Tools jigs and Die Design

BY FISHA BIRUK
(MEng5323)

1
 CHAPTER two
2. MILLING FIXTURES
2.1: introduction
Milling is one of the important operations in production processes.
The design of milling fixtures involves specific considerations to forces which cause the
effects of vibrations or chatter.
 Rigidity of the total assembly, with particular reference to clamping, plays a vital role.
 It was explained earlier, that while clamps are designed as rugged, care needs to be taken
against indentation or damage due to heavy clamping force.
Vice-jaws are a very common clamping technique, with one of the jaws being fixed to the
fixtures and the other one in the pair being of floating type. 2
Milling fixtures have tenon strips at the bottom, which position the same in the milling table.(fig 1
illustrates this)

T-bolts are provided to fasten the fixture to the table. (fig 1 illustrates this)
• In addition to tenons and hold-down T-bolts, fixtures have setting blocks, which enable the cutter to
be placed accurately in relation to the work-piece. Figure 2 illustrates a setting block.
• These setting blocks are fastened by screws and dowel pins onto the fixture
body.
• These are generally high -carbon steel ground and hardened.
• In earlier times, the body of the fixture used to be made up of cast iron to
absorb vibration.
• But later on, cast steel or heavy fabricated sections started to replace cast iron
due to the advantage of quicker methods of fabricating them.
• Thus, the main components of a milling fixture are:
Frame to absorb vibration and chatter
Jaws or clamps to impart ruggedness in gripping
Tenons and T-bolts for clamping the fixture to the milling table
Setting block to identify and position the cutter accurately
in relation to the workpiece.
2.2 .CLASSIFICATION OF MILLING FIXTURES
2.2.1. Plain Milling Fixture
Special applications: They are used for milling single components.
The example shown in Fig. 5.3 has a locating pin in the centre and
two heel-type clamps.
Diamond Pin locator is provided to locate the auxiliary hole in the component.
A pair of tenons are provided with T-bolts to clamp the fixture to the milling table.
The said type has the setting block to align the cutter accurately with respect to the
component to be machined.
• Plain
Millin
g
Fixtur
e
2.2.2. Straddle Milling Fixture
• Special applications: This is similar to plain milling fixture except that here two milling cutters are
used simultaneously to machine two parallel surfaces in a single component.
• In the type shown in Fig. .4, two locators are used with a cam-type clamp.
 2.2.3.Gang Milling Fixture
• Special applications: Gang milling is an
operation wherein two or more
components can be machined
simultaneously.
• Figure 5 shows gang milling of bolt
heads. It may be noted that a single
setting block is being used to set one of
the cutters.
• The other milling cutters are positioned
relative to the one positioned with
respect to the setting block by means of
collars placed on the arbour.
Cont gang milling…
• Also, from the following figure it can be observed that a clamp can be used for milling keyway
slots in two shafts simultaneously.
• The number of components that can be machined together depends on the width of the machine
table.
• If the machined part needs to be true, arbours need to be rigid and
• supported adequately.
• Alternatively, the number of components machined at a time can be minimized.
2.2.4. Indexing Milling Fixture
• Special applications: As explained for indexing jig in previously, indexing fixture follows the
same principle.
• Indexing fixtures are mainly used in operations where slots have to be milled in equal spacing
or interval.
• Indexing mechanism is spring actuated. It has a knob, which engages onto the grooves (which are
equally spaced) machined to an indexing plate.
• The component to be machined is fastened to the index plate, so as to move in unison with
the index plate.
2.2.5. Hydraulic Fixtures
• Special applications: Hydraulic fixtures are used in heavy milling operations requiring uniform
clamping force.
• These fixtures are also used when mass production is adopted, when the operator is likely to get
fatigued due to repeated physical operation of the clamps.
Milling fixture example
• The chosen component has two sets of slots to be milled at an angular
difference of 90°.

• Hence, an indexing milling fixture is designed to meet the requirements.

Cont..
• The fxture has an indexing plate which revolves about its spindle.
• Rotation of the index plate spindle is designed to take place over a cylindrical
bush made of wear-resistant material like brass.
• Two sets of sliding ‘V’ clamps, consisting of two bolts each, are provided to clamp
the component as well the index plate during the milling operations.
• Indexing mechanism consisting of indexing pin, cylinder, spring and a knob, is
provided to carry out the indexing operation.
• Setting block made of hardened steel and a pair of tenons are also provided.
• Rotation of the index plate will be 90° to-and-from and will not be for complete
revolution.