MOHAMED SATHAK ENGG COLLEGE,KILAKARAI

DEPARTMENT OF MECHANICAL ENGINEERING QUESTION BANK

Sub. Name: Design of Jigs, Fixtures & Press Tools(elective) Year/Sem: IV/VII
UNIT-I PART-A (PURPOSE TYPES AND FUNCTIONS OF JIGS AND FIXTURES) 1. Differentiate between jigs and fixtures. 2. Define locating devices. 3. Define clamping devices. 4. Sketch a latch clamp. 5. State the significance of clamping force in relation to cutting force. 6. Define fool proofing. 7. State the various locating elements used in jigs and fixtures. 8. Mention the locating methods. 9. Define jack pin locator. 10. What is the use of dowel pins? Give one example? 11. Sketch a Bayonet clamp. 12. Define stack clamping. 13. List out the some power clamping. 14.Define the term fixture. 15. What are the two factors involved in clamping force?. 16. What is meant by angular location? 17. Where should the locators contact the part? Why? 18. Mention the errors that are to be considered while designing jigs and fixtures. PART-B 1. Mention the advantages of jigs and fixtures 2. Describe the design principles for jigs and fixtures. 3. Explain briefly materials used in jigs and fixtures. 4. Describe the elements of jigs and fixtures. 5. Describe the accessories of jigs and fixtures. 6. Explain briefly 3-2-1 location of principle. 7. Explain briefly with neat sketch cylindrical and adjustable locators. 8. Explain briefly non-conventional clamping. 9. Explain briefly with neat sketch latch and wedge clamping. 10. Explain briefly magnetic clamping. 11. With a neat sketch explain pneumatic and hydraulic clamping. 12. What is meant by vacuum clamping? 13 .Discuss in detail the principles of jig and fixture design and mention the uses of jigs and fixtures. 14. Sketch and explain a fixture which uses both mechanical and pneumatical energy for Operation. 15. List any four types of jigs and fixture construction? State the advantages of each and Discuss the relative merits of each.

16. Explain the advantages to be obtained from the use of pneumatic and hydraulic clamping devices. 17. Discuss about the different types of error analysis in jigs and fixtures. 18. Explain the working principal of Air to- hydraulic booster with simple sketch. 19. What are the various location devices? Explain any four of them in with the aid of suitable sketches. 20. Explain with the help of suitable sketches the operation principles of power clamping Systems .Also, state its advantages. 21. (a) State any four types of power clamps. (b) Explain the working of a fluid power clamp used to clamp a cylindrical component. (c) How does the degree of roughness determine whether a surface is flat , circular or irregular?

UNIT-II PART-A (JIGS) 1. What is the function of jig bushes? 2. When will press fit bushes or fixed bushes be used? 3. Specify the condition of using plain and flanged bushes in jigs. 4. How liner bushes are used? 5. What are the different types of jigs? 6. Define sandwich jig. 7. State the provision made on latch or leaf Jig. 8. What are the disadvantages of leaf jigs? 9. Sketch the channel jig. 10. What are the advantages of trunnion jig? 11. Define indexing device. 12. What is the use of indexing jig? 13. What are various possibilities to operate automatic drill jigs? 14. Sketch a shaped drill bush. 15.differentiate between post and pot jig. 16. What are the two types of press fit bushes?. 17. State the purpose of a jig plate. 18. What class of jig would normally be used to tap holes? 19. What is the primary function of a linear bushing? 20. Sketch a locating bush. 21. Give the names of any four types of jigs. PART-B 1. Describe the important elements of any jig. 2. Explain any four types of drill bushes with sketch. 3. Discuss the various types of drill bushes. 4. What is a drill jig? What are the requirements of drill jigs? 5. Describe the working of rack and pinion operated drill jig and compare the pneumatic jig.

6. Design a drill jigs make a hole of diameter 8mm as shown in figure and also mention the part list.

7. Design a suitable drill jig which can be used to drill holes on the itch circle diameter of a Flange coupling and make a neat sketch of it . 8. Sketch and explain a turnover jig and mention its uses. 9. W hat is the primary function of a linear bushing? List out any four types of drill bushes With its method of fixing and locking. 10. Sketch and explain any eight parts of a box jig with suitable diagram fixtures. 11. Explain following automatic drill jigs mechanisms with sketch. 12. Describe the following with simple sketch. (a) Plate jigs (b) Latch jigs (c) Angle plate jigs (d) Box jigs 13. Design and draw to scale any two views of a suitable drill jig to drill two 10mm hole on the component shown in fig.1.

14. Design and sketch any two vies of a suitable drill jig to drill an oil hole of size 3mm for the given job shown in fig.2.

15. With neat sketches explain the uses of plate and channel jigs.

16. Draw any two views of a turnover drill jig to drill, four 12 holes in the flange of housing shown in fig. The housing is complete except for these holes.

17. Draw any two views of Latch jig to drill four, 10 holes in a costing shown in fig.

UNIT-III PART-A (FIXTURES) 1. What is the use of fixtures? 2. What are the standard work holding devices in lathes? 3. State any four design points should be considered while designing lathe fixtures. 4. What is the function of mandrels in turning fixture? 5. Mention the application of turning fixture. 6. What are the various types of milling fixtures? 7. How is cutter setting done? 8. What are the factors to be considered while string milling fixture selection? 9. What ate the factors to be considered while selecting gang milling fixture? 10. What are the various machine tools used for boring? 11. Define key way broaching fixture. 12. What are the ways the work piece can be held for machining on a surface grinder? 13. What are static fixtures?

14. What is meant by pressing fixture? 15. What are the steps involved in operating pressing fixtures? 16. List out the type of locators and clamping device used in welding fixture. 17. What is the use of stop pin in machine vices? 18. What is meant by cutter setting? 19. When indexing fixtures are used?. 20. What is meant by inspection?. 21. List any three basic types of jigs used for welding? 22. What is meant by modular fixture? 23. Sketch a machine vice with special extension jaws. PART-B 1. What are the design factors to be considered while designing a lathe fixture? 2. Briefly explain the construction and working of faceplate turning fixture. 3. Explain any one type of lathe mandrel. 4. List out the various types of milling fixtures and explain any two in detail. 5. Define the tennon and setting block in milling fixture. 6. Explain with a neat sketch the working of a gang milling fixture and compare with straddle milling fixture. 7. Differentiate straddle milling fixture and key-way milling fixture. 8. Define broaching and explain the types of broaching fixtures with neat sketch. 9. Design a milling fixture to make a slot of 120 X 120 X 15 as shown in figure.

. 10. What are factors to be considered while designing milling fixture? 11. Sketch and explain a turning fixture which can be used for holding non-cylindrical components available components in lathe for turning. 12. Design, sketch and explain a broaching fixture used for broaching keyways in a fiange. 13. (i) Illustrate the working of a lathe fiture. (ii) Illustrate the working of gang milling fixture.

14. Write short notes on inspection and welding 15. Design the welding fixture for the machine cover shown in Fig.1

16. Describe about the different types of surface grinding fixture with sketches. 17. Design a suitable milling fixture to cut a keyway of size 33mm on a solid shaft of 30mm Diameter and 100mm length. 18. With proper sketch explain the operation of a modular fixture with example used in practice. 19. With neat sketches explain the assembly and and inspection fixtures. 20. Draw any two views of a milling fixture to mill 20x6 slot shown in fig.

21. Draw any two views of a turning fixture to bore 30 shown fig.

UNIT-IV PART-A
(PRESS WORKING TERMINOLOGIES AND ELEMENTS OF DIES AND STRIP LAY OUT)

1. What are the applications of press working operations? 2. How is the cutting operation carried out? 3. How is forming operation carried out? 4. List out the various cutting operations. 5. Name some types of forming operations. 6. List out the press working terminology. 7. What is the purpose of pilot? 8. Classify presses according to the mechanism used for applying power to ram. 9. Mention any four important factors to be considered while selecting a press. 10. Write down the formula for calculating tonnage limited by the motor. 11. Define clearance. 12. What is the significance of die and punch clearance? 13. Explain the function of bolster plate in press tool. 14. Write down the formula for calculating the smallest hole that can be punched in a Sheet metal? 15. In what way the operations are carried out in progressive die. 16. State any two advantages and disadvantages of progressive dies. 17. Difference between compound die and combination die. 18. Differentiate progressive dies with compound dies. 19. What is a press tool?. 20. Differentiate cutting and forming. 21. Mention the effect of insufficient clearance between punch and die. 22. What is meant by clearance? Why it is important in shearing operation? 23. What is the purpose of shear angle found on a punch or die? 24. Differentiate punching from blanking. 25. Classify the presses according to the mechanism used for applying power to ram.

PART-B 1. Describe briefly the various press working operations. 2. Write short notes on terminology. 3. What are the factors to be considered while selecting a press? 4. Explain briefly the functions of following parts in press tool. (i) Stripper (ii). Pilots (iii). Shedder. 5. Explain fixed stripper and spring loaded stripper with sketch. 6. Sketch complete die- set assembly. 7. Describe with neat sketches any two dies used in press working operations. 8. Describe with a neat sketch a compound die and compare its merits and demerits with combination die. 9. Explain with example center of pressure. 10. Differentiate between compound die, combination die and progressive die. 11. Write short notes on the following. (i) Bending and forming die (ii). Combination and compound die. (iii). Calculation of center or pressure with example. 12. Find center of pressure as shown in figure.

13. Sketch the assembly of a die set and explain the uses of various components available In the die set. 14. Explain the step-by-step procedure for the computation of capacities and tonnage Requirements for drawing operation by assuming a suitable example. 15. How the fly press differ from power press? Describe the construction and working of a Power press with the help of suitable sketch.

16. Discuss briefly any four possible for the component shown in Fig Equal angle section. 17. Describe about the types of layout and also explain the calculation percentage utilization of stock in strip in layout with neat sketches. 18. (a) Write short notes on. (i) Arch press. (ii) Eccentric driven press. (b) Describe the working principal of mechanical press and Hydraulic press. 19. (a) (i) Differentiate between progressive die and a compound die. (ii) Calculate the maximum punch force necessary to blank a steel washer 44 mm outside diameter and 22.25 mm inside diameter and 1.6 mm thick, s = 400 N/mm2 20. What is strip layout? What are the different ways of making strip layout for regular and irregular shaped blanks? 21. Draw any two views of a compound die for blanking and piercing operation and indicate any eight major parts and explain their function for the component shown in fig.

22. Draw any two views of a progressive die and indicate any eight major parts for component shown in fig.

UNIT-V PART-A (DESING AND DEVELOPMENT OF DIES) 1. Write down the formula for calculating cutting force required in a cutting operation? 2. Write down the formula for calculating drawing force required in drawing operations. 3. How is the press capacity determined for exerting force in drawing? 4. Write down the formula for calculating bending force in a press working operations. 5. What is the purpose of stocks-stop? 6. What does meant by bending allowance? 7. What is meant by flash and gutter? 8. List any eight sheet metal cutting operations. 9. What is combination Die?. 10. Why is the wheel dressing often attached directly to the grinding fixture? 11. What is a progressive die? When should a progressive die be used? 12. What is called simple die? 13. What is spring back in bending? PART-B 1. Write short notes on bending, forming and drawing. 2. Write down the step by step design procedure of cutting dies 3. Write down the step by step design procedure of drawing dies 4. Design for drawing die as shown in figure from medium carbon steel take ft = 36 KN/CM 2

All dimensions are in cm 5. Sketch and design a drawing die as shown in figure from medium carbon steel 3600 Kg/CM 2

All dimensions are in cm 6. Explain with example to estimate the number of draws in drawing process. 7. Write short notes on types of forming dies,

8. Sketch and design a blanking die to make 30mm diameter part from 1.6mm thick mild steel metal. Take 320 N/mm2 9. Sketch and design a blanking die to make 25mm diameter part from 2mm thick medium carbon steel metal. 10. Sketch and design a blanking die to make diameter 30mm part from 3mm thick carbon steel sheet metal. Take fs = 32 Kg/mm 2 11. How to calculate bending allowance in bending process? Explain. 12. What is spring back? And how is it controlled in bending die? 13. Write short notes: (i) Design of drawing die (ii). Design of bending die. (iii).Types of cutting operations. 14. Calculate the developed length of part as shown in figure.

All dimensions are in mm 15. Explain modern press tool with application. 16. Sketch and explain a compound die and list the types of components made using components made using compound die. 17. List the various design considerations in forging and casting and explain their importance with relevant to the process. 18. Design and sketch any two views of a progressive die to manufacture the outer plate of a cycle-chain links. 19. A steel cup of height 30mm and internal diameter 40mm with a flange width of 10mm is to be deep drawn from a sheet 1mm thick , Determine the diameter of the blank and the drawing force. What is the draw ratio? Can the cup be in a single operation and sketch any two views of a draw die? 20 (a) Explain the common procedure to determine centre of pressure. (b) Differentiate between combination die and progressive die. 21. Equal number of circular blanks of 60mm and 100mm in required for a product line . Sketch the single row and nested layouts for the circular blanks and calculate the percent Utilization of material .What is the better layout? What is the increased saving in material? Assume that the raw material can procured in coil form. Margin and bridge may be taken as 2mm.

22. A rectangular steel component of size 20 60 mm is to be make from 4 mm thick sheet Sketch the scrap strip by layout and determine the percentage of stock used. 23. Design and draw any two view of a progressive die to make a steel washer of 30 mm outside Diameter with 15 mm hole 1.6 mm thick steel sheet. The ultimate shear stress of the material is 320 N/mm2. 24. With a neat sketch explain the working of a progressive die and mention its advantages and Disadvantages. 25. Explain the working of a compound die with a neat diagram and mention its applications, merits and demerits over progressive die. 26. Design and draw any two views of a drawing die for the work piece shown in fig. (a) calculate the following at the early stages of the design procedure ; (i) percent reduction ,(ii) depth of draw and draw ratio,(iii) number of draws required and (iv) drawing force (v)die clearance, (vi) blank size (vii) radius on punch and die, and (viii) relationship of punch nose radius and die radius.

27. Design and draw any two views of a bending die for the component shown in fig.