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DFM Lecture Notes

The document discusses the introduction, elements, classification, and types of jigs and fixtures. It covers topics such as locating elements, clamping elements, tool guides, open and closed jigs, template jigs, plate jigs, sandwich jigs, angle-plate fixtures, vise-jaw fixtures, indexing fixtures, multi-station fixtures, profiling fixtures, fundamental aspects of jigs and fixtures, datum features, loading and unloading, clamping, tolerancing significance, and basic supporting and locating principles of fixture design.

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Shreya Uppu
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© © All Rights Reserved
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Download as PDF, TXT or read online on Scribd
36 views

DFM Lecture Notes

The document discusses the introduction, elements, classification, and types of jigs and fixtures. It covers topics such as locating elements, clamping elements, tool guides, open and closed jigs, template jigs, plate jigs, sandwich jigs, angle-plate fixtures, vise-jaw fixtures, indexing fixtures, multi-station fixtures, profiling fixtures, fundamental aspects of jigs and fixtures, datum features, loading and unloading, clamping, tolerancing significance, and basic supporting and locating principles of fixture design.

Uploaded by

Shreya Uppu
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Introduction to Jigs & Fixtures

1
Jigs & Fixtures: Elements and their Function

 Jig/Fixture Body
 Locating Elements
 Clamping Elements
 Tool guide(jigs bushing)

Fig. Typical Jig

Fig. Typical Fixture 2


Jigs & Fixtures: Elements and their Function
 Body- Main purpose is to support and house the job

 Locating elements- The pins of various design and made of


hardened steel are the most common locating devices used
to locate/position a work piece in a jig or fixture.

 Clamping elements- 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.

 Tool guide (in case of jigs)- To locate the tool relative to the
work, using jigs bushing and templates. Also useful when
the stiffness of the cutting tool may be in sufficient.

3
Classification and Types of Jigs

Classes of Jigs:
 Drilling Jigs
 Boring Jigs

Fig. Drilling Jig

Fig. Boring Jig


4
Types of Jigs:
Drill jigs are divided into two general types, open and closed,
refer to how the tool is built.

 Open jigs are for simple operations where work is done on


only one side of the part.
 Closed or box, jigs are used for parts that must be machined
on more than one side.

5
Template Jigs- Normally used for accuracy rather than speed.
This type of jig fits over on the work and usually not-clamped.

Plate jigs - Similar to templates. The only difference is that


plate jigs have built-in clamps to hold the work.

Fig. Template Jig Fig. Plate Jig 6


 Sandwich jigs: Form of plate jig with a back plate. This type
of jig is ideal for thin or soft parts that could bend or warp
in another style of jig.

 Angle-plate jigs: Used to hold parts that are machined at


right angles to their mounting locators. Pulleys, collars, and
gears are some of the parts that use this type of jig.

Fig. Sandwich Jig Fig. Angle-plate Jig


7
 Leaf jigs (small box jigs) with a hinged leaf to allow for easier
loading and unloading . The main differences between leaf
jigs and box jigs are size and part location.
 Indexing jigs are used to accurately space holes or other
machined areas around a part.

Fig. Leaf Jig Fig. Indexing Jig 8


Classification and Types of Fixtures
Fixtures are normally classified by the type of machine on
which they are used, for example milling fixture, turning
fixture, welding fixture, assembly fixture etc.

9
 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 angle-plate fixture is a variation of the plate fixture. With


this tool, the part is normally machined at a right angle to its
locator.

Fig. Angle-plate Fixture


Fig. Plate Fixture 10
Vise-jaw fixtures: For machining small parts. With this type of
tool, the standard vise jaws are replaced with jaws that are
formed to fit the part.

Indexing fixtures: Similar to indexing jigs. These fixtures are


used for machining parts that must have machined details
evenly spaced (milling of gear tooth, splines etc.).

Fig. Vice-jaw Fixture


Fig. Indexing Fixture
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 Multistation fixtures: Primarily for high-volume production
runs, where the machining cycle must be continuous. Duplex
fixtures are the simplest form of multistation fixture.

 Profiling fixtures: To guide tools for machining contours that


the machine cannot normally follow. These contours can be
either internal or external.

Fig. Duplex Fixture Fig. Profiling Fixture


12
Fundamental Aspects of Jigs
 Unique location of components with respect to the jig.

 Ease of loading and unloading the components.

 Clamping of the components so as to impart adequate


clamping force and also to have ease in operation.

 Guiding the drills/reamers

 Provision for swarf removal.

 Proper fastening methods to hold the jig to the table.

 Provision for replacement of bushes, in case different tools


like reaming subsequent to drilling.
13
Fundamental Aspects of Fixtures
 Unique & foolproof location of components on the fixture.

 Clamping techniques to be adopted to deploy adequate


forces without damaging the component.

 Techniques for the ease of clamping like quick acting screws,


cam clamps, hydraulic clamps, etc.

 Provision for easy loading and unloading of components.

 Provision for swarf removal .

 Fastening of fixture to the machine table or chuck or collet.

 Design of tenons at the bottom of the fixture so as to locate


the fixture with respect to the machine table.
14
Fig. Fixture holding a component (Inspection)
15
Following aspects should also be taken into account
in the design of jigs and fixtures:

 Consideration of sequence of operations given in the


process planning chart.

 Study of the detailed drawing of the component critically,


i.e., the dimensions which are provided with tolerances.

 Consideration of the manufacturing defects such as


(a)shrinkages, (b) blow holes, (c) inclusions as in the cast
bodies, (d) distortions as in the case of welding and
fabricating fixture body or frame.

16
Features: Locating/Datum Surface
 A datum feature is an important functional surface where all
other dimensions will be specified with reference to it.

 A Datum is a perfect point, line, plane or surface but only exists


theoretically. However a Datum Feature is a tangible surface,
point or axis on a part where that theoretical datum is located.

17
Loading/Unloading
and Clamping (12 DOF)

18
Tolerancing on Fixtures: Significance

19
Next Topic: 4 SupportingFig.and Locating
Basic Principles
steps of fixture design
20

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