Lab Session: 01

Objective:
Study of Jigs and Fixtures.

Theory:

Production Devices:
Production devices generally work holders with/without tool guiding/seating arrangement. These
are called jigs and fixtures. Jigs and fixtures are special purpose tools used for large-scale
production. The production of components with the help of jigs and fixtures is based on the concept
of interchangeability, where components are produced within established tolerances.
 Jigs are provided with tool guiding elements such as drill bushes. These direct the tool to
the correct position on the workpiece. Jigs are rarely clamped on the machine table because
it is necessary to move the jig on the table to align the various bushings in the jig with the
machine spindle.
 Fixtures hold the workpiece securely in the correct position with respect to the
machine/cutter during operation. There are sometimes a provision of the fixture for
‘setting’ the tool with respect to the workpiece/fixture, but the tool is not guided as in a jig.
Fixtures are often clamped to the machine table.

The main difference between jigs and fixtures is jig is a guiding device for the tool and also
designed in such a way that the workpiece can be quickly inserted and removed before and after
operation fixture is a device used for holding the workpiece during the operations. It does not
contain any special arrangement for guiding the cutting tools as in the case of jigs. Its name is
derived from the fact that it is always fastened to the machine in a fixed position. Fixtures are used
whenever operations like milling, shaping and planning need to be performed with the help of a
clamping device.

1. 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 parts of the machine fit properly in assembly, and all
similar components are interchangeable.
 Skill Reduction - 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 of the tool. Any average person can
 be trained to use jigs and fixtures the replacement of a skilled workman with unskilled
labor can affect a substantial saving in labor cost.
 Cost Reduction - Higher production, reduction in scrap, easy assembly and savings in
labor costs result in a substantial reduction in the cost of workpieces produced with jigs
and fixtures.
 Precision and Accuracy – Assures the accuracy of components

2. Elements of Jigs and Fixtures:

1. Locating Elements - These position the workpiece accurately with respect to the tool
guiding or setting elements in the fixture.
2. Clamping Elements - These hold the workpiece securely in the located position during
operation.
3. Tool guiding and Setting Elements - These guide or set of the tools in the correct position
with respect to the workpiece. Drill bushings guide the drills accurately to the workpiece.
Milling fixtures use setting pieces for correct positioning of milling cutters with respect to
the workpiece.

3. Principles of Jigs and Fixtures Design:

1. The Component Study - Identify the operations sequence, list out the maximum number
of operation to be performed on the machine. Carefully study the type and capacity
machine.

2. Production Requirements - Design the equipment on the basis of actual production

requirements. This leads to a decision for use of manual, semi-automatic or automatic
tooling arrangements.

3. Location - Location points are provided on the jigs and fixture to ensure equal distribution
of the clamping force throughout the whole series of operations. Whenever possible, the
locating and supporting surfaces should be hardened material and wear resistant, since the
cutting tool comes into contact with time and again. Thus the hardened surfaces wear
quickly. The degree of accuracy of the component depends much on its exact location. The
design of jigs and fixtures is such that the movement of components is restricted. The
location should be foolproof so that there is no possibility of placing the component in a
wrong position.

4. Loading - The layout of a jig or fixture must provide adequate hand clearance for loading
and unloading so that all manipulations of the workpiece can be performed easily.

5. Tool, Accessories and Standard Parts - The design of tools, accessories and standard
 parts must be such that the use of standard items is maximized.

6. Rigidity - The design should be robust recommended material should have shock
absorbing and force absorbing capacity.

7. The clearance between Jigs and Fixture - Adequate clearance should be maintained.

8. Swarf Clearance - Share corner must be avoided as scarf has the tendency to accumulate
there.

9. Clamping - Clamp the component directly above the points supporting the work,
otherwise springing action will occur in the work-piece.

10. Ejection of Component - Design consideration requires easy ejection of components

(particularly heavy ones) from jigs and fixture. It saves time and increases productivity.
Pneumatic devices are very suitable for easy and quick ejection of components.

11. Spring Location - The appropriate number of locations for any operation is there I a plane.
The component rests on these points without rocking. Further support if needed, should be
spring loaded, as spring will automatically adjust their positions by raising or falling.

12. Jig Base - Normally jigs and fixture are bolted to machine tables in case this is not so, they
are provided with four feet instead of the flat bottom. This enables easy squaring of the
jigs in case of a chip lying in between the jig base and machine base.

13. Where - An error arises in component due to wear, dirt, chips, and burrs. Insert wear-
resisting materials in areas subjected to wear. Wear-resistant surfaces should be as small
as small as possible and easily replaceable.

14. Bushes - Bushes are provided on jigs for guiding drills, reamers and a boring tool to desired
positions. These are used in a hardening position, which eliminates full hardening of the
plate.

15. Coolant Passage - To increase tool life and keep the component cool, a coolant is provided
to the cutting edges in sufficient quantity. The design of the fixture should be such that the
scarf is washed away to clear off the locating aces. The flow of the cutting fluid should be
automatic.

4. Materials used in Jigs and Fixtures:

Points need to be considered while selecting materials used in jigs and fixtures:
1. Ease of availability of materials
2. The ability of the material to withstand the stresses expected when in service
 3. Ability to retain size and shape over a long period of service
4. Damping capacity
5. Corrosion resistance

Jigs and fixtures are made from a variety of materials, some of which can be hardened to resist
wear. It is sometimes necessary to use nonferrous metals like phosphor bronze to reduce wear of
the mating parts, or nylons or fiber to prevent damage to the workpiece. Given below are the
materials often used in jigs, fixtures, press tools, collets etc.

 High-Speed Steels (HSS) - These contain 18% (or 22%) tungsten for toughness and
cutting strength, 4-3% chromium for better hardenability and wear resistance and 1%
vanadium for retention of hardness at high temperature (red hardness) and impact
resistance. HSS can be air or oil hardened to RC 64-65 and are suitable for cutting tools
such as drills, reamers, and cutters.
 Die Steels - These are also called high carbon (1.5—2.3%) high chromium (12%) (HCHC)
cold working steels and are used for cutting press tools and thread forming rolls. Hot die
steels with lesser carbon (0.35%) and chromium (5%) but alloyed with molybdenum (1%)
and vanadium (0.3-1%) for retention of hardness at high temperature are used for high-
temperature work like forging, casting and extrusion.
 Carbon Steels - These contain 0.85-1.18% carbon and can be oil hardened to RC62-63.
These can be used as tools for cutting softer materials like woodwork, agriculture, etc. and
also for hand tools such as files, chisels, and razors. The parts of jigs and fixtures like
bushings and locators, which are subjected to heavy wear can also be made from carbon
steels and hardened.
 Collet Steels (Spring Steels) - These contain about 1% carbon and 0.5% Manganese.
Spring steels are usually tempered to RC 47 hardness.

5. Drill Jigs:

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 metal filings removal and cleaning.
 Lightweight to minimize operator fatigue, due to repeated handling.
 Prevention of loss of loose parts by chaining them to the jig body.
6. Types of Jigs

Following are some of the commonly used jigs in the production.

 Plate Jigs and Channel Jigs with workpiece pots

Figure 1: Plate Jig

Figure 2: Channel Jig

 Angle plate Jigs

 Turn-over Jigs
 Leaf or Latch Jigs
  Box Jigs

Figure 3: Box Jig

 Trunnion-type Indexing Jigs

 Sandwich and Pump Jigs
 Local Jigs
 Pot Jigs

7. Types of Fixtures:

Following are some of the commonly used fixtures in the production.

 Plane Milling Fixture

Figure 4: Component
 Figure 5: Plane Milling Fixture

 Turning Fixture
 Broaching Fixture
 Grinding Fixture
 Planning Fixture
 Shaping Fixture
 Welding Fixture

8. To Do Assignment:

Select any of the three jigs and fixtures given in the above types and complete the lab report for
each jig and fixture selected as per the study questions given below. Format for one jig is given
below.
Angle Plate Jig
Discuss the following points related to angle plate jig.

a. What is angle plate jig? What types of workpieces does it accommodates?

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b. List down the main components of angle plate jig.

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c. Write down some merits, demerits, applications and limitations of angle plate jig.

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d. Describe angle plate jig in any real application scenario (attach a picture in which operation
is performing on the jig)

e. Manually sketch the angle plate jig.