1. What is the universal distinction between a Jig and a Fixture?

Both jigs and fixtures hold, support, and locate the workpiece. A jig, however, guides the
cutting tool. A fixture references the cutting tool. The differentiation between these types of
workholders is in their relation to the cutting tool
2. How are Jigs identified?
Jigs are further identified by their basic construction. The two common forms of jigs are
open and closed. Open jigs carry out operations on only one, or sometimes two, sides of a
workpiece. Closed jigs, on the other hand, operate on two or more sides. The most-common
open jigs are template jigs, plate jigs, table jigs, sandwich jigs, and angle plate jigs. Typical
examples of closed jigs include box jigs, channel jigs, and leaf jigs
3. How are fixtures most often identified?
Fixtures have a much-wider scope of application than jigs. Fixtures are most often identified by
the machine tool where they are used.
4. What are the two meanings of “tool”; why is it important to make the distinction?
The term “tool” encompasses both jigs and fixtures. Essentially, it is a generic term
describing a workholder which is identified with a part or machine. Sometimes “tool” is used to
refer to a cutting tool or a machine tool, so it is important to make clear distinctions.
5. What is a broader term used for jigs and fixtures?
Another term which describes both jigs and fixtures is “work- holder.” A broad term, it
frequently identifies any device which holds, supports, and locates a workpiece. In addition to
jigs and fixtures, vises, collets, clamps, and other similar devices are also workholders
6. What is the major separation of permanent and temporary workholders?
The major difference between permanent and temporary workholders is the cost/benefit
relationship between the workholder and the process. Some applications require jigs and
fixtures solely for speed; others require less speed and higher precision. The requirements of the
application have a direct impact on the type of jig or fixture built and, con- sequently, the cost
7. Give two examples of a general purpose workholder.
Since they are not part-specific, their versatility allows for repeated use on a variety of
different or limited-production runs. The general-purpose nature of these workholders
necessitates a higher level of operator care and attention to maintain consistency and accuracy
8. What are the three main groups of workholders?
➔ Permanent Fixturing (special purpose)
➔ Modular Fixturing
➔ General Purpose (Vises, chucks, subplates, and table-mounted clamps)
9. Give applications for jigs and fixtures aside from machining.
● EXTERNAL-MACHINING APPLICATIONS:
○ Flat-Surface Machining
■ Milling fixtures
■ Surface-grinding fixtures
■ Planing fixtures
■ Shaping fixtures
○ Cylindrical-Surface Machining
 ■ Lathe fixtures
■ Cylindrical-grinding fixtures
○ Irregular-Surface Machining
■ Band-sawing fixtures
■ External-broaching fixtures
● INTERNAL-MACHINING APPLICATIONS:
○ Cylindrical- and Irregular-Hole Machining
■ Drill jigs
■ Boring jigs
■ Electrical-discharge-machining fixtures
■ Punching fixtures
■ Internal-broaching fixtures
● NON-MACHINING APPLICATIONS:
○ Assembly
■ Welding fixtures
■ Mechanical-assembly fixtures (Riveting, stapling, stitching,
pinning, etc.)
■ Soldering fixture
○ Inspection
■ Mechanical-inspection fixtures
■ Optical-inspection fixtures
■ Electronic-inspection fixture
○ Finishing
■ Painting fixtures
■ Plating fixtures
■ Polishing fixtures
■ Lapping fixtures
■ Honing fixtures
○ Miscellaneous
■ Layout templates
■ Testing fixtures
■ Heat-treating fixtures

1. Where should locators contact the part?

The primary function of any locator is to reference the workpiece and to ensure repeatability
The best machined surfaces to use for location, when available, are machined holes
least likely to be affected by machining or other operations

2. Explain the six-point locational method?

The most-common way to locate a workpiece from its external profile is the 3-2-1, or six-point,
locational method. With this method, six individual locators reference and restrict the
workpiece.

three supports on the primary locating surface restrict five degrees of freedom

Adding two locators on a side restricts eight degrees of freedom.

Adding a final locator to another side restricts nine degrees of freedom, completing the 3-2-1
location.

3. What is repeatability?
Repeatability” is the ability of the workholder to consistently produce parts within tolerance
limits, and is directly related to the referencing capability of the tool
4. What is meant by the term referencing?
“Referencing” is a dual process of positioning the workpiece relative to the workholder, and the
workholder relative to the cutting tool.

5. What percentage of part tolerance is applied to the tool?

20-50%

6. What is the purpose of fool proofing the tool?

Foolproofing prevents improper loading of a workpiece. The problem is most prevalent with
parts that are symmetrical or located concentrically. The simplest way to foolproof a workholder
is to position one or two pins in a location that ensures correct orientation. With some
workpieces, however, more-creative approaches to foolproofing must be taken
7. What is duplicate locating?
Using more than one parallel surface to locate a part
Duplicate locating ensures that a workpiece is consistently placed in the same position relative
to the cutting tool or other parts.
● Precision
● Stability
● Reliability

8. Where should the clamp contact the part?

At the most rigid point
clamps must hold the workpiece against the locators without deforming the workpiece and to
resist any secondary forces generated in the operation. this means positioning the clamps
directly over the supporting elements in the baseplate of the workholder

9. What will happen if clamped areas aren’t supported?

● Loss of Precision:
○ When clamped areas lack support, the workpiece may shift or move
during machining or assembly.
○ This can result in inaccuracies in the final product, affecting critical
dimensions and tolerances.
● Breakage of Clamps:
○ Clamps are designed to hold the workpiece securely in place.
○ Without proper support, the clamps may experience excessive forces
(such as cutting forces during machining).
○ Consequence: The clamps can break, compromising the workholding
system.
● Workpiece Instability:
○ Unsupported clamped areas allow the workpiece to move or vibrate.
○ This instability affects the machining process, leading to poor surface
finish or even tool breakage.
● Safety Risks:
○ If clamps aren’t adequately supported, there’s a risk of the workpiece
becoming dislodged.
○ Consequence: The workpiece could run free, posing safety hazards to
operators and damaging equipment.
● Interference with Cutting Tools:
○ Clamps that extend into the machining area can interfere with cutting
tools.
 ○ Consequence: Tool collisions may occur, damaging both the tool and the
workpiece.
● Reduced Clamping Pressure:
○ Proper support ensures that clamps exert sufficient pressure on the
workpiece.
○ Unsupported areas reduce the effective clamping force.
○ Consequence: Workpiece movement or inadequate clamping may result.

10. What causes tool forces and how can they be used as an advantage?
Tool forces are generated during cutting operations. When a tool (such as a drill, milling cutter,
or lathe tool) interacts with a workpiece, several forces come into play:
● Cutting Force: The force exerted on the tool due to material removal.
● Thrust Force: The axial force along the tool’s direction.
● Radial Force: The force perpendicular to the tool’s axis
● Shear Force: The force that causes material deformation and chip formation.
Tool forces can be directed strategically to hold the workpiece securely in place

11. What determines the type and amount of necessary clamping force?
By the tool forces working on the part and way the part is positioned

12. Where should the bulk of the tool thrust be directed?

Into the most solid part of the tool body

1. How thick should the jig plate be to support bushing?

from 1/16” to 3/8”

2. How much chip clearance should be allowed between the bushing and workpiece when
drilling and reaming?
● Drilling: The recommended chip clearance between the bottom of the bushing
and the top of the workpiece should be ½ to 1½ times the tool diameter. This
allows room for chip removal and helps prevent abrasion of the bushing.
● Reaming: When reaming, a slightly smaller chip clearance is advisable. Aim for ¼
to ½ times the tool diameter.

3. Drill bushings are identified by letters and numbers, identify the following
P-20-16-.1250?
● Type: The letter P indicates that this is a press-fit bushing.
● ID Sizes: The numbers 20-16 refer to the range of internal drill sizes this bushing
can accommodate. Specifically, it fits drill diameters from 1/8 inch (0.1250
 inches) to 3/16 inch (0.1935 inches) or equivalent metric sizes (e.g., #30 to #10
or 3.20mm to 4.90mm).
○ OD Length: The outer diameter (OD) of the bushing is 5/16 inch

4. What are the three general categories of drill bushings and define each?
● Permanent Bushings: Definition: Permanent bushings are fixed in place and
remain permanently installed in the jig or fixture.
● Renewable Bushings: Definition: Renewable bushings are replaceable and can be
easily removed and replaced when worn out.
● Air-Feed-Drill Bushings: Definition: These bushings are specifically designed for
air-feed drilling machines.

5. What is the purpose of liner bushings?

Liner bushings are permanently installed bushings used to hold renewable drill bushings. The
liner’s inner diameter (ID) has a precise sliding fit with the renewable bushing’s outer diameter
(OD). Here’s why they’re essential:
● Locating Accuracy: Liner bushings accurately position the renewable bushing, ensuring
precise alignment during drilling or machining operations.
● Wear Protection: By protecting the jig plate from wear and damage caused by frequent
bushing replacement, liner bushings extend the jig’s lifespan.

6. How much interference is ideal when installing a bushing in a mounting hole, what
other factors affect the size of the mounting hole?
An interference of approximately 0.0005 to 0.0008 inches is often adequate
● Material Thickness: The length of the drill bushing should accommodate the thickness
of the material being drilled. Thicker materials require longer bushings.
● Drill Bit or Tool Length: Consider the tool length used with the drill bushing. The bushing
should allow full insertion of the drill bit while maintaining stability during drilling.
● Drill Depth Requirement: Ensure that the bushing’s length aligns with your desired drilling
depth.
● Type of Bushing:
○ Headless Press-Fit Bushings: These require slightly more interference to resist
drilling thrust.
○ Headed Press-Fit Bushings: These need less interference.
● Bushing Wall Thickness: Thinner-walled bushings are more prone to distortion.
● Jig-Plate Material: Less ductile materials require less interference

7. What is the main function of a tool body?

The tool body provides the mounting area for all the locators, clamps, supports, and other
devices that position and hold the workpiece.
8. What are the three general categories of tool bodies and what are the main advantages,
disadvantages of each?
● Cast Tool Bodies:
○ Advantages:
■ Stability: Cast bodies offer inherent stability due to their solid
construction.
■ Reduced Machining Time: Casting shapes the body close to the final
form, minimizing machining requirements.
■ Material Distribution: Casting ensures uniform material distribution.
■ Vibration Damping: Cast bodies absorb vibrations effectively.
○ Disadvantages:
■ Limited Customization: Cast bodies may not be easily modified or
adapted for specific needs.
■ Material Limitations: The choice of materials is restricted to those
suitable for casting processes.
● Welded Tool Bodies:
○ Advantages:
■ Customizable: Welded bodies allow flexibility in design modifications.
■ Adaptability: Welding enables combining different components.
■ Ease of Repair: Welded joints can be repaired or modified.
○ Disadvantages:
■ Stress Concentration: Welded joints may create stress concentration
points.
■ Complexity: Welding requires skilled labor and precise alignment.
■ Potential Distortion: Heat from welding can distort the body.
● Built-Up Tool Bodies:
○ Advantages:
■ Reduced Tooling Lead Time: Built-up bodies are quicker to assemble.
■ Construction Time Savings: Assembly is faster than other methods.
■ Adaptability: Components can be added or removed as needed
■ Reusability: Built-up bodies can be reused for different workpieces.
○ Disadvantages:
■ Assembly Complexity: Proper assembly and alignment are critical.
■ Maintenance: Regular inspection is necessary to ensure stability.
■ Material Compatibility: Components must be compatible in terms of
material properties
9. Name 3 categories of jigs?
● Template jigs, plate jigs, table jigs, sandwich jigs, and angle plate jigs,box jigs,
channel jigs, and leaf jigs
10. Name 3 categories of fixtures?
 ● Milling fixtures, lathe fixtures, sawing fixtures, and grinding
fixtures,straddle-milling, plate-type mill fixture
11. Name 3 general purpose work holders?
Since they are not part-specific, their versatility allows for repeated use on a variety of
different or limited-production runs. The general-purpose nature of these workholders
necessitates a higher level of operator care and attention to maintain consistency and accuracy