Class-1

Jigs, Fixture & Gauges Design

1. Design of Jig Bush
2. Design of Drill Jig
3. Design of Fixture
4. Design of Gauges

1. Design of Jig Bush:

Drill Bushes:
Jigs uses drill bushes for guiding the drill, reamer and other cutting tool to the work piece.

Generally, these are made up of tool steel and are hardened to RC60 to 64 to provide wear
resisting surface.

They are precision made, i.e. outside being ground and inside either ground or lapped within
0.008 mm concentricity.

Generally, the length of bush should be twice the diameter of the bushing hole.

The bushing hole should be very close to the diameter of the drill but should not be so tight that
drill will drag into the bushing.

Drill bushings are identified by letters and numbers. These letters and numbers describe the basic
form and specific sizes of each bushing, in a format established by the American National
Standards Institute (ANSI).

This format consists of one to four letters to identify the bushing type, an OD size in 64ths of an
inch, a length size in 16ths of an inch, and the ID of the bushing stated to four decimal positions.
Jig Bushing:
Jig bushings must be positioned properly. Some of the principles which must be considered are:

1. The bushings should be correctly placed according to the requirements of the work piece.

2. The design must provide machined locating spots for all jig bushings.

a. Especially on jigs with cast iron bodies, finished spots should be provided

where bushings are to be installed.

b. The material should be thick enough to provided sufficient bearing support for

the bushings.

3. Jig bushings should be placed so that they will not interfere with locating and

clamping accessories.

4. When reaming and tapping operations are necessary, space should be provided for the removal
of slip bushings.

5. Proper clearance should be provided between the end of the bushing and the work piece.
Usually a clearance of not more than one diameter of the drill is sufficient for this purpose.

A good rule to follow is to allow about the length of this drill point between the end of the
bushing and the work.

Installation of Drill Bushes:

In jig work correct fitting of drill bushing is important. If they are not properly

installed they could fall out during use or bind and break the tool. Figure shows the correct

method of installing these bushings.

Installation of jig bushings following norms are to be observed:

1. Size of Mounting Holes:

Holes meant for receiving the drill bushings must be made undersize and be perfectly round to
allow the bushing to fit correctly in case of press fit bushing.

2. Jig Plates:

These plates will hold and position the drill bushings. The thickness is dependent on the size of
the busing used. The bushing should be long enough to support and guide the tool properly.

Usually

L = d to 2d

Where L = Length of Bushing

d = tool diameter

The wall thickness of the bushing should be able to withstand all the cutting forces and maintain
tool accuracy.
3. Bushing Clearance:

For most applications there should be a gap between the bushing and the work for the
chip clearance known as the bushing clearance. This should be one to one and half times
the tool diameter(d to 1.Sd).

In case of precision and extreme accuracy works, the clearance should be less.

Most applications, the end of the bushing should not touch the work.
A clearance of one to one and a half times the tool diameter is sufficient for the required chip
clearance,
Figure. Exceptions to this rule occur when extreme accuracy is called for, when accuracy
in secondary operations is necessary, and when drilling into irregular surfaces. In these
cases, the bushing should be as close to the work as possible to permit the required. precision,

Figure. Occasionally a bushing must be altered, as shown in the example with

the inclined and curved surfaces. Here it is important to remember that if the end of the
wear rapidly if the bushings are unnecessary close if they are placed too far away,
precision is lost.
4. Burr Clearance:

When installing bushings, another important factor to remember is burr clearance.

In any drilling operation; two burrs are produced, primary and secondary. Figure. The
primary burr is made on the side opposite the drill bushings; the secondary burr is
produced at the point where the drill enters the work. These burrs must be considered and
sufficient clearance provided.

Another problem facing the tool designer is placing bushings for holes that are
close together. Figure. In these cases thin wall bushings can sometimes be used.

Figure shows another method of grinding flats on adjacent bushings to allow for clearance.
When necessary, holes can be drilled and reamed and the bushing alternated from one hole to
the other.
Bush Fits:
Drill tolerance = h8
Liner in Jig Plate = H7 - n6
Slip renewable bushing in liner = F7 - m6

Bush Material:
Standard drill bushings are manufactured from either C1144 Stress proof steel or other high
carbon steels.

The bushings are heat treated to achieve an ID Rockwell hardness of C62-64.

Optional materials such as tungsten carbide, 52100 steel, A2 tool steel, D2 tool steel, M2 tool
steel, 416 stainless, 440C stainless, 17-4PH stainless, 303 stainless, 660 bronze, Ampco 18
bronze, Oilite, and brass are available as specials.

EN 36, MS C14 Case depth 1.5mm

EN 31,52100 0.6C carbon steel,
T10Mn2W50 Cr45 OHNS.

Grinding:
Internal grinding + Copper lap for 0.012 mm

Hardening :
Even red heat, slowly, quenching, left in air to cool
HRC- 63 ± 2, case depth 1.5mm

Design of standard bushing & empirical formulas:

All standardized outside diameters are in multiples of 1/64 (0.156) inch and all
lengths are in multiples of 1/16 (0.0625) inch.

The standard lengths of the press fit portion of these jig bushings are based on standardized or
uniform jig plate thickness of 5/16, 3/8, %, %, 1, 1 3/8, and 1% inches.

Drill bushings in metric sizes are readily available from major bushing manufacturers, although
not at this time considered shelf items.
Standard jig bushings are designated by the following system:

1. Inside diameter:
The inside diameter of the hole is specified by decimal, letter, number, or fraction.

Type Bushing:

The type of bushing is specified by letters:

S- for Slip Renewable

F- for Fixed Renewable
L- for Head Liner
HL- for Head liner
P- for Headless Press Fit
H- for Head Press Fit

2. Body diameter:
The body diameter is specified in multiples of 1/64 inch.
For example, a % inch body diameter = 32/64 = 32.

3. Body length:
The effective or body length is specified in mu1tiples of 1/16 inch.
For example, a 1/2 inch length = 8/16 = 8.

4. Unfinished Bushings:
All bushings with grinding stock on the body diameter are designated by the letter U following
the number.
Tolerance on fractional dimensions where not otherwise specified shall be plus or 1
minus 0.010 inch.

The maximum and minimum values of hole size, A, shall be as follows:

Diameter A must be concentric to diameter B within 0.0005 T.I.V. on finish ground

bushings. The body diameter B, for unfinished bushings, is larger than the nominal
diameter in order to provide grinding stock for fitting to jig plate holes.
The grinding allowance is:

0.005 to 0.010 inch for sizes 5/32, 13/64, and 1/4 inch.
0.010 to 0.015 inch for sizes 5/16 and 13/32 inch, and
0.015 to 0.020 inch for sizes 1/2 inch, and up.

The length C is the overall length for the headless type and length under head for the head type.

When renewable wearing bushings are used with liner bushings of the head type, the length
under the head will still be equal to the thickness of the jig plate, since the head
of the liner bushings will be countersunk into the jig plate.

All bushings ranging from 0.0135 through 0.0125 inch will be counter bored to provide for
lubrication and chip clearance. However, bushings without counter bore are optional and are
furnished upon request.

The size of the counter bore is the inside diameter of the bushing plus 1/32 inch.

The included angle at the bottom of the counter bore is 118 degrees, plus or minus 2 degrees.

The depth of the counter bore ranges from 1/2 inch for the smallest bushings to
5/8 inch for the largest bushings and is adjusted to provide adequate drill bearing length.

Bushings are straight both inside and out. Older literature shows jig bushings that
are tapered on the outside but this can be considered obsolete.

The upper corners, on the inside, are given a liberal radius (radius D in figure) to allow the drill
to enter the hole easily, while the outer corners, at the lower end of the outside, are chamfered so
that it is easier to drive the bushing into the hole when making the jig, and also to prevent the
sharp corner on the bushings from cutting the metal in the hole into which the bushing is driven.

In addition, it is recommended (but not standard practice) to relieve the outer surface at the
lower end by 0.001 to 0.002 inch on the diameter, on a length equal to 1&1/2 to 2 times the
length of the chamfer.

Bearing length for the drill within the bushing ideally should be a function of the. drill
diameter. A bearing length that is too short causes premature wear, while one that is tool
long causes excessive friction (the twist drill is never a precision tool).

If there are no overriding conditions, a bearing length of 2 times the drill diameter can be taken
as a good, workable average.
There are, however, other considerations, such as the need for sufficient length of pres seat in the
jig wall and for adequate thickness of the bushing head.

An analysis of the standard tables shows a wide range of bearing length for each drill size
The ratio of bearing length (taken as the average of the table values for each drill size) to
drill diameter varies from 7 for 1/2 inch diameter drills to about 1% for 1 inch diameter drills
and down to 0.08 for large drills about 2 inches in diameter.

Empirical Formulas:

Very wide, very long, and very large bushings are the three most common types of
nonstandard bushings that must be individually designed and specially made.

Very wide bushings are for sequences of operations such as those shown in figure, where one
hole is drilled to two diameters, or where a drilling operation is followed by counter boring,
countersinking, or spot facing to a diameter significantly larger than the hole diameter;
perhaps followed by reaming.

The diameter of the liner is slightly larger than the diameter of the counter boring tool. The drill
'bushing fits the liner with the sliding fit for slip bushings.

The hole diameter in the bushing is the drill diameter with normal clearance, and other
dimensions on this bushing can be calculated by the formulas below.

The counter bore requires no bushing since it is guided by the pilot in the drilled hole. The
reamer bushing differs from the drill bushing only in hole diameter.

Very long bushings are of one of the types shown in figure. The letter symbols
sued in the following formulas are the standard letter symbols from figure plus the following:

Bearing length = L,
Wall thickness = T =1/2(B-A) and
Flange width on head = G = 1/2(E-B).

The basic dimension is the hole diameter A. According to an old rule of thumb, the
bearing length can be taken as:
L=2A

This bearing length will generally work well. It is long enough to provide sufficient bearing
surface but not long enough to cause excessive friction. However, it is larger than is
needed for large drills, while small drills, from 1/4 inch (6 mm) diameter on down, can well
use a longer support. A more sophisticated approach would be to take:

Millimeter Dimensions:

L=5√A +10mm

for tools with sharp edges, such as drills; and

L=4√A +10mm

for tools with smooth shanks, such as boring bars, rose reamers, etc.
for minimum wall thickness, take:

Body diameter will then be:

B = A + 2T, or
B = A + 2T + O.8mm
Depending on whether at not the bushing is counterbored.
For the corner radius at the inlet end, take:

for the normal height of the head, take:

 2. Design of Drill Jig:
Design Consideration in Jigs:
(a) The main frame of jig must be strong enough so that the deflection of jig is as minimum as
possible.

This deflection of jig is caused due to the forces of cutting, clamping of the work piece or
clamping to the machine table.

The mainframe of the jig should have the mass to prevent vibration and chatter.

(b) Frames should be built from simple sections so that frames can be fastened with screws or
welded, whenever necessary.

Those parts of the frame that remain intact with the jig may be welded.

The parts needing frequent changing may be held with the screws. Where the body of jig or
fixture has complex shape, it may be cast from good grade of cast iron.

(c) Clamping should be fast enough and require least amount of effort.

(d) Clamps should be arranged so that they are readily available and may be easily removed.

(e) Clamps should be supported with springs so that clamps are held against the bolt head
wherever possible.

(f) If the clamp is to swing off the work, it should be permitted to swing as far as it is necessary
for removal of the work piece.

(g) All locators, clamps should be easily visible to the operator and easily accessible for
cleaning, positioning or tightening.

(h) Provision should be made for easy disposal of chip so that storage of chips doesn’t interfere
with the operation and that their removal during the operation doesn’t interfere with the cutting
process.

(i) All clamps and support points that need to be adjusted with a wrench should be of same size.
All clamps and adjustable support points should be capable of being operated from the fronts of
the jig.

(j) Work piece should be stable when it is placed in jig. If the work piece is rough, three fixed
support points should be used.

If work piece is smooth, more than three fixed support points may be used. Support point should
be placed as farthest as possible from each other.
(k) The three support points should circumscribe the centre of gravity of the work piece.

(l) The surface area of contact of support should be as small as possible without causing damage
to the work piece. This damage is due to the clamping or work forces.

(m) Support points and other parts are designed in such a way that they can be easily replaced on
failure.

Location:
One of the most important requirements of a successful jig design is that when work piece is
machined and removed from the jig, the operator should be able to put another work piece
quickly into jig, clamp it and machine it to the dimensions with given tolerance.

Principles of Location:
(a) Relate the location to dimensional requirements of work piece.

(b) It is preferable to use most accurate machined surface for location. If there is variation on the
selected surface, the new surface will also contain variations and one can get work piece with
defects.

If most accurate machined surface is not available, select better machined surface out of
available machined surfaces.

(c) Prevent motion along and around X, Y, Z.

(d) Location system should provide easy and quick loading and unloading of work piece with
minimum motions.

(e) Avoid redundant locators. Redundant locator means more locators are provided than required
for support. If three supports are sufficient and one places four supports also, then fourth support
is redundant. There are stool stands on four legs. But stool can also stand comfortably on three
legs. In this case fourth leg is redundant one.

(f) Prevent wrong loading of work piece by fool-proofing.

Clamping:
Clamping is accomplished by clamps. Clamps hold the work piece, which is firmly engaged with
locators during operation.
The clamping system should be strong enough to withstand forces developed during operation.

At the same time, clamping force should not damage the work piece. The timing required for
loading and unloading must be as minimum as possible. Clamping must be positive when
subjected to vibration, chatter etc.

Principles of Clamping:
(a) Clamps should be positioned in such a way that clamping force shall act as a strong,
supported part of the work piece. Clamping on unsupported part bends the work pieces. This will
affect the accuracy of the operation. A vertical hole drilled in bent work piece will become
angular when the unclamped work piece come back to original shape.

(b) Clamping system should not obstruct the path of loading and unloading.

(c) Clamping system should be capable of holding the work piece securely against the forces
developed during the operation.

Also clamping system should not damage the work piece with excessive pressure.

For clamping weak work piece, the clamping force should be distributed over larger area of the
work piece.

While clamping soft work piece, clamp should be fitted with pads of softer material such as
nylon or fiber to prevent damage to the work piece.

(d) Clamping time should be minimized by using handles, hand wheels, hand knobs, Tommy
bars, knurled screws etc. Clamp can be loosened or tightened manually without using spanners
because spanner will increase the motion of picking, aligning etc.

(e) If the number of clamps are to be loosened or tightened repeatedly, then it is preferable to use
hydraulic or pneumatic clamping. This will reduce operators fatigue and saves clamping time
also. Power clamping provides loosening and tightening simultaneously.

(f) The clamping points should be provided with sufficient radius. This radius will take care of
variation in the work piece. Sphere heel pin is used to allow tilting of the clamp.