DESIGN OF JIGS & FIXTURES

 Some machining operation are so simple which are done quite easily, such
as turning, the job is held in position in the chuck and turning operation is
done easily.

 No other device is required to hold the job or to guide the tool on the
machine in such an operation.

 But some operations are such type in which the tool is required to be
guided by means of another device and also some jobs are of such forms
which are required to be held in position on the machine by means of
another device.

 The device which guides the tool is called jig and the device which holds
the job in position is called fixture. 34
 …Cont
 Jigs and fixtures are tools which are used to facilitate
production (machining, assembling and inspection
operations), when work piece is based on the concept of
interchangeability according to which every part will be
produced within an established tolerance.

 Jigs and fixtures provide on means of manufacturing

interchangeable parts since they establish a relation with
predetermined to tolerance between the work and cutting
tool. They eliminate the necessity of a special set up for
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each individual park.
 …Cont
 Generally; a jig may be defined as a device which hold and position the
work; locate or guides the cutting tool relative to the work piece.
 Jigs are used on drilling, reaming, tapping and counter boring operations.

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 A fixture is a work holding device and position the work; but doesn’t
guide, locate or position the cutting tool
 The setting of the tool is done by machine adjustment and a setting
blocker using slip gauges.
 Fixtures are used in connection with turning, milling, grinding, shaping
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and planning operations.

 ADVANTAGES OF JIGS AND FIXTURES

a) Productivity

 Jigs and fixtures eliminate individual marking, positioning, and

frequent checking.

 This can reduce operation time and increase productivity.

 Two or more workpieces can be machined simultaneously.

a) Interchangeability

 Jigs and fixtures facilitate uniform quality in manufacturing.

 There is no need of selective assembly.

 Any parts of the machine fit properly in assembly and all similar
components are interchangeable.
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 a) Skill Reduction

 Jigs and fixtures simplify locating and clamping of the workpieces.

 Tool guiding elements ensure correct positioning of the tools with

respect to the workpieces, it makes the use of lower skilled labor
possible.

a) Cost Reduction

 Higher production, reduction in scrap, easy assembly and savings

in labor costs result in substantial reduction in the cost of
workpieces produced with jigs and fixtures.

 They decrease the expenditure on the quality controls of the machine

parts. 39
DIFFERENCE BETWEEN JIGS AND FIXTURES
40
…Cont

41
…Cont
42
 JIGS

 Increasing the productivity and accuracy are the two basic aims of mass
production.
 Hence using of jig to position and guide the tool to its right path is
preferred rather than using scribers, square, straighteners or center
punch etc.
 Thus, the productivity is increased which is done by eliminating
individual positioning, marking and frequent checking.
 One does not need to repeatedly clamp and unclamp the object for
various purposes like positioning as the locating, clamping and guiding
of the tool is done by the jig itself.
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 CLASSIFICATIONS OF DRILLING JIGS

The most common jigs are drill and boring jigs.

 These tools are fundamentally the same. The difference lies in the
size of the drill bushings.
 Boring jigs usually have larger bushings.

Jigs are further identified by their basic construction. The two common forms of jigs
are open and closed.

1. Open jigs: carry out operations on only one, or sometimes two, sides of a
work piece. The most common open jigs are template jigs, plate jigs, table
jigs, sandwich jigs, and angle plate jigs.

2. Closed jigs: on the other hand closed jigs, operate on two or more sides.
Typical examples of closed jigs include box jigs, channel jigs, and leaf jigs.
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 1. TEMPLATE JIG

 This is the simplest type of jig; it is simply a plate made to the shape and
size of the work piece; with the require number of holes made it.

 It is placed on the work piece and the hole will be made by the drill.

 This type of jig is suitable if only a few parts are to be made.

 Bushings may or may not be provided in template jig. The factor on which
the availability of the bushing depends is the number of jobs to be
manufactured.

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 2. PLATE TYPE JIG

 This is an improvement of the template type of jig.

 In place of simple holes, drill bushes are provided in the plate to guide the
drill. The work piece can be clamped to the plate and holes can be drilled.

 The plate jig is employed to drill holes in large parts, maintaining accurate
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spacing with each other.
 3. OPEN TYPE JIG

 In this jig the top of the jig is open; the work piece is placed on the
top.

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 4. CHANNEL JIG
 The channel jig is a simple type of jig having channel like cross section.
 The component is fitted within the channel is located and clamped by
locating the knob.

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 5. LEAF JIG
 It is also a sort of open type jig, in which the top plate is arrange to swing
about a fulcrum point, so that it is completely clears the jig for easy loading
and unloading of the work piece.

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 When the holes are to drill more than one plane of the work piece, the jig has
to be provided with equivalent number of bush plates.

 It is used where there is drilling at number of distinct angles.

 One side of the jig will be provided with a swinging leaf for loading and
unloading the work piece, such a jig would take the form of a box.

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 53

FIXTURES
As we all know a fixture is a production tool which is mainly
used to locate, hold and support the workpiece firmly
to the table.

Fixtures have a much-wider scope of application than jigs.

These work-holders are designed for applications where the

cutting tools cannot be guided as easily as a drill.

There are many standard work holding devices such as jaw

chucks, machine vises, drill chucks, collets, etc. 54
 TYPES OF FIXTURES

The names used to describe the various types of

fixtures are determined mainly by how the tool is
built.
• Plate Fixtures
• Angle plate fixture
• Indexing fixture
• Vice fixtures
• Multi-station fixture 55
 a)Plate Fixtures

 Plate fixtures are the simplest form of fixture. The basic fixture is made
from a flat plate that has a variety of clamps and locators to hold and locate
the part.

 The simplicity makes it popular. 56

 b) Angle-Plate Fixtures
 Angle-plate fixtures are a modification of plate fixtures in that rather
than a reference surface parallel to the mounting surface, it is set
perpendicular to the mounting surface.
 That is; the part normally machined at a right angle to its locator.
 While most angle-plate fixtures are made at 90 degrees, there are times
when other angles are needed. In these cases, a modified angle-plate
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fixture can be used.
 c) Vise-Jaw Fixtures
 The machine vice is the simplest milling fixture.
 It is mounted on the machine table T-slots by using T-bolt, helix nut
and washer.

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 Vise-jaw fixtures are used for machining small parts. With this
type of tool, the standard vise jaws are replaced with jaws
that are formed to fit the part.

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 d) Indexing Fixtures

 Indexing fixtures are used to reference workpieces that need

machining details set at prescribed spacings.
 Indexing fixtures must have a positive means to accurately locate and
maintain the indexed position of the part.

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 e) Multi-Part or Multi-Station Fixtures

 Multi-part or multi-station fixtures are normally used for either

machining multiple parts in a single setup, or machining individual
parts in sequence, performing different operations at each station.

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 In addition to their basic construction, fixtures may be
classified in respect to the process or machine tool to
be used in the machining process.

 Milling fixture
 Lathe fixture
 Grinding fixture

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i) Milling Fixtures

 A Milling fixture is a work holding device which is firmly clamped to the

table of the milling machine.

 It holds the work piece in correct position as the table movement carries it
past the cutter or cutters.

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 Design principles of the milling fixtures

 Some of the principles of milling fixture design are;

 Pressure of cut should always be against the solid part of the fixture (fig a).

 Clamps should always operate from the front of the fixture (fig b)

 The work piece should be supported as near the tool thrust as possible (fig c)

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 ii) Lathe Fixtures (Turning fixtures)

 Work holding devices include two to six jaw chucks and collets of
varying shapes and diameters.

 Three-jaw chucks used for circular and hexagonal work.

 Four jaw chucks are ideal for gripping round, square, hexagonal and
irregularly shaped workpieces.
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 Magnetic chuck; it has the advantage of holding iron or steel parts.

 The parts that are too thin or that may be damaged if held in a
conventional chuck.

 Suitable only for light operations.

 A magnetic chuck consists of an accurately centered permanent

magnet face.

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 Basic Design Principles for Turning or Lathe Fixtures

 To avoid vibration while revolving, the fixture should be accurately

balanced.

 The fixture should be rigid and overhang should be kept minimum

possible so that there is no bending action.
 Clamps used to fix the fixture to the lathe should be designed
properly so that they don’t get loosed by centrifugal force.
 The fixture should be as light weight as possible since it is rotating.

 The fixture must be small enough so that it can be mounted and

revolved without hitting the bed of the lathe.

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 iii) Grinding Fixtures
The two major types of grinding fixtures are those used for
surface grinding and cylindrical grinding.
The magnetic table is the preferred work holding device on
surface grinders.

Workpiece can be quickly mounted and removed and also

distortion caused by mechanical clamping eliminated.

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 The work piece can be held for machining on a surface grinder in the
following ways:
 It may be clamped directly to the machine table or to an angle
plate and so on,
 It may be held in a vice.
 The work piece may be held by means of a magnetic chuck .
 Here the work piece is held without any mechanical clamping.

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 ELEMENTS OF JIGS AND FIXTURES

 Various elements of jigs and fixtures and their details are follows;

1. Body 3. Clamping devices

2. Locating devices 4. Tool guide (jigs bushing)

1. Body
 Its main purpose is to support and house
the job.

 Jig bases are leaf jig, channel jig, box type Figure: Milling fixture base
jig, etc.

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 2. Locating Devices
 The pins of various design and made of hardened steel are the most common
locating devices used to locate a work piece in a jig or fixture.

2.1 Pin-type
 Pin type locators are used for smaller holes and for aligning members of the
tool.

 It is a precision locating pins with a tapered tip foe easy loading and a shoulder
to resist downward forces.

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The pin may be classified as follows;

(a)Locating Pins
When reamed or finally finished holes are available in work
piece, these can be used for locating purpose of the manner
as shown,

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 b) Support Locating Pins
 With these pins (also known as rest pins) buttons or pads the work piece with
flat surfaces supported at convenient.

 Support pins with flat head are usually employed and provided location and
support to machine surface, because more contact area is available during
location. It would insure accurate and stable location.

 Adjustable type support pins are used for work piece whose dimension can
vary. For example, sand casting, forging or unmachined faces.

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 c) Diamond or Relieved Pin Locator
 Diamond pin is normally used along with the round pin to reduce the
time it takes to load and unload the tool.
 In use, the round pin locates the part and the diamond pin prevents
the movement around the pin

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 2.2 Vee Locator
 Vee locators are used mainly for round work.

 They can locate flat work with the rounded or angular

ends and flat discs.

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 2.3 Fixed-Stop Locator
 It is used for parts that cannot be placed in either a nest or a vee
locator.
 They are either machined into the tool body or installed.

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 2.4 Adjustable Locator
 Adjustable support or locator is used when the surface is rough
or uneven.
 Normally used with one or more fixed stop locator to allow any
adjustment needed to level the work.

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 Locating principles
3-2-1 Principle of Fixture Design

For a fixture designer, the major portion of design time is

spent deciding how to locate the work piece in the fixture.

This principle of location of fixing points on the workpiece

is also named as 3-2-1 principle of fixture design as number
of points selected at different faces of the workpiece are 3,
2 and 1 respectively.

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79
 3. Clamping devices

 If the work piece cannot be restrained by the locating devices or elements, it

become necessary to clamp the work piece in jig or fixture body.

 The purpose of the clamping is to exert a pressure to press a work piece

against the locating surfaces and hold it there in a position to the cutting
forces.

The commonly used clamping devices are follows;

3.1 Clamping Screws

 Clamping screws are used for light clamping.

 Screw clamp exerts adequate force.

 It also resists tendency of loosening set up by vibration.

 But the disadvantage is that they are slow and may not be suitable for high
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production.
 3.2 Hook Bolt Clamp
 This is very simple clamping device and is only suitable for light work
and where usual tip of the clamp is inconvenient. The typical hook bolt
clamp is shown;

3.3 Bridge Clamp

 It is very simple and reliable clamping device. The clamping force is
applied by spring loaded nut.

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 3.4 Heel Clamp
 These consists of a rusted plate, center stud and heel.

 This trap should be strengthen at the point where the hole for the stud is cut
out, by increasing the thickness around the hole.

 The design differ from simple bridge clamp in that a heel is provided at the
outer end of the clamp to guide its sliding motion for loading and unloading
the work piece.

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83
 Principles of clamping
 Various principles are followed during the clamping operation.
 Some of them are listed below;

 Clamping elements must hold the work piece firmly engaged

with locating elements during the operation.

 The clamp must not damage or deform the part but the clamping
force must not be less.

 Clamp should be fast acting and allow rapid loading and

unloading of parts.
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  Clamping system should be positioned at thick sections of the workpiece.

 Clamping force shall be directed towards support /locators.

 Clamping time should be minimized by using hand knobs, tommy bars,

knurled screws, handwheels and handles, so that clamp can be tightened or
loosened manually without spanners.

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 Example
Design and draw a channel jig for mild steel component as shown in the figure
to drill a hole of 18 mm diameter.
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Solution;
The design procedures are;
 Selection of Bush
 Selection of locator
 Selection of Clamps
 Design of jig body
 Bill of Materials

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1. Selection of Bush
 Outside diameter – Push fit or Press fit
 Inner hole – Running Fit
 Bush Selection; headed fixed type

 Given hole diameter is 18mm; based on the given hole

diameters the following dimensions are given;
 Tolerance for inner diameter of bush =
d1F7 (running fit) from the standard design
+0.041
data for bush is =18−0.020 .
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92
 d2 = 30mm, since the outside diameter tolerance is d2h6 push fit) and

from the standard design data of bush the tolerance of

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94
 l1= 20mm, l2 = 15mm and d3 = 35mm.

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2. Selection of locator

 The thickness of jig plate must be equal to distance, l2 of bush = 15mm.

 For better rigidity of the channel jig two (2) locators and clamps on both
sides are used.

 Selecting the locating pin corresponding to jig plate thickness.

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 Width of workpiece 45mm which is equal to the width of the jig.
 Use 2 locators for perfect alignment at a width of 45mm.
 ‘D’ value must be less than the width of the jig; for example, if we select
25mm for D value, the values of h1 and h2 becomes out of the jig body.

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 h1 value must be less or equal to the jig plate thickness (15mm).
 So that the appropriate value of ‘D’ is selected as 16mm.
 Based on the value of ‘D’, the values of other dimensions are selected from the
standard design data of locating pin;

 Locator head diameter (D) = 16mm and d = 15mm,

 h1 = 14mm and h2 = 22mm,
 d1= 12mm and d2 = 11.5mm.

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99
4. Selection of clamp
 In order to clamp the righthand side of workpiece, pressure pad with
assembly can be used.

 Two clamps can be selected for better rigidity of jig.

 The pressure pad be fixed at the end of the clamp.

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101
 Outer diameter of pressure pad selected as d1= 16mm; which is 16 +16 = 32mm,
which is less than the width of the workpiece (45mm). so based on the outer
diameter other dimensions of the pressure pad selected as;

 d4 = 64mm
 f = 3.5mm
 h = 9.5mm
 d5 = 12mm
 d6 = 7mm
 d7 = 2mm
 size of screw M8

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1

03