UNIT 5

JIGS AND FIXTURES

INTRODUCTION
Jigs and fixtures have become such a necessary part of
mode rn manufacturing that an understanding of the
principles involved, as well as examples of those which
have proved successful, is a necessity in every shop.
A jig or fixture is any device that guides drills or other
tools so as to produce work that is interchangeable
within the tolerances set by manufacturing requirements.
A jig is a work-holding device which is not fastened to
the machine tool on which it is used. A fixture is also a
work-holding device but one that is bolted or otherwise
fastened to the machine.

Contd.
Often the terms "jig" and "fixture" are confused or used
interchangeably; however, there are clear distinctions
between these two tools. Although many people have
their own definitions for a jig or fixture, there is one
universal distinction between the two.

Both jigs and fixtures hold, support, and locate the

workpiece. A jig, however, guides the cutting tool. A
fixture references the cutting tool. The differentiation
between these types of workholders is in their relation to
the cutting tool.

A jig guides the cutting tool,

In this case with a bushing.

A fixture references the cutting tool,

in this case with a set block.

JIGS
The most-common jigs are drill and boring jigs..

These tools are fundamentally the same. The difference lies

in the size, type, and placement of the drill bushings.
Boring jigs usually have larger bushings. These bushings
may also have internal oil grooves to keep the boring bar
lubricated.
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.

CONTD
The two common forms of jigs are open and closed.(On the
basis of basic construction)
Open jigs carry out operations on only one, or sometimes two,
sides of a work piece.
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.

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.

Types of Workholders (Jigs and Fixtures)

Permanent and Temporary Workholders
Permanent Jigs and Fixtures
General-Purpose Workholders
Modular Fixtures

Modular workholders combine ideas

and elements of both permanent and
temporary workholding to make
inexpensive-yet-durable workholders.

A permanent workholder
used for a drilling operation.

Advantages of Jigs and Fixtures

Productivity: Jigs and fixtures eliminate individual marking,
positioning and frequent checking. This reduces operation time
and increases productivity.

Interchangeability: Jigs and fixtures facilitate uniform quality in

manufacture. There is no need for selective assembly. Any part of
the machine would fit properly in assembly, and all similar
components are interchangeable.

CONTD
Skill Reducing: Jigs and fixtures simplify locating and
clamping of the workpieces. Tool guiding elements
ensure correct positioning of the tools with respect to the
workpieces. There is no need for skillful setting of the
workpiece or tool.
Cost reduction: Higher production, reduction in scrap,
easy assembly and savings in labor costs result in
substantial reduction in the cost of workpieces produced
with jigs and fixtures.

Applications for Jigs and Fixtures

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

INTERNAL-MACHINING APPLICATIONS:
Cylindrical- and Irregular-Hole Machining
Drill jigs

Boring jigs
Electrical-discharge-machining fixtures
Punching fixtures

Internal-broaching fixtures

MATERIALS USED IN JIGS AND FIXTURES

High Speed Steels (HSS)

Die Steels
Carbon steels
Collet Steels (Spring Steels)
Oil Hardening Non-Shrinking Tool Steels (OHNS)Case
Hardening Steels
High Tensile Steels

Locating Principles
Basic Principles of Locating:

To perform properly, workholders must accurately and

consistently position the workpiece relative to the cutting tool,
part after part. To accomplish this, the locators must ensure
that the workpiece is properly referenced and the process is
repeatable.

CONTD
Referencing and Repeatability:

Referencing" is a dual process of positioning the

workpiece relative to the workholder, and the
workholder relative to the cutting tool.
"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.

Forms of Location
There are three general forms of location: plane, concentric,
and radial.

Plane locators locate a workpiece from any surface. The

surface may be flat, curved, or have an irregular contour. In
most applications, plane-locating devices locate a part by its
external surfaces
Concentric locators, for the most part, locate a workpiece
from a central axis. This axis may or may not be in the center
of the workpiece. The most-common type of concentric
location is a locating pin placed in a hole.
The third type of location is radial. Radial locators restrict the
movement of a workpiece around a concentric locator

ANALYSING MACHINING FORCES

The most-important factors to consider in fixture layout are the
direction and magnitude of machining forces exerted during
the operation.

Cutting force (lbs)=

Cutting forces in a milling operation

should be directed into the solid jaw
and base of the vise.

LOCATING GUIDELINES
The following are a few guidelines to observe in choosing and
applying locators:

Positioning Locators: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.
Controlling Chips:
Chips are an inevitable part of any machining operation and
must be controlled so they do not interfere with locating the
workpiece in the work holder. Several methods help minimize
the chip problem.

Few more guidelines are:

Preventing Improper Loading
Using Spring-Loaded Locators
Determining Locator Size and Tolerances

Locator sizes are always

based on the maximummaterial condition of the
workpiece features.

Spring-loaded locators help ensure the

correct location by pushing the
workpiece against the fixed locators

LOCATING METHODS
A workpiece can be located from:
Plane Surface

Adjustable support for

rectangular workpieces

Adjustable
locators

Location from Profile

Sighting location

Profile location by pins

Location nests.

Location from Cylinder

Locators subjected to
axial pull.

Prevention of jamming

CLAMPING
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 clamping.
Factors in Selecting Clamps:
Holding the Workpiece Against Locators
Holding Securely Under Vibration, Loading, and Stress
Preventing Damage to the Workpiece
Improving Load/Unload Speed

Selecting Clamp Size and Force

Approximate clamping forces of

different-size manual clamp straps with
a 2-to-1 clamping-force ratio.

DRILL JIGS AND JIG BUSHES

The following are the requirements of a good drill jig:
Quick and accurate location of the workpiece
Easy loading and unloading of the workpiece and prevention
of wrong loading.
Prevention of bending or movement of the workpiece during
drilling.
Ample chip clearance with facilities for swarf removal and
cleaning.
Light weight to minimize operator fatigue due to repeated
handling.

Drill Bushes
Drill jig are bushes to guide drills, reamers and other
cutting tools to the workpiece. Bushes are made of
water hardening carbon steel with 0.85-1%carbon
and 0.5-0.9% manganese, and is hardened to RC
60-64 to minimize wear due to contact with hard,
rotating tools.

TYPES OF DRILL BUSHES ARE:

Press Fit Bushes:


Renewable Bushes:

Slip Bushes:

VARIOUS TYPES OF DRILL JIGS

Depending upon their construction and method of operation,
drill jigs can be broadly classified as follows:
Plate jigs and channel jigs with workpiece pots
Angle plate jigs
Turn-over jigs
Leaf or latch jigs
Box jigs
Turnnion-type indexing jigs
Sandwich and pump jigs

Plate drill jig

angle plate jig