requi r e d depth th e mi l lin g machi ne saddle is ,

move d in un til one e dge of th e cut te r regi sters wi th a p oint

inch to the left of the c e nt e r ; fo ur cuts are then made ,

complet ing o n e S ide of the clutch tee th To m ill th e other side .

of the teeth th e milli ng machin e saddle i s move d out until

,

th e other side of the cutter re gis t ers wi th a point inch

 MI LL I NG FI X TURE S 2 23

t o the ri ght of the cent e r The head is th e n ind exed i re volu

.

t i on to m i ll t h e S ide of the fir s t tooth and the n i revolution ,

for takin g each of the three rema ining cu t s Th e clu t ch t e eth .

a r e cut a li ttle off cent e r i n ord e r t o gi v e th e c l u t c he s th e r e

quire d amount of clearanc e .

The i deas embodi ed in th e design o f thi s spe cia l fix t ur e may

sugge s t oth e r us e s for a t oo l of thi s kin d wher e it i s r e qu ired
to p erform millin g dril ling a n d oth e r o pe rati ons o n work for
, ,

whi ch the regular mi llin g mach in e di vi din g h e ad i s not sui table

- .

F i g 15
. . Contin u ou s M illing F ixt ur e for Lib t y M
er ot or

C nn ct ing- d
o e ro s

Co nti nuou s Milling F ixtur e F ig I 5 shows a cont in uous

. .

mill in g fix t ur e whi ch i s emp l oyed f or the mil l ing of connecting

rods o n a doub l e spindl e ve rtica l mi lling machi n e F our sur
-
.

faces ou the rods are m il l e d at once the top and bottom surfaces
,

at each en d bein g m ill e d simultaneously The main spindle .

,

whi ch i s p ro vi ded wi th t wo cutters one for the upper and on e ,

for the l ower surf ace m ills the outer end of the rod whi le the
, ,

auxi liary spindl e wit h cutters mounted in a S imilar manner

mill s the ins id e end of th e rods F ourtee n connecting-rod s ar e
.

m oun te d in th e fixtur e a t a tim e a n d as th e fixture rota te s o n

,

th e tabl e th e fini sh e d rods ar e t ak en ou t and n ew rods ar e

,

i nsert e d b y the op erator whi l e the work progr e sses E very .

other jaw for holding the connecting rods is fixed while e very -
,

a l ternate jaw is pivoted at one end B y clamping against one .

2 24 J IG D E S I GN
rod with a clamping screw at th e extreme end of the pivo te d
clamp pre s sure is brough t to b e ar upon the ends of th e c on
,

ne c t in g rods
- o n e ach S i d e of the pi vot e d clamp thus maki ng ,

the clamping v e ry rapi d A t the in side end one cl am p a l so

.
,

holds two rods in p lace This clamp is provided wi th a sma ll

.

pin which fits into a slot in the clamping stud so tha t wh en , ,

tightened th e clamp must always be in one po sition and cann ot

,

com e out far enough to interfere with the milling cut t ers .

F i g 16. . F i
xt ur e u
for Ro gh - ini ng m a Cir cul ar S l ot in S ight -b ar
Rad ial Milling F ixt ure s R adial fixture s are so called .

becau s e they are u s ed for machining parts to a gi v en radiu s .

In general the work holding part of the fixture is eithe pivoted

,
,
- r

or i s guided by a curved track so that i t i s given a circular mo

tion when i n us e S ome ingeni ou s ra di al fixture s u s ed for
.

machi ni ng the S ight bars o f naval gun moun ts at the plant of

-
,

the M ead M orri s on M fg C o E ast B o s ton M as s will be

- . .
, , ,

de s cribed The radial or circular surface of the sight bar mu s t

.
-

be so nearly perfect that the sight may be operated through

its complete range of adju s tment s without any binding action
and without perceptible lo t motion between the mo ving part ss .

Th e curved surface s of the sight —bar and of the bearing in the

sight bar bracket mu s t be exactly concentric with the axi s
-
 J G
I D E S I GN
th e same radi us as the S lot B in th e fix t ur e A we ight i s at .

t ach e d to the sad dl e of the machi ne by means of a wi r e cabl e

which is con ne cted at D The obj e ct of u sing a weight i s to
.

hold block C in contact wi th the slot on one side and thus by ,

eliminating all p lay it is po ssible to secure a higher degre e of

accuracy A two lipped end mi ll is used for thi s operat i on
.
- - .

The slot is mi lled in ch wide a n d 3 inch deep 1 .

An other ra di al fix t ure of th e gen era l t ype just d e scri b e d i s

F i g 18
. . Ra a D iff t O p ti
di l Milling F ixt ure u se d fo
S ight -br e re n e ra ons on ar

shown in F ig 7 Thi s fixture i s for the bronze bracket through

. 1 .

which the S ight bar slides whe n be ing elevated or lowered

-
.

It h as a curved slot which must b e mi lled to the same radiu s

as the sight bar to avoid any cramp in g or b inding action A
—
.

fini shed s urface on the bracket A is clamp ed again s t a top plate

or bridge B of th e fixture and it i s further located by a plug C
,

at the right The ba s e of the fixture fits between curved track s

.

or gui ding strips D A t one end of the fixture a tran sv ers e

.

slot is formed and thi s i s engaged by a block pivoted t o a nut

,

through whi ch the feed screw pa ss e s The feed s crew i s con

- .
-

ne c t e d by gearing E with the regular feed rod of the machine -

,
 MI LL I NG FI XTU RE S 22 7
-

m
and as t h e ovabl e secti o n of th e fixtur e i s f e d along a slot is ,

milled to the s ame radius as the tracks .

P ivot e d Typ e of Ra d ial F ixtur e T he curved si des of th e

.
—

S i ght bar and also the b e veled surface s along one edge ar e
-

milled by mean s of a radial fixture of the typ e shown in F ig 8 . 1 .

Thi s g eneral s tyle of fixture is u s e d extensi vely in connection

wi th oth e r o p erations on the si ghting mechan i sm It has a very .

heavy base casting A wh i ch is bolted to the tabl e of th e ma

,

ch ine Th e sight bar B i s held on the sw inging part C of

.
-

the fix ture whi ch i s p ivot e d at D At th e work holding end

,
.
-

of t he swmgi ng member there is a swi vel ing nut through which

p asses a f e ed screw Thi s feed screw i s connected by gearing
- -
.

l oca te d a t th e en d of the table wi th the regular feed screw of -

the machi n e th e nut in the m illing mach ine havin g been re

,

move d ; consequently , whe n a sight bar is be ing milled the

“

-
,

p art C of t he fixture i s gi ven a circular mo vement about the

‘

pivot D as t he p ower f eed trav e rses i t from one end of its swing
to the oth e r Th e i llustrati on shows the machin e m illing the
.

beve l e d ed g es on the top o f t he S igh t bar Wh e n the S ides - .

are bein g m ill e d the cutter S hown at E is us e d A fter o n e s ide

,
.

h as be e n milled the stops F are transf e rred to the opposite

,

side so t hat th e y wi ll not in t e rfer e with the cutter The gage .

u s ed for t e st ing th e radius of the inner surface forms part of

the fixtur e and consi sts of a bar G whi ch is free to S lide through
,

a block H Th is block i s also free to turn about the sam e p ivot

.

which i s us e d for th e swingin g p art of the fixture The radi us .

of the sight bar i s t e sted by bringing the g ag e p o int into con

-

tact w i th i t and the n not ing th e p ositi o n of the end of bar G

relat ive to the outer surface of b l ock H When the e nd of the .

bar and the surfac e of the block are exactly in the sam e plane ,

as indicat e d by tests made wi th a d i al gage the work i s correct ,

.

The S ight-bar i s located in th e fix ture b y th e fini shed face of

the head which also s e rve s as a common locat ing point for
,

many other operat i ons Th e re is considerable o v erha n g of the

.

fixtur e relative to the machi ne table and i n order to avoid ,

sag the overhangin g part is counterbalanced by a heavy weight

,

attached to one end of the wi re cable J which p asses over p ulleys

fastened to the ceiling .
J IG D E S I GN
230 J IG D E S I GN
 MI LLI NG FI XTURE S 23 1

with thi s fixtur e the attach e d cables E an d F p ass in g ove r

,

pul leys abo ve Thes e weights not only counterbalance the

.

ove rhanging parts of th e h e avy fixture but also make it easier ,

to el evate t he kne e for fee di ng th e cutter down past t h e work .

Rad al i F ixt u r e h aving H a n d a nd P ow e r Ope r at e d F e e d

- .

Th e yoke of the sight mechani sm is a cast steel member which -

c arr ie s the telescopes at i ts forward e nd and is attac h ed at the

Fi g 21
. . F i tu
x re for M illin g C urv d O p
Li e e nings in B z
ron e Re c o il ne r s

rear to the sight-bar There are some ra di al m illin g operati ons

.

on the rear end of th e yoke The cur ved surface s at the end .

of the yoke are m ill e d to the requi red radius by a typ e of fix

ture whi ch in many respects is s imil ar to the radial desi gns
, ,

already referred to in connect i o n wi th th e si ght bar Th e

‘

- .

base of the fixture !se e F ig 2 ) is bolted to the t able of a column

. 0

and knee typ e of mi l lin g machi ne and the upper part B is free
-
,

to swing about a p ivot located at the requ i red ra di al di stance .

One radi al mill ing O peration is t h at of form -mi l ling the worm -gear
segm en t in wh ch worm teeth ar e cut later to mesh wi th a worm
i

whi ch enab les th e yok e to b e adjusted horizontally S evera l .

I s]
23 2 J I G D E S I GN
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234 J IG D E S I GN
again t the roller ; therefore when the mi ll ing machi ne table
s ,

i s fed in a lengthwi s e direction the former and liner turn in ,

uni on as the curved section of the openi ng is mil led Two

s .

lugs on the hub of the weight le ver alternately engage a s top

as the le ver i s turned from one po s ition to the other and in ,

this way either the lower or upper side s in the ma s ter former
are held again st the roller C The liner h as a similar opening .

on the oppo site S ide which is milled by S imply connecting the

,

upper end of link D wi th the oppo site end F of the double

exten sion arm !se e end view F ig ,
.

D u pl e x F ixt u re for Rou ti ng O il-gr oove s A duplex type .

of fixture u s ed for routing oil groov e s in bronze bu shi ngs is -

shown in F ig 2 3 The rout ing operation is performed on two

. .

bu shing s imultaneously and a drilling machi ne i s used for

s
,

the operation The oil groove s of the bu shings in thi s par

.
-
,

t i cu lar ca s e extend around about two thi rd s of the circum

,
-

ference of the bu shing and branch out into a Y shape at each —

end The horizontal spindle of the fixture is rotated for feeding

.

the bushing past the routing tool s by handwheel A which , ,

serves to revolve a worm me shin g wi th wheel B The axi al .

movement of the fix ture spindl e is derived from cam groove s

on each side of gear B The S hafts C and D carryi ng the roll e rs
.

have rack teeth whi ch engage the segment gears formed on

the pivoted lev er E B y swinging this lever in o n e di rection
.

or the other the rollers are altern ately engaged When th e

, .

left hand roller i s engaged with its cam gr oove the left ha nd
-
,
-

branches of the Y S haped oil groo ve s on each bushing ar e

- -

milled and when the right hand roller is mo ved inward the
,
-

ri ght hand bran che s of the o il groov e s are milled

- -
.

P l aning F ixt ur e s F ixture for plani n g are as e ss ential for

. s

interchangeable manufacturing as are drilling jigs or mill ing

fixture s P laning fix ture s s erve primarily the purpo s e of locating
.

and holdi ng the work but they are often provi ded with s etting
,

pieces or templet s whi ch are u ed for s etting the cutting tools s

so that the work is always machined in a certain relation to

th e locating means o n the fixture itself S ome mi lli ng fixtures .

al s o have thi s tool sett ing feature - .

The strength of fixtures S hould be gov e rne d by the kind of

 P LAN I NG FI XTU RE S 23 5

operat i o n to b e carrie d out o n th e w ork whi l e in t he fix ture ,

whether p la ning m il ling slotting e t c a n d how much stock

, , ,
.
,

i s to b e r emo v e d A m ill in g fixtur e as a rul e mus t b e made

.
, ,

strong e r tha n a p l ani ng fix tur e b e caus e a m illi ng cu tt er or

,

d inarily t akes a h e avi er ou t than a p lani n g t oo l M a n y of the .

f e atur e s of te n found on mil l ing fix tures may b e app lie d to p l aner

fix tures wi th whatever cha nge may b e ne c e ssary o n accou n t of
the parti cular ope rati on r e qui r e d A s a rule mi ll ing and p lan.
,

ing fixtures are provi d e d wi th a t o ngu e o r k e y in th e base for ,

locatin g them o n the ma chi ne tabl e S uit abl e lu g s sho u l d a l so .

be provided for clamping th e fixtur e t o th e p lat en .

The most commonly used fix ture for p l a ning S haping an d , ,

milling is th e vi se S tandard vi ses ar e indi sp e n sab l e in p l ane r

.

or mil lin g machin e work or o n the shap er a n d by slight cha n g e s ,

they can be us e d for a large vari ety of small e r pi ec e s Th e .

regular vi se jaws ar e often r ep l aced by fal s e jaws whi ch may ,

be fitted wi th locating p in s a n d s e a t s a n d h e l d t o t h e vi s e t h e ,

same as the re gul ar jaws Vi s e s wi th fa l s e vi s e jaws ar e e s

.

p e ci ally ada p ted for m i l l i ng o pe rat i o n s but v i ses are n o t usually

,

employ e d for long work sp ecial fixtur e s b eing commonly used

,
.

P lan ing F ixtu r e s fo r Lath e Carr i ag e Cas ting A ssume t hat .

-

a s e t of planing fixtur e s for the p iece s hown in F ig 2 4 is re .

quired Th e work i s a S lide or carri age for a lath e The finish

. .

in g marks gi ven o n a n umb e r of th e surfac e s in di cate where th e

work i s t o be fin i shed In t h e first p lace i t must b e con s i der e d
.
,

from whi ch sid e s to l ocate and how to l ocat e and hold th e work
,

without springin g it a n d in wha t ord e r th e o pe rat i ons should

,

be p erformed to b e st advan tag e F ig 2 5 S hows a fixtur e for . .

roughin g out th e w ays on th e bot t om Th e s lid e i s l ocat e d on .

three fixed l oca t ing p oint s A a n d the s l i d in g p o in t B Thi s .

lat t e r is adjustable in ord e r to en ab l e p l aning t h e s li d e as ne arly

as p ossibl e to uni form thi ckne ss S ometim e s i f t h e p arts A .
, ,

F ig 2 4 b e vel toward the en ds lugs G may b e added ; t h e s e

.
, ,

can th en b e fini shed a n d us e d for locatin g purpos e s Th e car .

riage as shown in F ig 2 i s furth e r located aga in st th e p in s C

, 5 .
,

in ord e r t o in sur e t ha t th e cross s li d e of t he carri ag e wil l b e

-

squar e with th e bot t om ways The S l id e i s brough t up s i d e

.

wi s e again s t t h e pin D an d th en cl ampe d do wn i n co n venient

,
236 J G
I D E S I GN

F i g 24 L tha e C arr i age C as t i ng m pl

An E xa e of W or k i ll u s tr at i ng Po i nt s
i u D ign
. .

in P l an e r F xt r e es

F i g 25
. . F ixt ur e u hp
for Ro g - l ani ng Way s for Carri age Cast ing
23 8 JIG D E S I GN
The fix ture for th e next o pe ration is S hown in F ig 2 6 Thi s . .

fixtur e is made to receive th e carri age and locate it by the n ow

rough-finish e d ways ; in t his fixture t h e cross slid e dove tail is
,
-

plan e d Th e S lide rests on four fin ished p ads A an d th e s traight

. ,

S i d e B o f th e w ays in th e sl i d e brou gh t u p a g a in s t t h e fin i sh e d

F i g 27
. . F ixt ureB tt m W y
for F ini s h-pl
aning o o a s

surfac e s C If no other part i s ava il able for clamping th e fixtur e

.

on the machi ne t able lugs E ar e added If ther e ar e no ta per

,
.

ing surfaces th e fixture can b e loca te d o n th e machin e tabl e

,

by a ton gue or by placing a fini sh e d side again st a parallel .

Th e slid e or dove t ail is now rough e d out an d it i s usually suffi

ci e nt ly accurate practice to fini s h it in t h e sam e s e tt in g e s ,
 P LAN I NG FI XTUR E S 239

p e c i ally as S l ides mus t always be scrap e d and fit t ed t o suit the

machi n e o n which th ey ar e to be us e d .

The nex t ope ra tio n woul d b e pe rform e d in th e fix tur e illus

t ra t e d in F ig 2 7 Th e ca rriag e i s h e r e l o cat e d b y t h e dovetail
. .

an d by th e pin B an d he l d b y a gib C or by strap s a n d scr ews

, , ,

as S hown It will b e n ot i ced t hat with t h e gi ven d e sign th e

.
, ,

s t rap s an d scr ews mus t be r emove d e ach t ime a n ew p ie c e is

in sert e d whi ch i s a n u n d e s i rabl e fe atur e of t h e fixture If
, .

parts A in F ig 2 4 p roj e c t out t oo f ar so t hat a light fini sh in g

.
,

cut would caus e sp rin ging t h e y are supp orted by S li ding po ints
,

or other adjus t abl e l oca ting m e an s .

I f t h e doveta il in th e S l id e h a d S im pl y b een rough finish e d

-

in t h e fix t ure in F ig 2 6 th e fini sh ing o f the b otto m ways could

.
,

have b een do ne in th e fixture in F ig 2 7 a n d the n after h avin g .

, ,

fin ish e d t h e b otto m w ay s in thi s fixture the work could again ,

have b een l ocat ed in t h e fix t ure in F ig 2 6 an d th e dovetail .

,

fin i sh e d ; thi s mi ght in sure mor e accura te work in some cas e s .

In t h e cas e jus t descri bed the work r e quire s three d iff e r en t

,

fixt ur e s to b e compl e t e d The numb e r of fix tures to use i n

.

each cas e i s en t ir ely d epen d ent upon t he n a ture of th e work .

Wh en t h e r e i s a l arg e amoun t o f work of th e sam e kin d to b e

done s ev er al fix tures o f t h e sam e type ar e made up for th e sam e
,

piece and wh en in us e t h e s e fixtur e s ar e p l ac e d in a row o n the

,

tab l e of t h e machin e .

G ang-plani ng F ixt ur e s It i s very commo n in pl ane r p rac

.

ti ce to loca te a n umb e r o f dupl i cate cast in gs or f or ging s in a

row extending l engt hwi s e o f t h e t ab l e a n d then p l an e t h em all
a t th e sam e tim e Gan g p l ani n g i s oft e n don e wit hou t a spe c ial
.

fix ture by simp ly cl amp ing th e work d i rectly up on the t abl e

, ,

bu t fix ture s mak e it po ssibl e to s e t up work mor e rapidly and

accura tely B es id e s ma n y p iec e s ar e o f such a shap e t ha t a
.

fixtur e i s ne c e ssary in order to hold t h em in t h e corr e ct p osit i on

for planin g An examp l e of w ork r e qui ring a fix tur e i s S hown
.

in F ig 2 8 Twenty three for gin gs ar e p l ane d at o ne t im e and

. .
-

four cu tting t ools ar e us e d two b ein g h el d in th e s id e h e ads

,

whi le two are a t tached t o t h e h e ads of th e cross ra il The forg - .

in g s are l o ca t e d at ri ght a ngl e s to th e l e ng t h of the p lane r tab l e

.
2 40 J IG D E S I GN
 C H AP T ER X

AD J US TAB LE X
F I TURE S F O R TURRET LATHE S AND
VE RTI C AL
B O RI N G I S M LL
When p i ec e s of th e sam e type but of vari ous s izes are to
, ,

be mach ined on the turret lathe or verti cal boring mill it is ,

somet imes de sirable to design t h e t ools and fixtur e s in such a

way that they can be adap t e d t o handle the d iff e rent p i eces ,

thus avo idin g the n e c e ssi ty of p rovi ding a s ep arate tool or

fix ture for each pi ec e N aturally wh en th e p roduct i on i s la rg e
.
, ,

such a p rocedure as thi s would b e unp rofitable becau s e th e

'

t ools could only be used o n on e pi ece a t a t ime and a lot o f ,

piec e s of one size m ight b e held up f or a consi derable tim e wai t

ing for a lot of anoth e r S iz e to be mach ined When however
.
, ,

the work comes along in lots of from I 00 to 2 00 pie ces a gr ea t ,

saving in tool cost can be eff ect e d by the us e of adjustabl e

tools and fixtures providing the de sign of the p arts is such tha t
,

i t wil l perm i t of followin g thi s p racti c e Much depends upo n

.

the shape of the work to be held and its machin ing requiremen ts .

There ar e in s tances wh en the desi red results may be obta in ed

by simple means and there ar e other ca s es which requir e th e
,

application of considerable ingenu it y in order to avoid com

plication s in the de sign P roperly design e d an d car eful ly bu ilt
.

tool s and fixtures of th e adju s table typ e ar e profitable invest

ments on certain classes of work and the ir advi sability should
,

be carefully con sidered when several pieces of the same general

type are to be handl e d The great e s t forethought i s neces sary
.

in de signing fixtures of thi s kind in order to make sure that

,

e very point for e very piece h as rece iv ed proper con siderati on .

There is probably no other type of fixture whi ch requi res so

much care in i t s design and for that reas on the important
,

p oint s given herewi th should be mo s t carefully noted .

Important P oint s in D e s ign . The number of pieces to

I .

be machin ed should be the firs t po in t consider e d as thi s natu ,

rally has an eff e ct on th e d e sign of th e tools and fixtures .

242
 AD J U STAB LE FI XTUR E S 243

2 . The l arge st and small e st pie c e s in t h e group should be

s e lect e d and the machi ne on which the work is to be done
,

S hould be determ in ed accordi ng to the s iz e s of th e se p i eces .

If the variat i on in size i s con siderable it may be economical ,

t o do a p art of the work on one machine and th e rema inder o n

another in which ca s e the fixture should be so made that i t
,

can be adapted for u se on both machines Th e re may even be .

ca s es when the range of sizes is s o great that two or more fix

tures may b e nece s sary one of which can b e us e d on one machi ne
,

and the ot her on a diff erent one ; or they can be made inter
changeable providi ng the speeds on both machi nes gi ve r ang e
,

enough to handl e the w ork Th e se p o int s should b e car e fully

.

consider e d .

3 . The accuracy r e qu i r e d in t h e fin i sh e d work S hould b e

n oted a n d care taken to provid e mea n s of up keep o n surfaces

or locating p o i nts that are subject to wear There may be .

occasi onal in s tances on work requi ring extreme accuracy whe n

, ,

i t may be nece ss ary to pro vi de mea n s of adjustm e nt for truing

u p the fixture so that it wi ll a lway s run pe rf e ct ly conc en tri c
wi th the sp in dl e o f th e machi n e .

4 Rigi dity in work hol di ng d e vi c e s a n d t ools sh o uld r e ce i v e

.
-

ca reful attenti on ; an d overhan g from the spin dl e turr e t or

c u t off s li de S hould be ke p t dow n t o a m inimum
, ,

- so that chatt e r
,

will not r e sult from lack of supp or t These po int s ne e d mor e

consi derat i on when the tools a n d fixtur e s ar e t o b e us e d o n
the horizontal typ e of machi ne t han wh e n a ve rti cal machin e
,

is to be emp loyed .

5 . C lamp in g d e vi ces f or adjus t ab l e fix tur e s shoul d b e l a i d

out !by m e ans of a p ie c e of trac ing p ap er) for e ach pie c e t o
be handled so that there wi ll be no chance of clamp s b ein g t oo
,

long too short or imprope rly p ro p ort i oned for som e of th e

, ,

work E rrors are v e ry l ikely to occur in t hi s p art of the d e s i gn

.

unless the greatest care is used ; and ther e are also ca s e s when
the work varie s in thi ckn ess as well as in d iam ete r ; therefor e ,

thi s p o in t mu st be ca reful ly con sider e d .

6 P rovi s i on for clea nin g the fixt ur e mus t b e mad e so tha t

.
,

all loca ting po int s an d su rfac es wil l be rea d ily accessible I f .

2 44 JIG D E S I GN
several sizes of s tuds or l ocatin g rin g s ar e to b e us e d t hey mus t ,

be so arranged that chi p s and dirt wi ll not int e rfere with the
p roper location of the work They must also b e p lac e d so t h at
.

they can be easily replace d or remove d

“

7 .The adjustments w hi ch are necessary to prov i d e for

handling variou s sizes of work should be carefully studied an d ,

sui table provi sion should be made so that the changes from o n e
s etting to another wi ll always be un i form and vari atio n s i n ,

the work cannot occur due to errors in adjustment If n e cessary .

,

setting gage s can be made for the vari ous p i eces to be handled ,

or a s ep arate set of screws or other adjustable locat ing members

c an be made for each p iece and pro p erly stamped to a vo id m i s
takes The nature Of the work h a s a grea t deal to do with the
.

method used to secure uni form adjustmen ts and sp ecifi c cas e s ,

will be noted in followin g p aragrap hs .

8 C on venience and rap i d i ty of o p eration S hou ld b e gi ve n

.

con sideration and provision S hould be made for setting up

,

the work in as short a time as possible The fixture s hould b e .

so arranged that the work can o nly b e set up in the correct

way and it S hould b e as ne arly fool proof as p ossible
,
“ -
!
.

9 .The cost of the fixture shou l d be ke p t down to the low e st

figure that i s con sis tent wi th go o d d e sign because the numb e r ,

of p ieces to b e machi ned is comp arat ively small If th e work .

for whi ch the fixture i s mad e i s of such a nature that it i s not

li k e ly to be changed a little mor e latitude is p ermiss i ble ; but
,

as changes in design are always possib l e i t i s advi s able n ot t o ,

make an elaborat e fix tur e .

1 0 Th e safety of t he op era t or sh ou l d a lways b e cons id e re d

.
,

and p rojecti g lugs s e t screws or other parts wh i ch mi ght

n -
, ,

catch in hi s cl othi ng should be elim inated from the design .

O ther p o ints i n de sign not mentioned in the fore g o in g wil l be

sp ec ifically mentioned throughout thi s chap ter ; commen ts
will be made and faulty points criticiz ed and discussed
, .

The three or four jawed chuck is perhap s t h e most fre

-

quently used of all th e holding devi ces which are adjustable

to tak e vari ous s izes of work There are als o collet s of numer
.

o us kin ds whi ch are adjustable wi thin certa in limi ts and s tep

, ,
246 J IG D E S I GN
and fin i shed pi ec e s principally for bar work or som e thing of
a similar character Wh en a round piec e of work is to be mad e
.

up in s everal S izes and is of simple form it may often be handled ,

to good advantage in a set of soft jaws appli ed to a three jawed —

universal chuck These jaws are bored out on the machine

.

to the exact diameter of the finished work and when s e t up o n ,

the piece they p resent a good holding surface with su fficien t

accuracy for the ordi nary run of commercial work .

Ad j u st ab l e F ix t ur e for H ol d ing Ca stings of D iffe r ent D iam

e t e rs . F ig. I S hows at A and L the smallest and larg e s t S izes

of castings to be machined on a horizontal turre t lath e ; and

there were two intermediate S izes whi ch were also handled on
the same fix tures A special nose piece C i s scr ewed to the
.
-

end of the spindle and has a hub at its forward end on which
the locatin g ring B !upper view) is fix ed The fini sh e d portion .

of the work fits this ring at D and is drawn back aga in st i t by

the collar G ; th e rod E pa ss es through the sp indl e and i s pulled
back by m e ans of a handwheel at th e end whil e th e key F ,

prevents it from turning The forward end of the rod is .

threaded to receive the knurled finge r nut H whi ch has a —

S pherical b e ar i ng i n the collar G to e qualize th e pressure In .

setting up th e work the piece is placed o n the locat ing ring

, ,

the collar G i s slipped over the end of th e rod E and the

knurled nut H is rapidly scr ewed on wi th the fingers after ,

which the handwh eel at th e end of the sp indle is u s ed to

tighten th e collar A long boring tool J is us e d to rough out
.

the shoulder e d portion of the work and t o bore the bearing ,

and it wi ll b e not e d that although thi s tool has considerable

overhang it is well s e t up in the tool holder K an d given addi -
,

t ional strength by th e us e of two t o olp os t s .

The larger p ie c e L sh own in the lower part of t h e illustra

,

ti o n i s s e t up o n th e rin g M locat ing on the surfac e 0 whi ch

, ,

ha s b e en p revi ously bored A larger collar N i s used for clamp

.

ing thi s p ie c e With th e exception of the locating rin g and

.

collar all of the other parts of the holdi ng devi ce are the sam e
,

as in the p rece d ing insta n c e A ddit ional rings and collar s f or

.

th e inte rmed i at e S ize s make t h e fixture comp l e t e It wi ll be .

 AD JU S TAB LE FI XTUR E S 247

n ot e dthat th e re are two holes in the front of th e nose piece -

,

whi ch are so p laced that a r od may b e u s ed to dr i ve off the

locat ing rin gs when chang in g o ver th e fixture for anoth e r s ize
of work Thi s fix ture i s S impl e and comparatively inexp e ns iv e
.
,

F ig 2
. . H l d i g B l-g Bl k f V i u S iz
F ixt ur e for o n e ve e ar an s o ar o s es

y et i t i s adap t e d for use on four piece s of work of different S izes

and th e chang e s required are of such a nature that they may
be perform ed quickly so that th e re i s very little loss of time .

It may fut h e r be noted that the boring tool is the same in

I 6 ]
 248 J IG D E S I GN
each ca se and that the adj u s tment for diff er e nt diameters is
obtained by the cross sliding mo vement of the t urret .

Ad j u stab le F ixtur e for S pe cial e ve l g e ar B lanks

B - The .
—

work A shown in F ig is a special be vel gear blank and these

. 2 -
,

gears are us e d in a gr e at number of s ize s on textile machinery .

The pieces were held in the firs t setting by the i nterior and were
machined on the sid e having the be veled surface and on the
periphery ; they were al so partially under cut along the edge -

of the rim in order to p rovide a clamping s urface during the

second s etting E xtreme accuracy was required i n the work
.
,

and yet there w e re so many S izes to be handled that the con

s tructio n of s ep arat e fixtures was deemed inad vi sable A .

S pecial fac e plate B was therefore de s i gned having thre e radial

, ,

doveta il slot s C !uppe r vi ew) in i ts face ; and a small portion F

of each of thes e slots was l e ft straight to assi st in locating the
movabl e jaws D These jaws were mad e of steel and were
.

radially adjustable t o vari ous di am e ters be ing clamp ed in any

,

d e sired posi tion by means of the screws G and the do vetail

s hoes E . A numb e r of set s of soft steel supplem e ntary j aws H
were drawn back into a seat on the main jaws by the two screws
J and were bored in place to the d i ameter of the out side of
the gear the main j aws being set in place to a n approximation
,

of the correct diameter in each instance .

The clamps K were drawn down upon th e fini sh e d portion

of the work by means of th e screws L in the j aws A bushing .

M was set in the c e nter of the faceplate and us e d as a guide

for the pilot N of the boring bar P which was held in the
-

turret The tool 0 was used to bore the hole whi le the tool Q
.

faced the unfini sh e d portion of the gear blank the latter tool ,

being held in two t oolp ost s R on th e cut off S lide In handling

- .

some of the larger g e ar blanks a supplem entary h e ad T !lower

,

vi ew) was placed on the end of the boring bar and held in place-

by the screws U on th e fiat t e d portion of the bar Thi s head .

gave good support to the tool S wh i ch was used for boring the
larger sizes of gear blanks Thi s tool was held in pla ce by the
.

s crews X and V the latter pa ss ing through the hole pro vided
,

for it in the bar F ine adj u s tment s were provi ded for in the
.
2 50 J I G D E S I GN

F ig 4
. . Si mmF ixt u
e re for H l di
o ng Th S iz f S t l Fl
re e es o ee ange s , wh il e
bo ri ng , f cing
a , and cutt ing P cking G v
a roo e s

The s crews N are set in to the ring from th e rear a n d ar e

located in different place s for the variou s rings The fixture .

has three T s lots G in order that the clamp s E may be con

—

ve ni e nt ly adjustable by means of th e T bolts F wh i ch en ter -

 AD J U T S ABLE FI XTUR E S 251

the se slots The boring and shoulder work performed o n the

.

p i e c e i s accomplish e d by th e shove l nos e d tool 0 wh i ch i s

-

moun t e d in the tool holder P o n the turr et T hi s is an example

- .

o f a fix t ur e d e s igne d for sta n dard work of various S izes coming

t hrough in small lots and wh i ch requ i r e s extreme accuracy in

,

machinin g The fix t ure i s a comp act desi gn and i t i s built

.

cl ose in to t h e sp indle so that a l though the fix ture i tself is ,

heavy th e re i s so li tt l e ove rhan g t hat the we ight i s of small

,

imp ort a n ce .

Ad j u s t ab l e Fixt ur e s for th e Ve r t i c al B or ing Mill Th e .

—

t ab l e of a vert i cal boring m il l i s so arra n ged that i t may be

us e d ei ther as a facep lat e or as a chuck wi th provi sion for clamp
ing in t h e T-S l ots wh en ne c e ssary Th i s i s a di sti n ct advantage .

in ma ny kinds of work and espe c ially so wher e a numb e r of

pie ces of s im i l ar co n struct i o n a n d d iffer e nt siz e s are t o b e
h a n dl e d F ig 4 shows a s imp l e fix tur e for ha n dling thr ee S iz e s
. .

o f s t e e l flanges A Th e bas e C o f the fixt ure is made of ca s t

.

ir o n an d i s c e nt e red by a p lu g D in th e table hole ; a n d i t is

f as tene d down to th e t ab l e by m e a n s of th e scr ews F which enter
sh oes in the T sl o t s I n th e upp er i llustrati on the work A has
- .
,

be e n pr e vi ousl y turne d fac e d a n d partially under cut t o pro

,
-

vi de f or cl amp in g and i t i s h e ld during th e first s e tt ing by

,

means o f jaws o n t h e in si d e of the flan ge .

On the s e co n d s e t tin g !shown in th e up p er i llustrat i o n) the

ope ra ti on s p erform e d consist o f bor ing t h e hole facing the ,

flange as far as th e cl amp s and cutt ing the packing groo ves O
,
.

The loca ting rin g B i s slippe d o n th e fini shed port i on of the

,

bas e a n d i s drawn down by th e screws E The clamps H are .

supp or te d a t th e ou te r e n d b y th e wood en blocks K and are ,

drawn down upon the work by nuts and wash e rs J through

t he m e d i um of the T -bolts G wh i ch ar e adju s tabl e rad i ally in
t he t abl e S lots The bori ng bar L i s us e d for borin g th e interior
.
-

of the flan ge wi th th e tool M w hil e th e s ide h e ad !not shown) ,

f ac e s the fla nge a n d cuts the p ack ing groov e Th e l ow e r illus .

t rat ion shows the fixture adapt e d for hold in g t h e larg e st piece

Q wh i ch i t handles In this case.the r i ng N i s made of some ,

wha t d iff erent shape so tha t i t wil l locate properly on the

2 5 2 J IG D E S I GN

F ig 5 M th d
e o of h l ding Th
o re e z
Si e s ofW or k whi c h h as b e e n b or e d
H
. .

and fcd
a e and h as h ad t h e ol e s d r ill e d in F l an g e

fini shed portion of the ba s e C All other portion s of the fixture

.

are th e same as in the preceding in s tance the clamp s H being ,

moved outward in the T slot s a su fficient amount to take care

-

of the work of larger diameter The tool s for boring facing .

, ,

an d cutting the packing groo ves P are al s o the same .

2 54 J IG DE S I GN
tion cut approx imately central with th e cored ho l e at Y F our .

hole shav e also be e n jig drilled at J Two S izes of the s e brack e t s

- .

were made several time s each year in lots of t e n or twelve so ,

that the expen s e of a comp l ete fix tur e f or machini n g e ach pi ece

F ig 6 . . p
In e x e ns i ve F ixt ure for Hol di ng Tw
o Si z e s of B ck e t
ra s

would hav e been excessive in view of the number Of pi e ces

produced The following equipment proved s atis factory : An
.

angle plate B is tongued on the under side F to fit one of the

-

table T slot s and is held down by s crews !not s hown ) The

-
.
 AD JU S TABLE FI X TUR E S 2 55

di stanc e E f or
the two s izes of bracke ts is e asily d e t e rmi ned by
placing a stud G i n the cent e r hole of the table and locating
the angl e plate B from it The bracket i s placed in position
- .

on the angle plat e so t hat the to ngu e H fits into th e groo ve

-
,

F ig 7. . Adj u t
s ab el F ixt u f re or H l d ing
o Th r e e S i z e s of B z
r on e
W or m-g e ar c
S e t ors

an d the bolts J ar e passed through th e hol e s in the brack et a n d

tightened by the nut s at K .

A l i ttle freedom is a l lowed in the bolt holes and the finished

e dge of the bracket res t s on the pins C Two special j aws Q ar e .
256 J I G DE S I GN
fix ed in p osi tio n o n th e t ab l e bu t may b e adjuste d radi ally
when nece ssary to brin g t h em int o the corr e ct p osi ti o n for the
other s iz e of bracket Th e jaws are p rovi d e d wi th set scr ews O
.
-

whi ch are adjusted t o supp ort th e ove rhanging e n d o f t h e

bracket a ft e r which they are l ocke d by th e ch e ck nu t s a t P
,
- .

The j aws are k eyed at S to th e sub jaws of th e table ; a n d th e -

clamps N ar e used o n th e unfi ni shed port i on of the bracket ,

being t ighten e d by the nuts a t R so that t h e surfac e t o b e ma

chined is clear of int erfer en c e s Th e boring bar L i s u s ed to
.
-

bore the hole an d th e S i de head t ool M fac e s t h e p ad Thi s is

- .

another example of a table bein g us e d wi th a fac ep lat e havi ng

adjustable moving parts on i t .

Ad j u s t ab l e F ixt ur e for a B r onz e Wormge ar S e c t o r

- The .

fixture S hown i n F ig 7 was d e signe d t o ha n dl e t hr e e size s of

.

the bronz e worm gear sectors A Th e bas e B of the fixture i s

- .

c ent ere d on th e t able by m e an s o f th e s tud G in the c enter

hole and i t i s clampe d secur el y by m e an s of thr ee scr ews P
,

which ent e r shoes in the table T slots An adjustab l e V block - .

-

C i s mou n ted on a fini shed pad a n d ton gued o n th e u n der s i de

to fit the slo t D All the jaws o n th e tabl e chuck ar e removed
.

and a special jaw K i s substi tut e d for one of th e m Thi s jaw .

is S lightly u n der cu t o n i ts fac e to ass i st in hold in g down th e

-

work an d at the sam e t ime i t forc e s the hub of th e cas t in g up

,

into the ve e locating b l ock A S lot 0 i s cu t in t h e bas e of the

.

fixture in order to allow the n ecessary movem en t for thi s jaw .

The hub rests o n a h eadl e ss set-scr ew H whi ch i s tapp ed in to

the bas e and two oth e r adjusti ng screws ar e provi ded at J
,
.

These are adjusted by m ean s of a wr e nch after the jaw has b ee n

tightened The set screw H howeve r rema in s set after it has
.
—
, ,

been adjus te d to su i t th e parti cular pi ece which i s b eing ma

chined A dri ving screw at L takes t h e thrust of th e cu t and
.

may be remove d a n d place d in either of t h e holes M or N when

u s ed for the oth e r p i eces In settin g th e V block for an other
.
-

dia me te r of hub it is o nl y ne cessary to loosen the screws F

,

and move th e block radially to the desi r e d p osition The jaw K .

is readil y set to siz e while th e scr e ws J an d L ar e p lac e d in hol e s

provided for them .
2 5 8 J IG D E S I GN
de signs wi ll be described so that the vari ous de vice s shown
may be applied to a wide range of work .

It is well to state that i n conn e ction wi th the applicati on of

the floating p rincip le the greatest care must be u s ed in the
,

de sign in order to mak e sure that it is correctly applied as ,

i t is quit e po s sible to obtain a float in s ome portio n of a “ !

devi ce or tool which bein g of faulty con s truction w il l not

, , ,

produce the results de sired .

Important P oint s in th e Applic ation of th e F loating P rincipl e .

In order to obt ai n the mo s t s atis factory r e sult s in it s app li ca

t ion a few point s are here noted which are worthy of attention
,
.

I As appl i ed to clamping or holding methods the greate s t

.
,

car e must be u s ed in order to make sure that the float ing action
i s not constra ine d in any one direction but w il l o p erate equally ,

well a n d wi th uni form pre ssure on the requir e d area F ric .

t ional res i s tance may at time s be s u ffi cient in cases of this k ind
to cau s e imp erfect work by reason of unequal pre s sures o n the
work itself When the clamp ing action is appli ed to a rough
.
,

surface still greater care mu s t be used in t hi s regard a nd th e

, ,

amoun t of float must be so proportioned that i t will tak e care

of a consi derab l e vari ation in the ca s tings or forgings Wh en a .

great number of p ieces are to be handled s everal pattern s are ,

often used and the s e will be found to v ary s omewhat so that

there are slight diffe rences i n the re sulting castings F or thi s .

reaso n due al lowanc e must b e made

,
.

2 Whe n app l ied to methods of locating th e work or as

.
,

supp ort ing p oints on whi ch i t re s ts the con s truct ion mus t b e
,

su ch that i t wil l not by any p o ssibility cause di stortion If .

s p ri n g s are us e d under sup porting plug s which are afterward

t o b e l o ck e d in p ositio n the spri ng s mu s t be proport i oned so

,

that they wi ll n o t be strong enough to cau s e a n y trouble by

forcing the p i e ce out of its tru e p ositi on Al so when support s .

are placed against fini shed surface s they S hould be so arranged

t ha t t hey wi ll not injure them In locat ing a p iece of work from
.

two pr evi ou sly machined surface s whi ch are i n di fferent planes ,

the float action mu s t be very carefully studi ed so that the con

-
,

t acts are pos i ti ve ly a s sured and no til ting of t h e work will

,
 TH E F L O ATI NG PRI N CI PLE 2 59

re sult There are occasional in stances which requi re t h e l oca

.

tion of a p iece of work from a p reviously machined surface in ,

connection wi th a thr e aded p orti o n by which i t must be clamped .

In a case of thi s ki nd th e float mus t be made so t hat i t will

,
“ !

F ig 1
. . Pi t D il l J ig h ing F l ti g Cl mp
s on r av oa n a s

take car e of a p ossible la ck of co n centri ci ty between the thr ead

and t h e oth e r fini sh e d surfac e s and a t the same t im e p rovi de
means of equalizin g var iati ons i n th e al ignmen t o f th e t hr e ad .

3. L ock i ng dev i c e s for float i ng m e mb e rs must b e so ar

ranged that the members can be pos it ively locked or clam p ed
wi thout cau sing any change in the i r po si ti on s A turni ng .
2 60 JIG D E S I GN
action such as m ight b e caused by th e e n d of a scr ew agains t
a locat ing point is often sufli cie nt to throw the work out of i ts
correct position The interp o sing of sho e s between screw s an d
.

floatin g m e mbers wi ll p r e vent any t rouble of t hi s k ind .

O th e r p o ints in construct i on and de s ig n will b e note d in

conn e ct ion wi th the examples to be descri b e d .

P i s t on Dr ill J ig with F lo ati ng Clamps A v e ry g o o d ex

.

ample of a drill jig whi ch i s p rovi ded wi th a float ing cl amp to

work on a rough surface i s shown in F ig the work b ein g a
. I ,

pis ton cast ing A whi ch has bee n p revi ousl y mach ine d at B .

The body of the j i g G is of sem i box sect i on and i s p rovi ded wi th

-

feet D on whi ch i t may b e rested both during the l oading and

,

when under the drill A hardened and groun d s te el s t ud E is

.

let into the casting at one end and serves as a locat in g p o in t for
the machi ned int e ri or of the p i ston B A stud C i s f urt her p ro
.

vid e d to gi ve the correc t locat i o n to th e wr i s t p i n boss e s -

.

As t h e e nd of the p i ston i s of sp herical shape and in the rough

stat e al so it i s ne cessary to p rovi de a means of clamping whi ch
,

will so adjus t it s elf t o t h e inequali t ies of th e cas ting that an

equa l p ressur e will b e obtai ned so that there will be no t e ndency
to t ilt the work A heavy latch M i s p ivoted on the p in L and
.

i s slo t ted at the other e nd t o allow the passa ge of the thumb

screw N whi ch i s used to clamp i t i n posi ti on A sp e ci al screw .

0 i s t h re ad e d in to t h e lat ch and i s bal l en ded at P s o that it

-
‘

has a spheri cal beari ng aga inst the float in g c lamp Q The .

screw S keep s i t in p osition but i t wi ll be noted tha t clearance

,

is pro v i ded t o a l low for the float in g moveme n t around the body
of the scr ew Thre e p in s R are set 1 2 de gr e es ap art in th e
. 0

face of the float in g clamp so tha t a firm thr e e -p o in t b e aring is

assured In order t o a ssi s t i n s upporting the work un der th e
.

p re s sure of the dri ll two s pring p ins T are provi ded these
,
-
,

bein g set in t h e form of a ve e near the front end of the pi s ton .

They are encased in a screw bu sh ing U and are l ocked in p osi

t ion by m e ans of set screws not shown aft e r they have b een
-
, ,

allowed to sp ring up against th e p i ston casting !In order to .

avoid confus ion in the drawing one of the s e p in s is shown at

,

an angle of 4 5 degree s from i t s actual posi tion ) .

262 J IG D E S I GN
other work has been don e upon i t the S i des b eing l ef t in th ei r
,
.

natural forged shape Six holes ar e t o be dr il led around the

.

rim as S hown at N and it will b e s een that som e care i s ne ce s

, ,

s ary i n th e locat ing and clam pin g arrangem e nts so that the

resulting hol e s will be parallel wi th th e axi s of t h e col lar The .

j ig body C i s of cast i ron and i s p rovided wi th a harden e d a n d

,

ground st eel l ocating col l ar B on whi ch the p revi ously machi ned
interi or of the ring i s locat e d Th e ring i s p laced o n this steel
.

collar restin g again s t the single s teel bush i n g D whi ch i s i ns e rted

in t h e body of th e j ig Two oth e r bush in g s E ar e arranged
.

1 2 0 d e grees apart a n d are provid e d wi th very li g

,
h t c oil sp rings
whi ch forc e them u p against th e un d e r s ide of t h e ring Th e .

shoes F ar e then set up aga inst th e angu l ar cut o n t h e s e bush ings

by m e an s of the scr ews H Th e smal l s et scr ews G b e ar aga in s t
.
-

th e fla t t ene d s ide of th e shoes and p r event th em from turn ing .

I t will b e n o te d that the angula r cut on th e body of the bushings

is such as t o preven t th em from p ushi ng down under the pres
sure of th e drill .

The bushin g plat e J i s locat e d o n t h e s t ud Q an d i s p r e v ent e d

from turn in g by the pin K whi ch fits th e slot L i n th e bod y of
the jig S ix bushings N ar e set in to the plat e at e qual in tervals
. .

A nu t P a n d a C washer 0 p ro vid e for r e ady removal of the

-

plate an d draw i t down solidl y o n th e top of th e locat ing rin g B .

Th e three pointed screws M are s et in to t h e work sl ightly to

prevent any change in its location It i s w ell to n o te that i t .

would have cost no more to machi n e one si de of th e work while

it was being bored thus obvi ating th e n e ce s si ty of th e floating
,

locat ing bushings .

Dr ill J ig with F l oat ing B u sh i ngs and Lo cati ng Ve e s A .

somewhat p eculiar condit i on i s S hown in F ig 3 the work A

,

.
,

being a be llcr ank of ordinary constructi on such as is used i n

large quantiti es in automobile work There are som e in s tances .

o n work of thi s k ind when a vari at i on of 5 7 inch or mor e i n 1

th e c ente r to c enter di stances i s not consi dered of ext reme

- -

imp ort anc e but i t i s quite i mportan t t o have the holes as near
,

t h e cent e r of the bo ss e s a s po ssible In order to counteract .

variation s in the ca s tings and s till obtain hole s which are central
 THE F L O ATI NG PRI N C I P LE 2 63

on th e bosses it was n e cessary to adopt s ome sort of float ing

,

co n structi o n such as that S hown in th e illustratio n A number .

.

of jigs of t hi s kin d ar e in us e in a l arg e automob il e factory and

their act i on i s ve ry sat i sfactory In t he instanc e shown the
.

work i s l ocated o n a stud J from th e previ ously r e amed hole in

the hub It s hould al s o b e noted that both hub s and bos s e s
.

have been faced to S ize previous to the drilling operation A .

D ill J ig wit h F l ti g B u hi g d L c t i g V
F ig 3
. . r oa n s n s an o a n ees

sliding V block Q i s carefully fitted to the slot E in the body

-

of th e jig and on i t is mounted the bush ing plate P in which

,

the bushing D i s carried A fter the piece has been p laced in

.

posi tio n th e S lidi ng block is p u shed forward by the operator

unt il th e ve e C com e s up again s t th e boss on th e cast ing and
locat e s i t Th e thumb scr e w F locks the block firmly i n p o
.
-

si t i on an d the sli d ing clamp G holds th e work A nother

, .

block S i s a l so cut out i n the form of a ve e at L but i s no t ,

17 ]
2 64 J IG D E S I GN
tongued on its lower side to fit a S lot a s in th e oth e r insta n c e
,
.

A bus hi n g p lat e R i s mounte d on i t wi th a bushi ng K a t the

forward end The under si d e o f th e block has two n arrow
.

bear ing surfac e s N an d M an d it i s free to swivel in any d ire c

t ion re quire d by the slightly varying p osi ti ons of the bos s .

F ig 4 . . M illi ng F ixt ur wi th F l
e o at ing C l mp
a s and Lc
o at or

The thumb crew 0 holds it in place after i t has b e e n located

-s

by the operator Th e other clamp H i s then us e d to hold the

.

piece firmly A drill j ig of thi s kind i s n o t su it e d t o a ll classes

.

of work but i t pro v ed s atisfactory in thi s case ; the fl o a tin g

,

action gives excellent results when absolute accuracy in the

product is not requi red .
 TH E F LO ATI NG PR IN C I PLE 2 67

Lo cati ng D e vi c e ing Pr e s s ur e Compe n s ato r

wi t h F loat .

The work A shown in F ig 5 h a s been part ially machined in

,
.
,

a p revious operat i on and th e flange has also been drilled so

,

that one of the holes can b e used for dri ving purpos e s The .

machi ne to whi ch thi s d e vi c e i s applied i s a turret lath e of

the horizontal typ e and th e body B is s crewed to th e spin dl e
,

en d C in the u sual man ne r The pin T i s set into a boss in

.

th e face of the fix ture and acts as a dri ver in o ne of the flange

‘

hol e s Two steel rin gs F and G ac t as approximat e locators

.

for the work when it i s first p lac e d on the fix ture Two cy .

lind ri ca l st ee l cams H and J are accurately ground to fit the

cen tral hole in the fixtur e an d ar e op erated by the rod M
,

whi ch i s threaded right an d l e ft hand respecti vely at N and -

, ,

0 E ach cam is mi lled to a 2 0 degr ee angle at K and L three

.
-
,

of these S lots be in g equally spaced around the periphery so

that the i r angular surfac e s control the mo vem en t of the locat
i ng pin s D and E The coil springs retur n the pins to an in
.

act ive p osi ti on wh en released by the cams A plug P i s placed .

in the sp indl e as shown i n th e illustration for the purpose of ,

providing a s e at for the co il sp ring Q whi ch assi sts in th e r e

leasing of th e pins a f ter the machi ning h as been done The .

two s top pin s R an d S lim i t the movement of th e cams and

-

tak e all th e thrust o f th e twistin g actio n of the operating

s crew .

In thi s co nne ctio n it i s well to not e that th e s e stop p in s are -

a ni ce fit in the cam slots while th e locating pins have a S ide

,

Cleara n c e in the an gular slots of inch so that th ere i s no

p oss ib ili ty of trouble be in g caused by frictio n a t these p oint s .

A tt en t i o n i s f urth e r called to the fact that the actio n of the

cams i s such that a true floating moti o n i s produced wh en the
screw i s op era t ed so that all of th e locat in g pins are set up
wi th a n equal amoun t of pressure A floatin g acti o n of this .

n atur e may b e rea di ly app l i ed to ho l din g fix t ur e s for a great

v ar i ety of work .

Ch ucking F ixt u r e wi th F l o at i ng C l amp s a nd Tap e r Lo cati n g

Plug . A som e what u n usual co n di tio n i s shown in F ig 6 .
,

t h e work A b eing a sp eci al clutch flywheel which has been

2 7 0 J IG DE S I GN
lugs on the int e ri or of the castin g pre vent e d th e work from be
ing held in a three jaw chuck on account of interference s with
—
,

the jaws A two jaw chuck was therefore utilized and inter
.
-
, , ,

fe re nc e s thereby a voided A s the centering action of a chuck

.

of thi typ e is very unc ertain wh e n used for holding work by

s

an interior surface of comparatively large diameter som e method ,

of locating was necessary which would at the same t ime center

the casting and yet not cause troub l e by i nterferin g wi th the
,

lugs on the interi or of the flywh e e l !The lugs on th e interior .

of the casting are not shown i n th e il lus t rat i on in ord e r to ,

avoid confu si on ) .

The chuck body B is s crewed to the spindle C in th e usual

F ig 7
. . Two - a j w d C hu ck
e arrange d wit h a Floati ng J aw

manner and is provided with two special jaws one of whi ch E , , ,

i of plain de ign ha vin g two bearing surfaces on the in ner rim

s s

of the fly wheel ca s ting The other D is groove d to fit the

.
, ,

chuck like the regular jaw but i s very much wider as i t comes
,

above the face of the chuck Thi s portion i s turn e d to a radius

.

at H and given an angle of 0 degree s at the same t ime in order

1

to counteract the li fting tendency which might cau s e trouble

when the j aws were tightened The floating member or rocker .
“

F i s mounted on thi s jaw as shown in the illu stration and i s ,

limited in i t s movement by the two s crews G and the elongated

hole s in the rocker Thi con truction gi ve s a very good center
. s s
 TH E F L O ATI NG P RI N C I P LE 2 7 1

F ig 8
. . Pi t
s on C huck h avi ng F l oati ng C l mpi
a ng F e at ur e s
2 7 2 J IG D E S I GN
ing action and the rocker jaw h as sufficient float to take
,

care of variations in the ca s ting .

Pi s t on Ch uc k h aving F lo ati ng Clamping F e atur e s The .

work A shown in F ig 8 is a large automob ile pi s ton which

,
.
,

h as been bored and faced o n th e open e nd to a predetermined

s ize and whi ch is to be completed in thi s sett i ng concentri c ,

and s quare wi th the fini shed porti on P revi ous to this s etting .

and after the borin g and facing operation th e wrist pin hol e ,
-

i s rough drill e d in a j ig in order to facilitat e th e holding of the

-

work on the fixture .

The cas ting is located on a hard ened and ground st e el r in g

F which i s forced o n the body of the fix ture B and a small ,

annular groov e on the ring prev ents trouble or e rrors in lo

cat ing whi ch might be caused by the presence of chi p s or dir t
,

on the locating surface The body of the fixtur e is held in

.

place on the table of the machine by th e bolt s C whi ch enter

the table T-slots and it is ce nter e d on th e table by the plug D
,

whi ch is forced into it at S The clamp ing p in L is ball ended

.
-
,

and h as a spherical p ortion in the center also It is slott e d .

at N so tha t the pin M i n th e draw bar G will enter the S lot -

as i t i s pas s ed t hr ough the wr i st p in holes and bring up aga in st

-
,

the shoulder so as to center the clamping pin in the p i ston A .

great deal of strain is taken by thi s clamp ing p in and for this ,

reason it i s made of tool s te el and spring tempe r ed so tha t ,

ther e wil l be le ss chance of br eakage .

The draw bar G is also of tool steel and i t is ke yed with a

-
,

Woodruff key at H to prevent it s turn ing the key being a ,

slidi ng fit i n the body of the fix ture The lower end of the rod .

i s threaded wi th a 4 pi tch A cme thread double left ha n d

-
, ,
-
,

to fit the op eratin g nut Q thi s latter b eing provi ded with a

,

handl e R whi ch ext end s out through a cored openi ng 0 i n

the fixture Th e p e rm i s sibl e movement of thi s handle is suf
.

ficie nt to produce a vertical mo v ement of fig inch o f the draw

bar which is ample for the purpose of clamping and releasing
, .

A thru s t collar P i s interposed between the operat in g nut and

the boss on the under side of the fixture and a coil spring J ,

keep s the rod up so that the clamping pin may be ea sily placed
2 74 J IG D E S I GN
as the float ing action of the pin with i t s three point bearing -

equalizes all pres sures and at th e same time provide s a very

,

s ecure method of clamp ing the work .

Ch u ck Jaw s wi th F loa t in g Lo c a t i ng P oi nt s The work A .

,

s hown i n F ig 9 is to be bored shouldered and faced complete

.
, ,

in one settin g and on account of its length it was considered

,

nece ss ary to provi de addi tional supporting po in ts bes i des the

j aw surfaces A set of special jaws B is keyed to the sub jaws
.
-

in the table at D ea ch speci al jaw be ing shoul d e r e d at C to

,
'

support the work .

The brackets E are tongued at F to fit the speci al jaws and

ar e secured thereto by the screws G The e bracket s act as a . s

F i g 10
. . Gr inding F i t u x re for S t e e l C o ll ar s

supp ort for the steel floating ring M in which the thre e spri ng
pins J are p laced E longated holes at p oints N allow t he
.

required floating acti on the ring bein g clamped by the collar

,

head screws The brackets on whi ch th e ring rests are p ro

.

vi d e d with a S helf H whi ch i s o ffset s li ghtly from the c en ter

so as to give the nec e ssary wi dth for th e screws In using the .

device the screws L and N are l oosened an d the work placed

, ,

i n the jaws which ar e t hen t ightened while the ri ng float s

,

suffici ently to allow for vari ati ons It will be not e d that the .

p in s be in g sp ri g co n trolled adapt themselves to the ca s ting

, n -
,

an d are there locked by the s crew s L after which the ring it elf , s

is clamped by the collar head s crews N -

.
 TH E F LO ATING PRI N CI P LE 27 5

Al though the floating acti o n of thi s d e vi c e was sat i sfac to ry ,

t h e dri ving or gri pp in g p ower was foun d insufli cie nt to hold

t h e work securel y and i t b e came ne c e ssary to re p lace the
,

sp ring pin s wi th square h e ad set scr ews cup p o in t e d th e rin g

- -- -
, ,

b eing ta ppe d out to r e ce ive th em The ring was th en all owe d

.

t o float whil e t h e s e scr ews we r e lightl y s et up o n th e w ork

af te r whi ch th e c lampin g scr ew s N wer e tight ene d A f te r t h i s
.

chang e in constructi o n th e act i on o f th e m e chani sm was much

,

imp ro ved and th e dri ving p ower was fo un d su fficient

, .

F loat ing Clam pi ng Ring o n G r ind ing F ixt ur e Th e w o rk A

.

shown in F ig 0 is a st ee l casting whi ch i s t o be gro un d on

. 1 ,

th e tw o ext e ri or surfac e s A n ose pi ece D i s screwe d t o t he

-
.

e nd of th e spindl e E and i s p rovi d e d with a hard e ned a n d grou n d

locat ing rin g B on whi ch the work locates Th e s t ud C i s forc e d
.

i n t o the n os e-pie c e and is threaded on i ts ou te r e n d to r e c ei v e

a sph e ri cal nut F The collar G is concaved t o th e sam e radi us
.

as the spherical portio n of th e nut so t ha t it floa t s aga in s t the

en d of the work .
 C H AP T E R X I I

APPLICATI O N OF TH E T HR EE —
P O IN T P RIN C IPLE
IN F I XT URE S
The three point principle is illustrated by a s tool having
-

thre e legs S uch a stool wi ll be firmly sup ported even when

.

placed upon an uneven surface which is not the case if a s tool

,

having four legs i s used If a jig having four feet is placed

.

upon th e table of a machine and there is a chip under on e of

,

the feet this will cause the jig to rock wh en pressure is applied
,

to the upper side ; but if there were only three feet and the s e
were located with one foot on a line mi d way between the two -

feet at the opposite end of th e jig a chip under one foot would ,

not cause a rocking mo vem e nt The jig howe ver would be .

, ,

tilted upward and as explain e d in C hap ter I thi s might not

, ,

be noticed by the operator F or thi s reason four feet are

.
,

generally con sidered preferable when they S imply s erve to

support the jig or fix ture In the mechanical field however
.
, ,

the principle of three point support is applicable to many

-

clas ses of work and its importance is understood and made u s e

of in various kinds of machine and fixture work In the auto .

mobile industry alignment of the working parts is pre s erved

,

by making the power plant a self contained unit and h ay i ng -

it supported on three point s in order to equalize or neutralize

the twi sting action caused by the pas sage of the car over the
more or less uneven surface of the road If s ome pro vis ion of .

this kind were not made distortion of the parts would res ult
,

and they would consequently fail to operate properly .

In machine design the three point principle is utiliz ed in

,
-

numerou s ways S ometimes the bed of a lath e is supported

.

on two points at one end of the machine while the o th e r has

a single swiv el bearing or its equivalent The machines pro .

vi d e d with this feature are ea s ily set up without danger of

276
2 78 JIG D E S I GN
piece on three strips instead of on a cont inuous surface in order
to facili tate a s sembling When this is necessary it is advi s able
.
,

to make the strip s in such a way that they can be readily

replaced when worn .

The supporting po ints shou l d b e so locat e d that they can

be e asily r e ached for cl eaning in order that locat i o n s will not
,

be a ffect e d by an accumulation of chip s or dirt at important

points A djustable p oints S ho uld b e so arranged that d irt and
.

chip s will not c l o g the screws a n d thus mak e th e m d i ffi cult to

opera te Thi s p o in t in d e sign should r e c eive car e ful attentio n

.

when fix tur e s are de si gne d for us e on the ver ti cal t urret l athe
or verti cal bori ng mill On mach in es of th e horiz ontal typ e
.
,

l ess trouble i s likely to b e exp e ri enc e d in thi s r e spect b e cause ,

th e chips do not tend to fall o n the scr ews In e i ther case .

,

however it i s always well to provi de against a ny t rouble from

,

thi s source .

It is frequently desirabl e to i ns e rt hard ene d s tee l bu t to n s of

uniform height in the jaw scr ew hol e s in order to ra i s e a p ortion
of th e work above th e top s of th e s t an dard jaws so that t h e ,

work can be faced or under cut The s e buttons form an excel

- .

lent thre e p o int supp ort for th e work in addit i on to pe rf orm ing
-

th e fun cti on already m en ti on e d S hort p arallels cut from cold

.

roll e d st eel may b e used on a ve rti cal turr e t la th e and are

somewhat ch e ape r t han th e button s but they ar e O pen to the
,

obj e cti on of becomin g easily di splaced and lost .

Whe n it is n e cessary to arran ge p o ints to a c t as a ve e on long

cyl indri cal surfaces i t i s good practi ce t o make them so that
,

th ey can be adjust e d t o t ake up w e ar Thi s can e asily be done

.

by mean s of h e adless set-screws wi th check-nuts to lock them

securely in any p osi ti on ; and i t i s a bett e r co n st ruction to
p lac e one check nut o n th e outs id e an d another one inside
-
,

than t o have both nuts on on e si de of th e fix tur e wall The .

const ruction of the fixture will not al ways pe rmi t of u sing thi s
m ethod but when i t will very sati sfac t ory resul ts are obtained
, , ,
.

Wh e n the three po int support i s appli ed to th e fix ture i t s elf

-
,

the clamp screws whi ch hold th e fixture in place on the table

should be arrang e d at the po ints where the supports are placed ,
 THR E E —
P O I N T P R I N C I P LE 279

Fi g 1 Appli c
at i on of p P i ci pl
h l di ng F l ywh l whi l
Th r e e - oint r n e in o a ee e
p f m B
. .

er n d F cing O p
or ing oring ti na a e ra o s

and any clamp s for th e work it sel f shou l d b e as ne ar th e same

plac e as p ossible .

Th r e e po int S upport for F lywh e e l F ixt ur e

- Th e fix ture .

for the motor flywheel S hown at A in t h e upp e r p ar t of F ig . I

has a three po int support Th e flywheel is of such a d iameter

- .

that a s in gl e supporting po int i n on e of th e chuck jaws wou l d

18 ]
2 80 J IG D E S I GN
not b e sufficien t to resis t th e p re ssur e of th e cuttin g ac ti o n of
the variou s tools us ed in mach i ning The work is h el d by the
.

insid e in the sp e cial jaws B whi ch are r e lieved at E to p ermit

th e back-facin g of the rim Th e tools L and K whi ch ar e held
.
,

in a sp eci al tool b l ock o n the cut off sli d e ar e us e d for back

- -
,

facing and fini sh in g the p ad ; a n d othe r tool s !n o t shown) in

the turre t fac e the p orti on W of th e flywh eel Th e bor ing .

bar I has a pil ot H whi ch ente rs th e gui d e bushi ng G in th e

chuck to give gr e ater accuracy an d rigi di ty Two o f th e jaws .

are provi ded wi th spring p ins C whi ch are re l e ased an d l ocked

-

by the action of the screws F o n the sho e s D The stop -pin in .

the third jaw i s fix e d in ord e r t o give p osi ti ve l ongi tud in al loca

tion of the work Work of thi s ki n d i s ve ry frequ en tly l ocat e d
.

on the thr ee fixed en ds o f t h e jaw s a nd grippe d b y th e in si de

as shown but wh en thi s i s d one the r e i s always a chan ce of
,

in correct holding and p ossi b l e s lipp ag e du e t o spring o f the

casting S ometim e s t hi s resul ts in the p roducti o n of grooves
.

or a wavy surface on th e outsi d e of th e work .

In the seco n d s e tting of t h e work a fiXt ure i s us e d an d th e

p o in t of locati o n is th e r e c e ss whi ch has bee n machi n ed in the
firs t settin g Thi s locates th e pi ec e on a p lug M which is
.

shouldered at N and fits a ho l e p rovi ded for it i n th e cen ter of

the fixtur e Th e p re vi ously machine d surface W r e sts o n three
.

pin s P whi ch ar e of unif orm h ei ght and so arrang e d that they

leave a sl ight cl e aranc e b e tween t h e fac e of the p lu g M and the
face of the S houlder o n th e work Th e fixtur e body 0 is screwed
.

to the spindle and i ts exteri or forms a con t in uous rin g S so as

to make thi s surfac e cl e an an d avo id danger t o the op erator
through project in g lu gs e t c The work i s drawn back agains t
,
.

the pin s P by means of th e clamp s R throu gh the medi um of

the screws Q Work of this kind i s fr e quently held and drawn
.

down upon a cont inuous fin i shed surface in st e ad of a s eries of

p in s The d isadvan ta ge of a cont inuous surface i s that dir t
.

collects upon i t and ren d e rs loca tion un certain u nless great

care is taken to keep the fixture clean .

T e e point F i xt ur e for a P ot C a s t i ng
h r - The fixtur e shown
.
—

at H in F ig was arranged to hold the ca s ting A which is

. 2
282 J G
I D E S I GN
taken t o s ee t ha t th e amount o f cl e aran c e i s amp l e to tak e
care of any co n dit ion whi ch might b e foun d An in ch of clear .

ance all around is none too much o n a large cast ing The p ot .

fix t ur e H is centrally locat e d on th e table by the plug J and

i s fastened down by the T bolts O in the table s lots
- .

Th e set screws at B and C se r ve as locat ing p o ints for th e

-

casting There are two screws at B and one at C the la tter

. ,

being locat e d mi dway v ert i cally bet ween th e ot h e r two and

9 0 degrees from them Thi .s is somewha t contrary to th e usual

custom and in some cas e s might n ot b e found d esirab l e for

example when con siderable dep endenc e has to b e p laced on
,

the locating s crews to a s si st in dri ving the work In th i s case .

,

however ample provisi on for dri vin g i s obta ined Th e work is

,
.

forced o ver again s t p oints B an d C by the central set screw D -

of the thre e shown Wh en th e cast ing has been brou ght up

.

snugly into p lac e th e upp e r and l ow e r screws D are also

,

tightened P rotection against chip s i s p ro vi ded for in con

.

ne c t i on w i th thes e set scr e ws no p ort i on of the thr e ad E be i ng

-
,

expo s ed The work rests o n a fixed po in t G !shown in the

.

upp e r vi ew) which act s as a p o si t ive st op Two addi tional .

p o ints F are adju s table by m e an s of a wrench and th ei r t hreads ,

are protected from di rt by a cyli ndri cal portion above The .

openings P in th e wall of the fixture allow access for t he screws ;

the U-clamps L draw it down upon the poi n ts by m e ans of
the nuts and washers M o n the stud s K The cl amp s L b eing .

of U section ar e r eadily removabl e wi thout requi ring the nuts

-

and washers to be take n off The p lan view shows onl y one
.

clamp in posi ti on in order to S how thi s clearl y .

Two M e th od s of O b ta ining a Th r e e -point S uppo rt on a H ub

Cas ti ng . T he work A S hown in the u pp er p ort i o n of F ig 3
-
, .
,

is a hub cast ing of large s ize a n d the method to b e described

,

was first sugge st e d in connecti on wi th the han dl ing of thi s work .

The ide a was abandoned however in favor of t h e m e thod

, ,

shown at th e lower part of the illustrati on In the up pe r illus .

t rat ion th e jaws C are mount e d o n the ra i s ing blocks E and

,

tongued to th em a t D while th e rai s ing blocks are ton gued

,

and f asten e d t o t he sub jaws of th e tabl e at F Three hardened

- .
 TH RE E —
P O I NT P RI NCI P LE 2 83

p o int s ar e s et in p roj e ctio n s of th e u ppe r jaws a n d the work

B
res ts on t h e s e p o ints A supp l em en tary cas ting G i s ce n t e r e d
.

on t h e tabl e by m e a n s o f th e hol l ow p l u g M w hi ch a l so act s

F ig 3 . . O ri g in
a l and I mpr ove d M th
e od s of l
h o d ing L
arg e H ub Casti ng b y
p
Th r e e - oi nt S u pport
as a gu id e for th e borin g bar pi lot O ; an d the u pp er p art of
-

thi s bush in g i s b e veled as shown bu t t h e edg e of th e hole i s,

l e ft S harp so tha t chips wi ll not be drawn down wi th the bar

an d ten d to destroy i t t og e ther with the bushin g Th e bas e of .
2 84 J IG D E S I GN
the fix ture is slotted at three p oints H to all ow t h e ne cessary
movem ent of the jaws ; an d th er e ar e t hre e lu gs mi dway b e
twe en the jaws on th e base in whi ch th e sp rin g pin s J are -
,

carried A fter the work has b e e n c en t e red by t h e jaws these

.
,

pins are releas e d and allowe d to come into co n tact wi th the

‘

work ; they are the n l ocked by th e se t scr ews L The borin g

- .

bar P i s of the multip le type having two tool s Q and R for ,

the two in si de di ameters The too l Z i s carri ed in the upper

.

part of the S ide head instead of th e l ow e r in ord e r t o e cono ,

miz e on th e l ength o f the borin g bar- .

A s the purp ose of three supp orting p o in ts J w as s im p ly to

steady the work i t was thought that a simpl e r d e si gn would
,

answer all purposes an d th e p r e vi ous m e thod was ther e fore

,

abandon ed in favor of the o ne shown in th e l owe r p art of

F ig 3. In thi s cas e the bushin g T i s us e d di rectl y in the center
.

hole of t he table and the boring bar i s made corr e s p o n dingly -

s horter The rai sin g blocks V ar e also l ow e r tha n in the pr e

.

vio u s case an d ar e keyed to th e sub jaws a t X in the same

,
-

manner The con structi o n of the jaws C i s i dent i cal in both

.

cases Thre e spri n g plungers S wi th knurled end s W are in serted

.

in the jaws and tightene d in any desired posi tio n by the s e t screws
-

U. Thi s method i s much s imp l e r than the other a nd po s sesses

the added ad vantag e s of be ing both cheap er and mor e e fficient .

F ixt ur e h avi ng Th r e e Clam p i ng J a w s a n d Th r e e Lo c ating

P ad s . The work illustrated at A in F ig 4 has b een partially .

bored and fac e d an d i n th e s e tting shown i t i s nece ss ary to

, ,

work from the p revi ou sly fini shed surfac e s The base cast .

ing E is slotted to r e cei ve the three stee l locating jaws C on

which the finish ed surface B locates Th e s e jaws are held in .

place by the scr ews D and ar e carefully fini sh e d aft e r being

drawn into pos i tion The base is c entered by the plug F in
.

the table hole G and is held down by the screws Q in the lugs P
, ,

on e of which is shown in the plan vi ew Three p ad s H are .

fini shed to support the flange an d a dr iver J is ins e rted in on e

of the s e pads The work i s clamped by m e an s of th e hook
.

clamps K in order to keep the di ameter of the fixture as s mall

as possible ; and a cap s crew L passe s through the hook clamp
- -
286 J G
I D E S I GN
A by th e interi or cored surface Th e bas e B i s mad e of cast .

iron and is c en tered on the table by m ean s of the hollow plug C .

It is h eld down by scr ews D whi ch en t e r sho e s in t h e t able

Mach i ner y

F ig 5 . . M e t h od of h oldi ng a Pi e ce of Work b y an Int e ri or Core d S urface

T S
-
l ots
The uppe r portion of th e fix t ur e E fi t s a ci rcular
.

to ngue F on th e bas e to which i t i s fast ene d by th e screws

,

G Th e upper portion E i s S lott e d to r e ce i v e the jaw s N and O

.
,
 T HRE E -
P O I NT P RI N CIP LE 287

and ther e ar e thre e p ai rs of jaws s e t 2 0 d e gr ee s ap ar t Th e

I .

uppe r p or ti on of the fix ture E i s made sep arat e i n ord e r to

facili ta te the machi n ing of th e sl ots Two cyl in dri ca l cams H
.

a n d J control the radi al movem en ts of th e jaws by m e ans of

the scr ew K whi ch i s thr e aded wi th a coars e p i tch left han d
- -

thr e ad in the l ow e r cam a n d a ri gh t han d thread in the upp er

-

cam The uppe r end o f the rod i s squar e d at L and i s operat e d

.

by a sock e t wren ch M In order t o p revent the ent ry of chip s

.

and di rt into th e m e cha ni sm a f el t washer S i s fas tene d t o

,

the upp er cam; an d s teel cove r-p la te R i s p l ac e d o n top o f

th e fix tur e and h el d in p l ac e by screws The harden e d st eel .

pi n T strik e s a gain s t the inne r cor e d surfac e a n d l oca te s th e

pi e c e ve rt i cally S lo t s ar e cut in th e uppe r p orti o n of th e fix
.

tur e E to a ll ow th e i nsertio n o f th e flat sp rings Q whi ch throw

.

the jaws back int o p o si ti o n up o n wi thdrawin g t hem f rom th e

work ; an d a sh eet s teel cover-p late P k eep s t h e di rt out o f
th e s e sl o t s Th e cams an d screw ar e suppo rt e d by the co il
.

sp rin g shown b el ow t h e l ower cam a n d the acti o n o f th e cam s

,

i s limi ted by the s cr ews U whi ch ente r s l o t s in th e cams Th e s e .

screws al so s e rv e t o p revent the r evo luti o n of th e cams A .

comb inat i on bori n g a n d r eaming bar W i s us e d for borin g an d

reaming th e hol e wh ile the o utsi d e surf ac e s ar e mach in ed by
vari ous t ools i n th e si d e he ad o n e o f th e se b ein g shown at V
,
.

I n t h e co ns t ructi o n of thi s d e vi c e it will be n o te d t ha t al

t hough S ix p o in ts or jaws ar e us e d for l oca t i n g t h e arran geme n t
,

i s such that they a ll b e ar a g a ins t t h e i n si de of t h e cast i ng wi th

a n equa l amount o f p r e ssur e a t th e same t im e c en t e rin g the
,

work from t h e c o r e d i nt e ri or AS t h e ri ght -and -l ef t scr ew o n

.

th e rod K i s ro t a te d th e two cams floa t ve rtically so that th e

,

p ressur e on the jaws is equa lized A devi ce of thi s ki n d is

.

usefu l in man y in stanc e s wh en work i s to b e hel d from an inte rn a l

cored surfac e .
 C H AP T ER X II I

SP E CIAL J IG AN D F I XTURE M E CHAN I S M S

N0 s ingle item i nfluences the production ra te to as grea t an
extent as the de sign of jig s and fixtures The saving of a few .

s econds clamping time mean s an increa s ed product i on that off

s et s a hi gh fir s t cost It is much ea ier for an operator to clamp

. s

h is work by tighten i ng one nut than the u sual three and aside , ,

from the s aving of time he i s expending le s s energy and works

,

to better adv antage to him s elf and hi s employer .

It is u sually nece ss ary to equalize the pre s sure in a j g before i

F ig . 1. S i mpl e way of C l mpi

a ng a B u hin g
s f or D illi
r ng

applying the clamping pre ssure When equalizing and clamp .

ing mechani s ms are both operated by a single clamping operation ,

the danger of clamping before equalizing the pressure can be

e li minated M any object to the term fool proof but the
.
-
,
!

amount of work spoiled or sprung by carele ss clamp ing justifie s

care i n designing jigs and fixture s that are at least error proof “ -

in thi s respect .

The m e chanism s described in this chapter are selected for

their sugg e stive value and only as much of th e fixtur e is shown as
,

288
2 90 J IG D E SI GN
variety of bu shin g s of v arious l e ngths the stud C b ein g m ad e to ,

sui t the longest piece of work .

C lamp s that have a tendency to draw the work down firmly

on t o the res t-p ins or s t op s are useful i n all classes of fixture s .

F ig 4 i llus t rat e s a S i mp le m e ans of accomp l i s hing th i s

. C are .

should be taken to see that the stop i s p ivoted above the p oi n t A

A nother a n d more ri gid de vi c e is illustrated in F ig 5 The . .

p lunger A carri ed i n p lunger B i s forced down a g ai ns t the 4 5 de

, ,
-

gree sid e of stop C compre ssing sp ring D A fixture tha t clamp s

,
.

two clamp with a down and in pre ssure is illustrated in F i g 6

s - - . .

F ig 3 C l m pi g B u hi g wh th W k
Me an s u d
se fo r a n s n en e or
V i i L gt h
. .

ar e s n en

S li d e s B are e qualiz ed by strap C and ball a n d socket was hers - -

D and E . Thi s fixture i u s eful for mil li n g and p rofiling as the

s ,

clamps and s top s are below the surface of the work F ig 7 S hows . .

two down and in clamp s equalized for holding a round p i ece o f

- -

bored work for a mi lling opera tion Lever A i s tapped to re .

c e ive screw B an d the clamp ing pre s sure equaliz es with lev er C
,

by mean s of rod D L evers A and C impar t a down -and in

.
-

p ressure to p lun g ers E This fixture can be app lie d to flat w ork
. .

I n the double movement clamp s hown in F ig 8 the clamp A is .

,

carried by the hinge B pivoted at C S crew E gives c l amp A

,
.
 J IG D E SI GN 2 9I

a down and in movement by means of a 4 5 -degr e e t ap er o n stud

- -

D . The stud D is milled off at F to give the clamp suffi cient

movement to remove th e work A mechani sm for drawing down .

both end s of two p i eces b y mean s o f a sin gle nut i s illustra t ed i n

, ,

F ig 9. E ach piece i s clamped i nd ep enden t ly thus maki ng i t

.
,

suitable f or u se on rough cas tings or forgin g s R od A running .

,

through the fixtur e carri es ball and-socket washers at each end

,
-

and draws the end clamps B and C together These clamp s are .

given a down and mov ement a g ai nst the 4 5 degree w e dg e

-i n - —

ends of rods D and E Th e clampin g thrus t a gai nst rods D an d

.

E impart s a downward movement to the i nner clam p s G an d H ,

F ig 4 S i m pl m
e e an s for F ig An t h Ex mpl f
5 o er a e o
D wi W or kd wn C l mp D wi ng t h W k
. . . .

ra ng t h e o a s ra e or
F r i ml y o nt o th e Loc ti ng
a d wn F ir ml y nt t h L
o o o e O
P ns i c ti ng P i n
a s

pulling the work down on the i nner re t pins Th e clamps are s - .

return ed by means of plungers K a n d spring J .

Th e fix ture illustra t ed i n F ig 0 shows a method of drawing . 1

do wn two clamps and thro wing the work agai nst the stop pin -

by a single clamping operati on Tighte ning nut A clamp s down .

clamp C and pulls up rod B against the 4 5 -degree tapered end

of rod D giving a lateral mov emen t against p lunger E P lunger
, .

E i s carri ed by the floating stud G On th e u p per e n d of stud .

G i s a 5 -degree taper that op erates agai ns t plunger H

I P lunger .

E im p ar t s firs t an up ward movem e n t to floatin g stud G which

, , , ,
292 J IG D E SI GN

M ach i ner y

F ig 6 F i xtu r e wi th A
rr ang e m e nt for C l ampi ng l am p s
Two C wi t h
wn- nd -i n
. .

a Do a P r e s s ur e

Fig 7 . . F ixt ur e h avi ng Two Eq uali zing Cla mp s

2 94 J IG D E SI GN
F ig . I 2 i llustra t es
a center clamp that gives a downward and
ou tward t hru s t by mean s of the taper e d end s of plate A whi ch is ,

carried by plunger B P lunger C wedge s down the p lunger D .

,

which is tapped into p lunger B P lungers B and D are held up .

F ig 9 M chani m
e s for D r awi ng d wn B t h
o o e nd s of T wo Pi e ce s by
i
. .

a S ngl e N u t

by a sp ring E A small pi n i n p lung er D allows a half turn o f

.

plunger B so that the work may be lifted ou t

, .

In the fixture i llustrat ed in F ig 4 the work !two clutch S hells) . I ,

is equalized and clamp ed by a single mo v ement of the handwheel

F ig 1 0. M th e od for D r awi ng d
o wn Two Cl a mp s and F or ci ng th e
W or k i p C m ping O p rati on
.

aga n s t th e S t o -p i n b y a S i ngl e la e

B, drawing out rod C again s t the collar D The section A A .

—

s hows how thi s collar equa lize s its thru t with plun ger s E and s

F. The collar D i s free to slip to either side as required for

e qualizin g The plunger E and F draw in rods G and H through
. s
 J IG D E SI GN 295

the m edi um of collars J and K The s trap M held c entral by a .

,

small sp rin g and p lun ge r equaliz e s the p ull on the center cl amp
, .

A ll clamp s are mad e to c l ear the work when it i s to be r e mov e d , ,

by means o f th e l ev e r L and the sys tem of l ev e rs shown in the

lower view .

Fig 11. Fi xt ur e for E qu ali zi ng t h Cl am pi ng

e Pr e s s ur e on Ei gh t
S m all W s h s
.

a er

Fi gs 3 an d 5 i llus t rate a small double mov e m e n t c l ampin g

. I I

mechani s m for h and mi lli ng or p rofiling us e I n F ig 3 the . . 1 ,

clamping pressure agai ns t clamp A also p ulls ou t p lun ger B ,

throwing u p plunger C and throwi ng the work aga i ns t stop E ,

by means of plung e r D S pring plunger G i s used to re turn

.

plun ger D In F ig 5 the pull through clamp A on p lunger B

. . I ,

19 1
2 96 J IG D ES I GN

F ig . 12. C e nt e r C l mp
a gi vi ng a Dwwo n ar d an d uw
O t ar d Th r u st

Fi g 13 . S mall D ub l M m
o e ove e nt C l m pi ng M ch ni m
a e a s for H d an
M ill ing fil i n g M c hi n
.

or Pro a es
2 98 J IG D E SI GN
the clamp i s hook e d over the flange C are must be t ak en tha t .

the p oint X is below the p ivot point of the pi e ce C .

F ig 7 illustrates par t of a heav y milling fixture for clamp i ng

. 1

agains t the stop plate A by mean s of the two p lungers B and

-
,

C by equalizing with the p lunger D a n d sleeve E working against

,

B and C with 4 5 degree wedge cut s - P rojectio n s on the work .

often prevent the u s e of plain clamps F ig 8 shows a re s ort . . 1

F ig . 15. A t h D ub l M
no er o e ove m e nt C l am pi ng M e c hani s m

to an u nusual but effici en t clamp to meet the s e condi ti on s

, ,
.

The use of plungers A and B permits the clamp to be operated

from the rear by mean s of a screw C and knob D When work .

is long in proportion to i t s width or when the locating pins mu s t

be placed clo e together as in the piece illu s trated in F ig 9
s ,
. 1 ,

there is danger of it cocking or binding between one locating

“ !

pin and the s crew if a plai n screw i s used to throw th e work

,
 J IG D E SI GN 2 99

again s t t h e loca ting pins Th e use of a roller instead o f a scr ew

.

pr ev en ts thi s T h e roller A wi ll turn until the work s t rikes

.

bo th stop pins In the de vice illustrat e d B and C are the fixed

- .
,

locati n g pins an d D the clamp screw t appe d into the bushing

, ,

F ig . 1 6. Cl a mpi ng W or k by H l di
o ng it b y Me an s of a F l ange

Fig 17. A H e vy M illi ng F ixt ur

a e wi t h E qual izi ng Cl a mpi ng
D e vi c e
.

E op e ra tin g t h e sli din g p lunger G It i s obvi ous tha t the work .

c an b e p reve n t e d f r o m b i nd ing b y us i n g tw o e qua lizin g p lu ng ers

to throw i t agai nst the locating pin s i nst e ad of a roller .

F ig 2 0 S hows the locating mechan i s m for a milling fix ture in

.

whi ch two pie c e s are located by two p lung e rs each all op era te d ,
3 0 0 J IG D E SI GN

F ig 18 S p ci l Typ
e a e of Cl a m p u s d wh
e e re Pro j ctie ons on th e
W k P Cl mp
. .

or r e ve n t th e us e of P l ain a s

F ig 19. i
U s ng a R oll e r t o P r e ve nt U ne qu al Bi ndi ng agai nst t h e
Lc i i
.

o at n g P n s
3 02
J IG D E SI GN
concav e surfac e o n an un usua l pie c e Th e wo rk i s c l ampe d .

agai nst the pads A and B on previ ously m i lled surfac e s by

, ,

mean s of two di fferentially op erated p lungers C and D simi lar ,

to a pre vi ously d e scribed devi ce To prevent spri nging u n der .

cut the work i s backed up wi th th e floating p lunger E on the

,

one side and F and G on the other The plungers are op erated .

by push-rods H and J These push rod s are han d op era te d an d

.
-

are clamp ed by the bushi ng K and star kn ob L .

F ig 22. Fi xt ure for M illi ng a C ncav S ur fac e provi d e d wi th

o e i
S l d i ng
u pport s und e r th e M ill d S u f c
.

S e r a e

S om e occasi ons ari se i n whi ch the 4 5 -degree p lung e rs do n ot

permi t of suffici ent c l ampi ng move men t The m e chani sm in .

F ig 2 3 was designed to o v ercome thi s objecti on

. An unusually .

larg e movement of t h e clamp is requi re d to clamp directly over

the r e st pin Rod A op era t ed by scr e w B i mp ar t s mov em ent
- .
, ,

to both p lung e rs C and D P lunger C p ulls clamp E down and

.

plunger D pushes up on clamp E through the p lu ng er G The .

wedg e angle b e twe e n p lungers C and D s hould be less than

that between plu ngers A an d C There i s consi d e rabl e fric tion
.

i n thi s mecha ni sm .
 JI G D E S I GN 3 3
0

F ig 23. M e chani s m wh e n an Un s u u ll y Lar g M

a e ove m e nt of th e
mp
.

Cl a i s Re qui r e d

Fi g 24. Ri gi d M ch ni m f
e a s or C l mpi
a ng at T h
re e P oi nt s b y
c w
.

M n ofea s O ne S re

A v e ry rigi d m e chanism for clamping a t three p oin t s by m eans ,

o f one scr ew i s shown i n F ig 2 4 I n thi s cas e it i s shown

,
. .
,

app li ed to a drill j ig but it i s rigi d e nough t o pe rmit i ts use in

,

milling or plani ng fixtures In th e se ca s es th e clamping pins

.
,
 D E SI GN
’

3 04 JIG

b e come re s t-pins an d are subject to the thr ust of th e cut S cr ew .

A thrust s against equali zing plunger B The de t ai ls of this .

p lunger mechani s m are illu s trated i n the e n g ravi ng P lunger B .

i s of le ss di ameter t han the dri lled hol e and re s ts o n th e piece C .

Thi s piece i s cut from a rod of the same di ameter as the hol e
and is u s ed to afford a fla t base for plunger B to re s t on and in sure

F ig . 2 5 . A S i mpl e E j ct i n g
e D e vi c e

full contact of the wedg e end a gain s t the plungers D and E .

P lung er G i s a duplicate of B and e qualize s the plungers F and H

by means of the same mechani sm .

C on siderable sav ing o f time may b e eff ect e d by the use of

ejectors F ig 5 is an examp le of the u e of an ejector P ush
. . 2 s .

rod A h as four notche s milled tapering on one end The pins .

 C H AP T E R X I V

PRO VID IN G F OR UP KE E P I N DE S IG N IN G J IG S
X
AN D F I TU RE S

The impor tan c e of p rovi ding for upkeep in th e d e s ign of the

vari ous typ es of fix t ures us e d in m anu fa c t u i ing work ca nn ot

be over-empha sized In many cases p rovi sio n for upkeep can

.

be incorporated in t h e desi gn without increa sing the first cost

of the fixtur e t o an y gr e a t ex ten t whi l e in other instan ces
,

con si derabl e extra outl a y may be ne cessary M uch dep en d s .

upon th e accuracy requ ir e d in th e finished p roduc t and th e

numb e r of pi ec e s whi ch are to b e machi n e d F or examp l e in .
,

gun work whe n grea t quant itie s of p ar t s ar e t o b e produc e d

, ,

no expens e i s sp ared i n making t h e fixtures in as durab l e a

mann e r as p ossibl e and in making p rovi si o n for the rep lac e
,

ment o f worn l ocatin g p oint s e t c On machin e t oo l work

,
.
,

howeve r d i screti o n mu s t be ex e r ci s e d so tha t the expense of

, ,

fixtures may be consi ste n t wi th t h e r e qu i r e d ra te o f p roducti o n

and accuracy of the work .

M an y factors i nflu e nc e des ign in thi s r e gard Th e size an d .

gene ral character o f t h e work d et erm in e th e t ype of machin e

on which t h e fixture i s to be used an d there fore the n e ed for
, , ,

stabil i ty and s tre ngth The number of piece s to b e machi ne d

.

i s a factor which must b e co n si der e d for i t i s a pp are n t that a

,

small number do e s n ot requi r e an y speci al car e to b e taken in

regard t o t h e mat t e r of upk eep In drill j ig work the locatin g
.
,

points bushings and feet may be mad e so that t hey can be

, ,

readily rep laced wh en abus e or w e ar o f thes e p ar ts tends to

cause imp erf e ct work The p robab l e ne c e ssi ty for r ep lac eme nt s
.

i s na t ura ll y d e t e rm ine d by th e rate of p roduc ti o n that i s re

q u i red
. J ig s a n d fixtures ar e often handled rou g h l y and th ey
should b e co n struc te d to wi thst an d such u s age Millin g fixtures .

are frequently requi re d to s t an d v e ry heavy cut tin g s o that

3 06
 PR O VI S I O N F OR U P KE E P 3 7
0

gre at rigi di ty i s an imp orta nt f e ature in th eir constructi o n In .

th e cas e of horizo n ta l t urr e t lathe fixtures or others which re

volve abou t a fix e d c ente r i t may frequently be found d e sira
,

ble to ma k e l ocatin g rings po ints or surfaces in such a way

, ,

that adjustm ent can conv enien tly be made abou t this center .

F ig 1
. . D ill J i g f
r or a Re c e iv r F
e or gi ng

i
P o nt s P e rtai n ing t o Upke e p A few noteworthy p o in ts of
.

co n s t ruct i o n are given herewith : Location of the work

I . .

Thi s is of primary i mp or t a n c e an d the vari ous fixed p oints

provi d e d in the fix ture should b e m ade in such a way tha t they
ca n either be read ily replaced or adjusted accordin g to c ir ,
3 0 8 J IG D E S I GN
cu mst ance s 2 The n umber of piece s t o b e machine d should
. .

receive p rope r consideratio n in the design both i n regard to ,

co s t of the fix ture and in regard to p robable n ece s s i ty of re

placements 3 Weight and rigidity of the fix ture This point
. . .

i s naturally somewhat dep en de n t up o n th e class of w ork for

whi ch i t is intended an d th e co nveni ence of ha n dling 4 Gib s
, . . .

In th e cas e of ind exi ng or slidi ng fixture s suitable p ro v isi on ,

should be made for adjus tmen t by mea ns of gib s or straps in ,

order that natural wear may be taken u p 5 R ev olving fix . .

tures F ixtures whi ch revolve about a fix ed ce n ter if subjected

.
,

t o hard usag e or i f u s ed for a great n umber of pieces may be ,

advantage ously p rovi ded wi th m e ans of adju s tment about the

c enter of r e volution Thi s i s a r efin eme n t that is very infr e
.

quently used and i t i s n ot nec e ssary in the majority of cas es

,

unles s extreme accuracy i s r e qui red Ther e are a few p oints in .

con struction which are app li cable p rincip ally to individual

cases Th e se w ill b e referred to later
. .

Dr ill J ig for a R e c e ive r F orging T he work A shown in .

—
,

F ig . Ihas been p revi ou sly faced milled and bored and tapped
, , ,

at the en d K leavin g four holes C D E and F to b e drilled

, , , ,

o n the jig S hown in the illustration This type of jig is built .

“

up en ti rely from st ee l p arts a rectan gular plat e formi ng the

,

base of th e j ig The work i s laid down o n the harden ed pin B

.

an d the heads o f the two j ig bu shi ngs C and D whi ch are ground
to a uni form surface The thr e aded plug at K is p rovi ded with
.

a knurl e d head L and draws the end of the r e c eiv er up again s t

the s teel block N whi ch is screwed an d doweled to th e j ig base .

A thrust washer is pro vi ded at M and a slight float is allow e d

betwe en the b l ock and the p lug The s tud G is screwed into .

the p late an d the s e t screw H ru nning through i t forms an

-

adju s table stop for the si de of the rece iv er check-nuts being ,

provided at J After the work has been drawn up by the

.

threaded plu g at K the set-screw in the s tud P i s us e d t o p ush

,

the work over again st the po int H .

The st e el cl amp O i s sl i d into posi ti on an d ti ghten ed an d ,

the set -screw R in the swi nging clamp Q at th e other end of

the work is brought to b e ar a t that point The clamp Q is .
3 10 I
J G D E S I GN
rounded so tha t di rt or chi ps can not lodge o n them an d caus e
faulty locating Th e pin D S im p ly acts as a stop for locatin g t h
.

in ternal boss e s o n th e work ; a n d fe et are provi d e d at B so that

the jig casting can b e s et u p on t his end for l oading purp oses
'

A swin ging clamp J i s provi ded at th e op en end of the j ig ,

and this clamp is p rovided wi th a rocke r G whi ch pivots o n the

pin H slot K being cut for i ts r e cep ti on
,
.

A sw in gi n g clamp scr e w i s l oca te d at L whi ch w orks in the

-
,

S lot on the e n d of the clam p J the nut an d wash e r at M being

,

us e d to draw i t up firmly An e qual iz ing acti on i s obtain e d in

.

t hi s manne r o n th e swive l H so th at p r e ssur e i s equally di s

,

tributed on th e en d of th e castin g As i t was n ec e ssary during.

the machining of thi s pie c e t o use s eve ral s iz es of tools a n d to

work from both sides of the cast in g i t was found advi sabl e to ,

use liner bushings P in order t o p r e ve n t un due w e ar Thes e .

bushings ar e hard ene d an d grou n d a n d forced i nto posi tion ; ,

an d the slip bushings Q are slott e d t o r e cei ve the pin R to pre

vent th em from turning Th e st ee l s tuds N an d O o n opp osi te
.

sides of th e j ig body ar e groun d t o a u ni form surfac e an d act

as f eet f or th e j i g .I n conn ect io n with t hi s j ig i t i s w ell t o n ot e
tha t al l p arts subj e ct to w e ar are r e adily rep lac e ab l e thus ,

making the life of t h e j ig almost ind e fini te .

Ind e xi ng F ixture for a Clutch G e ar In e very kin d o f .

in d exi ng m e cha ni sm o ne of t h e chie f po in ts in d e si gn i s to pr e

vent vari ati ons in th e spacing due to w e ar o n t he m e chani sm .

Th e fixtur e shown in F ig 3 i s so arranged that w ear on the

.

ind exin g p oi nt s i s automati ca lly take n u p by the cons t ructi o n

of the d evice so that th e p rovisi on mad e for i ts upk e ep is excel
,

l en t I n addi tio n to thi s f e a tur e the d e s i gn i s n ot ve ry expen sive

.
,

and it may be mad e up at much l e ss cost than many other kin ds

of ind exing devi ces Th e work A i s a clutch gear th e clutch
.
,

p orti on B of whi ch i s t o be mach in e d in thi s s e tti n g As t h e .

work has b een previ ously machi ne d all ove r it i s ne c e ssary to ,

work from t h e fin i sh e d surfac e s .

The body of th e fix ture G i s o f cas t i ro n an d i t i s p rovi ded

wi th two machi ne st ee l keys at P ; th e s e k e ys locate th e fixture
o n the tabl e by means of th e T S lots and the hold down bolts
- -
,

Q lock it securely in po sition The revolving portion of the fix

.
 PRO VI SI O N F OR UP KE E P 3 1 1

ture F is also of ca s t iron and has a beari ng all around on the

base whi le the c e ntral stud C i s u s ed as a locator for the work
,

at i ts u pp er end and holds t he re volving portion down firmly

,

by means of the nut and collar at H The fittin g at this point

.

is such that the fixture may be revol ved readily and yet is not
free en ough so t hat there is any lo s t motion A liner bu shi ng .

of hardened steel i s groun d to a n i c e fit on the central stud at E

F ig 3
. . In e s C l u t ch G
d e xi ng F ixt ur u e d f M illing T
or e e th in e ar

an d will wear almo s t indefinitely whi le an indexing ring L is

,

forced on the re volving portion F of the fixture and doweled ,

in i t correct positi on by the pin V and held i n place by the four

s

s crew s R The work i s held down firmly on the re volving por

.

tion by means of the three clamps J the s e being slotted at K

,

to facilitate rapi d remo val .

A steel index bolt M of rectangular section is care fully fitted

to the slot i n the body of the fixture and beveled at its i nner
,
2O J
3 1 2 J IG D E S I GN
end S so that it e nters the angular slots S and T of the index
rin g C learance is allowed between the end of the bolt and the
.

bottom of these slots so that wear is automat i cally taken care

of A stud O is screwed into the under side of the index bolt
.

and a stiff coiled spring at N keeps the bolt firmly i n po sition .

The pin U i s ob vi ou sly used for drawing the bolt back and
i ndexing the fixture P oint s worthy of n ote in the construction
.

of t hi s fixture are the liner bushing at E the steel l ocating ,

ring L and the automat i c method of taki n g up w ear by th e

,

angular lock bolt M .

F i xt ur e with Ins e rt e d Jaws The work shown at A in .

—

F i g 4 is a steel casting whi ch has to be finish e d on the in s i de

. .

F ig 4 F i xt u re provi d edwi t h I t ch ng b l J w
n er a ea e a s for H l di ng
o
D iff nt S iz f W k
. .

e re es o or

Th e s e cast ing s are made in two sizes one of which i s i nch ,

I

larger than t h e other It w as desired to us e the same fixture for

.

both pieces in order to avoid the exp ense of making two fix

tures !Th e larger piece of work i s shown in the ill u s tration )
. .

F or th i s purpose a fix ture D was de si gned to be screwed to the

end of the lath e spindle in the u sual manner There are four .

jaws B which rest i n slots around the in side of the fixture the se ,

jaws be ing drawn back into their seat s by the screws C in order
t o b e ground in place to the correct di ameter B eyond the .

e nds of the j aws th e pointed hollow s e t screws H are so placed

,
-

that they will com e opposite to the web portion of the casting .
3 14 J G
I D E S I GN
screwed to the nose of the spindle while the other C is adjustable , ,

on the fir s t piece In the illu stration piece C is S hown clamped

.
,

firmly agains t the body B of the fixture by the steel clamping

Fi g 6
. . i u
F xt re for H l di
o n g th e P art i ll y F i i h d C
a n s e as tin g A

ring D and the s crews E and it will fu ther be noted that there
,
r

i a slight clearance between the out ide diameter of the body B

s s

and the in ide of part C Three set crew F are equidi tantly
s .
-
s s s
 PRO VI SI O N F OR UP KE E P 3 1 5

placed aroun d the periphery of the ring C and thes e s e t screws -

are furnished with check nuts as shown B y looseni ng the

.
-
.

collar D and manipulating se t s crews F the worki ng p ortion s of

-
,

the fix ture can be readily trued up when they b e come slightly out
of true through u se or abuse A steel locat in g ring N is forced
.

on the ring C and i s ground to the s iz e of the interior gear .

The method of clampin g is somewhat out of the ordinary ,

con sisting of th e use of thre e clamp s G and an operating screw J ,

and a floating collar K The three clamps are placed 2 0

. 1

degrees apart and have slightly o versize holes through whi ch

the screws H pa ss Th e s e screw s have a ball surfac e on the
.

under s ide of the collar corresponding to a S imilar depre s si o n

in the clamp s themselves A steel bu shing M is fitted to the
.

body B of the fix ture and i s threaded with a coarse p i tch thread

,

which corresponds to that on the operat ing screw J A fter .

the clamp s G have b een swung into place on the ring g e ar a ,

few turn s of t he screw J set s all three of them with a uniform

pr e ssure through the medium of th e sph e ri cal collar K whi ch
bear s again st their inner S ides A lthough a fixture of thi s ki nd
.

is somewhat expen sive i n first cost all the parts can be r e adily,

replaced at a minim um exp en s e and the fixture may also be

kept true with the center of rotati on of th e sp indl e wi th ve ry
little trouble .

F ixt u r e for a H u b C as t i ng The work A S hown in F ig 6

.
, .
,

i s a hub casting whi ch has b e en pr e vi ously machin e d o n th e

surfaces B C and D The fixture E on whi ch it is held for
, ,
.

s ubsequent operat i on s i s made of cast i ron i t i s center e d o n

;
the table by the plug F and h e ld down by the s crews G which
enter the table T slots A steel locating ring H is forced o n
- .

the body of the fixture and forms the point of locati on for the
work Three studs J are s e t 2 0 degre e s ap art i n the base ; and
. 1

they are surface ground to the correct he ight to support the

work Th i s arrangement make s locations po si t ive regardless of
.
“

chi p s or di rt The clamp s K hold the work down on the pin s J

.
.

F eatures of t hi s fixture are the ease of replacement of th e locating

rings and poin ts and freedom from troubl e which might b e
,

cau s ed by an accumulat i on of chips or di rt .

3 18 I ND E X
B ox or cl ose d j igs ,
d e sign of

e xa mp l e s of

Bu his ng p l a t e for m u l t ip l e d rilling

l
h o d e rs ,
Bu his ng s d rill d r i vi ng fit all o w anc e s t abl e
, ,

d ri ll re m ovabl e t yp e t abl e
, ,
.

d rill s t a t i onary t yp e t abl e o f d i m e ns i ons

, ,

d rill t yp e s of
,
.

float ing and l oc at ing ve e s appl ie d t o d rill j ig

,

u
g id e , at t a ch d t d ill
e o r s

u
g id e , s pe ci l d sgin
a e

j ig all o w anc e s for grind ing and l apping

, ,
ta bl e
jig arb or fo r
,

jig d riving fit all o w anc e s

,
.

jig for rose c h uck ing re am e r s t abl e

, ,

jig grind ing and l apping

,

jig h ar d e ning
,

jig m at e rials for

,

jig m e t h o d of m aki ng
,

jig sc re w t yp e
,

jig s t at ionary d im e ns ions of

, ,

jig u se d a s l oc a t i ng m e ans
,

jig wh e e l s for i nt e rnal g ri nd ing

,

lini ng t ab l e o f di m e nsions
,

loose m e ans for p re ve nt ing t h e m f ro m

,
t u r ni n g .

re mov bl a e

re m v bl o a e, di m n i ns f
e s o o .

c w gn
s re ,
e e ra l n te o s

sc w u d
re ,
se a s l c t i ng m
o a e an s

slidi ng u d ,
se a s l c t i ng m
o a e a ns

sl ip g e ne,
ln ra ot e .

Camcl amping d e vi ce s .

C am- Op cl mping lid n d rill j g

e r at e d a s e o i

C h uckin g fixt u wi t h fl t ing cl mp nd t re oa a s a ape r l oc g pl ug

at i n

C h uck j w w i t h fl t i ng l c t ing p int

a s oa o a o s

C h u ck p i t n wi t h fl o t ing cl m p i ng f t u
,
s o ,
a a ea re s

t w —j w w i t h fl
o a t i ng j w
,
oa a .

C l m p ing nd l c t i ng d vic
a a t h e p oint
o a e e s, re -

C l am p i ng by m n f sc w s ea s o re

C l am ping d e vi c s e

app li c t ion o f fl t i ng p ri nc ip l
a oa e

ca m
d up l e x n dr ill j ig ,
o

e cc e nt ri c

fl at ing p incipl
o r e

for j i g s
sp e c i al .
 I NDE X 3 9
1

Cl am ping m mb e s l v and sp ing-op t d n j ig

e r ,
e er r e ra e o

Cl amp ing ing fl t ing on g indi ng fi t u

r ,
oa ,
r x re .

Cl amping slid c m pe t d n d rill jig e, a -o ra e ,

o

Cl amping w d g s o t p e gib f
,
e e r a r s or

Cl amp s di ff nt t yp e s pplie d t o j igs

,
e re a

fl t ing nd loc t o ppli e d t milling fixt u e

oa ,
a a r, a o r

fl t ing nd t p l cat ing p lu g f c h ucking fixt u

oa ,
a a er o or re

fl t ing appl i d t p i t n d ill jig

oa ,
e o s o r

float in g f p is t n ch uck
,
or o

for j igs .

for j igs , t y p e s o f
m ul l
t ip e , arr an e d t o
g e q u liz a e pre ss ure
q uick le re as in g .

t wo-p oi nt , at t a ch d e to j ig cove r
wh ich e xe r t c mb in
o ed in w ar d and do w nw ar d p r e ss u r e
C l o se d or b o x j i g s , d e s ig n of

e xa mpl e s of

C lu t ch ind ing fixt u e f m illing

es, ex r or O O O O O O O O O O O O O O O O O O O O O O

C lu t ch g i nd xing fix t u
e ar , f e re or

C llo h d sc w s d im n i n t abl
ar- e a re ,
e s o s, e .

C o mb in t i n d ill nd b ing jig

a o r a or

C ont in u us m illing fixt u o re

C d ill ing p i s t on j ig f
ross- r s, s or

C up nd c n l c t ing p i nt s f j i g
a o e o a o or s

C y lind e r fl ng jig a e .

Cy l ind li ne c il p file m ill ing fixt u

er r , re o ,
ro re for

-h ol e d r illi ng in s t u d s j ig for
D pee ,

De f e c t s c o mm o n t o ji g d e si gn

De sig n o f j ig s app l i c at ion o f cl am p s ,

.

cl d b x
ose or o

c mmon d e f c t
o e s .

d t il s f
e a o

g ne al e m k s
e r r ar .

o pe n t yp e
su mm y f p incipl s
ar o r e

Di a l pl t e p w p e s j ig f
a d ill i s, o er r s, or r n g
D wi g f j ig
ra n s or s .

D ill d b i g j ig c mbi t i
r an or n ,
o na on

D ill bu h i g d i i g fit ll w c
r s n s, r v n a o an e s , ta bl e .

re mov ble a ta bl e
s t at i o nary , t abl e of di m e nsions
D illi g d mi g j ig
r n an re a n .

D illi g jig f
r n i i ,
o r u se n v se

D ill jig d ig d f pid

r ,
es ne or ra i nd e xing
e q ui pp e d w it h d upl cl mping d ex a e vi e c
3 2 0 I NDE X
e qui pp d wi t h fl t ing bu h ing nd l c
e oa s s a o at i n g ve e s

e q uipp d wi t h mi lling t t ch m nt
e a a e

e xampl s f e o

f f k li nk s
or or

f m ch ining h al f h l s
or a o e .

f p w rp
or o d i l pl t
e re ss a a es

f ugh c ll r
or r o o a

mul t ipl f r y k nd e, o o e e s

m u l t ipl v ibl t yp
e , re e rs e e

Op e n, d e sign of

Op e n , e xa mp l e s of

o p e n t yp e
O p e n t y p e d e sign of ,

p i st on w i t h fl o a t ing cl am p s
,

O
q ui ck- pe rat ing
wi t h au t om a t i c l o c at i ng d e vi c e s
wi t h cam-op e rat e d cl amping Slid e
D ri vi ng fit all o w anc e s fo r d r ill bu sh i ngs ,
t ab l e

bu hings
fo r jig s

D upl e x cl mping d a c
e vi e o n d ri ll j ig

D upl e x fix t u e r

for rou t ing oil g - r oov e s

E cc e nt ric cl mping d vic s a e e .

E j c t ing d evi c
e n m illi ng fi xt u e o re .

E q u l i z ing t yp e s f cl am p i ng d vi c e
a o e s

F ac ing b osse s in p i s t ons j ig ,

for
F e e t for j i gs .

bl
t a e of d i m n i ns e s o

F ixt u e f r L i nc l n t y p e mi lli ng m ch i ne
r ,
o o a

h v ing i nt ch ng bl j w
a er a ea e a s

milling .

p l ning
a .

F l nge jig
a

F l o t ing b u h i ng
a nd l c t i ng v
s pp l ie d t d i ll j ig
s a o a ees a o r

F l oat ing cl m p ing f t u a f pi t n ch uck ea re s , or s o .

F l oat ing cl am p ing ing on g ri nd ing fixt u r re .

F l at ing cl m p s nd l o c at o
o a pp li d t o mi ll ing fi t u
a r a e x re .

F l o t ing cl m p and t p
a a l c t ing p lu g f ch u cking fixt u
s a er o a ,
or re

F l oat ing cl m p s pp l i d t o p i t on d ri ll ji g
a a e s .

F l o t i ng j w f
a t wo j w c h u ck
a or -a

F l oat ing l c t i ng p oi nt f
o a ch uck j w s s, or a .

F l oat ing p e ss ur c o m p ns t
r f l c t i ng d v i c e
e e a or , or o a e .

F loat ing p inc ip l e s pp l i e d t fi xt u w k

r ,
a a o re or

im p ort nt poi nt s in app li c t i n

a a o .

F lywh e e l fixt u e t h re e p oi nt u pp t r ,
- s or

F ork li nk s d rill jig fo ,

r
3 2 2 I NDE X
l ce d u
ge ne r a p ro re

g n e l m k
e ra re ar s

p incip l
r f es o

s umm y f p in c ip l
ar o r es

J ig dr aw ing s .

J ig fe e t
ta bl e of di m e n s io n s

J ig l c o a t i ng p o i nt s
ad j u st ab l e for w o r k ,

J ig
s, ad j u s t abl e b o r ing

a l ignm e n t o f, wh en ho l e s ar e a t an ang e l
b ing
or

b ori ng f imp l d ,
o s e e s ign

b ing u pp t d
or ,
s or e on w k or

b ox
box or cl ose d d e s ign of

cl m p f
a s or

c mb in t i n b i ng nd d ill
o a o or a r .

d ill d ign d f
r ,
es p id ind ing e or r a ex

d ill qu ipp d wi t h fl t ing b u h ing

r ,
e e nd l c oa s s a o a t ing v e e s

d ill qu ipp d w i t h m ill ing t t ch m nt

r ,
e e a a e

d ill x m p l s f
r ,
e a e o

d ill f f k l ink
r ,
or or s .

d ill f r m ch ining h l f h l
r ,
o a a o es

d ill f
r ,
u gh c ll
or ro o ar

d i ll ing and e mi ng
r r a .

d ill q u ick p
r , t ing -o e ra

d ill wi t h u t m t i c l c t i ng d vi c
r ,
a o a o a e es

d ill w i t h
r ,
m p t d cl mp ing l id
ca -o e ra e a s e

e xa mp l f C l d b x es o os e or o .

f b i ng h l
or or th t n t p ll l
o es a ar e o ar a e .

f c ss d illing pi t ns
or ro - r s o .

f d rilli ng t n ng l
or a a a e

f d i ll ing d p h l
or r in t ud ee o es s s

f d i ll ing h nd w h l i m
or r a ee r

f d rill ing p w
or p di l p l f o er r e ss a a es

f d illi n g ing
or r r

f f cing b
or a in pi t n o sse s s o s

f m ul t ip l b i ng
or e or

f s t igh t nd ng l
or ra d ill ing a a u ar r

f or supp t ing b n n id f h l
or ar o o e s e o o e

f u p t b ri ng
o r- ar o .

h vi ng
a ck s u p n wh ich t b t u n d v
ro er o o e r e o er

i nd i ng m u nt d n t u nni ns
ex ,
o e o r o .

i nd i ng p
ex t d b y h nd l v
,
o nd f t t
e ra e a -e er a o o - r e ad e l
ind xi ng p vi d d w i t h w k l oc t i ng d e vi c
e ,
ro e or — a es .

l c t i n g w k b y m n f p i n nd t u d
o a or ea s o s a s s .
 I ND E X 3 23

mu t ip le d ri ll ,
fo r y o k e e nd s .

mul t ip l e dr il i ng , l re ve r si bl e t yp e
Op e n, d e sign of

op e n d r ill e xam p l e s of ,

Op e n t ype
op e n t y p e d e si gn o f ,

pi s t on d rill wi t h fl o at ing ,
cl mp a s

c w nd nu t s f
s re s a or , ta bl es

sc w t igh t ning d
re e e vi e s c fo r
t
s ar h nd w h l f a ee s or , ta bl e

s wi nging l v fo ea es r

t yp e s of

uni v e r sa l
w igh t f
e o

wi t h l v e er an d s p ri ng-op e rat e d cl mping m mb

a e e rs

J ig n d fi t u
s a x re s .

d iff e r e n c b tw
e e een

o bj ct e of .

p r o vi d in g for up k ee p

i
Jgs-
c w l t ch
re a e s, di m e n s i o ns , ta bl e

K e y w ay s u se d as m e ans o f l c o at i n g w k or

Kn b o s, di m e nsi o ns , ta bl e

Lap ,
e x t e rna l ,
fo r j ig b u sh ings
for jig bu sh in s g .

L apping nd g i nd ing b u h ing

a r s s

a ll w nc fo t bl
o a es r, a e

L pping jig b u h i ng b siv s u s d

a s s, a ra e e

L t ch f j ig di m n i ns t bl
a es or s, e s o ,
a e

L t ch n u t d i m n i n t bl
a s, e s o s, a e

L t h c i g c t ing p l ning fixt u f

a e a rr a e as ,
a re or

L v winging f j ig
ea es, s ,
or s

Lin e c il cy lind p fil mi ll ing fix t u f

e r, r o
‘
er, ro e re or

Lining bu h ing t b l f d im nsi n

s s, a e o e o s

L c t ing and cl m ping d vic e s t h p i nt

o a a e ,
re e - o .

L c t ing by k y w y i n t h w o k
o a , e a s e r

by m n f V—bl ck
ea s o o s

Loc t ing d vic

a u t m t ic f d ill j ig
e e s, a o a ,
or r

d o u bl e t h e p in t re - o

sp c i l on jig
e a , .

wi t h flo t ing p u c mp n ta r e ss re o e s a or

L oc t ing in j ig by m ns f p in nd s t u d s
a s ea o s a

Loc at in g p int o s .

a d j u t bl s a e

cu p nd c n a o e
3 24 I ND E X
fl o a t in g ,
fo r h c uck j w s a .

for w k or

Loc a t ing fl t ing b u h ing ppli d t d ill j g

ve e s and oa s s a e o r i

Loc w k by m n f c w nd sl id ing b u h ing

at i n g or ,
ea s o s re a s s

f m fini h d h l s
ro s e o e

Loc t nd fl t i ng cl mp ppli d t m illing fi t u

a or a oa a s a e o x re

L cking t i gg f winging bu hi ng p l t
o r er or s s a e .

Lub ic t i n of j ig
r a o s .

M at e r i a s , l for j i g bu sh i n s g
for j igs
Ml c m nt pp li d t dr ill j ig
i li ng at t a h e a e o

M illing fixt u re s .

f ng ul
or a w k ar or

f c nt inu u mi lling
or o o s

h ving l t e l nd ngul
a a d j u t m nt
ra a a ar a s e .

i nd ing f ex clu t ch ,
or es

ind xing f e ll p t
,
or r o e r se ar a o r

l v p t d f m illing il g v i n b u
e e r -o e ra e ,
or o — r oo e shi ng

p fi l fo
ro c il cy l ind lin
e, r re o er er

di l
ra a

st d d l fo mi lli ng t gi v n l ngt h
ra e ,
r o e e

wi t h flo t ing cl mp s nd loc t
a a a a or

M ul t ip l b ing j ig f e or ,
s or

M u l t ip l d i lling jig f v ibl t yp

e r o re e rs e e .

M ul t ip l e d il ling p l t b u hi ng h l d
r f a e, s o e rs or

M ul t ip l e d ri ll jig fo y k nd r o e e s

N u t s l at c h , , di men i s o ns , ta bl e

O groo ve s , d
il-
up l ex fi tu x re for ro u t i ng
bu sh ing l v
in s, e e r-o p e ra t e d fixt u f milling re or

O p e n d ill j i g d ign
r s, es of

x mp l s
e a f e o

Op e n j ig s , d e s ign of .

Op e n t y p e of d r il l j ig s

P i ns and u d s u d in j ig l c t ing m
st se s as o a e ans

Pi t on ch uck wi t h fl t ing cl mping f t u

s oa a ea re s .

Pi t n d ill jig wi t h fl t ing cl mp

s o r , oa a s

Pi t ns j ig fo cr s d i lling
s o , s r os - r

j ig s f f c i n g bor s a osse

Pivot e d t yp of d i l fixt u e ra a re

Pl ning fixt ur s
a e

f r l t h c ri g c s t ing
o a e ar a e a

gang
radi a l
Pl at e bu sh ing h l d o e rs fo r m u l t ip l e ll
d ri i ng
3 2 6 I ND E X
T h re e -po in t l c g and cl am ping d e vi c e s
o a t in .

Th r e e -p oint o at ing d e vi c e d o u bl e
l c ,
.

Th re e -p o in t p rinc ip l e app li c a t i on t o fix t u re s
,

Th re e -p oint s upp or t fo r fl ywh e e l fixt u re .

Th umb nu t s d im n i ns t bl
-
,
e s o ,
a e .

Th umb sc e w s di m n i n t bl
- r ,
e s o s, a e

T ru nni n t ypo f ind xin g j ig e o e s

Tu t l t h s ad j u s t bl fixt u
rre a e f,
a e re s or

Two-j w ch u ck w i t h fl t ing j w
a ,
oa a

Unive rsal j igs

Up k ee p p rovi d ing
,
for , in j ig and fi tu
x re d e sign

V bl ck s u d l c
- o se as o at in g m e ans i n j i gs
V t ic l b ring mill
er a o s, ad j u s t abl e fix t u r e s for
Vi d rilling jig
se

Vi j aw d e t ch bl
se s, a a e

Vi se s provid e d wit h d ill j ig

r at t a ch m e nt s

W ed ge or t ap e r gib s for cl mp ing

a

W e i g h t o f j ig s
Wing-nu t s d im e nsions t abl e
, ,
.

Work-l oc at ing d e vic e on in d e xi ng j i g

Wor m-ge ar se c t or ad j u s t abl e fixt u re for,