DEPARTMENT OF MECHANICAL ENGINEERING

ME 2029 DESIGN OF JIGS, FIXTURES & PRESS TOOLS

TWO MARKS QUESTION
WITH ANSWER
UNIT II
1. Which is the main element of a jig?
Jig body.

2. Where are jig feets provided?

The jig feets are provided at the bottom of the jig .
3. What is the function of jig bushes? [Anna Univ.Apr'04]
Drill bushes are used to guide drills, reamers and other cutting tools into the proper position on the workpiece.
4. State the purpose of a jig plate.
A jig plate carries the drill bush for guiding the tools.
5. Why locators are necessary in jigs?
Locators are used to rest the workpiece in proper position of the jig.
6. State the use of clamps.
Clamps are used to hold the workpiece firmly against all disturbing forces occurred by machining operations.
7. What are the materials generally used for making drill busltes?
1. Tool steel 2. Water hardening carbon steel
8. When willpress fit bushes or fixed bushes be used?
These types of bushings are used when little importance is put on the accuracy or finish.
9. What are the two types of press fit bushes?
1. Plain or headless bushes 2. Flanged or headed bushes
10. Specify the condition of using plain and flanged bushes in jigs .
Plain bushes:
These are mainly used when the free surface is required on the. Top face of the jig plate.
Flanged bushes:
It is employed when the jig plate into which it is installed in thin.
11. State the purpose of providing liner in renewable hushes.
Liner is used to provide hardened wear resistance on mating Surfaces.

12. How tile rotation and movement of bush can be prevented?

By providing set screws, the bushes are retained with the jig plate.
13. When slip bushes are used?
Slip bushes are mainly used when a hole in the workpiece requires two operations. Example: Performing both
drilling and reaming in a same jig plate.
14. Why threaded bushes are used in jig plates?
Threaded or screwed bushes are used to hold the bush in place as well as to make the bush adjustable.
15. Liner bushes are known as ?
Master bushes
16. How liner bushes are used?
Liner bushes are always used in conjunction with a renewable or slip bushes.
17. Tell the other name of special hushes.
Non-standard bushes
18. What are the different types of jigs?
1. Plate jigs 2. Latch or leaf jigs 3. Channel jigs 4. Box jigs
5. Angle plate jig 6. Turnover jig 7. Pot jig
19. Define sandwich jig. [Anna Univ.Apr'05]
These jigs are a form of plate jig with a back plate. This type of jig is ideal for thin or soft parts that could bend
or wrap in another style of jig. Here again, the use of bushing is determined by the number of parts to be made.
20. State the provision made on latch or leaf jig?
Leaf plate is capable of swinging about a fulcrum point so that it can open or close the load or unload the
workpiece.
21. What is the disadvantage of leaf jigs?
1. Clips may accumulate inside and cause trouble unless provisions are made for them.
2. Drill bushings are fitted in the leaf, play in pivoted and may affect drilling accuracy.
22. State the materials used for fabricating channel jigs.
1. Cast Iron 2. Mild steel plates.

23. When will box jigs be used?

When holes are to be drilled in more than one faces of the workpiece, box jigs are used.
24. Distinguish between a plot jig and a box jig. [Anna Univ.Nov'08]
In channel jigs, holes are drilled only in face but holes can be drilled on more than face using box jigs.
25. Distinguish between a pot jig and a box jig. [Anna Univ.May'07]
In a pot jig, holes are drilled in hollow cylindrical components having flanges with relatively smaller outside
and inside diameters but holes can be drilled on more than face using box jigs.
26. What are the operations that can be performed using post jigs?
l. Drilling 2. Reaming
27. Sketch the channel jig. [Anna Univ. Nov'04 & Apr'06]

28. State the

provision
made on angular post jig to drill run and removal of the workpiece.
The drill bushes are extended and shaped.
29. What is the main advantage of turnover jig?
Workpiece having no suitable resting surface can be drilled conveniently with turnover jigs.
30. What are the two important parts of pot jigs?
1. Pot or bottom part 2. Bush or jig plate

31. When will solidjigs be more suitable?

It is a very simple form of jig used for drilling holes in articles of simpler shapes and relatively smaller sizes.
32. At what condition, the trunnion jigs are used?
When a large, heavy workpiece are to be drilled from a number of sides so that the faces requiring drilling
operations can be easily turned and positioned.
33. What are the advantages of trunnion jig? [Anna Univ. Nov'04]
(i) The workpiece is located and clamped to the carrier which also carries the drill plates.
(ii) The carrier is mounted on trunnion so that it can be rotated from face to face.
(iii) It can be positioned and locked using an indexing device.
34. Define indexing device. . [Anna Univ. Apr'05]
Device used for dividing the rotation of the circular workpiece into equal number of portions is known as
indexing device.
35. What is the use of indexing jig?
Indexing jigs are used to drill series of holes in a circle on the face of a workpiece.
36. How can we identify universal jigs?
Universal jigs are those having either adjustable or adaptable with more than one drilling jobs.
37. How do automatic drill jigs differ from other jigs?
All the functions of jigs are performed automatically without any manual adjustment.

38. Illustrate the working of an automatic drill Jig. [Anna Univ. Nov'08]
Automation may be full or partial. In fully automated jigs, all the functions of jigs are performed automatically.
The function of operator is limited only to the loading of workpiece and control the performance of jigs and
machine tools. In partially automatic jigs or semi-automatic jigs, some of the steps or processes are automated.
These processes or steps include loading and unloading of workpiece by various methods; clamping and
unclamping of workpiece; removal or push-out of workpiece from the work zone.
39. What are the various possibilities to operate automatic drill jigs?
 1. Mechanical 2. Pneumatic or air operated
3. Hydraulic operated 4. Pneumo-hydraulic
40. What is the use of fixtures?
Fixtures are used to hold the workpiece during machining operations.
41. When are the fixtures used?
When the components to be produced are in larger number, fixtures are used.
42. What are fixtures?
Some type of tooling used in positioning parts relative to each other for fabricating purposes are commonly
referred to as fixtures.
43. What are the standard work holding devices in lathes?
1. Chucks 2. Collets 3. Face plate 4. Mandrels
44. How can a lathe fixture be clamped to the lathe? [Anna Univ.May'08 & Nov'08]
These fixtures are normally mounted on the nose of the machine spindle or on a faceplate and the workpiece is
held on them.

45. Write the specific requirements of a turning fixture. [Anna Univ.May'07]

1. The fixture should be accurately balanced in order to avoid vibrations while revolving.
2. Clamps and other holding devices should be designed in such a way that they will not be loosened by
centrifugal force.
3. There should be no projections of the fixture which may cause injury to the operator.
4. The fixture should be light in weight as far as possible, since . It IS rotating,

46. How are face plate turning fixtures located?

Face plate turning fixtures are located on the face plate by means of two dowel pins and secured by T-bolts
inserted into T-slots in the face plate.
47. What is the function of mandrels in turning fixture? [Anna Univ. Apr'05]
It is used to hold the hollow workpiece, mandrels.
48. State the use of built-up turning fixture.
These fixtures are used for boring and facing operations on a bearing housing.
49. Mention the application of turning fixture. [Anna Univ. Nov'04 & Apr'06]
The fixture body is designed to drill a hole in the face of a cubical shaped workpiece.
50. The table is relative to the cutters with the aid of the in a milling
machine mounted with milling fixtures.
[Ans: Positioned, Setting block]
51. Why is clearance provided in the milling fixture?
It is provided for the easy disposal of large quantity of swarf.
52. Mention any four essential features made on milling fixtures.
1. Base 2. Tenon strips 3. Setting block 4. Locating elements
53. Note down the purpose of using base on a milling fixture.
The base of a milling fixture should absorb the cutting forces during machining.

54. How can be maximum accuracy produced on work while using tenon strips?
The two tenon should be placed as far apart as possible.
55. What for setting block is used in conjunction with fixture?
It is used to reduce the setting time of the milling cutter with respect to workpiece.
56. List out the various locators used in fixtures.
1. Cylindrical locating pin, 2. Diamond pin locator, 3. Screws and dowels, etc.
57. State the purpose of using in-built clamping element.
The fixture with in-built clamping element has provided for rigidly clamping the workpiece.

58. What are the various types of milling fixtures?

l. Special vice jaws 2. Simple or plain milling fixture 3. Straddle milling fixture
4. String or line milling fixture 5. Gang milling fixture 6. Indexing milling fixture
7. Key-way milling fixture 8. Boring fixture.
59. Name any four essential features of a milling fixture. [Anna Univ. Nov'08]
(i) Base (ii) Setting block
(iii) Locating elements (iv) Tenon strips (v) Clamping element

60. Mention the special provision made on a setting block plain milling fixture.
Setting block has two setting faces-one for 'depth' setting and the other for 'transverse' setting.
61. How does straddle milling fixture differ from plain milling fixture?
The milling fixture in which two sides of a boss is to be milled.
62. How is cutter setting done?
The 'cutting setting' is done by using machined side faces of the casting below the rest pad.

63. What are the factors to be considered while string milling fixture selection?
1. The length depends on size of workpiece. 2. Length of milling machine table.
3. Length of stroke of table.
4. The workpiece should be clamped properly to ensure accurate machining.
64. How machining operations are performed using gang milling fixture ?
More than two cutters are mounted on the arbor and several faces of the workpiece are milled simultaneously in
one feed.
65. What are the factors to be considered while selecting gang milling fixture?
1. The large profiled portion behind the workpiece takes the load of cut.
2. The selection of number of cutter for gang milling is made by considering the positive deflection of the arbor
due to its loading.
3. The arbor must run truly for high quality work. This could be achieved by proper support to the arbor.
4. The cutting forces should not act against the clamp but against a solid mass of metal supporting the
workpiece.
5. Sufficient clearance should be provided for swarf disposal due to large amount of chip collected.
Tools
66. When are indexing fixtures used?
When a number of surfaces to be milled on a periphery of a workpiece are gear teeth, slots, splines in shafts,
etc.
67. What are boring fixtures? How do you classify them? [Anna Univ. Nov'04 & Apr'05May'09]
This fixture which is used for cutting internal key-ways in pulleys, gears, sprockets, etc is known as key way
broaching fixture.

Boring fixtures can be divided into two general classes:

(i) The fixture guides the boring bar as in drill jigs and it is more appropriately called as a boring jig, and
(ii) The fixture holds the work in the proper relation to the bar as in mill fixture.
Boring bars may be classified according to its length as
(i) stub bar, (ii) single-piloted bar, (iii) Double-piloted bar.

68. How is boring operation carried out?

(i) Boring bar is stationary and the workpiece moves into the bar.
(ii) The workpiece is stationary and the bar moves into the workpiece.
69. What are the various machine tools used for boring?
(i) Lathes (ii) Drill presses (iii) Milling machines
(iv) Jig boring machine and (v) Vertical or horizontal boring mills.
70. State the classification of boring bars.
(i) Stub bar (ii) Single-piloted bar (iii) Double-piloted bar
71. What are the different types of broaching operations?
 (i) Keyway broaching (ii) Hole broaching (iii) Gear broaching
72. How are broaching operations classified?
(i) Internal broaching (ii) External broaching
73. Where key-way broaching fixtures are used?
These fixtures are used for cutting internal key-way in pulleys, gears, sprockets, etc.
74. How are external surface broaching fixtures used in machining?
External broaches are used for producing external surfaces, splines, gears and required profiles.
75. State the use of grinding fixtures.
Several different forms of fixtures are used on grinding machines to locate, hold and support the workpiece
during the operations.
76. What are the various type of mandrels used in cylindrical grinding fixture?
(i) Taper mandrel (ii) Straight mandrel (iii) Combined taper and straight mandrel.
77. Where is surface grinding used?
Surface grinding is used widely in manufacturing industries to finish lengths and thicknesses of the workpiece
within precise tolerances.
78. What are the ways the workpiece can be held for machining on a surface grinder?
(i) Workpiece may be clamped directly on the machine table (ii) It may be held in a vice
(iii) It may be held by means of a magnetic chuck or a vacuum chuck
(iv) It may be held in a special fixture
79. What are the various shapes of magnetic chuck available?
(i) Rectangular (ii) Circular (iii) V-block
80. What is the use of vacuum chucking?
The non-magnetic materials made workpiece are very conveniently held by means of vacuum chucking.
95. What are tile important elements of inspection fixtures?
(i) Locating element (ii) Clamping element
(iii) Gauging element (iv) Auxiliary element
96. A mechanical dial gauge acts as an fixture.
[Ans: Inspection]
97. What are welding fixtures? State tile general purpose of a welding fixture: [Anna Univ. May'09]
A welding fixture is used to hold the workpiece in the proper position for fabrication of the workpiece by
welding. The welding fixtures comprise the usual locating and clamping elements used in other fixtures.
98. Mention any two design principles applicable to welding fixture.
(i) Welding spatter should not be allowed to fall on the threaded parts of the clamping elements.
(ii) Welding fixture should not be so designed that it does not get overheated due to continuous work.

99. List out the type of locators and clamping devices used in welding fixture.

Time
Locators Clamping devices
1 Pads Screw clamp

2 Bosses Strap clamp

3 Studs Swinging clamp

4 V-blocks C-clamp

5 Lugs Eccentric clamp

6 Screws, pins Toggle clamp

100. What is the use of tack welding fixture?

Tack welding fixtures are used to locate the components of a weldment in their correct relationship with proper
clamps while a welder tacks them together prior to their final welding.
101. State the purpose of providing central boss in a wing nut welding fixtures.
The central boss is located by a loose female spigot to facilitate expansion due to heat during welding.

102. How can be falling of welding spatter prevented in using angle frame welding fixture?
The base plate of the fixture is milled with grooves below the welding area to provide positive clearance
between workpiece and the base.

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103. List down the modular fixturing systems.
(i) Sub-plate systems (ii) 'T' -slot systems (iii) Dowel-pin systems.
104. What devices are mainly used to assemble modular elements? [Anna Univ.May'08]
Modular fixturing is a work-holding system which uses a series of reusable standard, continents to build a wide
variety of special-purpose work-holding devices. These types of fixtures are assembled with a variety of
standard tooling plates, supports, locating elements, clamping devices and similar units.

105. Write down the advantages of modular fixture.

(i) Modular fixturing offers a wide range of features components that greatly reduce the costs of
building special tooling. Even though its initial cost is high, it can save money and time.
(ii) Load time is reduced considerably with modular fixturing. Savings of 80% or more over
conventional tooling are common.
(iii) Reusability is another advantage of modular fixturing. Once a tool has been built and used, it can
be disassembled and its elements used for other fixtures.
(iv) Versality is also an advantage of modular fixturing. Almost any tool can be built with these sets.
Even multi-part work-holders are quite easy to assemble.
(v) Modular fixturing also serves as excellent alternatives to conventional tooling for very short runs
to work out problems before hard tooling is built.

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REVIEW QUESTIONS
1. Explain briefly main elements of jig and fixture. [Anna Univ. Nov'05]
2. Discuss the advantage of jigs and fixtures. [Anna Univ. May '06]
3. Outline the principles of jigs and fixtures design. [Anna Univ. May '06)
4. What are the main objectives to be considered while designing jig and fixture? [Anna Univ. Nov'05]
5. Explain any four types of drill bushes with sketch. [Anna Univ. Nov'04 & Apr '06)
6. Discuss the various types of drill bushes. [Anna Univ. Apr '05]
7. What is a drill jig? What are the requirements of drill jigs? [Anna Univ. Apr '04]
8. Describe the working of rack and pinion operated drill jig and compare with pneumatic jig.
9. Explain with example of turnover jig. [Anna Univ. Apr'04]
10. Write short notes on adjustable jig and turnover jig. [Anna Univ. Nov'04]
11. Sketch the box jig and turnover jig. [Anna Univ. Apr '05]
12. Explain briefly box jig and turnover jig. [Anna Univ. Nov'05]
13. Sketch and explain any eight parts of a Box jig with suitable diagram. [Anna Univ. Nov'08]
14. Sketch and explain Box jig. [Anna Univ. Apr '08]
15. Explain the working of pneumatic jig with a neat sketch.
16. Write short notes on the following topics:
1. Hydraulic operated jigs, and 2. Pneumo-hydraulic jigs.
17. Sketch and explain air operated drilling jig components. [Anna Univ. May'09]
18. What are the design factors to be considered while designing a lathe fixture?
19. Illustrate the working of a lathe fixture. [Anna Univ. Nov'08]
20. Briefly explain the construction and working of faceplate turning fixture.
21. Explain anyone type of lathe mandrel. [Anna Univ. Apr '04]

22. Write a short note on built-up turning fixture.

23. What are factors to be considered while designing milling fixture? [Anna Univ. Nov'04]
24. Explain in detail the construction and working of milling fixtures.
25. List out the various types of milling fixtures and explain any two in detail.
26. Differentiate straddle milling fixture and key-way milling fixture.
27. Illustrate the working of gang milling fixture. [Anna Univ. Nov'08]
6. Explain the working of milling fixture with example used in practice. [Anna Univ. Apr '08]
28. Define the tennon and setting block in milling fixture.- [Anna Univ. Apr'04)
29: Explain with a neat sketch the working of a gang milling fixture and compare with straddle milling fixture.
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30. Describe the working of indexing milling fixture.
31. (100 x 20 x 4) Welding must be done on front and rear side of the plates. [Anna Univ. Apr '08]
32. Briefly explain each type of boring bars with neat sketches.
33. Briefly explain welding fixture. [Anna Univ. Apr '04, Apr '05 & May '07]
34. Classify assembly fixtures and explain anyone in detail.
35. Define broaching and explain the types of broaching fixtures with neat sketches.
36. What are the precautions should be taken while designing external broaching fixture?
[Anna Univ. Apr '04]
37. Describe the construction and working of planning and shaping fixtures with neat sketches.
38. Design a suitable milling fixture to cut a keyway of size 3x3 mm on a solid shaft of 30 mm diameter and
100 mm length. [Anna Univ. Nov'07]
39. 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 plate. [Anna Univ. Apr'08]
40. List out the types of welding fixtures and explain any two in detail.
41. What are the design principles applicable only to the welding fixtures?
42. Write short notes on inspection and welding fixtures. [Anna Univ. Nov'08]
43. Explain briefly welding fixture and grinding fixture. [Anna Univ. Nov'05 & May '06]
44. Explain the components of inspection fixtures.
45. Explain briefly universal jig and plastic jig. [Anna Univ. Nov'05]

46. Explain the important accessories of jig and fixture. [Anna Univ. Nov'05]
47. Explain various inspection devices. [Anna Univ. Apr '06]
48. List any four types of jigs and fixture construction? State the advantages of each and discuss the relative
merits of each. [Anna Univ. Nov'08]
49. List out the types of grinding fixtures and explain each. considered while designing
[Anna Univ. May '07]
50. What are the factors to be grinding fixture.
51. With proper sketch explain the operation of a modular fixture with example used in practice.
[Anna Univ. Nov'07]
52. 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. [Anna Univ. May '09]

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53. Design a drill jig makes a hole of diameter 10mm shown in Figure 2.150 and also mentions the part list.
[Anna Univ. Apr '05]

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 54. Design a drill jig to make hole of 10 mm, as shown Figure 2.151 and also mention the part list.
[Anna Univ. Nov'05]

55. Design a drill jig to make hole of 10 mm, as shown Figure 2.152 and also mention the part list. [Anna Univ.

Nov'05]

56. Design a drill jig to make hole of 10mm, as shown in Figure 2.153 and also mention the part list.

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[Anna Univ. Apr '06]

57. Design a drill jig makes a hole of 10mm, as shown in Figure 2.154 and also mentions the part list.
[Anna Univ. Apr '06]

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58. Design a simple solid-type for use when drilling the four 12mm diameter hole in the stem of the pin shown
in Figure 2.155. The pin is complete except for this hole.

59. Design a drill jig for use when drilling the four 6mm diameter holes in the square flange of the Elbow
shown in Figure 2.156. The face of the square flange has been machined prior to this drilling operation.

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60. Design a drill jig for drilling and spot facing the 25mm diameter boss of the connection shown in Figure
2.157. This is done after the flange is drilled.

61. Design a milling fixture to make a slot of 20mm , as show Figure 2.158. [Anna Univ.Nov '04]

62. Design a milling fixture to make a slot of 30 x 10 x

10mm as show in Figure 2.159.
[Anna Univ.Nov '04]

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63. Design a milling fixture for Use when milling the 8mm slot in the base shown in Figure 2.160. This is the
last machining, operation to be done on the base. Details of the milling, machine table are given in the same
Figure.

64. Design a turning fixture, 60mm, component shown in Figure 2.161. face for the given

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65. Design an index milling fixture for use when milling the 6mm
wide slots in the cover shown in Figure 2.162. The cover is complete
except for these slots. One slot is to beproduced right across the

component, the fixture indeed through 90 and the second slot milled right across. The" milling machine table is
shown in Figure 2.162.

66. Design a milling fixture on the following cases for the given component shown in Figure 2.163.
(a) Bosses facing, (b) 8mm wide slot
For the same Figure, design a drill jig for the following cases.
a) 25 and (b) 10.

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67. Design and draw atleast two views of a milling fixture for making a slot of 8 mm wide x 15 mm deep ona
dome pin, as shown in Figure 2.164. Number the parts and prepare part list. [Anna Univ. May '07]

68. Design a milling fixture to make a

slot of 70 x 10 x 10 nun as shown in

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Figure 2.165.
[Anna Univ. Nav'05]

69. Design a milling fixture to make a slot of 70 x 10 x 10 mm as shown in Figure 2.166.

[Anna Univ. Nav'05]

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