Chapter 4 Basic Construction Principles

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Jig & Fixtures Design

Chapter 4 Basic Construction Principles


Objective
• After completing this unit, student should be
able to:
– Identify the characteristic of tool bodies.
– Identify various drill bushing.
– Describe the proper placement and clearance for
drill bushings.
– Identify common jig and fixture hardware.
3.Drill
bushing
2.Preformed
materials
4.Set blocks
Basic
construction
principles
1. Tool 5.Fastening
bodies devices
Tool Bodies
• Tool body provides a rigid base for mounting the
locators, supports, clamps, and others.
• Size/shape of the tool body are determined by
the size of the part operation to be performed.
• Choice of material and method depends on
economy, required rigidity, accuracy and
projected tool life.
• Tool body are made in three general forms ( cast,
welded and built up)
• Material used- steel/cast iron/ aluminum/
megnisium/ epoxy/ resin/ and wood)
Cast tool bodies
• Made of cast iron, cast aluminum or cast resin.
• Advantages – stability, saving in machine time,
good distribution of material. Also best for
part nesting and offer vibration dampening.
• Disadvantages- higher cost due to required
pattern and longer lead time.
Welded tool bodies
• Usually made from steel/aluminum/ or
magnesium.
• Advantages- high strength/rigidity/design
versatility/ easy of modification/ and short
lead time.
• Disadvantages- cost of secondary machining.
Built-up tool bodies
• Made from almost any material, such as steel/
precast section/ aluminum/ magnesium/ and
wood.
• Advantages- adaptability of tool bodies/
design versatility/ easy of modification/ and
short lead time.
Preformed materials
• Can greatly reduced cost of any tool body. Since
preformed materials are available in a verity of
size and shape. The time to machine tool body is
also greatly reduced.
• The most common preformed material:
– Precision ground flat
– Cast bracket materials
– Precision ground drill rod
– Structural steel section
– Precast tool bodies.
Drill Bushings
• Used to locate and guide drills, reamers, taps,
counterbores, countersink, spotfacing tools,
and other rotating tools commonly used to
make or modify a hole.
• Drill bushing are usually hardened and ground
to exact sizes to ensure the needed
repeatability in the jig.
Type Of Bushing
• Renewable Bushing – 2 type ( slip and Fixed )
– Slip – renewable bushing
• Used when more than one operation is perform in the
same location such as drilling and reaming.
– Fixed – renewable bushing
• Used when only one operation is perform in each hole.
• Held by a mechanical clamp and take considerably
longer to remove than slip-renewable bushing take.
• Press Fit bushing
– Made in two general forms, head or headless.
– No bushing change are required. (repeated changes can
effect their accuracy).
• Linear bushing
– Available in head or headless type and press into jig plate.
• special purpose bushing
– allow for special jobs.
– Great diversity of drilling operations
common to manufacturing demands a
variety of special bushing.
• Template bushings
– Used for installations in thin jig plates.
– Bushing is press into the hole and lock
ring is installed on opposite side.
• Oil-groove bushings
– Lubricant of the bushing
for continuous high
speed drilling
operations.
• Knurled and serrated bushings.
– Knurled are made with a diamond pattern knurl, while
serrated have straight knurled pattern.
– A- used for applications where the bushing is cast , potted,
or embedded into a jig plate. (Diamond + grooves )for
maximum grapping area.
– B&C- serrated bushing cast into the jig. Where B pattern,
grooves body helps to maintain the grip of bushings.
Pattern C used for press-fit installations in jigs plates made
from soft materials.
Installing Drill Bushings
• Correctly fitting drill bushings are important in jig work.
• If the drill bushings are not properly installed, they could fall
out during use or could bind and break the tool.
• Proper sizing of mounting holes. Allow the bushing to fit
correctly.
Jig Plates
• Hold and position the drill bushings.
• Thickness of jig plate is depend on the size of the bushing
used.
• As a rule, the bushing should be long enough to support and
guide the properly.
• The wall thickness of the bushing should be able to easily
withstand all cutting forced and maintain tool accuracy.
Bushing clearance
• For most application, the end of the bushing should not touch
the work.
• Clearance is 1 to 1 and ½ time to tool diameter of tool. (chip
clearance)
• When extreme accuracy is needed, bushing should be as close
to work as possible to permit the requirement precision.
• Proper bushing clearance is important to the overall function
of any jig.
Set of block
• Setting the cutter for fixtures requires a different method
from that for jigs. Set blocks and feeler gauges are used to set
the relationship between the work and tool for machining
operation such as milling, turning and grinding.
• Set of block also known as setup gauge and normally located
directly on the fixtures.
• Feeler gauges to ensure the proper clearance prevents
damage and wear to the set block when setting the cutter.
Fastening Device
• Many types of fasteners are used in building
jigs and fixtures.
• Screw, nuts, bolts, washer, lock rings, keys and
pins are used to make tools.
• Used a standard hardware
• Special bolts and fasteners cost more money
Cap screws
• The socket-head cap screw is the most common type of screw
used in jig and fixtures work.
• Provide superior holding power with easy installation and
minimal space requirements.
• Have variation of screw form.

Flat head
button
head
socket

Socket
head
Set Screw
• Set screw is another type of screw widely used in jig and
fixtures work. Standard set screw available in many sizes and
point style and figure.
Nuts and washers
• A variety of nuts and
washers are also
commercially available to
assist the tool designer.
Special purpose bolts and nuts
• Jig and fixtures are normally design used a standard hardware
items.
• Occasionally required a special purpose bolts and nuts to hold
special tools to machine tables.
Retaining rings
• Another type of fastener that can save many
hours of work is the retaining the ring, which
available internal and external styles.
Dowel Pin
• Dowel pins are normally used with screws to keep mated
parts aligned.
• 5 most dowel pin are:
– Plain
– Tapered
– Pull
– Grooved
– spring
Lifting device
• Mechanical lifting devices should always be
used for tools weighing. (lighter tool maybe
not required)
• To make moving and positioning the jig and
fixtures safer.
• The handle selected should be strong enough
to support the weight of the tool.
Question
• ????????..........

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