JIGS AND FIXTURES

HISTORY

The first manufactured products were made one at a time. Early artisans started with little more
than raw materials and a rough idea of the finished product. They produced each product piece by
piece, making each part individually and fitting the parts into the finished product. This process took
time. Moreover, the quality and consistency of products varied from one artisan to the next. As they
worked, early manufacturing pioneers realized the need for better methods and developed new ideas.

Eventually, they found the secret of mass production: standardized parts. Standard parts not only
speeded production, they also ensured the interchangeability of parts. The idea may be obvious today,
but in its time, it was revolutionary.

These standard parts were the key to enabling less -skilled workers to replicate the skill of the
craftsman on a repetitive basis. The original method of achieving consistent part configuration was the
template. Templates for layout, sawing, and filing permitted each worker to make parts to a standard
design. While early templates were crude, they at least gave skilled workers a standard form to follow
for the part. Building on the template idea, workers constructed other guides and workholders to make
their jobs easier and the results more predictable. These guides and workholders were the ancestors of
today’s jigs and fixtures.

Yesterday’s workholders had the same two basic functions as today’s: securely holding and
accurately locating a workpiece. Early jigs and fixtures may have lacked modern refinements, but they
followed many of the same principles as today’s workholder designs.

 INTRODUCTION :-
Mass production method demand fast and easy method of positioning work for accurate operation
on it.
 Jigs and Fixture are production tools used to accurate manufacture duplicate and
interchangeable parts.
  Jigs and Fixture are specially designed so that large number of computers can be machined or
assembled identically, and to ensure interchangeability of components.
 The economical production of engineering components is greatly facilitated by the provision of
jigs and fixtures.
 The use of a jig or fixtures makes a fairly simple operation out of one which would otherwise
require a lot of skill and tome.
 Both jigs and fixtures position components accurately; and hold components rigid and prevent
movement during working in order to impart greater productivity and part accuracy.
 Jigs and fixtures hold or grip a work piece in the predetermined manner of firmness and loc ation,
to perform on the work piece a manufacturing operation.
 A jig or fixture is designed and built to hold, support and locate every component (part) to ensure
that each is drilled or machined within the specified limits. The correct relationship and alignment
between the tool and the work piece is maintained.
 Jigs and fixtures may be large (air plane fuselages are built on picture frame fixtures) of very
small (as in watch making). Their use is limited only by job requirements and the imagination of
the designer.
 The jigs and fixtures must be accurately made and the material used must be able to withstand
wear and the operational (cutting) experienced during metal cutting.
 Jigs and fixtures must be clean, undamaged and free from swarf and grit. Components must not
be forced into a jig or fixture.
 Jigs and fixtures are precision tools. They arte expensive to produce because they are made to
fine limits from materials with good resistance to wear. They must be properly stored or isolated
to prevent accidental damage, and they must be numbered for identification for future use.

 DEFINTIONS AND CONCEPT OF JIG AND FIXTURE

(A) JIG:-

 Jig is a frame of body which holds and positions the work and guides the cutting tool during the
machining operation (drilling, reaming, tapping etc.). Jigs are usually fitted with hardened steel
bushings for guiding drills or other cutting tools.
 The work piece to be drilled is held and positioned in the drilling jig. Bushes guide the drill for
making holes at the desired positions in the work piece.
 In the shop, drill jigs are the most-widely used form of jig. Drill jigs are used for drilling, tapping,
reaming, chamfering, counterboring, countersinking, and similar operations. Occasionally, drill jigs are
used to perform assembly work also. In these situations, the bushings guide pins, dowels, or other
assembly elements.

Jigs are further identified by their basic construction. The two common forms of jigs are open and
closed. Open jigs carry out operations on only one, or sometimes two, sides of a workpiece. Closed
jigs, on the other hand, operate on two or more sides. The most -common open jigs are template jigs,
plate jigs, table jigs, sandwich jigs, and angle plate jigs. Typical examples of closed jigs include box jigs,
channel jigs, and leaf jigs. Other forms of jigs rely more on the application of the tool than on their
construction for their identity. These include indexing jigs, turnian jigs, and multi-station jigs.

Specialized industry applications have led to the development of specialized drill jigs. For example,
the need to drill precisely located rivet holes in aircraft fuselages and wings led to the design of large
jigs, with bushings and liners installed, contoured to the surface of the aircraft. A portable air-feed drill
with a bushing attached to its nose is inserted through the liner in the jig and drilling is accomplished in
each location.

(B) FIXTURE

 A fixture is a production tool that locates, holds and supports the work securely in fixed
orientation with respect to the tool so that the required machining operations can be
performed.
 A fixture differs from a jig in the sense that the fixture does not guide the cutting tool. If is
used only to hold work rigidly while machining operations such as milling, planning,
shaping etc. are being performed on the work piece.
 Fixture used for machining small parts. The standard vise jaws have been replaced with
jaws which are formed to fit the part.
 A fixture should be securely fastened to the table of the machine upon which the work is
done.
 Fixtures are designed to hold work for various operations on most of the standard
machine tools (e.g. a milling machine).
 Fixtures vary in design from relatively simple tools to expensive, complicated devices.
Where jigs are connected with operations, fixtures most commonly are related to specific machine
tools.
Thus the most common jigs are drilling jigs, reaming jigs, assembly jigs, etc. In these uses they
usually are not fastened to a machines tool or table but are free to be moved so as to permit the
proper registering of the work and the tool.
Fixtures, on the other hand, most frequently are attached to some machine tool or table.
Consequently, they are associated, in name, with the particular tool with which they are used, e.g.,
milling fixtures, broaching fixtures, grinding fixtures, assembly fixtures etc.
Jigs are lighter than fixtures, for quick handing ; fixtures are heavier in construction and are bolted
rigidly on the machine table.

Figure 1-2. A fixture references the cutting tool, in this case with a set block.
 Tool or Tooling

The term “tool” encompasses both jigs and fixtures. Essentially, it is a generic term describing a
workholder which is identified with a part or machine. Sometimes “tool” is used to refer to a cutting tool
or a machine tool, so it is important to make clear distinctions.

 Workholders

Another term which describes both jigs and fixtures is “workholder.” A broad term, it frequently
identifies any device which holds, supports, and locates a workpiece. In addition to jigs and fixtures,
vises, collets, clamps, and other similar devices are also workholders.

 PERMANENT AND TEMPORARY WORKHOLDERS

Jigs and fixtures are most often found where parts are produced in large quantities, or produced to
complex specifications for a moderate quantity. With the same design principles and logic, workholding
devices can be adapted for limited-production applications. The major difference between permanent
and temporary workholders is the cost/benefit relationship between the workholder and the process.
Some applications require jigs and fixtures solely for speed; others require less speed and higher
precision. The requirements of the application have a direct impact on the type of jig or fixture built and,
consequently, the cost.

 Permanent Jigs and Fixtures

Workholders for high-volume production are usually permanent tools. These permanent jigs and
fixtures are most often intended for a single operation on one particular part. The increased complexity
of permanent workholders yields benefits in improved productivity and reduced operator decision-
making, which result in the tool having a lower average cost per unit or per run. Therefore, more time
and money can be justified for these workholders.

In the case of hydraulic or pneumatic fixtures, inherent design advantages can dramatically
improve productivity and, hence, reduce per-unit costs even further, even though the initial cost to
construct these fixtures is the most expensive of all fixture alternatives. In some cases, where machine -
loading considerations are paramount, such as a pallet-changing machining center, even duplicate
permanent fixtures may be justified.

Permanent jigs and fixtures are typically constructed from standard tooling components and
custom-made parts. Figure 1-3 shows a typical permanent workholder for a drilling operation.

Figure 1-3. A permanent workholder used for a drilling operation.

Low-volume runs and ones with fewer critical dimensions are often produced with throwaway jigs
and fixtures. These tools would typically be one-time-use items constructed from basic materials at
hand and discarded after production is complete. Although throwaway jigs and fixtures are technically
permanent workholders, in effect they are actually temporary.

 General-Purpose Workholders

In many instances, the shape of the part and the machining to be performed allow for the use of a
general-purpose workholder such as a vise, collet, or chuck. These workholders are adaptable to
different machines and many different parts.

Since they are not part-specific, their versatility allows for repeated use on a variety of different or
limited-production runs. The cost of these workholders would usually be averaged over years and might
not even be a factor in job-cost calculations. The general-purpose nature of these workholders
necessitates a higher level of operator care and attention to maintain consistency and accuracy. For
these reasons, general-purpose workholders are not preferred for lengthy production runs.

 DESIGN CONSIDERATIONS

The principal considerations when choosing among workholder varieties fall into three general
categories: tooling cost, tooling details, and tooling operation. Although eac h of these categories is
separated here, in practice they are interdependent. The following are some design differences and
considerations for permanent, general-purpose, and modular workholders.

 APPLICATIONS FOR JIGS AND FIXTURES

Typically, the jigs and fixtures found in a machine shop are for machining operations. Other
operations, however, such as assembly, inspection, testing, and layout, are also areas where
workholding devices are well suited. Figure 1-7 shows a list of the more-common classificati ons and
applications of jigs and fixtures used for manufacturing. There are many distinct variations within each
general classification, and many workholders are actually combinations of two or more of the
classifications shown.

EXTERNAL-MACHINING APPLICATIONS:
Flat-Surface Machining
• Milling fixtures
• Surface-grinding fixtures
• Planing fixtures
• Shaping fixtures

Cylindrical-Surface Machining
• Lathe fixtures
• Cylindrical-grinding fixtures

Irregular-Surface Machining
• Band-sawing fixtures
• External-broaching fixtures
INTERNAL-MACHINING APPLICATIONS:
 Cylindrical- and Irregular-Hole Machining
• Drill jigs
• Boring jigs
• Electrical-discharge-machining fixtures
• Punching fixtures
• Internal-broaching fixtures
NON-MACHINING APPLICATIONS:
Assembly
• Welding fixtures
• Mechanical-assembly fixtures
(Riveting, stapling, stitching, pinning, etc.)
• Soldering fixtures

Inspection
• Mechanical-inspection fixtures
• Optical-inspection fixtures
• Electronic-inspection fixtures

Finishing
• Painting fixtures
• Plating fixtures
• Polishing fixtures
• Lapping fixtures
• Honing fixtures

Miscellaneous
• Layout templates
• Testing fixtures
• Heat-treating fixtures

Figure 1-7. Typical applications of jigs and fixtures

 ADVANTAGES OF USING JIGS AND FIXTURES
i. Manufacturing costs are reduced when large number of identical and inter -changeable parts are
produced using jugs and fixtures.
ii. Jigs and fixtures eliminate marking out of the work piece before machining, thereby reducing
the producing the production time.
iii. Since work piece is automatically located in the right position, and the tool is guided.
a. Machining accuracy is improved,
b. Simi-skilled workers can be employed.
iv. Production work is rapid.
v. Productivity is improved.
vi. Assembly work of (component) parts is facilitated because they are identical and
interchangeable.
vii. Due to high clamping rigidily of jigs and fixtures, high power machines can be used and a t
higher speeds, feeds and depth of cut.
viii. Since setting up of the work on the machine becomes easier, it reduces fatigue incurred by the
workers.
ix. Quality of the component parts improves.
x. The above mentioned advantages ultimately result in overall economy.

 DEGREES OF FREEDOM
 An unrestricted object in space is free to move in any of twelve possible directions, and thus is
said to have twelve degrees of freedom.
 A rectangular object with three axes or planes, along which movement may occur.
 An object is free to revolve around or move parallel to any axis in either direction. To visualize
this, the planes have been marked “X -X”, “Y-Y” and “Z-Z”.
 Figure 3-1. The twelve degrees of freedom
Locators provide a positive stop for the workpiece. Placed against the stop, the workpiece cannot
move. Clamps, on the other hand, rely only upon friction between the clamp and the clamped surface to
hold the workpiece. Sufficient force could move the workpiece. Clamps are only intended to hold the
workpiece against the locators

 PRINCIPALE OF LOCATION
 The term location refers to establish a definite relationship between the work piece and the
cutting tool or jig or fixture.
 Correct location of the work piece with respect to the cutting tool is essential in order to produce
accurate, identical and interchangeable parts.
 The function of location is done by locators and the movement of part (work piece) is restricted
by clamps.
 Each jig or fixture is composed of a number of elements of which clamps and locators are the
most important to consider in connection with locating the work piece.
 Locating elements place the work piece in essentially the same position cycle after cycle.
 A rectangular block/part is free to move in any direction and has twelve degrees of freedom.
 In order to accurately locate a part in a jig or fixture, all these twelve movements must be
restricted by arranging suitable locating points and then clamping the part in position.
  For restricting the movements, pin-type or button-type locators may be used. They minimize the
chance of error by limiting the area of contact and raising the part above the chips.
 By placing the part on a three pin base five directions of movement (#2, #5, #1, #4 and #12) are
restricted.
 To restrict the movement of the part around the “z-z” axis (i.e.#3 and #6 and in direction #8, two
more pin-type locators are positioned

Thus, a six pin locati ng method restricts nine degrees of freedom as explained above and it is
the most common external locator for square or rectangular parts.
The remaining directions, #9, #10, and #11 can also be arrested by using three additional pins
(one for each freedom). But then it will prevent fixing the part in the jig or fixture. Therefore, the
only way to restrict the remaining three degrees of freedom is by using suitable clamping
devices. Clamping devices will also resist cutting forces.
Solid supports are fixed-height locators. They precisely locate a surface in one axis. Though solid
supports may be machined directly into a tool body, a more-economical method is using installed
supports, such as rest buttons.

Adjustable supports are variable-height locators. Like solid supports, they will also precisely locate
a surface in one axis. These supports are used where workpiece variations require adjustable support
to suit different heights. These supports are used mainly for cast or forged workpieces that have
uneven or irregular mounting surfaces.

Equalizing supports are a form of adjustable support used when a compensating support is
required. Although these supports can be fixed in position, in most cases equalizing supports float to
accommodate workpiece variations. As one side of the equalizing support is depressed, the other side
raises the same amount to maintain part contact. In most cases adjustable and equalizing supports are
used along with solid supports.

Locating a workpiece from its external edges is the most-common locating method. The bottom, or
primary, locating surface is positioned on three supports, based on the geometry principle that three
points are needed to fully define a plane. Two adjacent edges, usually perpendicular to each other, are
then used to complete the location.
 The most-common way to locate a workpiece from its external profile is the 3-2-1, or six-point,
locational method. With this method, six individual locators reference and restrict the workpiece.

As shown in Figure 3-4, three locators, or supports, are placed under the workpiece. The three
locators are usually positioned on the primary locating surface. This restricts axial movement
downward, along the -z axis (#6) and radially about the x (#7 and #8) and y (#9 and #10) axes.
Together, the three locators restrict five degrees of freedom.

Figure 3-4. Three supports on the primary locating surface restrict five degrees of freedom.
The next two locators are normally placed on the secondary locating surface, as shown in Figure 3 -
5. They restrict an additional three degrees of freedom by arresting the axial movement along the +y
axis (#3) and the radial movement about the z (#11 and #12) axis.
 Figure 3-5. Adding two locators on a side restricts eight degrees of freedom.
The final locator, shown in Figure 3-6, is positioned at the end of the part. It restricts the axial
movement in one direction along the -x axis. Together, these six locators restrict a total of nine degrees
of freedom. The remaining three degrees of freedom (#1, #4, and #5) will be restricted by the clamps.

Figure 3-6. Adding a final locator to another side restricts nine degrees of freedom, completing the 3 -2-
1 location.
Although cylindrical rest buttons are the most-common way of locating a workpiece from its
external profile, there are also other devices used for this purpose. These devices include flat-sided
locators, vee locators, nest locators and adjustable locators.
 Referencing and Repeatability

“Referencing” is a dual process of positioning the workpiece relative to the workholder, and the
workholder relative to the cutting tool. Referencing the workholder to the cutting tool is performed by the
guiding or setting devices. With drill jigs, referencing is accomplished using drill bushings. With fixtures,
referencing is accomplished using fixture keys, feeler gages, and/or probes. Referencing the workpiece
to the workholder, on the other hand, is done with locators.

If a part is incorrectly placed in a workholder, proper location of the workpiece is not achieved and
the part will be machined incorrectly. Likewise, if a cutter is improperly positioned relative to the fixture,
the machined detail is also improperly located. So, i n the design of a workholder, referencing of both
the workpiece and the cutter must be considered and simultaneously maintained.

“Repeatability” is the ability of the workholder to consistently produce parts within tolerance limits,
and is directly related to the referencing capability of the tool. The location of the workpiece relative to
the tool and of the tool to the cutter must be consistent. If the jig or fixture is to maintain desired
repeatability, the workholder must be designed to accommodate the workpiece’s locating surfaces.

The ideal locating point on a workpiece is a machined surface. Machined surfaces permit location
from a consistent reference point. Cast, forged, sheared, or sawed surfaces can vary greatly from part
to part, and will affect the accuracy of the location.

 LOCATING GUIDELINES

No single form of location or type of locator will work for every workholder. To properly perform the
necessary location, each locator must be carefully planned into the design. The following are a few
guidelines to observe in choosing and applying locators.

 Positioning Locators

The primary function of any locator is to reference the workpiece and to ensure repeatability.
Unless the locators are properly positioned, however, these functions cannot be accomplished. When
positioning locators, both relative to the workholder and to the workpiece, there are a few basic points
to keep in mind.
 Whenever practical, position the locators so they contact the workpiece on a machined surface.
The machined surface not only provides repeatability but usually offers a more -stable form of location.
The workpiece itself determines the areas of the machined surface used for location. In some
instances, the entire surface may be machined. In others, especially with castings, only selected areas
are machined.

The best machined surfaces to use for location, when available, are machined holes. As previously
noted, machined holes offer the most-complete location with a minimal number of locators. The next
configuration that affords adequate repeatability is two machined surfaces forming a right angle. These
characteristics are well suited for the six-point locational method. Regardless of the type or condition of
the surfaces used for location, however, the primary requirement in the selection of a locating surface is
repeatability.

 . LOCATING DEVICES:-

Introduction
 Locating devices place the work piece in essentially the same position, in a jig or fixture, cycle
after cycle. In this sense, the locator provides a reference point from which all sizing or spacing
may be accomplished.
 Parts are made in almost every possible shape and size The tool designer must be able to
accurately locate each part, regardless of how it is made. To do this, the tool designer must
know the various types of locators and how each should be used to get the best part placement
with the least number of locators.
 Solis supports are easiest to use. They can either be machined into the tool base or installed.
This type of support is normally used when a machined surface acts as a locating point.
 Adjustable supports are used when the surface is rough or uneven, such as in cast parts.
There are threaded type, spring type, and push type of adjustable supports.The threaded type is
the easiest, most economical and has a larger adjustment range than the others.

Adjustable locators are normally used with one or more solid locators to allow any adjustment needed
to level the work.
  Equalizing supports are also a form of adjustable support. They provide equal support through
two connected contact points. As one point is depressed, the other raises and maintains contact
with the part. This feature is especially necessary on uneven cast surfaces.

 Locators for locating from an Internal Diameter

 Locating a part from a hole is the most effective way to accurately position work.
 Several types of locators are used for locating work from holes.
 A few types used for large holes. When large hole; locate the work, fasten the internal locator
with both screws and dowels.

With shank-type locator, it is a good practice to use the press fit rat her than the threaded locator for
accuracy.
 Pin-type locators are used for smaller holes and for aligning members of the tool. When pins
are used for alignment special bushings should also be used so that can be replaced when they
wear.
A pin common to jig and fixtures is the diamond or relieved pin. A diamond pin when used along with a
round pin makes it easier to locate a part than to locate the part on two round pins. In use, the round pin
locates the part and the diamond pin prevents the movement around the pin.

Locating from an External Profile

 The most common method of locating work in the early stages of machining is to do so from an
external profile or outside edge.
 Profile locators position the work in relation to an outside edge or the outside of a detail, such
as a hub or boss.
 The following are a few examples of the most common ways a part can be located from its
profile.
 Nesting locators position a part in a depression or recess of the same shape as the part.
Nesting is the most accurate from of location device for profile location. Since the nest must
conform to the shape of the part, nests are very expensive to design for complicated shapes.

 Ring nest is the most common type and is normally used for cylindrical profiles.
The full nest type encloses shapes other than cylindrical,
 Vee locators are used mainly for round work. They can also locate flat work with rounded or
angular ends. One advantage V-locators have over other locator is their centralizi ng feature.
 Fixed-stop locators are used for parts which cannot be placed in either a nest of V-locator.
 Installed fixed stop locators are normally more economical to use because of the time it takes
to make the machined locators. Since installed locators can be replaced when worn, the entire
tool body does not have to be made again.
 Adjustable-stop locators can also be used to keep the cost of a tool to a minimum. Since
these stops are adjustable, their position on the tool body does not have to be as closely
controlled.

 CLAMPING GUIDELINES

Locating the workpiece is the first basic function of a jig or fixture. Once located, the workpiece
must also be held to prevent movement during the operational cycle. The process of holding the
position of the workpiece in the jig or fixture is called clampi ng. The primary devices used for holding a
workpiece are clamps. To perform properly, both the clamping devices and their location on the
workholder must be carefully selected.

Factors in Selecting Clamps

Clamps serve two primary functions. First, they must hold the workpiece against its locators.
Second, the clamps must prevent movement of the workpiece. The locators, not the clamps, should
resist the primary cutting forces generated by the operation.

Holding the Workpiece Against Locators. Clamps are not intended to resist the primary cutting
forces. The only purpose of clamps is to maintain the position of the workpiece against the locators and
resist the secondary cutting forces. The secondary cutting forces are those generated as the cutter
leaves the workpiece. In drilling, for example, the primary cutting forces are usually directed down and
radially about the axis of the drill. The secondary forces are the forces that tend to lift the part as the
drill breaks through the opposite side of the part. So, the clamps selected for an application need only
be strong enough to hold the workpiece against the locators and resist the secondary cutting forces.

Holding Securely Under Vibration, Loading, and Stress. The next factors in selecting a clamp are
the vibration and stress expected in the operation. Cam clamps, for example, although good for some
operations, are not the best choice when excessive vibration can loosen them. It is also a good idea to
add a safety margin to the estimated forces acting on a c lamp.

Preventing Damage to the Workpiece. The clamp chosen must also be one that does not damage
the workpiece. Damage occurs in many ways. The main concerns are part distortion and marring. Too
much clamping force can warp or bend the workpiece. Surface damage is often caused by clamps with
hardened or non-rotating contact surfaces. Use clamps with rotating contact pads or with softer contact
material to reduce this problem. The best clamp for an application is one that can adequately hold the
workpiece without surface damage.

Improving Load/Unload Speed. The speed of the clamps is also important to the workholder’s
efficiency. A clamp with a slow clamping action, such as a screw clamp, sometimes eliminates any
profit potential of the workholder. The speed of clamping and unclamping is usually the most-important
factor in keeping loading/unloading time to a minimum.
Positioning the Clamps

The position of clamps on the workholder is just as important to the overall operation of the tool as the
position of the locators. The selected clamps must hold the part against the locators without deforming
the workpiece. Once again, since the purpose of locators is to resist all primary cutting forces generated
in the operation, the clamps need only be large enough to hold the workpiece against the locators and
to resist any secondary forces generated in the operation. To meet both these conditions, position the
clamps at the most-rigid points of the workpiece. With most workholders, this means positioning the
clamps directly over the supporting elements in the baseplate of the workholder,
The size of the clamp-contact area is another factor in positioning a clamp. To reduce interference
between the clamp and the cutter, keep the contact area as small as safely possible. A small clamping
area reduces the chance for interference and also increases the clamping pressure on the workpiece.
The overall size of the clamp is another factor to keep in mind. The clamp must be large enough to
properly and safely hold the workpiece, but small enough to stay out of the way.

Once again, the primary purpose of a clamp is to hold the workpiece against the locators. To do
this properly, the clamping force should be directed into the locators, or the most -solid part of the
workholder. Positioning the clamping devices in any other manner can easily distort or deform the
workpiece.

 CLAMPING DEVICES

Definition

• A clamp is a device that

a) Holds the work piece firmly against the locators provided, and
b) Also, resists all forces generated by the cutting action of the tool on the work piece or it can use
the cutting forces to its own advantage.
 A clamping device ensures proper location and centering of the work piece.

Requirements of Efficient Clamping

The axioms of successful clamping are that:

i. The wok piece must be clamped over a solid supporting point, and not at a position which is
liable to cause distortion.
ii. There should be dependable contact between the work piece and the clamping elements in
order to prevent displacement and vibration of the work piece during operation.
iii. The clamping devices of jigs and fixtures must be reliable in operation, simple in design and
convenient for maintenance.
iv. The clamping devices must not deform, bend, or damage the work piece.
v. The clamping devices should be such that the work pieces can be clamped and unclamped
with minimum effort of the operator and minimum loss of his time.
vi. Clamping dives should be wear resistant, and the parts subject to most wear should be
renewable.
vii. Clamps must be situated in such a manner that they may be tightened of lossened without
danger to the operator.
viii. Clamp forces should be exerted only on positively supported (or very rigid) parts of the work
piece.
ix. Clamps should be strong enough to resist bending.
x. Clamps should be placed in such a manner that a number of operations can be performed in
one setting.
xi. Fluted nuts, livers, handles, hydraulic or pneumatic devices are more convenient means of
clamping than the use of spanners, but if for cheapness or heavy duty, hexagon nuts are used,
one size of spanner should be used throughout.
xii. Reaction to cutting and clamping forces should be provided by the main frame of the jig or
fixture.
 Types of Clamps

• The type of clamp to be used depends upon:

1) the shape and size of the work piece,

2) the type of jig or fixture being used, and
3) the work to be done.

The tool designer should choose the clamp the clamp which is the simplest, easiest to use, and
most efficient.

• Different types of clamps are

a) Strap clamps
b) Screw clamps
c) Swing clamps
d) Hook clamps
e) Quick acting knobs
f) Cam action clamps
g) Wedge clamps
h) Toggle-action clamps
i) Power clamping
j) Chucks and vises
k) Non-mechanical clamping.
a) Strap clamps

-Strap clamps are the simplest clamps and are used in almost every area of jigs and fixture design
and construction. The basic operation of these clamps is the same as a lever.

-Strap clamps can be either manual (nuts, hand knobs and cams) or power driven (hydraulic of
pneumatic) devices.

b) Screw clamps

-Screw clamps offer almost unlimited application potential, lower costs, and in many cases, less
complex designs.

-Screw clamps use the torque developed by a screw thread to hold a part in place. This is done by
direct pressure or by acting on another clamp.

-The only disadvantage of using screw clamps id their relatively slow operating speeds.

c) Swing clamps

-A swing clamp combines the screw clamp with a swinging arm which pivots on its mounting stud.
The rapid action needed is accomplished by the swinging arm.

d) Hook clamps

-A book clamp is similar to a swing clamp.

-Hook clamps are useful in tight places pr where several small clamps must be used rather than one
large clamp.
e) Quick-acting knobs

-Quick acting knobs are useful for increasing the output of low cost tools. There knobs are made so
that when pressure id released, they can be tilted and slid off a stud. The knob is slid over the stud
until it contacts the part. It is then tilted to engage the threads and turned until tight.

f) Cam action clamps

-cam action clamps provide a fast, efficient, and simple wa y to hold work.

-Direct pressure cam clamps are avoided where there is a strong vibration present. This might
cause the clamp to locsen, creating a dangerous situation. direct pressure cam clamps must be
positioned. to resist the natural tendencies of the clamps to shift or move the work when the clamp
is engaged .To prevent this movement, the clamp is always positioned so the work is pushed into
the locators when pressure is applied.

-Indirect pressure cam clamp decreases the possibility of loosening or shifting the work when
clamping.

-There are three basic types of cams used for clamping mechanisms.

i. Flat eccentric
ii. Flat spiral
iii. Cylindrecal

g) Wedge clamps

-Wedge clamps apply the basic principle of wedge clamps-using-flat wedge and conical wedge
and conical wedge.

-Shows a conical wedge or mandrel, used for holding work through a hole.
h) Toggle-Action clamps

-Toggle clamps are fast acting.

-Due to the way they are made, they have the natural ability to move completely free of the work,
allowing for faster part changes.

-Toggle clamps possess high ratio of holding force to application force.

-Toggle clamps are made in four basic clamping actions

i) Power clamping

-Power clamping unlike manual clamping makes use of hydraulic power, pneumatic power or an
air-to-hydraulic booster.

-Power clamping though costly, has better control of clamping pressures, of clamping pressures,
less wear on moving parts of the clamp, faster operating cycles and higher efficiency.

j) Chucks and Vises

-Commercially available chucks and vises when modified to suit the job at hand greatly reduce
tooling cost. A special jaw chuck to hold a part.

k) Non-mechanical clamping

-The main types of non-mechanical clamps used for production manufacturing are;

-magnetic chucks

-vacuum chucks.

-Non-mechanical clamps hold parts which cannot be held practically in other devices because of
size, shape or the possibility of distortion.
-Magnetic chucks hold only ferrous metal parts.

-Vacuum chucks are used to clamps parts which are non-magnetic or which must be clamped
uniformly.

 TYPES OF JIGS

-Because jigs are designed to facilited to facilitate certain processes, they are made in several
basic forms and carry names they are descriptive of their general configurations or predominant
features.

-Jigs may be divided into two general classes:

Boring jigs, used to bore holes that are either too large to drill or must be made and odd size.

Figure 1-1. A jig guides the cutting tool, in this case with a bushing.

A. Drill gigs, used to drill, Ream, tap, chamfer, counterbore, countersink, reverse spot face etc.
 Drill jigs are of two types, open and closed.

Open jigs are used for simple operations where work is done on only one side of the part.

Closed or box figs are used for parts which must be machined on more than one side.

Drill jigs can further be classified as:

i. Template jig
ii. Plate jig
iii. Sandwich jig
iv. Angle plate jig
v. Box jig
vi. Channel jig
vii. Leaf jig
viii. Indexing jig
ix. Multistation jig
x. Ring jig
xi. Diameter jig

Template jig

-Template jig is the least expensive and simplest type of jig to use.

-This type of jig is normally used for accuracy rather than speed.

-Template jig fits over, on, or into the work and is not usually clamped.
-Template jigs may or may not have bushings.

Plate jig

-Plate jigs are similar to template jigs, except that, plate jigs have built-in clamps to hold the work.

-Plate jigs may be made with or without bushings.

Sandwich jig

-A sandwich jig is a form of plate jig with a back plate.

-A sandwich jig is very suitable for thin or soft parts which could bend or warp in another style of jig.

Angle plate jig

-An angle plate jig is used to hold parts which are machined at right angles to their mounting
locators.

-Pulleys, collars and gears use this type of jig.

Box jig

-A box jig or tumble jig totally surrounds the part. The part can be completely machined on every
surface without repositioning the work in the jig.

Channel jig

-A channel jig is the simplest form of box jig.

-The work is held between two sides and machined from the third.
Leaf jig

-Leaf jigs are characterized by a hinged cover or leaf that can be swung open to permit the part to be
inserted and then closed to clamp the part in position. A handle is provided for easier movement.

-Drill bushings are usually located in the leaf.

-Leaf jigs are normally smaller than box jigs.

Indexing jigs

-Indexing jigs are used to accurately space holes around a part. To do so, the jig uses either the part
itself or a reference plate and plunger.

Multistation jigs

-This type of jig is commonly used on multi-spindle machines. While one part is being drilled, another
could be reamed and a third counterbored. The final station is used for unloading the finished parts
and loading fresh parts.

Ring jigs

- Ring jigs are used only for drilling round parts, such as pipe flanges. Adequate clamping must be
provided to prevent the part from rotating in the jig.

Diameter jigs

- Diameter jigs provide a simple means of locating a drilled hole exactly on a diameter of a cylindrical
or spherical piece.
 TYPES OF FIXTURES
- Fixtures are normally classified by the type of machine operations for which they are used.
- The following is a partial list of different types of fixtures.

a. Welding fixture
b. Broaching fixture
c. Profiling fixture
d. Indexing fixture
e. Milling fixture
f. Tapping fixture
g. Duplex fixture
h. Vise-jaw fixture

Welding fixture

- a welding fixture will position different sections accurately, hold them firmly and prevent any
movement during welding operation. The fixture positions the work in such a way that the welding
can be carried out most conveniently in the flat position.

Milling fixture

- Such fixtures are used to perform a number of roughing operations in machining flat surfaces; they
can clamp from 3 to 4 times as many workpieces as a machining vise.
- In such fixtures, the required surface finish, parallelism and squareness of all the sides of a
prismatic part are easily obtained, even with relatively narrow tolerances. Such accuracy cannot be
obtained in a vise.
- Owing to the high accuracy of the elements of the fixtures, the quality of machining is considerably
higher in such fixtures than in vise.
- Milling fixture is used for machining the face of a gear box cover. The fixture has a loca ting stud
upon which the cover fits and is bolted thereto. The machining of the top face thus becomes a
simple vertical milling operation, the only to proviso being the removal of correct amount of metal to
give the correct dimension bet-been the inside boss and the machined face, and this is ensured by
the u
- se of a setting block. This enables the operator to adjust the cutter to the height required without
any necessity of measurement.

c) Broaching fixture

- Fixtures for internal broaching operations i.e., for broaching a hole in the workpieces that have a
machined end face or shoulder which is to be square to the axis of the broached hole.

d) Tapping fixture

- A tapping fixture for an elbow type component. The component is positioned securely in the
fixture for tapping the holes.

e) Profiling Fixture

- A profiling fixture is used to guide tool for machining contours which the machine cannot
normally follow. The contours can be either internal or external.

- The cam is accurately cut by maintaining contact between the fixture and the bearing on the
milling cutter. This bearing is an important part of the cutting tool and must always be used.

f) Duplex fixture

- A duplex fixture is a type of multi-station fixtures used primarily for high speed, high volume
production runs where the machining cycle must be continuous.
 - A duplex fixture uses only two stations. Once the machining operation is complete at station
one, the fixture is revolved and the machining is started at station two. During this period, the
machined part is unloaded from station one and a fresh part is loaded there, and so on.

g) Indexing fixture

- Indexing fixtures are used for machining parts which must have machined details evenly
spaced.

h) Vise jaw fixture

- A vise jaw fixture is used for machining small parts. With this type of tool, the standard vise jaws
are replaced with jaws which are formed to fit the part.

- Vise jaw fixtures are the least expensive type of fixtures to make. Their use is limited only by the
vises available.

 JIG AND FIXTURE CONSTRUCTION:-

The body of a jig or a fixture can be constructed by any of the following methods:

1) Casting 2) Fabrication 3) Welding.

In the last two methods, the body is made up from separate parts. The advantages of the cast
construction are:

i. Jigs and fixtures with complicated shapes can be easily cast.

ii. Cast iron has the property of absorbing and damping out the vibrations.
iii. Any number of castings with the same characteristics can be made from one pattern.
iv. If a cast jig or fixture drops down, it will probably break. It is not likely to bend and get out
of alignment so as to result in the production of defective pieces.
Fabrication has the following advantages:

i. Standard parts can be used to build up the body.

ii. The jig or fixture can be built up quickly by using standard parts.
iii. After use, the jig or fixture can be disassembled.

Welding has the following advantages:

i. The jig or fixture can be constructed speedily.

ii. The welded construction is cheaper.
iii. Less machining is needed than for fabricated parts.

Comparison. Casting is the most popular method. It is costly both in time and money but it
has the property of absorbing and damping out vibrations, a very useful characteristic for
milling fixtures. Castings are usually heavy and where lightness is needed, welded for
fabricated jig or fixture has the advantages. If a fabricated or welded jig or fixture gets
dropped, it will get distorted. The defect will remain unnoticed until the device is used again
when it produces defective piece. A cast construction will break rather than bend. For ease
and quickness of manufacture, the order is : a) Welded b) Fabricated c) Cast

The welded construction must be “stress relieved” by heat treatment, to relieve all internal
stresses induced during welding. Otherwise, the stresses will gradually distort the jug or
fixture, as they relieve themselves. Only after stress relief, can finish machining be done on
the construction, if accuracy is to be held. And, since machining must be done after assembly,
it is sometimes difficult to machine an internal surface of a welded construction.

In a fabricated construction, all the component parts can be completely machined before
assembly.

This is often an important enough advantage to offset the lesser cost of the welded
construction. Often a combination of the two methods is successfully used. In the fabrication
method, the construction is held together by screws and dowels. The screws serve only to
hold the parts together with the dowels assuring accurate alignment. Two dowels are sufficient
in any case, whereas the screws can be one or more as needed. A fabricated construction is
easy to repair, because disassembly is comparatively easy. To facilitate disassembly and
assembly, each dowel should be a press fit in one part and slip fit in the other.

Casting construction is sometimes used of the main body (especially for a jig) and other
pieces are welded or assembled to it with screws and dowels.