Module 6

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Manufacturing Science

Module-6
Jigs and Fixtures
Syllabus

Unit –6 Jigs and fixtures


Degree of freedom, 3-2-1 principle of location, General
guidelines to design Jigs and fixtures, advantages of jig and
fixtures
Jigs: Definition. Elements of jig with the types, Location
guidelines, Principles of clamping, Principles of guiding
element, Types of jigs, Design of Jigs
Fixtures: Definition. Elements of fixtures, Location
guidelines, Principles of clamping, Principles of setting
element, Types of fixtures, Introduction to modular fixture,
Pokayoke concept in jigs and fixtures.
Jig and Fixture
Jig – it is a device which holds and positions the
work, locates or guides the cutting tool relative
to the work piece and it is not fixed to machine
table. Lighter in construction.
Fixture- It is work holding device which only
holds and positions the work, but does not in
itself guide locate or position the cutting tool
.Heavier in construction.
Jigs are used for Drilling, Reaming, and Tapping
and counter boring etc.
Fixtures are used in connection with turning,
milling, shaping and grinding.
Jigs are called “Production Device”.
Fixture are called “Inspection Device”
The basic purposes of developing and using suitable
jigs and fixtures for batch production in machine
shops are
□ to eliminate marking, punching, positioning,
alignments etc.
□ easy, quick and consistently accurate locating,
supporting and clamping the blank in alignment of
the cutting tool
□ guidance to the cutting tool like drill, reamer etc.
□ increase in productivity and maintain product
quality consistently
□ to reduce operator’s labour and skill – requirement
□ to reduce measurement and its cost
□ enhancing technological capacity of the machine
tools
□ reduction of overall machining cost and also
increase in interchangeability.
Design principles Common to jigs and fixtures
1: Rigidity: Jigs and fixtures should be sufficiently stiff to secure
the preset accuracy of machining.
2: Fool proofing: It can be defined as “ the incorporation of design
feature in the jig or fixture that will make it possible to lead the
work into jig and fixture, in an improper position , but will not
interfere with loading and unloading the work piece.” There
are many fool proofing devices , such as fooling pegs, blocks
or pins which clears correctly position parts but prevent
incorrectly loaded parts from entering the jig and fixture body.
3: Clearance: Clearance is provided in the jig or fixture body
(A) to allow for any variation in component sizes specially casting
and forging.
(B) To allow for hand movements so that the work piece can easily
placed in the jig or fixture and removal after machining .
4: Burr Grooves: Jigs should be designed so that the removal of
the work piece is not obstructed by these burr for this suitable
clearance grooves or slots should be provided.
5: Ejectors:
The use of ejection devices to force the work piece
out from the jig or fixture is important in two
positions.
(A) the work piece is heavy
(B) machining pressure forces the work piece to the
slides or based on the jig or fixture and the
pressure and oil or coolant fill will cause the work
to stick and difficult to remove on small jigs and
fixtures , a pin located under the work will remove
the part radially.
6: Inserts:
To avoid any damage to fragile and soft work piece
and also to the finished surfaces of the work piece
while clamping. Inserts of some soft material such
as copper, lead , fiber , leather , hard rubber and
plastic should be fitted to the faces of the clamps.
7: Design for Safety:
(A): Sharp corner on the body of jig and fixture should
be avoided.
(B): Bolt and nut should be inside the body of jig or
fixture and not protrude on the surface.
8: Sighting Surface:
Machining on the work piece must be clearly visible to
the worker. He should not be required to bend its
neck for seeing the work piece or work surfaces.
9: Simplicity in design:
Design of the jig and fixture should be a simple one. A
complicated design require a large maintenance.
They should be easy to set , cheap in manufacture.
10: Economical:
Jig and fixtures should be simple in construction, give
high accuracy , be sufficiently rigid and lightly
weight. To satisfy these conditions an economical
balance has to be made.
Design Considerations For Jigs And Fixtures

Jigs and fixtures are manually or partially power


operated devices. To fulfill their basic purposes,
jigs and fixtures are comprised of several
elements.

□ base and body or frame with clamping features


□ locating elements for proper positioning and
orientation of the blank
□ supporting surfaces and base
□ clamping elements
□ tool guiding frame and bushes (for jig)
□ indexing plates or systems, if necessary
□ auxiliary elements
Fig. jigs and fixtures elements
Principles or rules of locating in jigs and
fixtures

□ For accurate machining, the workpiece is to be


placed and held in correct position and
orientation in the fixture (or jig) which is again
appropriately located and fixed with respect to
the cutting tool and the machine tool.
□ It has to be assured that the blank, once fixed or
clamped, does not move at all.
□ Any solid body may have maximum twelve
degrees of freedom( translation motion and
rotational motion) as indicated in Fig.
□ By properly locating, supporting and clamping
the blank its all degrees of freedom are to be
arrested as typically shown in Fig.
Fig. Possible degree of freedom of a solid body.
Principle of six point location of
a component (3-2-1 principle)

The three adjacent locating surfaces of the blank (workpiece) are


resting against 3, 2 and 1 pins respectively, which prevent 9 degrees of
freedom. The rest three degrees of freedom are arrested by three
external forces usually provided directly by clamping.
The above method of locating a workpiece in jig or fixture is called the
“3-2-1” or “Six point location “ Principle
Some basic principles or rules need to be followed while
planning for locating blanks in fixtures, such as

One or more surfaces (preferably machined) and /


or drilled / bored hole(s) are to be taken for
reference
The reference surfaces should be significant and
important feature(s) based on which most of the
dimensions are laid down
Locating should be easy, quick and accurate
In case of locating by pin, the pins and their
mounting and contact points should be strong, rigid
and hard
A minimum of three point must be used to locate a
horizontal flat surface
The locating pins should be as far apart as feasible
Use minimum locating points
Use mutually perpendicular planes
Elements of Jigs and Fixtures.

□ Various elements of jigs and fixtures and their


details are follows.
1: Body 2: Locating devices 3: Clamping devices
4: Tool guide(jigs bushing)
1: Body:
□ The jig body is generally made of cost iron by
casting process or fabricated by welding
together various slabs and bars of mild steel.
□ It may be heat treated to relief the stresses.
□ Body is the most prominent feature of the jig.
Its main purpose is to support and house the
job.
FIG. drill jig
2:Locating Devices
□ The pins of various design and made of hardened
steel are the most common locating devices used to
locate a work piece in a jig or fixture.
□ The shank of the pin is press fitted or driven into
the body of jig or fixture.
□ The locating diameter of the pin is made larger than
the shank to prevent it from being forced into the
jig or fixture body due to the weight of the work
piece or cutting forces.
Principle of six point location of
a component (3-2-1 principle)
Principle of six point location of a component
(3-2-1 principle)

As per six point location or 3-2-1 principle, workpiece can


be completely restrained with the help of three points in
one plane, two location points in the second plane and
one location point in the third plane.
Locating Devices
Parameters to be consider
1. Shape and size of the workpiece
2. Operation which is to be performed
3. Quantity and quality of the workpiece
4. Surface finish and accuracy available on the surface of the workpiece

Design Principles for locators


1. At least one datum or reference surface should be provided
2. For ease of cleaning , locating surfaces must be as small as possible.
3. Proper relief should be provided to remove burr.
4. For the location of rough surfaces , adjustable type of locators should be
provided
5. Sharp corners must be avoided
6. Locating pins should be easily visible and accessible to the operator.
Design principles for location purposes
Support Pins and Jack Pins

1. Fixed type support 2. Adjustable type 3. Support


pin support pin Pad
4. Spring Type Jack
pin
Locating by (a) flat surfaces and (b) types
of pins used
Locating Pins

2. Locating pin with collar


1. Plain cylindrical locating pin

3. Conical Pin locator 4. Pin locator with reverse cone


V-Locators

1. Fixed type V-Locators

2. Adjustable type V-Locators


Diamond Pin Locators
(Angular Locators)
Clamping devices
□ If the work piece can not be restrained by
the locating devices or elements, it
become necessary to clamp the work
piece in jig or fixture body.
□ The most common example of clamping
devices is bench vice.
□ 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.
□ In bench vice the movable jaw of the vice
exert force on the work piece , their by
holding it in correct position of location in
the fixed jaw of the vice.
A workpiece is securely held in the jig or fixture with the help
of clamping device against the cutting forces.

Principles of clamping
1. Clamp should be simple, quick operating and fool proof
2. A required pressure should be exerted by the clamp on the
surface of workpiece
3. A clamp should not bend under the pressure
4. A clamp movement should be accurate and quick acting
5. Spring should be provided to avoid lifting of clamp by hand
6. A clamp should be provided such that , different operations
can be performed on the workpiece, without disturbing
clamp setting.
Correct and incorrect clamping examples

31
Correct and incorrect clamping examples

32
Correct and incorrect clamping examples

33
Types of Clamping

1. Sliding clamp with a loose 2. Solid type heel clamp


heel clamp
3. Sliding clamp with a heel 4. Sliding clamp with an
made in the jig or fixture body adjustable heel pin
6. Edge clamp

5. Bridge clamp

7. Screw clamp
8. Hinged clamp
9. Latch clamp
10. Cam operated strap clamp
(Quick acting)
11 a.Free type C-clamp or C washer

11. C- clamp
Clamping by swing plates
Such clamping, typically shown in Fig. 8.1.19, are
simple and relatively quick in operation but is
suitable for jobs of relatively smaller size, simpler
shape and requiring lesser clamping forces.
Use of quick acting nut – a typical of such nut and its
application is visualized schematically in Fig
Bush Location
Tool Guide or Jig Bushing:
❖ Sometimes the stiffness of the cutting tool may be
insufficient to perform certain machining operations.
❖ Then to locate the tool relative to the work, use is
made of guiding parts such as jigs bushing and
templates.
❖ These must be precise, were resistance and
changeable.
❖ Jig bushes are used in drilling and boring, a bush fits
into the hole of the jig, through which the drill passes.
❖ The diameter of the bush depends on the diameter of
the drill. Different type of bushes are spot welded or
screwed with the jig.
❖ Headless type bushes are press fit into the hole of the
job. Bushes are general made of a good grade of tool
steel to insure hardening at a fairly no temperature and
to lesson the danger of fire cracking.
❖ Sometime the bushes for guiding tools may be of cast
iron.
❖ Hardened steel bushes are always preferable for
Press fit wearing bushes:
□ These bushes are used when little importance in put
on accuracy or finish and tool used is a twist drill.
These bushing are installed directly in the jig body
and are used mainly for short protection. There are
two design of press fit bushing:
□ A---Plain or headless bush
□ B--- Headed or flanged bush
Renewable bushes:

□ When the guide bushes requires periodic


replacement (due to wear of the inside diameter
of the bush).
□ Its replacement is simply by using a renewable
bush. These are of the flanged types and sliding
fit into the linear bush, which is installed press
fitted into the jig plate.
□ The linear bush provides hardened wear
resistance, mating surface to the renewable
bush. The renewable bushes must be prevented
from rotating or lifting with the drill.
□ One common method is to use a retaining screw.
Jig Bushes

1. Plain Bush 2. Flanged Bush 3.Screwed Bush

4. Inclined and Extended Bush 5. Renewable Bush


The types of jig construction are

(1) Casting- By casting we can made complex


parts.
(2) Fabrication- Standard part can be used to
build the body and quickly.
(3) Welding- By welding jig constructed
speedily.
The advantages are:
1) The jig can be constructed speedily.
2) The welded construction is cheaper.
3) Less machining is needed than for fabricated
part.
TYPES OF JIG
1) Template Jig:-
❖ This is the simplest type of drill jig. It is
simply a plate made to the shape and size
of the work piece with the required
number of holes made in it accurately.
❖ A simple template type of jig is shown in
figure. It is placed on the work piece and
the holes on the work piece will be made
by the drill which will be guided through
the holes in template.
❖ The plate should be hardened to avoid its
frequent replacement.
❖ This type of jig is suitable if only a few
parts are to be made.
Fig. Template
Jig
2) Diameter Jig:-
□ Diameter Jigs are used to drill holes on the
periphery of cylindrical or spherical work pieces.
3) Channel Jig:
In this type, the jig is made of standard steel channel section.
This jig can also be provided with swinging leaf to form a channel
and leaf jig.
4) Box Type Jig:
□ Box jigs (sometimes called closed jigs)
usually resemble a boxlike structure.
□ They can be used where holes are to be
drilled in the work at various angles.
□ Figure 1-7 shows a design of box jig
that is suitable for drilling the required
holes in an engine link. The jig is built
in the form of a partly open slot in
which the link is moved up against a
stop and then clamped with the clamp
bolt A, B, and C.
□ 5) Leaf Jig: -
□ A box jig with a hinged cover or leaf that may be
opened to permit the work to be inserted and then
closed to clamp the work in to position is usually
called a leaf jig.
□ Drill bushings are usually located in the leaf.
However, bushings may be located in other
surfaces to permit the jig to be used for drilling
holes on more than one side of the work.
□ Such a jig, which requires turning to permit work
on more than one side, is known as a rollover jig.
Types of Jigs

1.Templete Jig
2. Plate Type Jig
4. Swinging leaf type Jig
5. Channel Jig
Types of Fixtures

1. Setting block of milling fixture 2. Fixing of a lathe fixture


3. Simple welding fixture
4. Boring Fixture
4. Boring Fixture
Modular Fixture
Indexing Jigs and Fixtures
Indexing are preferred where there is a relationship
between holes or slots to be machined in a workpiece.

Indexing Methods
By rotating the component :- used in drilling, milling
and surface grinding
Indexing Devices

Indexing Plate
Pokayoke concept in jigs and fixtures

Poka-yoke is a Japanese term that means


"mistake-proofing". A poka-yoke is any mechanism in a lean
manufacturing process that helps an equipment operator
avoid (yokeru) mistakes (poka). Its purpose is to eliminate
product defects by preventing, correcting, or drawing
attention to human errors as they occur.
Poka-yoke can be implemented at any step of a
manufacturing process where something can go
wrong or an error can be made. For example,
a jig that holds pieces for processing might be
modified to only allow pieces to be held in the
correct orientation.
Shigeo Shingo recognized three types of poka-yoke for
detecting and preventing errors in a mass
production system:
•The contact method identifies product defects by testing
the product's shape, size, color, or other physical
attributes.
•The fixed-value (or constant number) method alerts the
operator if a certain number of movements are not
made.
•The motion-step (or sequence) method determines
whether the prescribed steps of the process have been
followed.
Solved Examples

Question 1-Design and draw drilling jig


for drilling holes in the component as Answer
shown in figure
Question 2 Answer
Answer

Question 3
Question 4

Answer
(iii) Design Considerations For Jigs
And Fixtures
Jigs and fixtures are manually or partially power operated
devices. To fulfil their basic purposes, jigs and fixtures
are comprised of several elements (as indicated in Fig.
8.1.3) :
• base and body or frame with clamping features
• locating elements for proper positioning and orientation
of the blank
• supporting surfaces and base
• clamping elements
• tool guiding frame and bushes (for jig)
• indexing plates or systems, if necessary
• auxiliary elements
• fastening parts
Therefore keeping in view increase in productivity, product quality, repeatability i.e.
interchangeability and overall economy in batch production by machining, the
following factors are essentially considered during design, fabrication and
assembly of jigs and fixtures :
• easy, quick and consistently accurate locating of the blank in the jig or fixture in
reference to the cutting tool
• providing strong, rigid and stable support to the blank
• quick, strong and rigid clamping of the blank in the jig or fixture without
interrupting any other operations
• tool guidance for slender cutting tools like drills and reamers
• easy and quick loading and unloading the job to and from the jig or fixture
• use of minimum number of parts for making the jig or fixture
• use of standard parts as much as possible
• reasonable amount of flexibility or adjustability, if feasible, to accommodate slight
variation in the job - dimensions.
• prevention of jamming of chips, i.e. wide chips-space and easy chip disposal
• easy, quick and accurate indexing system if required.
• easy and safe handling and moving the jig or fixture on the machine table, i.e., their
shape, size, weight and sharp edges and corners
• easy and quick removal and replacement of small parts
• manufacturability i.e. ease of manufacture
• durability and maintainability
• service life and overall expenses
(iv) Principles And Methods Of Locating,
Supporting And
Clamping Blanks And Tool Guidance In Jigs And
Fixtures
□ It is already emphasized that the main functions of the jigs and
fixtures are :
□ (a) easily, quickly, firmly and consistently accurately
■ • locating
■ • supporting and
■ • clamping

□ the blank (in the jig or fixture) in respect to the cutting tool(s)
□ (b) providing guidance to the slender cutting tools using proper
bushes

□ There are and can be several methods of locating, supporting and


clamping depending upon the size, shape and material of the job,
cutting tool and the machining work required. But some basic
principles or rules are usually followed while designing for locating,
supporting and clamping of blank in fixtures.
Vee block and cones should be used for self-locating solid and hollow
cylindrical jobs as typically shown in Fig. 8.1.6
Sight location is applicable to first – operation location of blank with
irregular surfaces produced by casting, forging etc. as indicated in
Fig. 8.1.7 when the bracket is first located on two edges to
machine the bottom surface which will be used for subsequent
locating.
Adjustable locating pin(s) as indicated in Fig. 8.1.3 is to be used to
accommodate limited part size variation
ο For locating large jobs by rough bottom surface one of the
three pins may be replaced by a pivoted arm as indicated in
Fig. 8.1.7. The pivoted arm provides wo contact points.
THANK YOU

78

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