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WORKSHOP THEORY AND PRACTICES- II

B.Tech 6th Semester Curriculum under ASTU
AEC, Mechanical Department
Instructor: Debottam Bhowmik, PMRF Scholar, IIT Guwahati
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Module 3: JIGS & FIXTURE

Outline
• Introduction
• Elements of Jigs & Fixtures
• Principle of Location
• Principle of Clamping
• Indexing Jigs & Fixtures
• Indexing Devices
• Fool Proofing
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BASICS
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Manufacturing VS Production
Basis of Manufacturing Production
Comparison
Definition Process of transforming raw Process that converts inputs
materials into ready goods, with like raw material to make
the help of machinery finished product, which may
or may not use machinery

Concept A process in which raw material is A process of converting

used to generate output. inputs into outputs.

Resources Men and Machine Men

Purpose Goods that are suitable for use Utility

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Primary VS Secondary Manufacturing

Primary Manufacturing Secondary Manufacturing

• Involves the extraction and processing • Process where raw materials obtained
of raw materials into basic forms to be from primary manufacturing are
used as input for further manufacturing transformed into finished goods through
processes. various processes

• Initial stage of production. • Subsequent stage of production

• Examples: Casting, Forging, Extrusion • Examples: Machining, Welding, Surface

etc. Finishing etc.
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Machining
Single Point Cutting Multi Point Cutting

• In SPCT, only one cutting edge is • In MPCT, multiple cutting edges or teeth
involved in removing material from the work simultaneously to remove material.
workpiece.
• This is typical in processes like milling,
• Turning operations on a lathe is a drilling, and grinding.
common application of single-point
cutting. • Higher material removal rates due to
multiple cutting edges; but the
• Slower material removal rates. mechanism is complex.
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Module 3: JIG & FIXTURE

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Introduction
• Jig is a device which holds and locates a workpiece and
guides & control one or more cutting tools

• It comprises of a plate, structure or box made up of metal

or non metal.

• The jig guides the workpiece, the cutting tool remains

stationary, and clamping secures the workpiece to the jig
for machining.
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Introduction
• Fixture is a work-holding device utilised to securely position,
support, and affix a workpiece in a stable position

• It comprises of different work holding devices, which are

clamped on the machine table to hold the work in requisite
position.

• Unlike jigs, fixtures do not guide the tool.

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Fundamental Differences
• A jig guides the tool in addition to holding the workpiece but
the fixture only position the workpiece.

• A fixture is heavier in construction and bolted on the machine

table, whereas the jigs are lighter for quicker handling.

• The fixtures are employed for holding the work in case of

milling or turning operations, whereas jigs are used for
holding the work & guiding the tool in drilling, taping
operations.
Fig: Jig (L) and Fixture (R)
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Advantages
• It increases machining accuracy, as the workpiece is properly located and tool is guided.

• It reduces the operator’s labour and consequent fatigue as handling operations are
minimized.

• It increases production capacity by enabling a number of workpieces to be machined in a

single set up.

• It reduces expenditure on the quality control of the finished products.

• It reduces the overall cost of machining by fully or partly automatizing the processes.
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Elements of Jig & Fixture

• Body: It is a plate, box or frame type
structure where components are located
for machining. The body should be quite
sturdy and rigid.

• Locatingelements: These elements

locate the workpiece in a proper
position with respect to the cutting
tool.

• Clamping elements: These elements Fig: Elements of Jig and Fixture

firmly secure workpiece in the located
position.
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Elements of Jig & Fixture

• Positioning elements: These have different types of fastening devices and it is used to
secure Jig or Fixture to machine at the proper position.

• Grinding and setting elements: These elements guide the cutting tool in case of jig and
help in proper tool acting in case of the fixture.
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Location
• The location refers to the establishment of a desired relation between the
workpiece and jig or fixture.

• The jigs and fixture must be designed in such a way that all possible movement
of the workpiece must be restricted.

• The locating points are determined by first finding out the possible degree of
freedom of the workpiece, which are then restricted by a suitable arrangement
termed as locators.
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Principle of Location
• In the fig, it can be observed that the rectangular block is free
to move along the three axis X, Y and Z.

• The body can also rotate about this three axis as well,
thus the total DOF six.

• In order to locate the block accurately, this six movements

has to be restricted by arranging suitable locating points
and then clamping the block in position.

Fig: DOF of a rectangular

block in space
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Six point / 3-2-1 location of a rectangular block

• To made the block rest on the jig body, it has to be located by using locating points, 3 base
pins, 2 pins in vertical plane, and 1 pin perpendicular to first two planes.

• The bottom of the block is supported against three points, the rear face against two points
and the side of block rests against single points, all protruding from jig body.

Fig: Side,
front and
top view
of the
locating
pins
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Continuation
• The three supporting pins restricts the downward movement of block along Z-axis.

• The movement along X and Y-axis are restricted by using double and single pins
respectively.

• The rotary movements of block about Y, Z and X-axis are also restricted by bottom, back,
and side pins.

• Thus these six points serves to locate the block correctly while restraining all the
movements.
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Six point location of a three legged object

• The object is resting on pointed legs on a flat surface.

• It is thus prevented to move along CD axis, and rotating

about EF & AB axis.
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• In the fig, it can be observed that front legs are made

ball ended and are made to rest on a V-groove.

• The spherical balls makes perfect mating surface

with V-groove.

• Thus the object is restrained to move along AB and

rotation about CD.
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• In fig, it can be observed that the rear leg also

made ball ended and is made to rest on a
separate V-groove set at right angle to first one.

• The body is now perfectly restrained against any

movement.
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Methods of Location
• There are different methods of locating a • Types of locators:
workpiece.
1. Flat Locator
2. Cylindrical Locator
3. Conical locator
• A particular locating arrangement is selected only 4. Jack pin Locator
after careful study about the type of work, type of 5. Drill bush Locator
operation, amount of accuracy required etc.
6. Fixed V Locator
7. Sliding Locator
8. Outside pin Locator
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Flat Locator
• Flat type locators are used for locating flat
surfaces of component.

• An undercut clearance is provided at the

bottom for collecting small metal chips or
the dust particles.

• Horizontal button flat locator is better than

the Vertical button flat locator as it has the
capacity to handle more end loads and
have provision for clearance.
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Cylindrical Locator
• The cylindrical locators are used in case of
components having drilled holes.

• Undercut is provided around the locator along the

work table for having proper clearance.

• The working surface of the locator is inserted

inside the drilled hole of the component to locate it
in the position.
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Conical Locator
• Conical locators are used locating components
having drilled holes.

• This locator is superior compared to the

cylindrical one because of its ability to
accommodate variation in hole diameter of the
component.
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Jack pin Locator

• Jack pin locators are used for supporting workpiece
from the bottom, while locating it.

• Mainly rough and unmachined components are

located by jack pin locator.

• The height of the pins are adjustable to

accommodate the variation in surface texture of the
component.
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Drill bush Locator

• It is used to locate the cylindrical workpieces.

• The drill bush and jig body have conical

openings for locating purpose.

• The drill bush sometimes serves the purpose of

guiding the tool.
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V Locator (Fixed/Sliding)
• These locators are used for components having
circular and semi circular profiles.

• This locator can be of two types fixed V locator

and adjustable V locator.

• The fixed type locator is normally fixed on the jig

and adjustable locator can be moved axially.

• The standard included angle for V-block is 90˚.

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Outside pin Locator

• These are used for locating components having
odd and irregular surface profiles.

• The pins are provided on the contours of the

outer profile of the workpiece.
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Clamping
• The clamps serves the purpose of holding the work pieces securely on the jigs or fixtures
against the cutting forces.

• The principles of clamping are as follows:

Types of Clamps:

1. Screw clamp
1. Hold the work rigidly against the disturbing forces. 2. Flat clamp
2. Keep the work firmly in contact with the locating pins. 3. Pivoted clamp
3. Quicker loading and unloading consideration. 4. Equalizing clamp
4. Should not distort or loosen when subjected to vibrations. 5. Latch clamp
6. Swing plate clamp
5. Should not damage the work.
7. Double acting clamp
6. Should be simple and fool proof. 8. Wedge clamp
9. Cam clamp
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Screw Clamp
• It is used to clamp the workpieces on the edges of the
jig or fixture.

• To clamp or unclamp any work, longer duration is

required.

• Large amount of effort has to be made to clamp or

unclamp a particular work.

• After clamping, a mark is left on the surface of the work.

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Flat Clamp
• It is used to clamp any work by its flat face.

• Mainly flat workpieces are clamped by using flat

clamps.

• By tightening the provided nut, the work is clamped

while using this nut.
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Pivoted Clamp
• This clamps eliminates the need of using the
spanner for clamping purposes.

• The work can be gripped quickly by rotating the

screw.

• The rotating screw actuates the pivoted on the face

of the work.
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Equalizing Clamp

• These clamps are used to clamp any work by exerting

equal pressure at two spots on the work face by the two
legs of the clamp.
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Latch Clamp
• Latch clamp is used to clamp any work by using a
latch and a pivoted leaf.

• The clamping or unclamping happens very quickly

by pushing the latch.

• The clamp does not exert high pressure on the

workpiece.
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Swing Plate Clamp

• Swing plate clamp is used to clamp or unclamp lighter

workpieces in quick duration.

• The clamp is operated by swinging the plate and locking it

in the required position by using a turning screw.
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Double Acting Clamp

• This clamp is employed to grip the work by rotating the
central screw.

• The rotating screw actuates two clamps at two works to

operate simultaneously.

• Sufficient gripping pressure by these clamps.

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Wedge Clamp

• This clamp is used to grip the work by using the

wedge block by rotating the screw.

• The wedge block grips the work against the fixed

surface fitted on the jig body.
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Cam Clamp
• It is used to clamp any work by actuating the cam handle
up or down.

• This type of clamp is not recommended where vibration is

present as it can slack the clamp.

• This clamp is extensively used in jig & fixtures due to its

rapid and convenient action.
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Fool Proofing

• The fool proofing means designing of jig and fixture with such devices so as to make it
impossible for the for an operator to insert the incorrect component in the required
position.

• This arrangement prevents the accidental error of the operator from spoiling the work.

• This is accomplished by using fouling pegs, cross frames, pins arranged within the jig or
fixture in such a way that it does not create interfere with the correct location of the work.