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DIFFERENT TYPES OF JIGS

AND FIXTURES
INTRODUCTION
 Jig and Fixture are production work holding
devices used to manufacture duplicate parts
accurately.
 They are special purpose tools used for large
scale production by semi skilled operator.
 They can also be used for small scale
production when interchangeability is important
by skilled machinist when the workpiece is
difficult to hold without special equipment.
INTRODUCTION
They are used in industry:
 To reduce cost of production
 To increase productivity
 To assure accuracy of component
 For mass production of component on its
repeatability basis
 For fully or partial automation of work
 To increase the versatility of the machine tool
 improve quality with greater machining accuracy
INTRODUCTION
 Jigs and fixtures are so closely related that the
terms are sometimes confused or used
interchangeably.
 The difference is in the way the tool is guided to
the work piece.
 Fixture locates, holds and supports the work
securely so the required machining operation
can be performed
 Jig not only locates and supports the workpiece
but also guides the cutting tool
INTRODUCTION
• The main construction difference between a jig
and a fixture is mass

• Because of the increased tool forces , fixtures


are built stronger and heavier than a jig would
be for the same part

• They are made basically the same way as far


as locators and positioners are concerned
INTRODUCTION
• The term jig should be used only for devices
employed while drilling, reaming or tapping holes
• It is not fastened to the machined on which it is
used
• So it may be moved around on the table of the
drilling machine to bring each bushing under the
drill
• It is not fastened to the drill press table for small
w.p, however holes above 0.25 inch in diameter are
to be drilled, it is usually necessary to fasten the jig
to the table securely.
INTRODUCTION
• Jigs make it possible to drill, ream and tap
holes at much greater speeds and with
greater accuracy
• Skilled workers are not required
• Responsibility for the accuracy of hole
location is taken from the operator and given
to the jig
• Jigs physically limit and control the path of
the cutting tool with the help of bushings
INTRODUCTION
• For machining operations like milling,
shaping, turning, broaching, etc., the term
fixture should be used
• A fixture hold and locates the work during
machining but does not contain special
arrangements for guiding the cutting tools
• A fixture is also fixed to the machine
• The accuracy of machining depends upon
the operator and construction of machine tool
TYPES OF DRILL JIGS
• Open Jigs:
Used for simple operations
Work is done only on one side of the part

• Closed or Box Jigs:


Used for parts that must be machined on
more than one side
Operations Common to a Drill Jig
TEMPLATE JIGS
 It is the form of jig consisting of a suitable material having
holes for correct location
 The plate serve as a template which is fixed on the
component to be drilled
 Template jigs are normally used for accuracy rather than
speed.
 Used for locating hole pattern on large workpieces
 Usually not clamped (self-clamping)
 It is the least expensive
 Simplest type of jigs
TEMPLATE JIGS
PLATE JIGS
 It is the modified form of the template jig
with jig bushes incorporated on the temple
 Consist of a single bush plate with a
provision for locating and clamping of w.p.
 They have built-in clamps to hold the work
 They use a flat plate containing bushing as
their main structural member
 All the details are attached and referenced
to this plate
 May or may not have legs
PLATE JIGS
• Easy part loading and unloading, chip removal by
providing clearance b/w plate and the w.p.
• Also called open jig
• Slip bushings for operations other than drilling
• Thin parts stacked for drilling several parts at one time
• These jigs are sometimes made with legs to raise the jig
off the table for large work.
• This style is called a table jig
• The feet provide square resting surface to the jig.
• The diameter of the jig feet should be bigger than the
slot of machining table to prevent the feet from falling
into the slots.
PLATE JIG
SANDWICH JIGS
 A form of plate jig with a back plate
 The w.p is clamped like a sandwich b/w
the base plate and the jig plate.
 This type of jig is ideal for thin or soft parts
that could bend or wrap in another style of
jig.
 Here, the use of bushings is determined
by the number of parts to be made and
diameter of the hole.
SANDWICH JIG
ANGLE-PLATE JIGS
• Used to machine parts at right angles to
their locators
• Pulleys and Gears use this type of jig
MODIFIED ANGLE-PLATE JIG
 which is used for machining angles
other than 90 degrees.
 Both of these examples have clearance
problems with the cutting tool.
MODIFIED ANGLE-PLATE JIG
MODIFIED ANGLE-PLATE JIG
BOX JIGS
• Surround the part totally
• Shape resembles a box
• In the figure, for loading, the cam rod is taken
out of the jig and the w.p placed in position
inside the jig
• The cam rod is then replaced and rotated to its
locking position
• This holds the work-piece firmly so that the
drilling operation can be performed
• Such jigs are generally used for components
having irregular shapes or that cannot be held
by common methods.
BOX JIGS
• Number of holes can be drilled
economically with box jig.
• One side is open for loading and
unloading the w.p and provided bushing
arrangements.
• The box jig can permits drilling of holes in
three sides of the work-piece and saves
times and increase production.
BOX JIG
CHANNEL JIGS
• The work-piece is mounted against the top and
one side of the jig
• It is clamped from the third side
• It’s a type of box jig
• Provides better stability and support for work-
piece
• This type is limited to work-pieces of simple
symmetrical shapes
• It mainly consist of the jig body, jig bush and
screws and w.p is clamped inside the channel
with the help of screw.
CHANNEL JIGS
V-BLOCK JIGS
• Used to drilling radial holes in cylindrical or
spherical workpiece.
• It mainly consist of the V-block clamping plate.
• The component is placed on the V-block and
clamped rigidly by means of a clamping plate
and bolt.
V-BLOCK JIGS
• These jigs may also be called diameter
jigs by some toolmakers.
GENERAL CONSIDERATIONS IN
THE DESIGN OF DRILL JIGS
Rigidity:
• Jig must be strong enough to withstand all forces
applied to it
• It must also resist deflections that may be the result
of excessive tightening of clamps that hold the w.p
in place
• The work must also be supported so that it does
not bend under drilling pressure
• Cast iron is generally used because it absorb
shocks and compressive forces.
GENERAL CONSIDERATIONS IN
THE DESIGN OF DRILL JIGS
 The layout of the jig must provide adequate
hand clearance for easily loading and unloading
and process for loading and unloading must be
quick
 Errors arise in components due to wear, dirt,
chips burns should be minimum
 Bushes are provided on a jig for guiding drills,
reamers and borings, for the desired positioning
GENERAL CONSIDERATIONS IN
THE DESIGN OF DRILL JIGS
 Entry provision of coolant: to increase tool life
and keep the components cool, a coolant is
provided in cutting edge in sufficient quantity.
 Design considerations require easy ejection of
the component from jig (particularly for heavy
ones) to save the operation time and increase
the productivity, pneumatic devices are very
suitable for easy and quick ejection.
GENERAL CONSIDERATIONS IN
THE DESIGN OF DRILL JIGS
Chip Control:
• Types of chips: segmental and continuous
• The segmental chip is preferred
• Space between the work and bottom of drill
bushings to allow chips to pass b/w the work
and busing plate (1- 1.5 times dia. of drill)
• Three ways of chip removal: coolant,
manually with brush or hook, compressed air
Chip Control:
GENERAL CONSIDERATIONS IN
THE DESIGN OF DRILL JIGS
Jig feet and legs:
• A drill jig should stand on four feet (Or legs)
rather than a flat surface
• Jig feet may be built into the jig body or purchased as
standard parts
• They are usually placed on the extremities of the jig
• Feet should be ground so that they are all in one
plane after they are mounted on the jig base
• When jig is bolted to machine table, usually provides
with four feet instead of a flat bottom, squaring
provides easily chip removal and sustainability.
Types of Standard Jig Feet:
GENERAL CONSIDERATIONS IN
THE DESIGN OF DRILL JIGS
Miscellaneous considerations:
• Sharp corners should be eliminated
• Provisions should be made for the coolant to get
to the drill
• Holes or passages for escape of the coolant
• Gripping surfaces should be knurled
• The jig should be large enough to hold it against
the torque of the drilling machine
• It must be easy to handle
METHODS OF CONSTRUCTION
• Generally jigs are constructed by holding the
components together mechanically
• This is referred to as built-up construction
• Adv.: All parts can be completely machined before
assembly and worn parts can be easily replaced
• Minor adjustments can be made during assembly
• Jigs of this type are held together by socket-head
cap screws and dowels
• Screw serve to hold the components together while
the dowels serve to hold the parts in alignment
METHODS OF CONSTRUCTION
• Welded construction is also used in
building a drill jig
• Drill jigs are sometimes constructed by a
combination of welding and mechanical
assembly
• The main body may be of welded
construction with the smaller components
attached by screws and dowels
• The main body of a drill jig may also be
cast
Materials for Jigs and fixtures
Following points for selection:
 Easily available
 Ability to withstand the stress expected in service
 Ability to retain its shape and size
 Corrosion resistance
 Cast iron is generally used as materials for jig and
fixture, light materials like brass, bronze, steels,
plastic can also be used.
 The choice of the proper material can also be
selected when the operating conditions are known.
FIXTURES
• Used to hold workpiece during machining

• Fixture is always fixed to the m/c table

• Classified by the type of machine on which


they are used
VISE FIXTURES
MILLING MACHINE VISES
VISE FIXTURES
• Sometimes standard m/c vises are adapted
with special jaws

• Special jaws are designed for workpieces


with irregular contours

• Used with various types of m/c tools


SPECIAL VISE JAWS
MILLING FIXTURES
• Used to hold the w.piece in correct relation
to the cutter
• Attached to m/c table with T-slots

PARTS OF MILLING FIXTURE:


(1) Base (2) Clamps (3) Rest Blocks
(4) Locating Points (5) Gaging Surfaces
BASE:
• Consists of base plate with flat & accurate lower
surface
• Various components are mounted on it
• It mates with the surface of milling m/c table
• Used as reference plane
• Has slots to clamp fixture to the table
• It has a keyway running lengthwise in the base for
two keys used to align the fixture on the milling
machine table
BASE:
• The fixture is attached to the milling-
machine table and held in alignment by
two keys attached to the fixture base
• These keys fit very closely into the T slot
of the mill table
• The fixture is held firmly to the table by T
bolts or hold-down clamps
Underside of Mill-fixture Base
Data required before starting the
design of a milling fixture
• The type of milling machine
• Dimensions of T slots
• The center-to-center distance of T slots
• The dimensions of the milling machine table
• The length of table travel in all three feed
movements

The center-to-center distance of T slots varies


from machine to machine
If the fixture is to be used on more than one
machine, it may be well to hold the fixture with
strap clamps
Strap Clamp Holding Fixture to
Machine Table
Effect of Cutting Forces on
Workpiece at Beginning of Cut
• Cutting forces exerted by a milling cutter
change as the cutter leaves or enters the
work and throw an extra load on clamps
• Clamps must not loosen by vibration
caused by interrupted cutting of mill cutter
• Interrupted cutting occurs at the beginning
and end of the cut
Effect of Cutting Forces on
Workpiece at Beginning of Cut
(a) Conventional milling: work is lifted up at
beginning of cut
(b) Climb milling: work is forced down at one
end but lifted up at the other
Accuracy of Contact Between
Bearing Surface and Workpiece
• A feeler gage of predetermined thickness
is inserted between the bearing surface
and the workpiece resting upon it
• Bearing surfaces are usually in the form of
pins, pads and plates
TYPES OF MILLING FIXTURES

• Milling Fixtures can be classified in a


variety of ways:
(1) According to the way the workpiece is
clamped, such as hand-clamping fixtures,
power-clamping fixtures, toggle fixtures
etc.
(2) According to the way the workpiece is
located, such as center fixtures, V-block
fixtures etc.
TYPES OF MILLING FIXTURES

(3) According to the method of presenting the


workpiece to the cutter, as rotary fixtures
where the workpiece is rotated under the
cutter. Indexing fixtures where the workpiece
is indexed into the next position during the
machining cycle.
(4) According to the milling operation performed
on work, such as face-milling fixtures, slab-
milling fixtures, slotting fixtures, string-milling
fixtures etc.
MILLING FIXTURES
SPRING TYPE FIXTURE:
MILLING FIXTURES
HYDRAULIC CLAMPING FIXTURE:
MILLING FIXTURES
CLAMP TYPE FIXTURE:
MILLING FIXTURES
VACUUM FIXTURE:
• It’s a suction holding device
• Used where holding without distortion is
vital
• Uses a vacuum pump
• Part acted upon by atm. Pressure
• It exerts a downward force on all sides
exposed to vacuum
VACUUM FIXTURE
GRINDING FIXTURES (Magnetic
chucking devices)
• Workpiece can be quickly mounted &
removed
• Distortion caused by mechanical clamping
eliminated
• Mild steel plates separated by nonferrous
ones
• Magnetic flux passes from magnetic chuck
through steel plates and workpiece
GRINDING FIXTURES
GRINDING FIXTURES (use of
magnetic chuck parallels)
GRINDING FIXTURES (use of
magnetic-chuck V block)
GRINDING FIXTURES
LATHE FIXTURES
Three-jaw Universal Chucks:
• Three-jaw chucks used for circular and
hexagonal work
• Three-jaw chucks are usually self-centering
• Three jaws move simultaneously when adjusted
• This simultaneous movement is caused by a
scroll plate into which all three jaws fit
• They are usually provided with two set of jaws,
one for outside chucking and the other for
inside chucking
THREE-JAW UNIVERSAL
CHUCK
LATHE FIXTURES
Four-jaw Independent Chucks:
• 4-jaw chucks are usually non-self-centering
• Each jaw can be moved independently
• Ideal for gripping round, square, hexagonal and
irregularly shaped workpieces
• The jaws can be reversed to hold work by
inside diameter
• Multi-jaw chucks (6 or 8 jaws) for special
purpose and high standards of accuracy
FOUR-JAW AND SIX-JAW
CHUCKS
LATHE FIXTURES
Magnetic Chuck:
• It has the advantage of holding iron or steel
parts
• The parts that are too thin or that may be
damaged if held in a conventional chuck
• Suitable only for light operations
• A magnetic chuck consists of an accurately
centered permanent magnet face
MAGNETIC CHUCKS
LATHE FIXTURES
Faceplates:
• Circular metal plate fixed to the end of spindle
• Used to hold work that is too large or of such a
shape that it cannot be held in a chuck or
between centers
• It has slots or threaded holes
• W.piece is clamped using T-nuts in the slots or
threaded holes
FACEPLATE AND T-NUTS
FACEPLATES
FACEPLATES
LATHE FIXTURES
Collet Chucks:
• that forms a collar around the object to be held and exerts a strong
clamping force on the object when it is tightened.
• A external collet is a sleeve with a (normally) cylindrical inner
surface and a conical outer surface
• Used for very small parts
LATHE FIXTURES
Collet Chucks:
LATHE FIXTURES
Mandrels:
• Mandrels are internal locators used for machining of the
outside diameter of the workpiece concentric with finished
bores.
• Mandrels are shafts specially made to hold work to be
machined concentrically around a previously bored or drilled
hole
• There are two general types, plain and expanding
• Plain mandrels have a 0.006-in. taper per foot
• There must be a mandrel for each hole size
LATHE FIXTURES
Plain Mandrels:
LATHE FIXTURES
Sleeve-type Expanding Mandrels:
• It is used for high degree of concentricity.
• It provides the adjustment of locating
diameter to suite the variation in the bore
size of the workpiece.
LATHE FIXTURES
Mandrel for Threaded Parts:
• Used for holding previously threaded
workpiece or w.p with internal threads

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