Manufacturing Technology MEC205

Jigs and Fixture

Jigs and Fixtures

Jigs and fixtures are the production devices that are used for the accurate production of repeated parts essentially for mass production. Location Clamping Support Resistance to Cutting forces Safety

Fixture
A fixture is a means through which a part is securely fastened to the machine tool table to accurately locate, support and hold the part during the machining operation.

Jig
A jig is a special class of fixture, which in addition to provide all the functions as above, also guides the cutting tool during machining. This is generally used for the operations such as drilling, boring, reaming, tapping, counter boring, etc.

 Jigs are commonly used for making parts that contain holes.

Jigs

Fixtures
Fixtures are widely used in large batch production to ensure the easy setup and achieving the desired accuracy.

Important parameters for Jig and Fixture Design

Functional Surfaces Location Surfaces Support Surfaces Clamping surfaces

Principles of location
Configuration is the major factor in determining how a work piece will be located Configuration of work piece is determined by combination of flat, circular and irregular surface.

Basic reference for location is a flat plane generally a m/c table

Locating from plane surface(3-2-1)

It is necessary to reduce the contact area of locating surface. A minimum of three points (locators) must be used to locate the work piece

Locating from plane surface

The locating points should be placed as far as possible to minimize the effect of inaccuracies in the work piece and locators.

Locating from plane surface

Locating from Circular surface

It is necessary to locate the axis of the circular work piece.

Locating from Circular surface

One commonly used method is referred as conical location and employed when locating is done from the hole.

Locating from Circular surface

V method primarily to locate round work piece with convex circular surfaces.

Locating from Circular surface

Variation in the work size will cause the axis of round work piece to shift

Locating from Circular surface

A method of locating from a circular surface so common that it is often overlooked is the use of Chucks.

Locating from irregular surface

Locating from irregular surface

Locating the remaining two surfaces

Locating from irregular surface

Locating the remaining two surfaces

Locating Methods and Devices

A round pin or Button is used firmly support or hold the work piece in position The Main Difference in the pin and button is length. Buttons are generally shorter than pins and are used for vertical location. Pins are usually used for horizontal location. Larger sizes are some time called plugs.

Pin and Button Locators

Type of pins
- (a) for flat surface - (b) for rough irregular surfaces - (c) for blind holes - (d) Locator pin - (e) support as well as locators - (f) contains dirt groove when installed in jig and fixture

Lock- Screw pins are sometime used where pin is subjected to excessive wear

Diamond pins

Rest Pads and Plates: Used to support and locate work vertically in a manner similar to rest buttons, but they are used with larger and heavier work pieces

Because of the larger bearing surfaces, rest plates are sometimes grooved to reduce bearing area and still provide support rigidity.

Nest or Cavity Location

Locating Methods and Chip Controls

Clamping

The Basic Principles of Clamping

The Work piece must be held rigidly while the cutting tools are in operation. The time required for loading and uploading the tool must be as short as possible. When subjected to vibration, chatter , or heavy pressure, the clamping must be positive; The clamp must not damage the work piece

The Basic Principles of Clamping

Clamping forces should direct towards the nest or locating surfaces. They should be arranged in such a way that the thrust of the cutting tool is away from the clamp Clamping forces should be applied over a heavy part of the workpiece whenever possible. Clamping mechanism should be designed in such a manner that they cannot be applied in any way except the correct one(Fool Proof).

Types of Clamps
Clamps can be classified in seven basic groups
Strap Cam Latch Screw Toggle Wedge Rack and pinion

Types of Clamps
Strap Clamps- The Simplest and probably most commonly used clamp.

A two piece spherical washer is some times used to provide proper seating of the nut ,washer and bar when the workpiece height varies.

Types of Clamps
Strap Clamps- The Simplest and probably most commonly used clamp.

Types of Clamps

Strap Clamps- The Fulcrum of the cam should be located as close as

possible to the work piece in order to obtain maximum mechanical advantage Other types of clamps based on lever principle are toe clamp(dog point clamp)

Screw Clamps
Screw clamps incorporate a screw thread to clamp a work piece. They have the advantage of exerting adequate force besides resisting loosening tendencies set up by vibration. Screw clamps vary from a simple set screw to complicated clamping assembly actuated by a screw clamps

Screw Clamps
Quick acting screw clamp Swing Clamp

Latch Clamps
This type of construction is limited to relatively light work, as it is difficult to secure rigidly.

Wedge Clamps

Toggle Clamps :- Depends upon the movement of rigid links for their
movement. These clamps have been used extensively to hold sheet metal parts in position while they are being welded or otherwise fastened and they provide relatively heavy clamping pressure, are quick acting, and give ample clearance for loading and unloading.

CAM Clamps
Properly designed cam clamp provide an effective and rapid means of clamping but they are not a positive clamping method and may loosen under vibrating forces The two main types of cam clamps are eccentric and spiral. An eccentric clamp is easier to make but does not lock as well as spiral cam

CAM Clamps
Various cam clamps

 Rack and pinion clamp Hydraulic and pneumatic clamping- Many of the previously mentioned clamps may be actuated by hydraulic or pneumatic methods. The advantage are faster clamping, uniform and equalized clamping pressures, and less operator fatigue. Pneumatically operated clamps differ from hydraulically operated ones in size of the cylinder, which is smaller with hydraulics because of the higher pressures.

Hydraulic and pneumatic clamps

Hydraulic and pneumatic clamps

Hydraulic and pneumatic clamps

Hydraulic and pneumatic clamps

Types of Jigs
Template jigs Plate jigs Universal jigs Leaf jigs Channel and tumble jigs Indexing jigs

Template jigs
No clamping arrangement Plates with bushing to guide the tool Directly placed on the part Simple Least expensive

Template jigs
Disadvantages Not as foolproof as other types Orientation of the hole pattern to workpiece datums may not be as accurate as other types They are usually not practical when locating datums are dimensioned

Plate jigs
The plate jig is so named because a plate containing bushings forms the main structural member. It is of open construction , sometimes called open jig Slip bushings may be used with liner bushings to allow operations other than drilling. The disadvantage of plate jigs are that only one surface can be drilled at one loading and drilling forces are generally directed towards clamping device It is therefore necessary that clamping device be rigid enough to withstand drilling forces

Universal jigs
Also called as Pump jigs Universal that can be used for any given part by adding the necessary locators and bushes The moving parts are completely protected from chips.

Leaf jigs
Hinged leaf with bushes which also applies the clamping force Leaf jigs can be loaded unloaded quickly and are suitable for complicated workpiece with irregular contours. The disadvantage of leaf jigs is that chips may accumulate inside and cause trouble unless provision is made for them. Play in the leaf may affect accuracy When bushings are loacted in the hinge plate , the hole pattern is foxed. The only chance of error is in the location of hole relative to the part outline.

Channel and tumble jigs(BOX)

This type recieves its name from the sahpe which , in general, resembles a box. For drilling in more than one surface(Tumble Jig) Some time box jigs are constructed in a channel shaped trough and clamped by means of screw. This type is limited to jobs having workpieces of simple symmetrical shape(Channel Jig)

Indexing jigs
To drill holes in a pattern Indexing arrangement

Jig Design Guidelines

Drill Jigs should be of light construction, consistent with rigidity to facilitate handling, especially when jigs have to be turned over so that holes can be drilled from more than one side. All unnecessary metal should be cored out of the jig body. If possible, eliminate spanners by the use of levers. Consideration should be given at the design stage to the use of standardised jig components.

Jig Design Guidelines

A jig which is not bolted to the machine table should be provided with feet, preferably four, opposite all surfaces containing guide bushings, so that it will 'rock' if not standing square on the table and so warn the operator. Clearance holes or burr slots should be provided in the jig to allow for the burr formed when the drill breaks through the Make all component clamping devices as quick acting as possible.

Jig Design Guidelines

Design the jig fool-proof by the use of foul pins and similar devices, that is arrange it so that the component, tools or bushes cannot be inserted except in the correct way. Make some locating points adjustable when the component is a rough casting and may be out of alignment Locate clamps so that they will be in the best position to resist the pressure of the cutting tool when at work. If possible, make all clamps integral parts of the jig and avoid the use of loose parts. Avoid complicated clamping and locating arrangements which are liable to wear or need constant attention. All sharp edges should be removed from the various detail parts of the jig.

 Provide handles or other devices wherever these will make the handling of the jig more convenient. Make, if possible, all locating points visible to the operator when placing the component in position in the jig so that the component can be seen to be correctly located. The operator should also be able to have an unobstructed view of the clamps. Springs should be used whenever possible to elevate the clamps clear of the component whilst being loaded or unloaded. Locating and supporting surfaces should, whenever possible, be renewable. Such surfaces should be of hard material.

Basic Design Steps

1. Method of locating the part identify the standard components required for locating purpose. 2. Design the clamping method. Make a proper choice of clamps C-washer, swing washer, nut, strap clamp, toggle clamp, etc. 3. Design any supports required 4. Design the jig bushes required. 5. Design the jig body.

Design Study Drill Jig

1. Method of locating the part The central hole which helps in locating as well as indexing for the hole. 2. Clamping can be done with a nut and a Cwasher 3. Indexing will have to be done with a plunger type retracting.