Introduction to Thermodynamics

Course Instructor :
Dr.S.Ramaswamy
Sub. Code & Name : ME8095 – Design of Jigs , Fixtures and
Unit Press Tools

Number : 3
Topic Number :

DEPARTMENT OF MECHANICAL ENGINEERING

INTRODUCTION TO JIGS AND FIXTURES

• Production devices are generally work holding devices, such

as work holders with/without tool guiding/setting
arrangement. These are generally called as jigs and fixtures.
• A jig may be defined as a work holding device which locates
and hold the component for a specific operation. It is also
provided with guiding elements.
• A fixture may be defined as a work holding device which
only holds and positions the workpiece. It does not guide the
cutting tools..

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FUNCTIONS OF JIGS:

1. To locate the hole in the appropriate positions.

2. To clamp the workpiece during Drilling, Reaming or
Tapping.
3. To guide the drills, reamers or tap into the proper position
on the workpiece..

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FUCTIONS OF FIXTURES:

1. To locate and position the workpiece relative to the cutting

tool.
2. To clamp the workpiece during machining , welding,
inspection or a assembly.

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ADVANTAGES OF JIGS AND FIXTURES:

1. It reduces the production time by eliminating the marking out,

measuring and setting the job.
2. It reduces the cost of production by eliminating the laying out of
work and setting up of tools.
3. It increases the machining accuracy as the work is rigidly fixed and
located and tool is guided.
4. It minimizes the machining time by increasing depth of cut, feed and
speed, due to better clamping rigidity of the job and guiding the tool.
5. Interchangeability of manufacture is achieved by enabling the
production of identical parts.

Department of Mechanical Engineering

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6. It minimizes the assembly cost due to interchangeability and
eliminating the operations , such as filling etc..
7. It reduces the operators fatigue , as the material handling is less.
8. Semi – skilled operators are sufficient to perform the operations ,
as the setting of the tool and work is simple. Therefore it also
reduces the labour cost.
9. It reduces the cost of inspection as the products are produced
with very less defects.
10.It minimizes the overall cost of production by partly or fully
automatising the process.

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 BASIC ELEMENTS OF JIGS AND FIXTURES:

I. LOCATING ELEMENTS: Location refers to the establishment of a

proper relationship between the workpiece and jig or fixture.
II. CLAMBING ELEMENTS: The main purpose of this element is to
exert a force to press the workpiece against the locating surfaces
and holds it against the action of cutting forces.
III. TOOL GUIDING & SETTING ELEMETS: Tool guiding elements are
mainly useful to the jigs. In jigs, a hardened bushing is fastened
to the sides of the jigs to guide the tool to its proper position in
the work. Tool setting elements are used in the fixtures where a
target or set block is used to set the location of the tool with
respect to the work piece within the fixtures.

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PRINCIPLES OF JIGS AND FIXTURES DESIGN:

1. Location:
1. Locating surfaces should be as small as possible and the location must
be done from the machine surface.
2. Sharp corners in the locating surfaces must be avoided.
3. Locating pins should be easily accessible and visible to the operator.
4. Adjustable locators should be provided for rough surfaces.

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 PRINCIPLES OF JIGS AND FIXTURES DESIGN:

2. Clamping :
i) Clamping should always be arranged directly above the points supporting the
work.
ii) Quick acting clamps should be used wherever possible.
iii) Clamps should not cause deformation of the workpiece.
iv) Position of clamps should provide the best resistance to the cutting tool.
v) Cutting forces of the tool should act against the solid part of the jig and not
against the clamps.
vi) All the clams and adjustments should be on the sides.

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PRINCIPLES OF JIGS AND FIXTURES DESIGN:

3. Loading and Unloading:

The loading and unloading process of the workpiece should b as
easy as possible. Loading and supporting surfaces are usually
made of hardened material and also it should be renewable
wherever possible.
4. Stability and Rigidity:
Jigs and fixtures should posses a high rigidity to withstand the
cutting forces. At last, four legs should be provided on the jigs for
the stability. The fixtures are rigidly fixed on the machine table.
The equipment is made as rigid as necessary for the operation.

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PRINCIPLES OF JIGS AND FIXTURES DESIGN:

5. Clearance for ships:

Adequate space in the form of channel ways should be
provided to enable the metal chips to be blown clear easily.
6. Fool proof design:
Jigs and fixtures should be fool proof besides being safe to
use. The design of jigs and fixtures is such that it is
impossible to use the workpiece and tool in any position
other than that the correct one. Locating pins are provided
for this purpose.

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PRINCIPLES OF JIGS AND FIXTURES DESIGN:

7. Provision for tool guides:

Provision for tool guides in jig bushing and cutter setting devices in
fixture should be made.
8. Provision for indexing:
The provision for indexing the workpiece should be made wherever
it is necessary. It enables the workpiece to divide into many
numbers of equi – spaced faces.
9. Weight:
Jigs and fixtures should be lighter in weight. Jig weight should be
kept below 15 kg since they are to be handled often.

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PRINCIPLES OF JIGS AND FIXTURES DESIGN:

10. Safety:
Jigs and fixtures are designed for safety. Handles and levers should
be large enough. All sharp edges should be removed or avoided.
11. Coolant supply:
Adequate arrangements must be made for the supply of coolant to
the cutting edges for reducing the friction.
12. Economy:
Jig and fixture should reduce machining and production costs by
providing ease of manufacturing.

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ESSENTIAL FEATURES OF JIGS OR FIXTURES:

1. Reduction of idle time: 1. Easy implementation

2. Cleanliness 2. Initial location
3. Replaceable parts or standardization 3. Position clamps
4. Provision for coolant 4. Clearance
5. Hardened surfaces 5. Ejecting devices
6. Inserts or pads 6. Rigidity and stability
7. Fool – proofing 7. safety
8. Economic soundness

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DIFFERENCE BETWEEN JIGS AND FIXTURES

Sl.No Jigs Fixtures

1. It holds, locate the workpiece and also guides the tool. It holds and positions the workpiece but does not guide
the tool.

2. Jigs are smaller in size and lighter in cosntruction Fixtures are usually massive and heavier in
construction.

3. Semi skilled workers can operate. Skilled operator is necessary as compared to jig.

4. Fabrication time and cost are less. Production time and cost are more.

5. Clamping with the table is often not necessary. It is bolted rigidly on the machine table.

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 Department of Mechanical Engineering
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