ME6006-Design of

Jigs, Fixtures &

Press tools

UNIT-1
UNIT I LOCATING AND CLAMPING
PRINCIPLES: Objectives of tool designFunction and advantages of Jigs and fixtures
Basic elements principles of location
Locating methods and devices Redundant
Location Principles of clamping Mechanical
actuation pneumatic and hydraulic
actuation Standard parts Drill bushes and
Jig buttons Tolerances and materials used.

Tool Design objectives

Tooling refers to the hardware necessary to
produce a particular components.
Tooling consists of
Cutting devices
Single point cutting tools
Multi point cutting tools
Jigs & Fixtures
Dies
Gauges

Jigs & Fixtures

Production devices are generally work holders
with or without tool guiding arrangement.
Jigs and Fixtures are designed to hold, support
and locate the work piece to ensure that each
part is machined within the specified tolerance.
Use of jigs and fixture is simpler,easier,faster
and more profitable method of manufacturing
different components under mass production.
Jigs and fixtures are designed to save
production time, to maintain dimensional
accuracy, to facilitate quick and
interchangeable assembly.

Elements of Jigs and

Fixtures
Locating elements
Clamping elements
Tool guiding and setting elements.

Jigs
It is work holding device that holds,
supports and locates the wokpiece
and guides the cutting tool for a
specific operation.

BORING JIG

Example for Jig

Fixtures
It is a work holding device that holds,
supports and locates the workpiece
for specific operation but does not
guide the cutting tool.
The fixture should be clamped to the
table of the machine upon which the
work is done.

Example for Fixture

Advantages of Jigs and

Fixtures

Productivity
Interchangeability
Skill Reduction
Cost Reduction

Difference between Jigs and Fixtures

S.N Jigs
o

Fixtures

1.

It holds and positions the

work piece but does not
guide the tool
Fixtures are usually
massive and heavier in
construction
Skilled operator is
necessary

2.

3.

4.
5.

It holds, locates the

workpiece and also
guides the tool
Jigs are smaller in
size and lighter in
construction
Semi skilled
workers can
operate
Fabrication time
and cost are less
Clamping with the
table is often not

Production time and cost

are more
It is bolted rigidly on the
machine table.

Principles of Jigs and

Fixtures
Location

Clamping
Loading
Stability and Rigidity
Clearance for Chips
Fool proof Design
Provision for tool guides
Provision for indexing
Weight
Safety
Coolant supply
Economy

Locating Principles
Location of the component is very
important aspect to influence the
accuracy of the finished product.
The each successive work piece
when loaded and clamped will
occupy the same position in the jig
or fixture.
Work holding device mainly
depends on the nature of work piece
and requirement of the machining

Six point Location Principles

Six point Location Principles

Pin 1,2 and 3

for z-z axis
translation
y-y axis
rotation
x-x axis
rotation
Pin 4 and 5
for y-y axis
translation
z-z axis
rotation
Pin 6

Principle of mutually perpendicular

planes

The "3-2-1" principle can also be put as a work piece may be

fully located by supporting it against three points in one plane,
two points in second plane and one point in a third plane.
These three planes are not parallel and are preferably
perpendicular to one another.
If the locating surfaces are not perpendicular to one another,
the difficulties will arise

 Principle of least point

Principle of Extreme positions
Principle of fool proofing
Redundant Locators

Types of locators

Pin and Button Locators

Cylindrical Locating Pins
Flat Locators
Conical Locators
Adjustable Pin Locators
Fixed V-locator
Adjustable Type V-locator
Bush Locators

Cylindrical Locating Pins

Flat Locators

Locating of work piece

Conical Locators

Adjustable Pin Locators

Fixed V-locator

Adjustable Type V-locator

Bush Locators

Bush Locators

Principles of Clamping
It is used to hold the work piece in the

correct relative position .

The clamping pressures should not be
directed towards the cutting operation.
Whenever possible, it should be directed
parallel to it.
The clamping pressure must only hold the
work piece and should never be great enough
so as to damage, deform or change any
dimensions of the work piece.
The clamping and cutting forces should be
directed towards the locating pins, otherwise
the work piece may get bent or forced away

cont

Clamping should be simple, quick and foolproof.

Complicated clamps lose their effectiveness as they
wear.
The movement of a clamp should be strictly limited and
if possible it should be positively guided.
Wheneverpossible,the lifting of the clamp by hand
should be avoided if it can be done by means of a spring
fitted to it.
The clamps should always be arranged directly above
the points supporting the work, otherwise the distortion
of the work can occur.
Fiber pads should be riveted to the clamp faces,
otherwise soft and fragile work piece can get damaged.
Clamping pressure should be directed towards the
points of support, otherwise work will tend to rise from
its support.

Clamping pressure

Clamping pressure

Position of Clamping

Clamping Devices
Mechanical actuating clamps
Screw clamps
Lever clamp or Strap clamp
Bridge clamp
Heel clamp
Edge clamp

Latch clamps
Hinged clamps
C-clamps
Cam operated clamps
Wedge clamp
Quick acting nut
Toggle clamps
Bayonet clamp
Hook bolt clamp
Equalizing clamp
Hydraulic and Pneumatic clamps

Screw clamp

Screw clamp

Simple , commonly used functions as

like bolt and nut

Bridge clamp

When nut is unscrewed , spring pushes clamp upwards

Sliding bridge clamp

Slot helps to avoid complete removal of nut

Solid heel clamp

A heel is integrated in part of jig or fixture

Loose guided heel clamp

Edge Clamp

Used when horizontal surface only to be machined

Swinging latch clamp

Ease entry and exit of work piece

Hinged clamp

Strap is hinged to enable the work piece to be loaded and unloaded

Cam-operated clamp

Locking is done with help of a hook type cam helps easy operation

Two way hinged clamp

Work piece is initially pushed against locating pins, by tightening nut

locates the work piece to the locators

Free C clamp

Simple quick in operation

Captive C-clamp

clamp is swung away to unload the work piece

Cam actuated plate clamp

Quick acting , provides necessary clamp pressure

Eccentric clamp

Same as strap clamp , hex nut heel pin replaced by cam

Wedge clamp

Wedge type toggle clamp

Horizontal movement cause vertical clamping force

Sliding bridge clamp

Internal parallel threads on either side to a limited length. Adv: plain portion
passes over the stud

C-frame type toggle clamp

Pusher type toggle clamp

Pusher rod is moved horizontally to clamp

Bayonet clamp

Bayonet is first pushed through straight groove to close distance after turning clockwise gets tightened

Hook clamp

Useful for light works

Equalising clamp

Clamp two or more workpieces at a time

Hydraulic clamping

Air to hydraulic booster

Parts of Jigs and Fixture

Base
Buttons
Pins
Handles and knobs
Lifting ring
Stock section
Threaded Fasteners

Base

Buttons

Pins

Handles and knobs

Lifting ring

Threaded Fasteners

Stock section

Drill Bushes

To guide drills, reamers and other cutting tools into the proper position of
work piece
tool steel and hardened, carbon steel 0.85-1%carbon and 0.5-0.9%
manganese
external surface is chamfered for easy entry in the bush plate
Press fit Bushes
Renewable Bushes
Slip Bushes
Linear Bushes

Press fit Bushes

Renewable Bushes

Slip Bushes

Linear Bushes