For simple components where

appearance is important, a sighting

plate can be provided. It is slightly
bigger than the workpiece. The
workpiece can be positioned on the
sighting plate in such a way that
there is equal margin on all the
sides as shown in
Figure 2.18.
For simple components where
appearance is important, a sighting
plate can be provided. It is slightly
bigger than the workpiece. The
workpiece can be positioned on the
sighting plate in such a way that
there is equal margin on all the
sides as shown in
Figure 2.18.
For simple components where
appearance is important, a sighting
plate can be provided. It is slightly
bigger than the workpiece. The
workpiece can be positioned on the
sighting plate in such a way that
there is equal margin on all the
sides as shown in
Figure 2.1
Location from profile
Sighting Plate: When appearance is crucial, a sighting plate larger than the workpiece is
employed. This plate allows the workpiece to be positioned with equal margins on all sides.
To locate a workpiece's profile, cylindrical pins can be used to enclose it. When there's
variation in workpiece dimensions between batches, an eccentric locator is employed. This
locator's eccentricity can be adjusted by rotating it to suit the workpieces in batch. In cases
where workpieces have a milled flat, the eccentricity of the locator can be set based on one
workpiece from the batch, ensuring accurate location for all workpieces in that batch.
To locate a workpiece's shape, a pocket or nest is made around it, matching its outer
profile. The nest's height is lower than the workpiece's to allow easy gripping for unloading. For
thin sheet metal, slots or ejection features help with unloading. A partial nest can also work.
Similar workpieces from the same die or mold can be precisely located using a close-fitting nest.
Indexing Plate
For precise positioning, the piece is held on a special plate that moves with it (see Picture 4.5).
This plate has tough parts or slots to reduce damage from being used a lot in making many items.

The plate can be turned around a center point and locked with a knob. A lever on the plate fits
into slots on the plate, helping to position the piece just right. The slots might be angled to stop
mistakes from wear. Also, a round part and a pin can be slanted to fix wear (see Picture 4.6).
Instead of a pin and part, a ball and a cone-shaped hole can be used (see Picture 4.7). The ball is
pushed into the hole by a spring. When the plate is turned with some force, the ball goes down
and waits until it lines up with the next hole. Once it does, the spring pushes the ball into the
hole, and the plate moves to the next spot. To move to the next spot, the plate has to be turned
again. After moving, the plate must be locked in place, and it must be unlocked when moving it.

Index milling

Index milling uses a table with multiple stations where different fixtures are set up. In a two-
station setup (see Figure 6.7), one station is for milling the workpiece, while the other is for
loading and unloading. After one workpiece is milled, it's swapped with a new one at the loading
station. When the milling is done, the table is rotated to bring the next workpiece to the milling
station. Meanwhile, the finished piece can be replaced with another at the loading station.

Rotary milling

Rotary milling involves mounting several workpieces on a rotating fixture. The fixture turns to
bring the workpieces to the milling cutter. As the fixture moves, finished workpieces are
swapped with new ones at the other end of the table (see Figure 6.8).
Reciprocal milling
Reciprocal or Pendulum Milling (Figure 6.9): In this method, there are two setups at each end of
the machine table. While one workpiece is being milled at one end, a new one is set up at the
other end. Once the milling is done, the machine table moves to switch the workpiece at the
opposite end. While the new workpiece is being milled, another fresh workpiece is set up at the
other end. This movement back and forth, like a pendulum, lets the machine mill workpieces at
both ends of the table alternately.

Advantages of jigs and fixtures

1. Increased Productivity: Eliminates individual marking, positioning, and frequent

checking, saving operation time and enhancing efficiency.
2. Interchangeability: Ensures uniform quality in manufacture, eliminating the need for
selective assembly and enabling proper fitting of machine parts.
3. Skill Reduction: Simplifies locating and clamping of workpieces, allowing average
individuals to operate effectively without the need for highly skilled labor.
4. Cost Reduction: Higher production rates, reduced scrap, simplified assembly, and
savings in labor costs lead to a substantial decrease in the overall cost of workpieces
produced with jigs and fixtures.