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DEFINITIONS
JIG
A Jig may be defined as a device which holds and locates
a work piece, guides and controls one or more cutting
tools.
FIXTURE
A Fixture may be defined as a device which holds and
locates a work piece during an inspection or for a
manufacturing operation. The Fixture does not guide the
tool.
ADVANTAGES OF EMPLOYING JIGS AND FIXTURES
LOCATORS
A locator is usually a fixed component of a fixture. It is used to establish
and maintain the position of a part in the fixture by constraining the
movement of the part. For work pieces of greater variability in shapes
and surface conditions, a locator can also be adjustable.
CLAMPS
A clamp is a force-actuating mechanism of a fixture. The forces exerted
by the clamps hold a part securely in the fixture against all other external
forces.
ELEMENTS OF JIGS AND FIXTURES
SUPPORTS
A support is a fixed or adjustable element of a fixture. When severe part
displacement/deflection is expected under the action of imposed clamping
and processing forces, supports are added and placed below the work
piece so as to prevent or constrain deformation. Supports in excess of
what is required for the determination of the location of the part should be
compatible with the locators and clamps.
Z+ Rotation X + -
Rotation Y + -
Y+ Rotation Z + -
X
X
X+
Based on the surface from which the work piece is located, the locators are
classified in to three groups
The main problem with using this type of locator is in the position of the work piece
relative to the work holder. The locating hole can contact the locator at any point on
its conical surface. So slight differences in the hole diameter affect the work piece
height, as illustrated in the figure This vertical height variation must be considered in
the design of the work holder.
ROUND LOCATING PINS
Round pins can be used for both internal and external work piece location. For internal
location, the diameter of the pin must match the size of the locating hole. These
locators come in many standard sizes, and are readily available,
For external location, the size of the locating pin is not as critical as internal. Here, a
standard pin size strong enough to resist machining forces is the best choice.
These pins have a shank larger than the head. The purpose of the shoulder is to
prevent the pin from being pushed into the tooling plate
Unlike the plain pins, shoulder-type pins are made in two styles Press-fit type and lock
screw type,
VEE LOCATORS
Vee locators are a specialized form of locating element. They are used mainly for
round or cylindrical work pieces. The two basic styles of Vee locators are the Pad
and the Vee Block as shown in the figure.
F -0.008
H
REDUNDANT LOCATION
Another condition to avoid in work holder
design is redundant or duplicate location.
Redundant locators restrict the same
degree of freedom more than once.
The work pieces in figure, show several
examples. The part at (a) shows how a flat
surface can be redundantly located. The
part should be located on only one not both
side surfaces. Since the sizes of parts can
vary, within their tolerances, the likelihood
of all parts resting simultaneously on both
surfaces is remote. The example at (b)
points out the same problem with
concentric diameters. Either diameter can
locate the part, but not both.
FOOL PROOFING
1) The work piece must be held rigidly while the cutting tools are in
operation.
2) The time required for loading and unloading the tool must be as short
as possible, which means the clamping device must be quick-acting.
3) when subjected to vibration, chatter, or heavy pressure, the clamping
must be positive.
4) The clamp must not damage the work piece.
TYPES OF CLAMPS:
STRAP CLAMPS
CAM CLAMPS :
Cam clamps are also based on the principle of the inclined plane. The most
common forms of Cam Clamps are the Eccentric Cam and Spiral Cam. Depending
on their arrangement, these cams can be used as Direct pressure Clamps or
Indirect pressure Clamps.
Spiral cams have a continious rise to lock positively at any point in the
clamping range
A toggle action locks positively because one of the pivots moves past
the center line of two other pivots, against a stop.
The four basic Toggle actions are as shown below
hold-down
push/pull,
latch
squeeze action.
LATCH CLAMPS :
The Latch Clamp is employed to clamp a job by a Latch. A pivoted latch and leaf is
used for this. The leaf is closed on the job and is kept in position by the Latch. The
work is gripped by the spring fitted to the leaf. To unload the work piece the laid end of
the latch is pushed by the hand to cause the leaf to swing open as shown in the
Figure.
ADVANTAGE :
The main advantage is the ease and
speed of manipulation .
DISADVANTAGE :
1.Construction is limited to relatively
light work.
2.Difficult to secure rigid clamping.
SCREW CLAMPS :
Screw clamps are among the simplest and least-expensive. Screw clamps offer the
designer more clamping options than many other clamps. For clamping effectiveness
and size/force ratio, screw clamps make excellent work holders as shown in the figure-
23a. But they also have a drawback; their inherently slow clamping speed limit their use
in high-production Jigs and Fixtures.
PLATE FIXTURE :
The Plate Fixture is the most-basic and most-
common fixture. The Plate Fixture is built with a mill
fixture base, cast flat section, tooling plate, or similar
plate material. All locators, supports and clamps are
mounted directly to the plate. A complete plate fixture
can be built using only standard, off-shelf
components.
ANGLE-PLATE FIXTURES :
Angle-Plate Fixtures are a variation of the basic Plate
Fixture. They are useful when the locating surface is at
an angle to the machine table. The two main variations
of Angle-Plate Fixtures are the right angle and modified-
angle plate fixtures. Right-angle Plate Fixtures, are
constructed at 90 degrees to the base. The right-angle
plate fixtures can be built with tooling blocks, T-cast
sections, L-cast sections, angle brackets, or any
comparable material. Adjustable angles or sine plates
may be used to build the modified-angle plate fixtures.
TURNING FIXTURE:
Commonly used work holding devices as
fixtures in Turning are Soft Jaws, Chucks,(as
Three Jaw and Four Jaw Chuck), Face Plate
etc.
Turning Fixtures are used for complicated work
pieces and are in effect simplification of the
technique of butting the work piece to a Face
Plate.
The Fixture body is located on the machine
spindle and bolted in position. It carries the
work piece location and clamping system.
Sometimes the work piece is located and
clamped to a separate shaft that projects from
the fixture body.
When the weight of the work piece and the
fixture are imbalanced, the balancing weight
may be incorporated.
A setting face machined relative to the location
system and a typical hardened setting piece is
used to set the depth of the tool.
A pilot bush may be used to guide the boring
bar.
MILLING FIXTURE :
A Milling Fixture is located accurately on the machine table and then bolted in position;
the table is positioned relative to the cutter or cutters with the aid of the Setting Block.
The work piece is located on the Fixture base and then clamped in position. The cutter
is not guided during cutting.
The location and clamping systems are similar to those used for drill jigs, but as the
cutting forces are high, interrupted, and tend to lift the work piece, the clamping forces
must be big; hexagonal nuts are usually used to clamp the work piece rather than hand
nuts. The details that are peculiar to Milling Fixtures are the Setting Block and the
Location Tenons.
Setting Block :
The setting block as shown in the figure, is located relative to the fixture location
system and retained in position by screws; it has two hardened setting faces, so that
the table can be positioned both horizontally and vertically (note that the table is
located from one side of the cutter only). The table setting is done with a 0.25 mm
feeler between the cutter and the setting face so that the block will not be damaged
by the cutter during machining. The setting block is positioned so that the cutter is
between the vertical face of the block and the operator during setting; this
arrangement gives maximum convenience for the operator during setting.
Tenons :
The two Tenons (as shown in the figure) are made from case hardened steel and are
located on the underside of the fixture base; these two tenons sit in one of the tee
slots that run along the length of the machine table so that the fixture is located
relative to the table feed; the two Tenons should be as far apart as possible, to
produce maximum accuracy. The Fixture is bolted to the table by two or four tee bolts
that are placed in the tee slots (these bolts are not called up as part of the fixture).
Example - 1