INTRODUCTION

Pipe Jigs and 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.

Jigs and fixtures are special purpose tool which are used to facilitate production
(machining, assembling and inspection operations), when work piece is based on the
concept of interchange ability 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
each individual park. So’ A jig is may be de-fined as a device which hold and
position the work; locate or guides the outing tool relative to the work piece and
usually not fixed to the m/c table. It is usually lightly in construction.

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. A fixture is hold or clamp-ed to the machine table. It
is usually heavy in construction. Jigs are used on drilling , reaming , tapping and
couter boring operations , while fixtures are used in connection with turning , milling ,
grinding , shaping , planning and boring operations. The use of jig and fixture makes
possible more rapid and more accurate manufacturing at a reduction of cost.

The jigs and fixture’s essential features-

.• Reduction of Idle time.

• Cleanliness.
• Standardization.
• Hardened surfaces.
• Position of clamps.
Fundamental principles of Pipe Jig and fixture:

i. Locating Points.
ii. Fool Proof.
iii. Clamping Device.
iv. Reduction of idle time.
v. Weight of Jigs and Fixture.

Design of Pipe jigs and fixture:

The creative tool design method has design a jig or fixture through functional
requirements. The goal is to find the balance combination at reasonable cost. The
design of jigs and fixtures is dependent on numerous factors which are analyzed to
achieve an optimum output. Jigs should be made of rigid light materials to facilitate
easy handling, as it has to be rotated severally to enable holes to be drilled from
different angles. It is recommended that four feet should be provided for jigs that are
not bolted on the machine tool, to enable the jig to wobble if not well positioned on
the table and thereby alert the operator. Drill jigs provide procedures for proper
location of the work-piece with respect to the cutting tool, tightly clamp and rigidly
support the work-piece during machining, and also guide the tool position and/or
fasten the jig on the machine tool. To achieve their expected objectives, jigs and
fixtures consist of many elements:
 Frame or body and base which has features for clamping;
 The accuracy and availability of indexing systems or plates;
 The extent of automation, capacity and type of the machine tool where jigs and
fixtures will be employed;
 Bushes and tool guiding frames for jigs;
 The availability of locating devices in the machine for blank orientation, and
suitable positioning;
 Auxiliary elements;
 The strength of the machine tool under consideration;
 The precision level of the expected product;
 Fastening parts;
 The available safety mechanisms in the machine tool;
The factors below are to be reflected upon during design, production, and assembly of
jigs and fixtures due to the targeted increase in throughput, quality of products,
interchangeability, and more accuracy.
 Guiding of tools for slim cutting tools like drills;
 Type of operations;
 Inspection requirements;
  Provision of reliable, rigid, and robust reinforcement to the blank;
 Production of jigs and fixtures with minimum number of parts;
 Fast and accurate location of the jig or fixture blank;
 Rapid mounting and un-mounting of the work-piece from the jig or fixture;
 Set up time reduction;
 Standard and quality parts must be used;
 Reduction of lead time;
 Easy disposal of chips;
 Enhanced flexibility.
A proper design must also incorporate tolerances at the design stage for jig andfixtures
components that are standardized

Uses / Advantage of Jigs and Fixtures:

1. Jigs and fixtures are used to reduce the cost of production as there use
elimination being out work and setting up of tools.

2. To increase the production by reduction of idle time.

3. To assure the high accuracy of the parts.

4. To provide for interchangeability.

5. To enables heavy and complex shaped parts to be machined by holding rigidly

to a machine.

6. To control quality control expenses.

7. Less skilled labor requirement.

8. Utilized time and enhanch prodactiity.

9. There use partially automates the machine tool.

10. Improve the safety at work, thereby lowering the rate of accidents.

11. The application of more than one tool simultaneously

on a work-piece can be achieved;
•Setting of higher values of some operating condition like depth of cut,
speed, and rate of feed can be attained because of the increased clamping capability
of jigs and fixtures

Jigs :

The most-common jigs are drill and boring jigs. These tools are fundamentally the
same. The difference lies in the size, type, and placement of the drill bushings. Boring
jigs usually have larger bushings. These bushings may also have internal oil grooves
to keep the boring bar lubricated. Often, boring jigs use more than one bushing to
support the boring bar throughout the machining cycle.

In the shop, drill jigs are the most-widely used form of jig. Drill jigs are used for
drilling, tapping, reaming, chamfering, counter boring, countersinking, and similar
operations. Occasionally, drill jigs are used to perform assembly work also. In these
situations, the bushings guide pins, dowels, or other assembly elements. Jigs are
further identified by their basic construction. The two common forms of jigs are open
and closed. Open jigs carry out operations on only one, or sometimes two, sides of a
work piece. Closed jigs, on the other hand, operate on two or more sides. The most-
common open jigs are template jigs, plate jigs, table jigs, sandwich jigs, and angle
plate jigs. Typical examples of closed jigs include box jigs, channel jigs, and leaf jigs.
Other forms of jigs rely more on the application of the tool than on their construction
for their identity. These include indexing jigs, trunnion jigs, and multi-station jigs.

Specialized industry applications have led to the development of specialized drill jigs.
For example, the need to drill precisely located rivet holes in aircraft fuselages and
wings led to the design of large jigs, with bushings and liners installed, contoured to
the surface of the aircraft. A portable air-feed drill with a bushing attached to its nose
is inserted through the liner in the jig and drilling is accomplished in each location.
In simple terms, the jig is a tool that guides the cutting (or machining) tool. The most
common type of jig is the drill jig, which guides the drill bit for creating holes at
desired locations. Using drill jigs increases production rate drastically by eliminating
the time spent using a square scriber, height gauge, centre punch, etc. The picture
below shows the functionality of a simple drill jig:

Fixtures

Fixtures have a much-wider scope of application than jigs. These workholders are
designed for applications where the cutting tools cannot be guided as easily as a drill.
With fixtures, an edge finder, center finder, or gage blocks position the cutter.
Examples of the more-common fixtures include milling fixtures, lathe fixtures, sawing
fixtures, and grinding fixtures. Moreover, a fixture can be used in almost any
operation that requires a precise relationship in the position of a tool to a workpiece.

Fixtures are most often identified by the machine tool where they are used. Examples
include mill fixtures or lathe fixtures. But the function of the fixture can also identify a
fixture type. So can the basic construction of the tool. Thus, although a tool can be
called simply a mill fixture, it could also be further defined as a straddle-milling,
plate-type mill fixture. Moreover, a lathe fixture could also be defined as a radius-
turning, angle-plate lathe fixture. The tool designer usually decides the specific
identification of these tools.

the applications and differences between jigs and fixtures, which although commonly
thought to be the same tool, are actually two separate devices used in the cutting and
machining processes.
The terms “jig" and “fixture" are many times referred as the synonyms of each other,
sometimes both the terms are used together as “jig fixture." Although, both jig and
fixture are used in mass production process, functionally the two are different tools..
The fixture is a tool which holds the work piece with the machine bed precisely at the
desired location. The fixture also reduces the nonproductive loading, unloading, and
fixing time of the work piece. For example, you need to use a milling machine for
giving a chamfer at the corner of rectangular work pieces. You can use a vice to hold
it in the desired position, but in that case every new work piece will take lots of time
for fixing it. On the other hand if you can make a milling fixture like the one shown
below and bolt the fixture to the milling machine bed, then you need not waste much
time for fixing the work pieces every time. You just place the work piece and it will
automatically aligned to the required angle, and straight away you run the machining
operation, no need to measure the angle, and no need to be worried about
the accuracy.

2. LITERATURE REVIEW

[1] Joshi, P. (2010). ?Jigs and Fixtures Tata McGraw Hill Education, New Delhi,
India.
Increasing the productivity and accuracy are the two basic aims of mass production.
As we know the solution to this is by reducing the set up cost of the machine and also
reducing the manual fatigue. In this case the device that caters our needs is the use of
jigs. Let us take one example. Let us consider that one gets an order of say 1000
products. There need to be three holes drilled on this product. In such a case the
designer tries to draw out every single hole with the help of square, strengtheners,
scribers and center hole. Hence using of jig to position and guide the tool to its right
path is preferred rather than using scribers, square, strengtheners or center punch etc.
Thus the productivity is increased which is done by eliminating individual
positioning, marking and frequent checking. Interchangeability is the chief advantage
here[3]. The successful running of any mass production depends upon the
interchangeability to facilitate easy assembly and reduction of unit cost. Mass
production methods demand a fast and easy method of positioning work for accurate
operations on it

[2]Nanthakumar, K. and Prabakaran, V. (2014). Design and Fabrication Testing of

Combined Multipurpose Jig and Fixture IOSR Journal of Mechanical and Civil
Engineering. www.iosrjournals.org.
The method is applicable for all microwave fixtures, except for those characteristics
are influenced by the relative positions of the adapters comprising the fixtures. In
contrast to the self-calibration techniques, the method does not have any frequency
limitations and does not need require any calibration standards for performing the
experiment. Furthermore, the results have given novel information about the effects of
slots and ground-bar extensions on the ground-shielded test fixture parasitic
component. To further optimize the layout of the ground shielded test fixture, it can be
totally upgraded to fully shielded structure. This reduces the test fixture dangling leg
impedance as validated by the experimental data. In all cases, the careful definition of
members based on manufacturing constraints and careful definition of KCs based on
customers‟ needs should proceed, in order to avoid a large number of unpractical
solutions. as the enumerative search presented does not only require a significant
amount of computation, but conflicts with many practical constraints, it is not
desirable to entrust the whole product geometry to the assembly synthesis method,
especially when the product geometry is fairly complex. Due to the singularity of the
design matrix of a multi station fixture system, the widely used D-optimal criterion is
not an appropriate design measure. The fixture system used in a four-station SUV side
frame assembly process, the revised exchange algorithm yields the optimal fixture
design the maximal sensitivity level Design and Fabrication Testing Of Combined
Multipurpose Jig and Fixture www.iosrjournals.org 87 | Page is only 72.3% of the
currently used fixture layout design. The reduction of 27.7% in sensitivity implies the
same amount of reduction in product variation level under the same variation inputs,
according to the definition of sensitivity.

[3] Lin, Q., Burdick, J., and Rimon, E. (2006). Constructing Minimum Deflection
Arrangements Using Invariant Norms IEEE Transactions on Automation Science and
Engineering, Vol. 3, No. 3.
This states is concerned with planning fixture arrangements of quasirigid workpieces.
Fixturing plays an important role in manufacturing and assembly applications. In these
applications, a workpiece is fixtured with some preloading forces by fixturing
elements, or fixels. The workpiece need not only be stable against external
perturbations, but must also stay within a specified tolerance in response to machining
or assembly forces. It has been theoretically and experimentally shown that the
deflection of fixtured objects due to contact compliance is a major source of geometric
error in machining operations, and that fixel geometry and layout can significantly
reduce such deflections. The grasping and fixturing literature has a long tradition of
using quality measures to quantify and select optimal contact arrangements. For
example, the authors in define as a quality measure the smallest singular value of the
matrix whose columns consist of the generating wrenches (i.e., wrenches due to unit
finger forces). Subsequent quality measures compute the maximal wrench ball
inscribed in the convex hull of the generating wrenches . Other quality measures either
minimize the worst-case finger forces needed to balance a collection of pure forces
acting on the object , or treat forces and torques lexicographically . Another notable
approach is based on assessing the static stability margin afforded by a given contact
arrangement. An alternative quality measure, suggested by Nakamuraetal, considers
the largest allowable dynamic perturbation to the contact positions that does not cause
slippage. However, all of these quality measures assume perfectly rigid bodies which
do not experience any contact deformation in response to applied loads. Moreover,
some of these quality measures employ ill-defined wrench norms. This paper clarifies
the meaning of frame-invariant velocity and wrench norms, and applies these notions
to define a frame-invariant object deflection measure.

[4]Kaija, T. and Heino, P. (2006). The Optimization of On-wafer Shield-Based Test

Fixture Layout? IEEE Transactions on Microwave Theory and Techniques, Vol. 54,
No. 5.
The people’s quest for manufactured goods has been growing rapidly over the years.
Therefore, to meet up with the high demand, manufacturers have reacted by
introducing innovative ways of manufacturing high quality products at a faster rate.
The production processes has witnessed numerous changes and evolution with the
introduction of numerous innovative manufacturing concepts which include Lean
Production System, Cellular Manufacturing, Single Minute Exchange of Dies, as well
as take Time Analysis. These creative approaches have necessitated the need for a
reliable and cheaper tools and work-holding devices. As the efficient running of a
manufacturing company which demands a prompt and simple work positioning
strategy for correct operations depends largely on the interchangeability of machine
components and workpieces, to ensure un-complication of assembly, and unit cost
reduction, as well as to become competitive, reduce the enormous manufacturing cost,
and also increase their profitability, the industry has resorted to streamlining its supply
chain in a bid to maintaining a very low amount of inventory. This has also led to the
demand for a better and cost effective work-holding devices which will ensure better
quality products, reduce lead time, and also increase throughput. Also, although some
machining operations are so straightforward, like in turning where the job is secured
tightly on the chuck while the turning operations are easily performed, some job sin
other operations may not be easily held on either the three or four jaw chucks, and
may also require the tools to be guided by the means of a different device. This
explains the need for production standard work-holding devices to increase the rate of
manufacturing. Jig is the device which guides the tool, while fixture is a device that
securely holds the job in position during machining operations

[5]Mechnol (2015). Applications of Jigs and Fixtures[Online]

The people’s quest for manufactured goods has been growing rapidly over the years.
Therefore, to meet up with the high demand, manufacturers have reacted by
introducing innovative ways of manufacturing high quality products at a faster
rate.The production processes has witnessed numerous changes and evolution with the
introduction of numerous innovative manufacturing concepts which include Lean
Production System, Cellular Manufacturing, Single Minute Exchange of Dies, as well
as Takt Time Analysis. These creative approaches have necessitated the need for a
reliable and cheaper tools and work-holding devices. As the efficient running of a
manufacturing company which demands a prompt and simple work positioning
strategy for correct operations depends largely on the interchangeability of machine
components and work-pieces, to ensure un-complication of assembly, and unit cost
reduction, as well as to become competitive, reduce the enormous manufacturing cost,
and also increase their profitability, the industry has resorted to streamlining its supply
chain in a bid to maintaining a very low amount of inventory. This has also led to the
demand for a better and cost effective work-holding devices which will ensure better
quality products, reduce lead time, and also increase throughput.

[6]Pachbhai, S. and Raut, L. (2014). A Review on Design of Fixtures International

Journal of Engineering Research and General Science, Vol. 2, Issue 2.
The fixture is a special tool for holding a work piece in proper position during
manufacturing operation. For supporting and clamping the work piece, device is
provided. Frequent checking, positioning, individual marking and non-uniform quality
in manufacturing process is eliminated by fixture. This increase productivity and
reduce operation time. Fixture is widely used in the industry practical production
because of feature and advantages. To locate and immobilize workpieces for
machining, inspection, assembly and other operations fixtures are used. A fixture
consists of a set of locators and clamps. Locators are used to determine the position
and orientation of a workpiece, whereas clamps exert clamping forces so that the
workpiece is pressed firmly against locators. Clamping has to be appropriately
planned at the stage of machining fixture design. The design of a fixture is a highly
complex and intuitive process, which require knowledge. Fixture design plays an
important role at the setup planning phase. Proper fixture design is crucial for
developing product quality in different terms of accuracy, surface finish and precision
of the machined parts In existing design the fixture set up is done manually, so the aim
of this project is to replace with hydraulic fixture to save time for loading and
unloading of component. Hydraulic fixture provides the manufacturer for flexibility in
holding forces and to optimize design for machine operation as well as process
functionability.

[7]Chennu, V. (2014) Jigs and Fixtures and their Purposes?

The successful running of any mass production depends upon the interchangeability to
facilitate easy assembly and reduction of unit cost. Mass production methods demand
a fast and easy method of positioning work for accurate operations on it. Jigs and
fixtures are production tools used to accurately manufacture duplicate and
interchangeable parts. Jigs and fixtures are specially designed so that large numbers of
components can be machined or assembled identically, and to ensure
interchangeability of components.

3.ELEMENTS OF JIGS AND FIXTURES

The body, Clamping devices, Locating devices, and Tool guide/bushes are the major
elements of jigs and fixtures.

2.4.1. The Body:

As the most outstanding element of jigs and fixtures, thebody is constructed by

welding of different slabs and metalsusually mild steel or by casting of cast iron. After
thefabrication, it is often heat-treated for stress reduction as itsmain objective is to
accommodate and support the job.The different types of jig bodies are as follows:
Channel body type -this is fabricated from the regularsteel channel.

Box body type - usually made very light, the box type jigbody is adopted where a
work-piece needs drilling in variousparts, hence the jig is fabricated to have a required
amount ofdrill bush plates.
Plane body type - this is the most common type of jigbody and is often applied when
the work-piece requiresdrilling or boring, hence the provision of drill bushes on it.
Leaf body type -usually made from block of steel as itholds and supports heavy
components.
Built-up body type - this is made from standard steel.

2.4.2. Clamping Devices :

Without sacrificing efficiency and effectiveness, the clamping devices must be very
simple and easy to operate.Apart from holding the work-piece securelyin place, the
strong point of clamping devices is its ability to withhold thestrain of the cutting tool
during operations. The bench vice isa popular example of a clamping device. The
need forclamping the work-piece on the jig or fixture is to applypressure and press it
against the locating components,thereby fastening it in the right position for the
cutting tools.
The familiar clamping devices include:
Clamping screws- they are used for not too rigidclamping.
Hook bolt clamp - a simple clamping device generallyused where the normal
clamping tip cannot fit in.
Latch clamp- his is a unique clamp which provides spacefor the loading and the
unloading of a work-piece through itslatch or lid.
Other clamping devices are the
C -clamp,
the Bridgeclamp,
and the Heel clamp,

2.4.3. Locating Devices

Made with hardened steel and with different designs, the pin is the most
popular device applied for the location of work-piece in jigs and fixtures.Thepin?s
shank is press-fitted or driven into a jig or fixture. The locating width of the pin is
made bigger than the shank to stop it from being pressed into the jig or fixture body
because of the weight of the cutting tools or work-piece. The pins are classified as
follows:
Locating pins – the locating pins are used for the location of the work-piece when
completed or reamed holes have been provided on the work-piece. The two types
of locating pins are cylinderical and conical locating pins.
Jack pins- jackpins also referred to as spring pins are used for the location of work-
piece whose dimension will vary during operation. The pin is designed to rise
under spring pressure or in the contrary the weight of the work-piece pushes it
down. As the position of the work-piece is firmly fixed, the locking screw is used
to fasten the pin in the desired position.
Support Locating/Rest pins - these pins which ensure reliable and secure location
are made to be either curved or flat. Those with flat heads are often used to
provide support and location to machine surface, as more contact area is
accessible during location. Because of their stability, the head The Design and Need
for Jigs and Fixtures in Manufacturing support locating pins are for supporting
coarse or rough surfaces during machining.

2.4.4. Jig Bushing or Tool Guide :

Guiding parts like jig bushings and templates which must be wear resistant,
interchangeable, and precise, are used to locate the cutting tool relative to the
component being machined. Jig bushes are applied in drilling and boring, here for
the drill to pass through, a bush fits into the hole of the jig. Bushes are mainly made
of reliable grade of tool steel in order to ensure hardening at a low temperature
and also reduce the risk of fire cracking. Although, hardened steel bushes are
preferred for guiding reamers, drills, and taps, the guiding tool bushings can also be
made of cast iron. The jig bushings are categorized into three: the linear wearing
bushes, press-fit wearing bushes, and renewable wearing bushes.
 4. SELECTION OF MATERIALS

There are a wide range of materials from where jigs and fixtures could be made,
to resist tear and wear, the materials are often tempered and hardened. Also,
phosphor bronze and other non-ferrous metals, as well as composites, and nylons
for wear reduction of the mating parts, and damage prevention to the
manufacturing part is also used. Some of the materials are discussed below:

 Phosphor Bronze: Phosphor bronze is used in the production of jigs and

fixtures for processes that involve making of interchangeable nuts in
clamping systems like vices, and also inoperated feedings that require
screws. As the manufacturing of screws is very expensive and also wastes a lot
of time, the reduction of their tear and wear is often achieved by using
replaceable bronze mating nuts made with phosphor bronze.

 Die Steels: the three variants of die steel - high chromium (12 %), high
carbon (1.5 to 2.3%), and cold working steels are applied in the production
of jigs and fixtures for the making of thread forming rolls, as well as cutting of
press tools. When alloyed with vanadium and molybdenum for it to retain
toughness at very high temperature, die steels are applied in the fabrication of
jigs and fixtures that are used in high temperature work processes which
include extrusion, forging, and casting processes.

 High Speed Steels: high speed steels which contain more quantity of
tungsten and less quantity of chromium and vanadium has high
toughness, hardenability, hardness retention at high temperature, and good
wear, tear and impact resistance. When tempered, they are applied in the
production of jigs and fixtures for reaming, drilling, boring, and cutting
operations.

 Carbon Steels: when tempered with oil, carbon steels are applied in the
making of some jig and fixture parts which are exposed to tear and wear like
the locators and jig bushes. ? Mild steels: mild steel which contain about
0.29% of carbon are very cheap and because of their easy availability
are often the choicest material for the making of jigs of fixtures.

 Other materials for the making of jigs and fixtures include: Nylon and fiber,
steel castings, stainless steel, cast iron, high tensile steels, case hardening steels,
and spring steels.
Name
Base plate
Material
Mild steel
No
1
Process
Milling,

Drilling
Grinding
Pillar En8 4 Hardening,
turning,
Grinding
M12 Mild steel 6 Standard
Drill brush OHNS 3 Standard
Strap Clamp C45 2 Standard
Locating Pin En24 Mild 6 Mill, grind, jig
Steel boring
Jig Plate En24 mild 1 Mill, Grind,
steel Jig boring

5. DESIGN OF JIG AND FIXTURES

The design of jigs and fixtures is dependent on numerous factors which are
analyzed to achieve an optimum output. Jigs should be made of rigid light
materials to facilitate easy handling, as it has to be rotated severally to enable
holes to be drilled from different angles. It is recommended that four feet should be
provided for jigs that are not bolted on the machine tool, to enable the jig to
wobble if not well positioned on the table and thereby alert the operator. Drill
jigs provide procedures for proper location of the work-piece with respect to the
cutting tool, tightly clamp and rigidly support the work-piece during machining,
and also guide the tool position and/or fasten the jig on the machine tool. To achieve
their expected objectives, jigs and fixtures consist of many elements: Frame or
body and base which has features for clamping; The accuracy and availability of
indexing systems or plates; The extent of automation, capacity and type of the
machine tool where jigs and fixtures will be employed; Bushes and tool guiding
frames for jigs; The availability of locating devices in the machine for blank
orientation, and suitable positioning; Auxiliary elements; The strength of the machine
tool under consideration; The precision level of the expected product; Fastening parts;
The available safety mechanisms in the machine tool; The study of the fluctuation
level of the machine tool. Figure 3.Major elements of jigs and fixtures. The factors
below are to be reflected upon during design, production, and assembly of jigs
and fixtures due to the targeted increase in throughput, quality of products,
Inter changeability, and more accuracy.
Guiding of tools for slim cutting tools like drills;
 Type of operations;
 Inspection requirements;
 Provision of reliable, rigid, and robust reinforcement to the blank;
 Production of jigs and fixtures with minimum number of parts;
 Fast and accurate location of the jig or fixture blank;
 Rapid mounting and un-mounting of the work-piece from the jig or fixture;
 Set up time reduction;
 Standard and quality parts must be used;
 Reduction of lead time;
 Easy disposal of chips;
 Enhanced flexibility. Spogel (2014),

advised that the design of jigs and fixtures must be fool-proof so that the tools,
bushes, and components cannot be inserted except in the correct way. Apart
from ensuring that locating points are made adjustable when the component is a
rough casting and may be out of alignment, he admonished that the clamps should
be located in the best position in order to resist the cutting tool pressure when at
work. A proper design must also incorporate tolerances at the design stage for
jig andfixtures components that are standardized.

Steps of fixture design

Successful fixture designs begin with a logical and systematic plan. With a complete analysis
of the fixture's functional requirements, very few design problems occur. When they do,
chances are some design requirements were forgotten or underestimated. The workpiece,
processing, tooling and available machine tools may affect the extent of planning needed.
Preliminary analysis may take from a few hours up to several days for more complicated
fixture designs. Fixture design is a five step problem-solving process. The following is a
detailed analysis of each step.

Step 1: Define Requirements

To initiate the fixture-design process, clearly state the problem to be solved or needs
to be met. State these requirements as broadly as possible, but specifically enough to
define the scope of the design project. The designer should ask some basic

Step 2: Gather/Analyze Information

Collect all relevant data and assemble it for evaluation. The main sources of
information are the part printprocess sheets, and machine specifications. Make sure
that part documents and records are current. For example, verify that the shop print is
the current revision, and the processing information is up-to-date. Check with the
design department for pending part revisions. An important part of the evaluation
process is note taking. Complete, accurate notes allow designers to record important
information. With these notes, they should be able to fill in all items on the "Checklist
for Design Considerations." All ideas, thoughts, observations, and any other data
about the part or fixture are then available for later reference. It is always better to
have too many ideas about a particular design than too few. Four categories of design
considerations need to be taken into account at this time: workpiece specifications,
operation variables, availability of equipment, and personnel. These categories, while
separately covered here, are actually interdependent. Each is an integral part of the
evaluation phase and must be thoroughly thought out before beginning the fixture
design.

Step 3: Develop Several Options

This phase of the fixture-design process requires the most creativity. A typical
workpiece can be located and clamped several different ways. The natural tendency is
to think of one solution, then develop and refine it while blocking
out other, perhaps better solutions. A designer should brainstorm for several good
tooling alternatives, not just choose one
path right away. During this phase, the designer's goal should be adding options, not
discarding them. In the interest of
economy, alternative designs should be developed only far enough to make sure they
are feasible and to do a cost estimate.
The designer usually starts with at least three options: permanent, modular, and
general-purpose workholding. Each of these
options has many clamping and locating options of its own. The more standard
locating and clamping devices that a designer
is familiar with, the more creative he can be. Areas for locating a part include flat
exterior surfaces (machined and
unmachined), cylindrical and curved exterior surfaces. The exact procedure used to
construct the preliminary design sketches
is not as important as the items sketched. Generally, the preliminary sketch should
start should start with the part to be
fixtured. The required locating and supporting elements, including a base, should be
the next items added. Then sketch the
clamping devices. Finally, add the machine tool and cutting tools. Sketching these
items together helps identify any problem
areas in the design of the complete fixture.
Step 4: Choose the Best Option
The total cost to manufacture a part is the sum of per-piece run cost, setup cost, and
tooling cost. Expressed as a
formula:

These variables are described below with sample values from three tooling options: a
modular fixture, a
permanent fixture, and a hydraulically powered permanent fixture.
Step 5: Implement the Design
The final phase of the fixture-design process consists of turning the chosen design
approach into reality. Final
details are decided, final drawings are made, and the tooling is built and tested. The
following guidelines should be
considered during the final-design process to make the fixture less costly while
improving its efficiency. These rules are a
mix of practical considerations, sound design practices, and common sense.
i. Use standard components: The economies of standard parts apply to tooling
components as well as to manufactured
products. Standard, readily available components include clamps, locators, supports,
studs, nuts, pins and a host of other
elements. Most designers would never think of having the shop make cap screws,
bolts or nuts for a fixture. Likewise, no
standard tooling components should be made in-house. The first rule of economic
design is: Never build any component you
can buy. Commercially available tooling components are manufactured in large
quantities for much greater economy. Inmost cases, the cost of buying a component is
less than 20% of the cost of making it.
Labor is usually the greatest cost element in the building of any fixture. Standard
tooling components are one
way to cut labor costs. Browse through catalogs and magazines to find new products
and application ideas to make designs
simpler and less expensive.
ii. Use prefinished materials: Prefinished and preformed materials should be used
where possible to lower costs and
simplify construction. These materials include precision-ground flat stock, drill rod,
structural sections, cast tooling sections,
precast tooling bodies, tooling plates, and other standard preformed materials.
Including these materials in a design both
reduces the design time and lowers the labor cost.
iii. Eliminate finishing operations: Finishing operations should never be performed
for cosmetic purposes. Making a
fixture look better often can double its cost. Here are a few suggestions to keep in
mind with regard to finishing operations.
iv. Keep tolerances as liberal as possible: The most cost-effective tooling tolerance
for a locator is approximately 30% to
50% of the workpiece's tolerance. Tighter tolerances normally add extra cost to the
tooling with little benefit to the process.
Where necessary, tighter tolerances can be used, but tighter tolerances do not
necessarily result in a better fixture, only a
more expensive one.
IMPORTANT CONSIDERATIONS WHILE DESIGNING JIGS AND
FIXTURES.
Designing of jigs and fixtures depends upon so many factors. These factors are
analyzed to get design inputs for jigs and
fixtures. The list of such factors is mentioned below :
a. Study of workpiece and finished component size and geometry.
b. Type and capacity of the machine, its extent of automation.
c. Provision of locating devices in the machine.
d. Available clamping arrangements in the machine.
e. Available indexing devices, their accuracy.
f. Evaluation of variability in the performance results of the machine.
g. Rigidity and of the machine tool under consideration.
h. Study of ejecting devices, safety devices, etc.
i. Required level of the accuracy in the work and quality to be produced.
MEANING OF LOCATION
The location refers to the establishment of a desired relationship between the
workpiece and the jigs or
fixture correctness of location directly influences the accuracy of the finished product.
The jigs and fixtures are desired so
that all undesirable movements of the workpiece can be restricted. Determination of
the locating points and clamping of the
workpiece serve to restrict movements of the component in any direction, while
setting it in a particular pre-decided position
relative to the jig. Before deciding the locating points it is advisable to find out the all
possible degrees of freedom of the
workpiece. Then some of the degrees of freedom or all of them are restrained by
making suitable arrangements. These
arrangements are called locators. These are described in details below.
1.PRINCIPLES OF LOCATIONS
The principle of location is being discussed here with the help of a most popular
example which is available
in any of the book covering jigs and fixtures. It is important that one should
understand the problem first. Any rectangular
body many have three axis along x-axis, y-axis and z-axis. It can more along any of
these axes or any of its movement can
be released to these three axes. At the same time the body can also rotate about these
axes too. So total degree of freedom of
the body along which it can move is six. For processing the body it is required to
restrain all the degree of freedom (DOF)
by arranging suitable locating points and then clamping it in a fixed and required
position. The basic principle used to locate
the points is desirable below. Six Points Location of a Rectangular Block. It is made
to rest on several points on the jig body.
Provide a rest to workpiece on three points on the bottom x-y surface. This will stop
the movement along z-axis, rotation
with respect to x-axis and y-axis. Supporting it on the three points is considered as
better support then one point or two
points. Rest the workpiece on two points of side surface (x-z), this will fix the
movement of workpiece along y-axis and
rotation with respect to z-axis. Provide a support at one point of the adjacent surface
(y-z) that will fix other remaining free
movements. This principle of location of fixing points on the workpiece is also named
as 3-2-1 principle of fixture design as
numbers of points selected at different faces of the workpiece are 3, 2 and 1
respectively. If the operation to be done on the
cylindrical object requires restriction of the above mentioned free movements also
than some more locating provisions must
also be incorporated in addition to use of the Vee block. Guohua Qin[1] focuses on the
fixture clamping sequence. It
consists of two parts:
a. For the first time he evaluated varying contact forces and workpiece position errors
in each clamping step by solving a
nonlinear mathematical programming problem. This is done by minimizing the total
complementary energy of the
workpiece-fixture system. The prediction proves to be rigorous and reasonable after
comparing with experimental data and
referenced results.
b. The optimal clamping sequence is identified based on the deflections of the
workpiece and minimum position error.
Finally, To predict the contact forces and to optimize the clamping sequence three
examples are discussed

Fig. 1 Scheme of 3-2-1 fixture setup

First mathematical modeling for clamping sequence is done then he determined the
contact forces in clamping
sequence as shown in fig. 1. After that he optimized of clamping sequence for higher
stiffness workpiece and low stiffness
workpiece. He found that with the use of optimal clamping sequence, good
agreements are achieved between predictedresults and experimental data and the
workpiece machining quality can be improved .
For a fixture designer, the major portion of design time is spent deciding how to locate
the work piece in the
fixture. You know that any free body has a total of twelve degrees of freedom as
below:
6 translational degrees of freedom: +X, -X, +Y, -Y, +Z, -Z
And 6 rotational degrees of freedom:
- Clockwise around X axis (CROT-X)
- Anticlockwise around X axis (ACROT-X)
- Clockwise around Y axis (CROT-Y)
- Anticlockwise around Y axis (ACROT-Y)
- Clockwise around Z axis (CROT-Z)
- Anticlockwise around Z axis (ACROT-Z)
You must fix all the 12 degrees of freedom except the three transitional degrees of
freedom (-X, -Y and -Z) in
order to locate the work piece in the fixture. So, 9 degrees of freedom of the work
piece need to be fixed. But, how? By
using the 3-2-1 method as shown below in fig. 2 :

Fig. 2 Available Degree of Freedom of Rectangular Block[

Now, rest the work piece at two points of side surface (XZ), and you will be able to
fix the +Y and ACROT-Z
degrees of freedom. Now, rest the work piece at one point of the adjacent surface
(YZ), and you will be able to fix the +X
and CROT-Z degrees of freedom. So, you can successfully fixate 9 required degrees
of freedom by using the 3-2-1
principle of fixture design.
Nicholas Amaral [6] develop a method for modeling workpiece boundary conditions
and applied loads during a
machining process, optimize support locations, using finite element analysis (FEA)
and analyses modular fixture tool
contact area deformation. The workpiece boundary conditions are defined by locators
and clamps. To constrain using linear
spring-gap elements the locators are placed in a 3-2-1 fixture configuration and
modeled using all degrees of freedom of the
workpiece. To model cutting forces during drilling and milling machining operations,
the workpiece is loaded. Fixture
design integrity is verified. To develop an algorithm to automatically optimize fixture
support and clamp locations. To
minimize deformation in workpiece, subsequently increasing machining accuracy
ANSYS parametric design language code
is used. Unnecessary and uneconomical “trial and error” experimentation on the shop
floor is eliminated by implementing FEA in a computer-aided-fixture-design
environment.
DIFFERENT METHODS USED FOR LOCATION
There are different methods used for location of a work. The locating arrangement
should be decided after studying
the type of work, type of operation, degree of accuracy required. Volume of mass
production to be done also mattes a lot.
Different locating methods are described below.:
Flat Locator
Flat locators are used for location of flat machined surfaces of the component. Three
different examples
which can be served as a general principle of location are described here for flat
locators. These examples are illustrated in Fig.3

Fig. 3 Flat locator

A flat surface locator can be used as shown in first figure. In this case an undercut is
provided at the bottom
where two perpendicular surfaces intersect each other. This is made for swarf
clearance. The middle figure shows flat
headed button type locator. There is no need to made undercut for swarf clearance. It
is used for locating components having
drilled holes. The cylindrical component to be located is gripped by a cylindrical
locator fitted to the jig‟s body and inserted
in the drilled hole of the component.
Jack Pin Locator
Jack pin locator is used for supporting rough workpieces from the button as shown in
Fig. 4. Height of the
jack pin is adjustable to accommodate the workpieces having variation in their surface
texture. So this is a suitable method
to accommodate the components which are rough and un-machined.

Fig. 4 Jack Pin Locator

Drill Bush Locator
The drill bush locator is used for holding and locating the cylindrical workpieces. The
bush has conical
opening for locating purpose and it is sometimes screwed on the jigs body for the
adjustment of height of the work.

Fig. 5 Drill Bush Locator[

Vee Locators
This is quick and effective method of locating the workpiece with desired level of
accuracy. This is used for locating
the circular and semi-circular type of workpiece. The main part of locating device is
Vee shaped block which is normally
fixed to the jig. This locator can be of two types fixed Vee locator and adjustable Vee
locator. The fixed type locator is
normally fixed on the jig and adjustable locator can be moved axially to provide
proper grip of Vee band to the workpiece.

Fig. 6 Vee Locator

Locating error and machining error were studied by systematic method of error
identification and calculation, in
which. using finite element analysis (FEA). The machining error, the surface error
shown in fig. 7 generated from machining
operations by Y. Wang
Fig. 7 Surface error sources
A methodology of machined surface error calculation and error decomposition was
presented in this paper. The research hasfocused on (a) surface error including both
locating error and machining error, also machining error generated during multi
machining operations was analyzed; (b) the sensitivity of individual errors was
investigated, and the resultant surface error
of locating and machining was evaluated against tolerance; and (c) the method is
suitable for both components with complex
geometry as well as simple geometry

Fig. 8 Tolerance of the sample feature

The surface error analysis of a sample feature of turbine blades was presented to
demonstrate the developed
procedure and analysis. The result suggested that the component does not satisfy the
tolerance requirement due to fixture
related errors such as clamping deformation shown in fig. 8, workpiece movement,
and workpiece twist. The methods of
error reduction were proposed
CLAMPING
To restrain the workpiece completely a clamping device is required in addition to
locating device and jigs and
fixtures. A clamping device holds the workpiece securely in a jig or fixture against the
forces applied over it during on
operation. Clamping device should be incorporated into the fixture, proper clamp in a
fixture directly influence the accuracy
and quality of the work done and production cycle time. Basic requirement of a good
clamping device are listed below :
a. It should rigidly hold the workpiece.
b. The workpiece being clamped should not be damaged due to application of
clamping pressure by the clamping unit.
c. The clamping pressure should be enough to overcome the operating pressure
applied on the workpiece as both pressure
act on the workpiece in opposite directions.
d. Clamping device should be capable to be unaffected by the vibrations generated
during an operation.
e. It should also be user friendly, like its clamping and releasing should be easy and
less time consuming. Its maintenance
should also be easy.
f. Clamping pressure should be directed towards the support surfaces or support points
to prevent undesired lifting of
workpiece from its supports.
g. Clamping faces should be hardened by proper treatments to minimize their wearing
out.
h. To handle the workpieces made of fragile material the faces of clamping unit
should be equipped with fiber pads to avoid
any damage to workpiece.
J. Cecil[5] proposed an innovative clamping design approach is described in the
context of fixture design
activities. The clamping design approach involves identification of clamping surfaces
and clamp points on a given
workpiece. This approach can be applied in conjunction with a locator design
approach to hold and support the workpiece
during machining and to position the workpiece correctly with respect to the cutting
tool. Detailed steps are given for
automated clamp design. Geometric reasoning techniques are used to determine
feasible clamp faces and positions. The
required inputs include CAD model specifications, features identified on the finished
workpiece, locator points and
elements
DIFFERENT TYPES OF CLAMPS
Different variety of clamps used with jigs and fixtures are classified into different
categories are discussed here:
Strap Clamp
This is also called edge clamp. This type clamping is done with the help of a lever
pressure acting as a strap on the
workpiece. Different types of strap clamps are discussed below.
Heel Clamp
Rotation of the clamp in clockwise direction is prevented and it is allowed in
anticlockwise direction. For releasing
the workpiece the clamping nut is unscrewed. The free movements in anticlockwise
direction takes place before un-securing
the nut to release the workpiece.

Fig. 9 Heel Clamp[

Bridge Clamp
The bridge clamp applies more clamping pressure as compared to heel clamp. The
clamping pressure experienced by
the workpiece depends on the distances „x‟ and „y‟ marked. To release the workpiece
the nut named as clamping nut is
unscrewed. The spring lifts the lever to release the workpiece.

Fig. 10 Bridge Clamp

Edge Clamp or Side Clamp
A side clamp is also known as edge clamp. In this case the surface to be machined is
always clamped above the
clamping device. This clamping device is recommended for fixed length workpiece.
Releasing and clamping of the
workpiece can be accomplished by unscrewing and screwing of the clamping nut
respectively
Fig. 11 Edge Clamp or Side Clamp
Screw Clamp
The screw clamp is also known as clamp screw. This clamping apply pressure directly
on the side faces of the
workpiece.

Fig. 12 Screw Clamp

There is a floating pad at their end to serve the following purposes :
a. It prevents displacement of workpiece and slip.
b. It prevents denting of clamping area of workpiece.
c. The available cushion prevents deflection of screw.
In addition to the above there are some disadvantages associated with this method.
The clamping pressure largely
depends on the workpiece; it varies from one workpiece to other. It is more time
consuming and more efforts are required.
Latch Clamp
Latch clamps are used to clamp the workpiece, the clamping system is normally
locked with the help of a latch
provided. To unload the workpiece the tail end of the latch is pushed that causes the
leaf to swung open, so releasing the
workpiece. Here time consumed in loading and unloading is very less as no screw is
tightened but clamping pressure is not
so high as in other clamping devices. Life of this type of clamping device is small.
Equalizing Clamps
Equalizing clamp is recommended to apply equal pressure on the two faces of the
work. The pressure applied can be
varied by tightened or loosening the screw provided for the purpose.
 Fig. 13 Equalizing Clamps
Power Driven Clamping
Light duty clamps are used manually because small power is required to operate these
clamps. Hand clamping leads
to application of variable pressure, operator‟s fatigue and more time consumed. The
power driven clamping over comes the
above mentioned problems of hand clamping. Power clamps are operated on the base
of hydraulic or pneumatic power.
Power clamps are high pressure clamping, these are quick acting, easily controllable,
reliable and less time c1.Fixturing Functional Requirements
From a layout point of view, fixtures have six basic functional requirements :
(1) Stable resting, (2) accurate localization. (3) support reinforcement, (4) stable
clamping, (5) foreclosure(or total restraint)
and (6) quality performance.onsuming.


Conclusion
Both the jigs and the fixtures are used to reduce the nonproductive time of any mass
production process. The principle of location or the 3-2-1 principle, CAD tools
(like ProE), and FEA tools (like ANSYS) are used for the design of the jigs as well
the fixtures. The jig is used for guiding the cutting tool (like a drill bit), and for doing
so, jigs have components like a bush, which comes in contact with the cutting tool. On
the other hand, a fixture never comes in direct contact with the cutting tool. Fixtures
assure the position and alignment of the work pieces for getting the required
machining operation done.