MODULE 3

Introduction – Elements of Jigs and Fixtures – Principle of Location – Locating Methods and
Devices –
Design Principle for Location. Clamping – Principles for Clamping – Clamping Devices.
Indexing Jigs
and Fixtures – Indexing devices. Fool- Proofing

Department of Mechanical
Engineering
Workshop Theory and
Practice-II

Module 3
Jigs and Fixtures

By
Palash Saikia
Department of Mechanical Engineering
JEC, Jorhat 785007
 MODULE 3
Introduction – Elements of Jigs and Fixtures – Principle of Location – Locating Methods and Devices –
Design Principle for Location. Clamping – Principles for Clamping – Clamping Devices. Indexing Jigs
and Fixtures – Indexing devices. Fool- Proofing

1. Introduction
1.1 Elements of Jig

Jig generally consists of locating element, clamping element and tool guiding or setting element.
Locating Elements

Locating elements position the workpiece accurately with respect to tool guiding elements in the jig.

Clamping Elements

Clamping elements hold the workpiece securely in the located position during operation.

Tool Guiding Elements

Tool guiding elements help in guiding the tools in correct position with respect to the workpiece. Drill
bushes guide the drills accurately to the workpiece.

1.2 Design Consideration in Jigs

a. The main frame of jig must be strong enough so that the deflection of jig is as minimum as possible.
This deflection of jig is caused due to the forces of cutting, clamping of the workpiece or clamping to
the machine table. The mainframe of the jig should have the mass to prevent vibration and chatter.
b. Frames should be built from simple sections so that frames can be fastened with screws or welded,
whenever necessary. Those parts of the frame that remain intact with the jig may be welded. The parts
needing frequent changing may be held with the screws. Where the body of jig or fixture has complex
shape, it may be cast from good grade of cast iron.
c. Clamping should be fast enough and require least amount of effort.
d. Clamps should be arranged so that they are readily available and may be easily removed.
e. Clamps should be supported with springs so that clamps are held against the bolt head wherever
possible.
f. If the clamp is to swing off the work, it should be permitted to swing as far as it is necessary for
removal of the workpiece.
g. All locators, clamps should be easily visible to the operator and easily accessible for cleaning,
positioning or tightening.
h. Provision should be made for easy disposal of chip so that storage of chips doesn’t interfere with the
operation and that their removal during the operation doesn’t interfere with the cutting process.
 MODULE 3
Introduction – Elements of Jigs and Fixtures – Principle of Location – Locating Methods and Devices –
Design Principle for Location. Clamping – Principles for Clamping – Clamping Devices. Indexing Jigs
and Fixtures – Indexing devices. Fool- Proofing
i. All clamps and support points that need to be adjusted with a wrench should be of same size. All
clamps and adjustable support points should be capable of being operated from the fronts of the jig.
j. Workpiece should be stable when it is placed in jig. If the workpiece is rough, three fixed support
points should be used. If workpiece is smooth, more than three fixed support points may be used.
Support point should be placed as farthest as possible from each other.
k. The three support points should circumscribe the centre of gravity of the workpiece.
l. The surface area of contact of support should be as small as possible without causing damage to the
workpiece. This damage is due to the clamping or work forces.
m. Support points and other parts are designed in such a way that they can be easily replaced on failure.

1.3 Presentation of Workpiece

The representation of workpiece is shown in Fig. 1. The workpiece is shown by chain dotted line. This
is because workpiece is assumed to be transparent. The elements of jig such as clamps, locators, supports
etc. are shown by continuous line.

Fig. 1 Representation of Workpiece

1.4 Location

One of the most important requirements of a successful jig design is that when workpiece is machined
and removed from the jig, the operator should be able to put another workpiece quickly into jig, clamp
it and machine it to the dimensions with given tolerance.

1.5 Principles of Location

a. Relate the location to dimensional requirements of workpiece.

 MODULE 3
Introduction – Elements of Jigs and Fixtures – Principle of Location – Locating Methods and Devices –
Design Principle for Location. Clamping – Principles for Clamping – Clamping Devices. Indexing Jigs
and Fixtures – Indexing devices. Fool- Proofing
b. It is preferable to use most accurate machined surface for location. If there is variation on the selected
surface, the new surface will also contain variations and one can get workpiece with defects. If most
accurate machined surface is not available, select better machined surface out of available machined
surfaces. Fig. 2 shows how to select accurate surface for location.
c. Prevent motion along and around X, Y, Z.
d. Location system should provide easy and quick loading and unloading of workpiece with minimum
motions.
e. Avoid redundant locators. Redundant locator means more locators are provided than required for
support. If three supports are sufficient and one places four supports also, then fourth support is
redundant. There are stool stands on four legs. But stool can also stand comfortably on three legs. In
this case fourth leg is redundant one.

Fig. 2 (a) and (b) Principle of Location

In order to locate the workpiece successively in holding device in the same plane, the device should
provide control through six degrees of freedom in space. Six degrees of freedom refers to three linear
motions and three rotational motions in the space. The movement along and around three mutually
perpendicular axis is shown in Fig. 2(a). When these six motions are controlled then only design of jig
is said to be good. The steel block floating in the space is shown in Fig. 2(b). Here the block is free to
move or rotate in any direction along or around three axes. If obstruction is placed in path of these
motions, it will eliminate degrees of freedom. The steel block is resting on three supports as shown in
Fig. 2(c). Hence, block is unable to move along z-axis. Also, block is unable to rotate about x- and y-
axis. But, the block moves along x- and y-axis while rotate about z-axis only.
 MODULE 3
Introduction – Elements of Jigs and Fixtures – Principle of Location – Locating Methods and Devices –
Design Principle for Location. Clamping – Principles for Clamping – Clamping Devices. Indexing Jigs
and Fixtures – Indexing devices. Fool- Proofing

Fig. 2(c) Principle of Location

Similarly, by adding two buttons (marked 1, 2 as shown in Fig. 2(d)), it is possible to prevent linear
motion of block along y-axis and also rotational motion around z-axis. In addition, adding pin (marked
3) as shown in Fig. 2(d), it is possible to prevent the motion of block along and around three mutually
perpendicular axes.

Fig. 2(d) Principle of Location

Fig. 2(d) also explains 3-2-1 principle of location. This 3-2-1 principle states that “a workpiece will be
completely confined when placed against three points in one plane, two points in another plane and one
point in third plane if the planes are perpendicular to each other”. Workpiece should be supported on
three buttons support for any holding device.

2. Types of Jigs
Depending upon method of operation and construction, drill jigs can be broadly classified as follows:

a. Plate Jig
b. Leaf Jig
c. Box jig
d. Indexing Jig
 MODULE 3
Introduction – Elements of Jigs and Fixtures – Principle of Location – Locating Methods and Devices –
Design Principle for Location. Clamping – Principles for Clamping – Clamping Devices. Indexing Jigs
and Fixtures – Indexing devices. Fool- Proofing
e. Pump jig

Plate Jig

This is the simplest type of jig. Plate jig consists of single bush plate. This plate has a provision of
loading and unloading of workpiece, clamping and chip removal. Fig. 3 shows the construction of plate
jig. The workpiece profile is located by six location pins and clamp by two knurled screws against
location pins. In any drill jig the workpiece should be supported adequately against bending due to the
downward thrust of drill. The disadvantage of plate jig is that only one surface can be drilled at one loading and
drilling forces are generally directed toward the clamping element. Hence, clamps should be rigid enough to
withstand drilling forces.

Fig. 3 Plate Jig

Box Jig

The shape of box jig is of box type. Fig. 4 shows the construction of box jig. The working of box jig is
as follows: Hole is drilled and then reamed when the workpiece is held by jig. The workpiece is inserted
in the jig. The cam rod is taken out of the jig and the workpiece placed in the position inside the jig. The
cam rod is then replaced and rotated to its locking position. This holds the workpiece firmly so that
drilling operation can be performed.
 MODULE 3
Introduction – Elements of Jigs and Fixtures – Principle of Location – Locating Methods and Devices –
Design Principle for Location. Clamping – Principles for Clamping – Clamping Devices. Indexing Jigs
and Fixtures – Indexing devices. Fool- Proofing

Fig. 4 Box Jig

Leaf Jig

These generally have hinged jig (bush) plate. The jig plate can be swung aside as shown by dotted line
in Fig. 5 to load or unload the workpiece from the top. After the workpiece has been located inside the
jig, the leaf is firmly closed and locked. The jig plate must have the resting face to ensure that the axis
of bushings is vertical during drilling. Jig plate must be clamped against the resting face by an eye bolt.
The open slot in jig plate and swinging eye bolt facilitate quick clamping and unclamping of the jig
plate. The hand knobs need to be loosened by only half a turn and the eye bolt swung to the position
shown by chain dotted line in order to permit swinging of the jig plate aside for loading and unloading
of workpiece from the top. Leaf jigs are particularly suitable for workpieces having location surfaces
and holes to be drilled on opposite sides.

Fig. 5 Leaf Jig

 MODULE 3
Introduction – Elements of Jigs and Fixtures – Principle of Location – Locating Methods and Devices –
Design Principle for Location. Clamping – Principles for Clamping – Clamping Devices. Indexing Jigs
and Fixtures – Indexing devices. Fool- Proofing
Indexing jig

When number of holes with the same size and pitch are to be drilled in a workpiece, then conventional
drilling takes more time to drill each hole individually and requires skilled worker for complete
production run. Also one cannot get required accuracy. This automatically increases the cost. This
arrangement is shown in Fig. 6. Such situation is avoided by using indexing jig. Indexing jig not only
saves the time and the cost but also increases accuracy. And unskilled worker may operate the indexing
jig. Linear indexing jig is shown in Fig. 7.

Fig. 6 Workpiece for Linear Indexing Jig

Fig. 7 Linear Indexing Jig

a. Indexing pin is first inserted into hole A. It is used as a stopper for drilling the first hole through
the drill bush.

b. The pin is removed from hole A after drilling. Then workpiece is moved toward right till the
centerline of drilled hole coincides with the centerline of bush B.

c. The indexing pin is inserted into the drilled hole in the workpiece through bush B.
 MODULE 3
Introduction – Elements of Jigs and Fixtures – Principle of Location – Locating Methods and Devices –
Design Principle for Location. Clamping – Principles for Clamping – Clamping Devices. Indexing Jigs
and Fixtures – Indexing devices. Fool- Proofing
d. In this way workpiece is indexed linearly to drill the next hole at 100 mm distance (i.e. pitch)
from the hole drilled previously.

e. By repeating step c, we can make number of holes at 100 mm pitch in the workpiece.

Rotary Indexing Jig

Rotary indexing helps in positioning a part accurately around the axis. It can be used conveniently for
drilling equi-spaced holes in cylindrical workpieces. Rotary Indexing is shown in Fig. 8.

Fig. 8 Rotary Indexing Jig

a. Workpiece is clamped and first hole is drilled through bush A.

b. Workpiece is unclamped and rotated clockwise to coincide the axis of drilled hole with the axis
of indexing pin.

c. The indexing pin is inserted in the drilled hole to index the workpiece for drilling the next hole.

d. The workpiece is clamped again before drilling the next hole. In this way, the rotary indexing
can be used to drill number of equi-spaced holes with only two guide bushes.

3. Clamping
Clamping is accomplished by clamps. Clamps hold the workpiece, which is firmly engaged with locators
during operation. The clamping system should be strong enough to withstand forces developed during
operation. At the same time, clamping force should not damage the workpiece. The timing required for
loading and unloading must be as minimum as possible. Clamping must be positive when subjected to
vibration, chatter etc.
 MODULE 3
Introduction – Elements of Jigs and Fixtures – Principle of Location – Locating Methods and Devices –
Design Principle for Location. Clamping – Principles for Clamping – Clamping Devices. Indexing Jigs
and Fixtures – Indexing devices. Fool- Proofing

Fig. 9 Distortion of Unsupported Part

3.1 Principles of Clamping

a. Clamps should be positioned in such a way that clamping force shall act as a strong, supported
part of the workpiece. Clamping on unsupported part bends the workpieces as shown in Fig. 9.
This will affect the accuracy of the operation. A vertical hole drilled in bent workpiece will
become angular when the unclamped workpiece come back to original shape as shown in Fig. 9
by dotted line.
b. Clamping system should not obstruct the path of loading and unloading.
c. Clamping system should be capable of holding the workpiece securely against the forces
developed during the operation. Also clamping system should not damage the workpiece with
excessive pressure. For clamping weak workpiece, the clamping force should be distributed over
larger area of the workpiece. While clamping soft workpiece, clamp should be fitted with pads of
softer material such as nylon or fibre to prevent damage to the workpiece.
d. Clamping time should be minimized by using handles, hand wheels, hand knobs, tommy bars,
knurled screws etc. Clamp can be loosened or tightened manually without using spanners because
spanner will increase the motion of picking, aligning etc.
e. If the number of clamps are to be loosened or tightened repeatedly, then it is preferable to use
hydraulic or pneumatic clamping. This will reduce operators fatigue and saves clamping time
also. Power clamping provides loosening and tightening simultaneously.
f. The clamping points should be provided with sufficient radius. This radius will take care of
variation in the workpiece. Sphere heel pin is used to allow tilting of the clamp. Clamping variable
workpiece is shown in Fig. 10.
 MODULE 3
Introduction – Elements of Jigs and Fixtures – Principle of Location – Locating Methods and Devices –
Design Principle for Location. Clamping – Principles for Clamping – Clamping Devices. Indexing Jigs
and Fixtures – Indexing devices. Fool- Proofing

Fig. 10 Clamping Variable Workpiece

Spherical washers between clamp and nut will take care of the misalignment between clamp surface and
clamping nut due to tilting of nut. Two pairs of washers have matching male female spherical seats. The
spherical bearing permits the washer to tilt with respect to each other. As the lower female washer tilts
with the clamp, upper male washer below the nut can remain square with the nut. The clamping pressure
from the nut to the clamp is transmitted by the spherical seat.

4. Design of Fixtures
4.1 Design Consideration in Fixtures

a. The main frame of fixture must be strong enough so that deflection of the fixture is as minimum as
possible. This deflection of fixture is caused because of forces of cutting, clamping of the workpiece
or clamping to the machine table. The main frame of the fixture should have the mass to prevent
vibration and chatter.
b. Frames may be built from simple sections so that frames may be fastened with screws or welded
whenever necessary. Those parts of the frame that remain permanently with the fixture may be
welded. Those parts that need frequent changing may be held with the screws. In the situation, where
the body of fixture has complex shape, it may be cast from good grade of cast iron.
c. Clamping should be fast enough and require least amount of effort.
d. Clamps should be arranged so that they are readily available and may be easily removed.
e. Clamps should be supported with springs so that clamps are held against the bolt head wherever
possible.
f. If the clamp is to swing off the work, it should be permitted to swing as far as it is necessary for
removal of the workpiece.
g. All locator’s clamps should be easily visible to the operator and easily accessible for cleaning,
positioning or tightening.
 MODULE 3
Introduction – Elements of Jigs and Fixtures – Principle of Location – Locating Methods and Devices –
Design Principle for Location. Clamping – Principles for Clamping – Clamping Devices. Indexing Jigs
and Fixtures – Indexing devices. Fool- Proofing
h. Provision should be made for easy disposal of chip so that storage of chips doesn’t interfere with the
operation and that their removal during the operation doesn’t interfere with the cutting process.
i. All clamps and support points that need to be adjusted with a wrench should be of same size. All
clamps and adjustable support points should be capable of being operated from the fronts of the
fixture.
j. Workpiece should be stable when it is placed in fixture. If the workpiece is rough, three fixed support
points should be used. If workpiece is smooth, more than three fixed support points may be used.
Support point should be placed as farthest as possible from each other.
k. The three support points should circumscribe the centre of gravity of the workpiece.
l. The surface area of contact of support should be as small as possible without causing damage to the
workpiece. This damage is due to the clamping or work forces.
m. Support points and other parts are designed in such a way that they may be easily replaced if they
break.

5. Types of Fixture and Its Industrial Applications

5.1 Vise Fixture

It is easy to clamp workpiece with regular shape and parallel sides in a vise. However, workpieces with
round or irregular shapes are very difficult to clamp properly. Hence, special jaws are created to hold
workpieces with irregular shape properly and at the same time, it also avoid damage to the important
surfaces. Various types of vise fixture are shown in Fig. 11(a), (b), (c), (d) and (e).

Fig. 11(a) Vise Jaws

 MODULE 3
Introduction – Elements of Jigs and Fixtures – Principle of Location – Locating Methods and Devices –
Design Principle for Location. Clamping – Principles for Clamping – Clamping Devices. Indexing Jigs
and Fixtures – Indexing devices. Fool- Proofing
Fig. 11(a) shows simple pair of jaws for holding round work piece. Fig. 11(b) shows pair of jaws for
holding a thin sheet of nonmagnetic material. Stop pin is used to prevent bending of the work piece by
the application of clamping force.

Fig. 11(b) Vise Jaws

Extended jaws for large work pieces are shown in Fig. 11(c). Here guide pins are used to secure
alignment. When it is necessary to hold the work piece firmly in all the directions, wedge type jaws are
useful. This arrangement is shown in Fig. 11(d). If the pressure exerted by the cutting tool is likely to
tilt upward one end of the work piece, then the link construction as shown in Fig. 11(e) should be used.
It is suitable for rough casting and forging because it permits considerable variation in dimensions of
workpiece.

Fig. 11(c) Vise Jaws; (d) Vise Jaws

 MODULE 3
Introduction – Elements of Jigs and Fixtures – Principle of Location – Locating Methods and Devices –
Design Principle for Location. Clamping – Principles for Clamping – Clamping Devices. Indexing Jigs
and Fixtures – Indexing devices. Fool- Proofing

Fig. 11(e) Vise Jaws

5.2 Milling Fixture

This holds the part in correct relation to the milling cutter. Fixture is attached to milling machine table.
Milling fixture consists of the base, clamps, rest blocks or nest, locating points and gauging surfaces.
The base of milling fixture consists of a base plate. A base plate has a flat and accurate undersurface
and forms main body on which various components are mounted. This surface aligns with the surface
of the mill table and forms the reference plane with respect to the mill feed movement. It may be
constructed of steel plate or cast iron, depending upon the size and complexity of the part. The slots are
provided in the base for clamping the fixture to the mill table. The base plate also has keyways along
with length of the base for two keys. These keys are used to align the fixture on the milling machine
table. The keys are pressed into the keyway at both ends of fixture and held there by socket head caps
screw. This arrangement is shown in Fig. 12. It is necessary to adjust the table by using feed movements
until the correct position is attained. This can be done by trial and error cuts in the workpiece. Milling
is always first operation.

Fig. 12 Underside of Milling Base

 MODULE 3
Introduction – Elements of Jigs and Fixtures – Principle of Location – Locating Methods and Devices –
Design Principle for Location. Clamping – Principles for Clamping – Clamping Devices. Indexing Jigs
and Fixtures – Indexing devices. Fool- Proofing
5.3 Facing Fixture

Milling machines are extensively used for facing seating and mating flat surfaces. Milling is often the
first operation on the workpiece. Fig. 14 shows simple face milling fixture. The workpiece is positioned
by three adjustable spherical ended pads ‘A’. These pads are adjusted to suit the variation in the size of
workpiece and lock in the position by check nuts. Two self-adjusting supports ‘A’ are pushed upward
by light spring. These springs are used to make sure that the support ‘A’ is positively in contact with the
workpiece. Clamping screw is used to lock support ‘B’. On tightening the edge clamp, the workpiece is
pushed against the fixed jaw. This jaw is keyed in the fixture body to provide solid support to workpiece
against the heavy thrust developed in the operation. The cutter should be fed to the workpiece in such a
manner that the milling thrust should be directed towards the solid support of fixed jaws. The setting
can be set in the path of cutter to set it before starting of facing operation. Four clamping slots are provided
to take care of the heavy forces developed during the operation.

Fig. 14 Face Milling Fixture

5.4 Boring Fixture

According to the type of boring operation, boring fixture are used. Boring Fixture may have
characteristics of a drill jig or a mill fixture. The workpiece always has an existing hole which is enlarged
by the boring operation. It may be final or may be preliminary to grinding and other sizing operation.

5.5 Face Plate Fixture

It can be used conveniently for machining of simple and small components. Addition of locators and
clamps on face plate help in quick location and clamping of workpiece as shown in Fig. 15. Face plate
fixture is useful for facing number of workpieces simultaneously on the lathe.
 MODULE 3
Introduction – Elements of Jigs and Fixtures – Principle of Location – Locating Methods and Devices –
Design Principle for Location. Clamping – Principles for Clamping – Clamping Devices. Indexing Jigs
and Fixtures – Indexing devices. Fool- Proofing

Fig. 15 Face Plate Fixture

5.6 Turning Fixture

These are generally special face plates. Their swing should be lesser than the swing of the machine.
These are used for quick location and clamping. Typical turning fixture is shown in Fig. 16. The
workpiece rests on angle plate and its boss is centralized with machine axis by sliding v-block which
can be operated with knurled screw. The overhang of turning fixtures should be minimum bare necessary
for the operation. Fixture should be balanced with workpiece in position. The clamping arrangement
should be capable of withstanding the various forces developed during operation.

Fig. 16 Turning Fixture (Boring and Facing Fixture)

5.7 Grinding Fixture

The standard magnetic tables are used to rest workpiece such that resting surface will be parallel to the
surface to be ground. However, for light workpiece with lesser resting area, the resting area tends to tilt
and fly off the magnetic table due to high speed of grinding wheel and due to high feed, also. Hence, it
 MODULE 3
Introduction – Elements of Jigs and Fixtures – Principle of Location – Locating Methods and Devices –
Design Principle for Location. Clamping – Principles for Clamping – Clamping Devices. Indexing Jigs
and Fixtures – Indexing devices. Fool- Proofing
is necessary to provide additional support by nesting the workpiece. This can be done by placing the
solid plates around the workpiece as shown in Fig. 18. The nest plates are held firmly by the magnetic
force of table with more weight and more resting area. The nest plates surround the workpiece from
outside and arrest its movement in the horizontal plane. Thus, this arrangement will help in preventing
it from flying off and tilting due to high speed and feed in grinding operation.

Fig. 18 Nesting

The maximum possible area of magnetic table should be utilized to grind as many workpieces as possible
in a single batch.

Example

Numbers of rounded workpieces are arranged in rows with common supporting nest plate around.
Thickness of nest plate should be less than finished height of workpiece to prevent disturbance of the
grinding wheel as shown in Fig. 19.

Fig. 19 Surface Grinding Layout