Introduction to JIGS AND FIXTURES

Introduction
The successful running of any mass production depends upon the interchangeability to facilitate easy assembly and reduction of unit cost. Mass production methods demand a fast and easy method of positioning work for accurate operations on it. accurately manufacture duplicate and interchangeable parts. Jigs and fixtures are specially designed so that large numbers of components can be machined or assembled identically, and to ensure interchangeability of components.

Jigs and fixtures are production tools used to

JIGS
It is a work holding de ice that holds, supports and locates the workpiece and guides the cutting tool for a specific operation. Jigs are usually fitted with hardened steel bushings for guiding or other cutting tools. a !ig is a type of tool used to control the location and"or motion of another tool. # !ig$s primary purpose is to pro ide repeatability, accuracy, and interchangeability in the manufacturing of products. # de ice that does both functions %holding the work and guiding a tool& is called a !ig. #n example of a !ig is when a key is duplicated, the original is used as a !ig so the new key can ha e the same path as the old one.

'()I*G JIG

+I,T-).S
It is a work holding de ice that holds, supports and locates the workpiece for a specific operation but does not guide the cutting tool. It pro ides only a reference surface or a de ice. /hat makes a fixture uni0ue is that each one is built to fit a particular part or shape. The main purpose of a fixture is to locate and in some cases hold a workpiece during either a machining operation or some other industrial process. # !ig differs from a fixture in that a it guides the tool to its correct position in addition to locating and supporting the workpiece. .xamples1 2ises, chucks

# 2IS.3J#/ +I,T-).

4ow do !igs and fixtures differ

JIGS 5. It is a work holding de ice that holds, supports and locates the workpiece and guides the cutting tool for a specific operation FIXTURES 5. It is a work holding de ice that holds, supports and locates the workpiece for a specific operation but does not guide the cutting tool

6. Jigs are not clamped to the drill press 6. +ixtures should be securely clamped to table unless large diameters to be drilled the table of the machine upon which the and there is a necessity to mo e the !ig to work is done. bring one each bush directly under the drill.

JIGS 7. The !igs are special tools particularly in drilling, reaming, tapping and boring operation. 8. Gauge blocks are not necessary. 9. :ighter in construction.

FIXTURES 7. +ixtures are specific tools used particularly in milling machine, shapers and slotting machine. 8. Gauge blocks may be pro ided for effecti e handling. 9. 4ea ier in construction.

#d antages of Jigs and +ixtures

;)(<-=TI2IT>1 Jigs and fixtures increases the producti ity by eliminating the indi idual marking, positioning and fre0uent checking. The operation time is also reduced due to increase in speed, feed and depth of cut because of high clamping rigidity. I*T.)=4#*G.#'I:IT> #*< ?-#:IT>1 Jigs and fixtures facilitate the production of articles in large 0uantities with high degree of accuracy, uniform 0uality and interchangeability at a competiti e cost .

 S@I:: ).<-=TI(*1
There is no need for skillful setting of work on tool. Jigs and fixtures makes possible to employ unskilled or semi skilled machine operator to make sa ings in labour cost. =(ST ).<-=TI(*1 4igher production, reduction in scrap, easy assembly and sa ings in labour cost results in ultimate reduction in unit cost.

+undamental principles of Jigs and +ixtures design

:(=#TI*G ;(I*TS1 Good facilities should be pro ided for locating the work. The article to be machined must be easily inserted and 0uickly taken out from the !ig so that no time is wasted in placing the workpiece in position to perform operations. The position of workpiece should be accurate with respect to tool guiding in the !ig or setting elements in fixture. +((: ;)((+1 The design of !igs and fixtures should be such that it would not permit the workpiece or the tool to inserted in any position other than the correct one.

 ).<-=TI(* (+ I<:. TIM.1 <esign of Jigs and +ixtures should be such that the process, loading, clamping and unloading time of the workpiece takes minimum as far as possible. /.IG4T (+ JIGS #*< +I,T-).S1 It should be easy to handle, smaller in siAe and low cost in regard to amount of material used without sacrificing rigidity and stiffness. JIGS ;)(2I<.< /IT4 +..T1 Jigs sometimes are pro ided with feet so that it can be placed on the table of the machine. M#T.)I#:S +() JIGS #*< +I,T-).S1 -sually made of hardened materials to a oid fre0uent damage and to resist wear. .xample3 MS, =ast iron, <iesteel, =S, 4SS.

=:#M;I*G <.2I=.1 It should be as simple as possible without sacrificing effecti eness. The strength of clamp should be such that not only to hold the workpiece firmly in place but also to take the strain of the cutting tool without springing when designing the !igs and fixtures.

.ssential features of Jigs and +ixtures

)eduction of idle time B Should enable easy clamping and unloading such that idle time is minimum =leanliness of machining process B <esign must be such that not much time is wasted in cleaning of scarfs, burrs, chips etc. )eplaceable part or standardiAation B The locating and supporting surfaces as far as possible should be replaceable, should be standardiAed so that their interchangeable manufacture is possible ;ro ision for coolant B ;ro ision should be there so that the tool is cooled and the swarfs and chips are washed away

4ardened surfaces B #ll locating and supporting surfaces should be hardened materials as far as conditions permit so that they are not 0uickly worn out and accuracy is retained for a long time

Inserts and pads B Should always be ri eted to those faces of the clamps which will come in contact with finished surfaces of the workpiece so that they are not spoilt +ool3proofing B ;ins and other de ices of simple nature incorporated in such a position that they will always spoil the placement of the component or hinder the fitting of the cutting tool until the latter are in correct pos

 .conomic soundness B .0uipment should be economically

sound, cost of design and manufacture should be in proportion to the 0uantity and price of producer .asy manipulation B It should be as light in weight as possible and easy to handle so that workman is not sub!ected to fatigue, should be pro ided with ade0uate lift aids Initial location B Should be ensured that workpiece is not located on more than 7 points in anyone plane test to a oid rocking, spring loading should be done ;osition of clamps B =lamping should occur directly abo e the points supporting the workpiece to a oid distortion and springing

 =learance B Sufficient amount of clearance should be pro ided around the work so that operatorCs hands can easily enter the body for placing the workpiece and any ariations of work can be accommodated .!ecting de ices B ;roper e!ecting de ices should be incorporated in the body to push the workpiece out after operation )igidity and stability B It should remain perfectly rigid and stable during operation. ;ro ision should be made for proper positioning and rigidly holding the !igs and fixtures Safety B The design should assure perfect safety of the operator

General rules for designing

=ompare the cost of production of work with present tools with the expected cost of production, using the tool to be made and see that the cost of buildings is not in excess of expected gain. <ecide upon locating points and outline clamping arrangement Make all clamping and binding de ices as 0uick acting as possible Make the !ig fool proof Make some locating points ad!ustable # oid complicated clamping arrangements

)ound all corners ;ro ide handles where er these will make handling easy ;ro ide abundant clearance ;ro ide holes on escapes for chips :ocate clamps so that they will be in best position to resist the pressure of the cutting tool when at work ;lace all clamps as nearly as possible opposite some bearing point of the work to a oid springing action 'efore using in the shop, test all !igs as soon as made

M#T.)I#:S -S.<
Jigs and +ixtures are made of ariety of materials, some of which can be hardened to resist wear. Materials generally used1 4igh speed Steel1 =utting tools like drills, reamers and milling cutters. <ie steels1 -sed for press tools, contain 5D carbon, E.9 to 5D tungsten and less 0uantities of silicon and manganese. =arbon steels1 -sed for standard cutting tools. =ollet steels1 Spring steels containing 5D carbon, E.9D manganese and less of silicon.

9. *on shrinking tool steels1

4igh carbon or high chromium 2ery little distortion during heat treatment. -sed widely for fine, intricate press tools.

F. *ickel chrome steels1 -sed for gears. G. 4igh tensile steels1 -sed for fasteners like high tensile
screws H. Mild steel1 -sed in most part of Jigs and +ixtures =heapest material =ontains less than E.7D carbon

I. =ast Iron1
-sed for odd shapes to some machining and laborious fabrication =I usage re0uires a pattern for casting =ontains more than 6D carbon 4as self lubricating properties =an withstand ibrations and suitable for base 5E. *ylon and +iber1 -sed for soft lining for clamps to damage to workpiece due to clamping pressure

55. ;hospher bronAe1 used for nuts as ha e high tensile strength

-sed for nuts of the lead screw

+actors to be considered for design of Jigs and +ixtures

5. =omponent3 <esign to be studied carefully .nsure work is performed in a proper se0uence Maximum operations should be performed on a machine in single setting 6. =apacity of the machine3 =areful consideration to be performed on type and capacity of machine. 7. ;roduction re0uirements3 <esign to be made on basis of actual production re0uirements. Then comes decision on manual and automatic tooling arrangements.

8. :ocation3 :ocation should ensure e0ual distribution of forces

throughout all se0uence of operation. :ocation should be hard resistant, wear resistant and high degree of accuracy. Mo ement of workpiece should be restricted. Should be fool proofed to a oid improper locations of the workpiece. Should facilitate easy and 0uick loading of workpiece. )edundant locators should be a oided. Sharp corners must be a oided.

#t least one datum surface should be establised.

9. :oading and -nloading arrangements3

There should be ade0uate clearance for loading and unloading. 4ence process becomes 0uick and easy. SiAe ariation must be accepted. It should be hardened material and non sticky.

F. =lamping arrangements3
?uick acting clamps must be used as far as possible. The clamping should not cause any deformation to the workpiece It should always be arranged directly abo e points supporting the work. ;ower dri en clamps are fa oured as they are 0uick acting, controllable, reliable and operated without causing any fatigue to the operators.

+eatures of clamps1 =lamping pressure should be low Should not cause distortion Simple and fool proof Mo ement of clamp should be minimum =ase hardened to pre ent wear Sufficiently robust to a oid bending G. =learance between Jig and =omponent3 To accommodate arious siAes if work =hips to pass out of the opening between them H. .!ectors3 To remo e work from close fitting locators. Speeds up unloading of the part from the tool and hence production rate.

I. 'ase and 'ody construction3

Methods used1 Machining, +orging and machining, =asting, +abricating, /elding.

5E. Tool guiding and cutter setting3

'y ad!usting the machine or using cutter setting block, the cutter is set relati e to the work in a fixture. The drill bushes fitted on !ig plates guides the tools.

55. )igidity and ibration3

Must possess enough rigidity and robustness. Should not ibrate as it may lead to unwanted mo ement of workpiece and tools.

56. Safety3
(peration should be assured full safety.

57. =ost3
Should be simple as possible. =ost incurred should be optimum.

58. Materials generally used3

Sl. No 5 6 7 8 9 Stud <rill"'ush ;in *ut Part Name Jig body =I MS Gun metal MS MS Material