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B.E./B.Tech. DEGREE EXAMINATION, MAY/JUNE 2009. Seventh Semester Mechanical Engineering ME 1009 DESIGN OF JIGS, FIXTURES AND PRESS TOOLS (Regulation 2004) (Common to B.E. (Part-Time) Sixth Semester -Mechanical Engineering Regulation 2005) Time : Three hours Answer ALL questions. PART A (10 x 2 = 20 marks) 1. Distinguish between jigs and fixtures. 2. List the standard parts used in jigs and fixtures fabrication. 3. What is the primary function of linear bushing? 4. How can the relation of the jig plate and vise jaw be accurately controlled? 5. What are boring fixtures? How do you classify them? 6. What are welding fixtures? State the general purpose of a welding fixture. 7. What factors should be considered for selecting an appropriate press for a given job? 8. What is the function of a stripper? 9. Distinguish between a compound die and a combination die. 10. Find die clearance range for shearing a 2 mm thick aluminum sheet. PART B (5 x 16 = 80 marks) 11. (a) What is meant by clamping? Explain the principles involved in the design of clamps? Or (b) Explain briefly the various types of errors accounted for in jigs and fixtures design. 12. (a) Design and draw a suitable drill jig to drill 4 holes of 5 mm diameter at 70 PCD on 120 mm diameter 60 mm thickness mild steel plate. Or Maximum : 100 marks

(b) Sketch and explain air operated drilling jig components. 13. (a) Design a broaching fixture to perform broaching operation on sides of a square block of size 50 mm x 50 mm. Or
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(b) 14.

Describe the various classification of milling fixtures. Describe

(a) How are the dies classified according to their construction? the different types.

Or (b) Find the total pressure, dimensions of tools to produce a washer 50 mm outside diameter with a 24 mm hole, from material 4 mm thick, having a shear strength of 360 N/mm2. 15. (a) Design and draw a suitable die for 25 mm x 20 mm mild steel plate with a 8 mm hole in the centre. Stock thickness is 0.75 mm Or (b) A shell shown in figure below has a height of 48mm and diameter of 48 mm. The corner radius 2 mm and sheet thickness 1 mm. Material : mild carbon steel. Design a die for drawing operation.

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B.E./B.Tech. DEGREE EXAMINATION, NOVEMBER/DECEMBER 2008. Seventh Semester (Regulation 2004) Mechanical Engineering ME 1009 DESIGN OF JIGS, FIXTURES AND PRESS TOOLS (Common to Automobile Engineering) (Common to B.E. (Part-Time) Sixth Semester Regulation 2005) Time : Three hours Maximum : 100 marks

(Approved design Data book is permitted) Answer ALL questions. PART A (10 x 2 = 20 marks) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Name any two materials commonly used in jigs and fixtures and their Hardness range. Write any two requirements of clamping devices. Distinguish between the channel and box jigs? Illustrate the working of an automatic drill Jig. Name any four essential features of a milling fixture. How can a lathe fixture be clamped to the lathe? List out the main parts of a power press. How will you select the proper material for press tools? What is the effect of excessive clearance upon die-cut metals? Differentiate between a cutting die and forming die. PART B (5 x 16 = 80 marks) 11. (a) List any four types of jigs and fixture construction? State the advantages of each and discuss the relative merits of each. Or (b) Explain the advantages to be obtained from the use of pneumatic and hydraulic clamping devices. (a) What is the primary function of a linear bushing? List out any four types of drill bushes with its method of fixing and locking. Or (b) Sketch and explain any eight parts of a Box jig with suitable diagram. (a) (i) (ii) Illustrate the working of a lathe fixture. Illustrate the working of Gang milling fixture. Or
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12.

13.

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(b) 14.

Write short notes on inspection and welding fixtures.

(a) How the fly press differ from power press? Describe the construction and working of a power press with the help of suitable sketch. Or (b) Discuss briefly any four possible for the component shown in Fig.

15.

(a) Design and sketch any two views of a progressive die to manufacture the outer plate of a cycle chain links. Or (b) A steel cup of height 30mm and internal diameter 40mm with a flange width of 10mm is to be deep drawn from a sheet lmm thick, Determine the diameter of the blank and the drawing force. What is the draw ratio? Can the cup be drawn in a single operation and sketch any two views of a draw die?

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B.E./B.Tech. DEGREE EXAMINATION, APRIL/MAY2008. Seventh Semester (Regulation 2004) Mechanical Engineering ME 1009 - DESIGN OF JIGS, FIXTURES AND PRESS TOOLS (Common to B.E (Part - Time) Sixth Semester Regulation 2005) Time : Three hours Answer ALL questions. PART A (10 x 2 = 20 marks)
1. What are the main differences between a jig and a fixture? 2. How can the fabrication tolerance for jigs and fixture be calculated? 3. Why should a jig have four feet and not three? 4. What is the primary function of a linear bushing? 5. How can a lathe fixture be clamped to the lathe? 6. What devices are mainly used to assemble modular elements? 7. What is the use of clutch in a power press? 8. What is the function of a stripper? When should a spring-load stripper be used? 9. What are the effects of inadequate clearance and excessive clearance upon die-cut metals? 10. What is a progressive die? When should a progressive die be used? PART B (5 x 16 = 8(Xmarks) What is six-point location principle? Explain it with the help of suitable sketches? Or (b) Explain the advantages to be obtained from the use of pneumatic and hydraulic clamping devices. 12. (a) Design and draw to scale any two views of a suitable drill jig for drilling the holes in the component shown in fig. 1. 11. (a)

Maximum : 100 marks

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Or
(b) Sketch and explain Box jig.

13.

(a)

Explain the working of milling fixture with example used in practice. Or (b) Design a welding fixture for welding a door main frame of dimensions (100 x 20 x 4) Welding must be done on front and rear side of the plates. (a) Describe the common mechanism used for ram driving in power presses. Or (b) What is strip layout? What are the different ways of making strip layout for regular and irregular shaped blanks? (a) A rectangular steel component of size 20 mm x 60 mm is to be made from 4 mm thick sheet. Sketch the scrap strip by layout and determine the percentage of stock used. Or (b) Estimate the blanking force to cut a blank of 25 mm wide and 30 mm long from a 1.5 mm thick metal strip, if the ultimate shear stress of the material is 450 N/ mm2. Also determine the work done if the percentage penetration is 25 percent of material thickness.

14.

15.

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B.E/B.Tech. DEGREE EXAMINATION, NOVEMBER/DECEMBER 2007. Seventh Semester (Regulation 2004) Mechanical Engineering ME 1009 DESIGN OF JIGS, FIXTURES AND PRESS TOOLS (Common to Automobile Engineering) (Common to B.E.(Part-Time) Sixth Semester Regulation 2005) Time : Three hours Maximum : 100 marks

Answer ALL questions. PART A (10 x 2 = 20 marks) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. What is meant by angular location? Where should locators contact the part? Why? What class of jig would normally be used to tap holes? What is the primary function of a linear bushing? How are cutters set in relation to the work in a milling fixture? List any three basic types of jigs used for welding? What is meant by clearance? Why is it important in shearing operation? What is the purpose of the shear angle found on a punch or die? Why is the wheel dressing often attached directly to the grinding fixture? What is a progressive die? When should a progressive die be used? PART B (5 x 16 = 80 marks) 11. (a) What are the various location devices? Explain any four of them in with the aid of suitable sketches. Or Explain with the help of suitable sketches the operation principles of power clamping systems. Also, state its advantages. (a) Design and draw to scale any two views of a suitable drill jig to drill two 10 mm hole on the component shown in fig.l.

(b)

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Or (b) Design and sketch any two views of a suitable drill jig to drill an oil hole of size 3 mm for the given job shown in fig.2.

13.

(a) Design a suitable milling fixture to cut a keyway of size 3x3 mm on a solid shaft of <p 30 mm diameter and 100 mm length. Or (b) With proper sketch explain the operation of a modular fixture with example used in practice. (a) (i) Differentiate between progressive die and a compound die. (ii) Calculate the maximum punch force necessary to blank a steel washer 44 mm outside diameter and 22.25 mm inside diameter and 1.6 mm thick, if s = 400 N/mm2. (8+8) Or (b) What is strip layout? What are the different ways of making strip layout for regular and irregular shaped blanks? (a) A rectangular steel component of size 20 mm x 60 mm is to be made from 4 mm thick sheet. Sketch the scrap strip by layout and determine the percentage of stock used. Or (b) Design and draw any two view of a progressive die to make a steel washer of 30 mm outside diameter with 15 mm hole from 1.6 mm thick steel sheet. The ultimate shear stress of the material is 320 N/mm2.

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ANNA UNIVERSITY, CHENNAI 25 MODEL QUESTION PAPER B.E. MECHANICAL ENGINEERING, VI SEMESTER ME339 - DESIGN OF JIGS, FIXTURES AND PRESS TOOLS TIME - 3 Hours MAXIMUM : 100 Marks ANSWER ALL QUESTIONS PART - A 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. (10 x 2 = 20 Marks)

When is a diamond-pin used for locations? Sketch a quick acting clamp. What is the difference between a jig and a fixture?. What is meant by fool proofing in the design of a jig? What is the purpose of a setting block in a fixture?. What are modular fixtures? Distinguish between blanking and piercing. Mention the significance of center of pressure as applied to Press tool design. What is the purpose of shear angle on a punch or die? What causes spring back in bending? PART - B (5 x 16 = 80 Marks)

11 .

A cup shown in Figure 1 is to be produced using a suitable drawing die. (i) Find the size of the blank and the number of draws required. (4) (ii) Sketch (without dimensions) the sectional front view of punch and die assembly and name the parts (6) (iii)Sketch the punch and die separately and indicate their dimensions. (6) a) (i) Explain the 3-2-1 locating concept using pins, with suitable sketches. Indicate where the clamping forces are to be applied. Is this locating concept limited to rectangular work pieces? (7)

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(ii) Sketch a simple vise that can be used for clamping work pieces. The fixed jaw, moving jaw and guidway are to be clearly indicated and a parts-list is also to be given. Also indicate how will you fix the vice on the table of a milling machine. (9) (OR) 12.b) (i) Sketch and explain V-type locating device having fixed-V and movable-V locator. Give details of guiding the movable-V locator. Give also an example of a component for which this type of locator can be used. (8) (ii) Sketch a strap type clamp for clamping a rectangular block. Give a parts list. Assuming that a milling operation is going to be performed on the block,
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compare the directions of tool force and 13. a) (i) Design and sketch a drill jig to drill the 20 mm hole in the component shown in Figure 2. (12) (ii) Discuss briefly the location and clamping arrangements used in your design. (4) (OR) b) (i) Design and sketch a drill jig to drill the 10 mm hole in the component shown in Figure 3, assuming that this is the last operation to be performed. (12) (ii) Discuss the location and clamping method employed in your design (4) 14. a) (i) A key way of 16 mm width, 6 mm depth and 45 mm long is to be milled on a 50 mm diameter shaft 150 mm long, at the middle of its length. Sketch a suitable fixture and indicate all the parts, if the operation is to be done using a vertical milling machine. (12) State how the cutter will be set before milling (4) (OR) b) (i) Explain with suitable sketch, how a fixture could be designed to broach a keyway in a gear blank. (8) (ii) Two plates are to be held at right angles to fabricate a L-shaped component by gas welding. Suggest a suitable fixture. (8) 15. a) (i) Explain briefly the function of the following parts applied to press working. Pilots Stock stop Knockout rod (6) (ii) Sketch a suitable press tool to manufacture square component 40 mm side having a central square hole 20 mm side, the material thickness being 1.5 mm. (10) (OR) b) The component shown in Figure 4 is to be manufactured using a progressive die. (i) Develop and sketch a suitable strip layout (6) (ii) Sketch the punches and dies of the progressive die, indicating how the stock is fed. (10)

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B.E/B.Tech. DEGREE EXAMINATION, MAY/JUNE 2007. Sixth Semester Mechanical Engineering ME 339 DESIGN OF JIGS, FIXTURES AND PRESS TOOLS Time : Three hours Maximum : 100 marks Answer ALL questions. PART A (10 x 2 = 20 marks)
1. 2. 3. 4. 5. 6. Explain the term redundant location. Sketch and write the use of a equalising clamp. Distinguish between a pot jig and a box jig. Write the specific requirements of a turning fixture. Distinguish between a setting block and stepping block. Write the work holding devices used for the following operations : (a) Eccentric turning (b) Cylindrical grinding (c) Surface grinding (d) T slot milling. Distinguish between a blanking die and a bending die. What is spring back in bending? Mention the methods of reducing cutting forces in piercing operation. Estimate the force required for a 90 bending of C 50 steel of 1.5 mm having a width of 1 m to be bent in wiping die. Take the die radius as 3 mm. PART B (5 x 16 = 80 marks) (a) Design and draw any two views of a jig for drilling 4 holes of diameter 4 mm at 90 mm PCD on the 3 sides of a 'Y ' flange as shown in Fig. 1. Prepare part list and number the parts.

7. 8. 9. 10.

11.

(b)

Or Design and draw atleast 2 views of a jig for drilling 4 holes of size 12
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on the Boss shown in Fig. 2. Number the parts and prepare part list.

12.

(a) Design and draw two views of a jig/fixture for machining the boss of size. 50 on the bearing bracket shown in Fig. 3.

(b) Design and draw atleast two views of a milling fixture for making a slot of 8 mm wide x 15 mm deep on a dome pin as shown in Fig. 4. Number the
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parts and prepare part list.

13. (a) Design and draw any two views of a jig for drilling 4 holes of 6 mm diameter at the 4 corners of a rectangular flange as shown in Fig. 5. Number the parts and prepare part list.

(b)

Design and draw any two views of a jig to make two holes of 12 mm
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on the fork given. Number the parts and prepare bill of material.

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(a) Sketch and design a progressive die to make a steel washer 30 mm outside diameter with 15 mm hole from 1.6 mm thick steel sheet. The ultimate shear stress of the material is 320 N/mm2. Or (b) Design a drawing die set for the production of cylindrical cups having a outer diameter of 50 mm and shell height of 40 mm. The thickness of the sheet metal is 0.75 mm. Material - Mild Steel. (a) (i)What is 3-2-1 principle of location? (4) (ii)Explain briefly about the welding fixtures. (6) (iii)What are the factors to be considered while designing grinding fixture. (6) Or (b) Write short notes on the following : (i) Materials used in jigs and fixtures (ii) Compound and combination dies (iii) Stretch forming (iv) Stripper and pilots.

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B.E./B.Tech. DEGREE EXAMINATION, MAY/JUNE 2006. Sixth Semester Mechanical Engineering ME 339 DESIGN OF JIGS, FIXTURES AND PRESS TOOLS Time : Three hours Answer ALL questions. Assume any missing data suitably wherever it is necessary. In figures, all dimensions are in mm. PART A (10 x 2 = 20 marks)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Differentiate between jigs and fixtures. , Define j ack pin locator. What is the advantage of swing plate clamp? Sketch the channel Jig. Mention any two advantages of fabricated Jig. Explain the function of fool proofing. Explain the function of bolster plate in press tool. What is the purpose of pilot? Differentiate between punching and piercing operation. Mention the application of turning fixture. PART B (5 x 16 = 80 marks) 11. (i) (ii) (a) Discuss the advantage of jigs and fixtures. Out line the principles of jigs and fixtures design. (8) (8)

Maximum : 100 marks

12.

13.

(i)Explain briefly with neat sketch non-conventional clamping. (8) (ii)Explain briefly 3-2-1 location of principle. (8) Or (b) (i)Explain briefly with neat sketch cylindrical and adjustable locators. (ii) Explain briefly with neat sketch latch and wedge clamping. (8) (a) (i)Design a drill jig to make hole of 10 mm as shown in Figure 1 and also mention the part list. (8)

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(ii)

Explain briefly any four types of drill bushes with neat sketches. (8) Or (b) (i) Design a drill jig to make hole of O 10 mm as shown in Figure mention the part list. (8)

2 and also

14.

(ii) (a)

Explain briefly welding fixture and grinding fixture. (8) (i) Explain briefly mechanical and hydraulic presses. (8) (ii) Design a milling fixture to make a slot of O 70 x 10 x 10 mm shown in Figure 3. (8)

as

15.

Or (b) Sketch and design a blanking die to make <D 30 mm part from 3 mm thick Carbon steel sheet metal. Take Fs = 32 kg/mm2. (16) (a) (i) Sketch and design a drawing die as shown in Figure 4 from medium carbon steel Ft- 3600 kg/cm2 . (8)

(ii) (b) (i) (ii) (iii)

Discuss the various inspection devices. Or Write short notes on the following : Bending and forming die. Combination and compound die. Calculation of centre of pressure with example.
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(8)

(5) (6) (5)

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B.E./B.Tech. DEGREE EXAMINATION, NOVEMBER/DECEMBER 2005. Sixth Semester Mechanical Engineering ME 339 DESIGN OF JIGS, FIXTURES AND PRESS TOOLS Time : Three hours Maximum : 100 marks

Assume any missing data suitably wherever it is necessary. In figures, all dimensions are in mm. Answer ALL questions. PART A (10 x 2 = 20 marks)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. What is meant by 3-2-1 principle of location? What is best method to locate a rough surface? What is advantage of conical locators? Explain the importance of clamping force. Define plate jigs. Sketch the indexing jig. Mention the application of turning fixture. What is the purpose of stripper? Define deep drawing. How is die life gauged? PART B (5 x 16 = 80 marks) (i) What are the main objectives to be consider while designing jig and f(8) fixture? (ii)Explain briefly main elements of jig and fixture. (8) (a) (i) Explain with neat sketch any two types of locating device. (ii) Explain with neat sketch any two types of clamping device. (8) Or (b) (i) Explain briefly neat sketch unconventional clamping. (8) (ii) Explain the important accessories of jig and fixture. (8) (a) (i) Design a drill jig to make hole of 10 mm as shown figure 1 and mention the part list. (8)

12.

13.

also

(ii)

Explain briefly universal jig and plastic jig.

(8) also

Or
(b) (i) Design a drill jig to make hole of 10 mm as shown figure 2 and mention the part list. (8)
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(ii) 14.

Explain briefly box jig and turnover jig. (8) (a) (i) Explain briefly welding fixture and grinding fixture. (8) (ii) Design a milling fixture to make a slot of 70 x 10 x 10 mm as shown in (8)

figure 3.

Or (b) (i) figure 4. Design a milling fixture to make a slot of 70 x 10 x 10 mm as (8) shown in

(ii)

Write short notes on shaping fixture and broaching fixture.

(8)

15. (a) Sketch and design a piercing die to make 35 mm square part from 2 mm thick carbon steel sheet metal. (16) Or (b) Write short notes on following : (i) Sketch combination die. (4) (ii) Describe various type of cutting operation. (6) (iii) Discuss the design procedure of drawing die. (6)
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