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Jigs and Fixtures

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By S K Mondal
1 2 3

Introduction
— Jigs and fixtures are devices that are used for
production of repeated parts essentially for mass
production.
You will get — Functionality of Jigs or fixtures:
‘‘maa’’ — Locating
for Preparation
— Clamping
— Supporting
— Resistance to cutting forces
— Safety

4 5 6

Jig Fixtures GATE - 1999

— Both jigs and fixtures hold, support, and locate the — Both jigs and fixtures Choose the correct statement:
work piece. hold, support, and (a) A fixture is used to guide the tool as well as to locate
— A jig also guides the cutting tool. locate the work piece. and clamp the workpiece
—A fixture has a (b) A Jig is used to guide the tool as well as to locate and
reference point for clamp the workpiece
setting the cutting tool (c) Jigs arc used on CNC machines to locate and clamp
with reference to the the workpiece and also to guide the tool
work piece. (d) No arrangement to guide the tool is provided in a jig.

For 2023 (GATE, ESE & PSUs) Page 1 of 7 S K Mondal (Ex. IES) (GATE Topper, IES Topper)
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 Purpose of using Fixtures and Jigs Design considerations for Jigs
— Eliminate marking, punching, positioning, and Fixtures
alignments etc. — Jigs and fixtures are manually or partially power
— Easy, quick and accurate locating, supporting and operated devices. comprised of several elements :
clamping the blank. — Base and body or frame with clamping features
— Guide the cutting tool like drill, reamer etc. — Locating elements for proper positioning and
— Increase productivity and maintain product quality. orientation of the blank
— Reduce operator’s labour and skill requirement — Supporting surfaces and base

— Enhancing technological capacity of the machine — Clamping elements

tools — Tool guiding frame and bushes (for jig)
— Reduce overall machining cost and increase — Auxiliary elements
Fig. Major elements of jig and fixtures
interchangeability. 10 — Fastening parts 11 12

IFS 2018 IFS 2018 3-2-1 Locating Principle

— A workpiece, just like any free solid body, has six
degrees of freedom (some researchers have referred
Explain the functions served by jigs and What is an indexing jig ? this to the twelve degrees of freedom by considering
fixtures. [ 3 Marks] the +/- movements in each category)
[ 7 Marks] — For locating it is necessary to arrest all these six degrees
of freedom to ensure the mechanical stability.
— A single locator in Plane 1 would arrest the linear
motion along the X-axis.
— A second locator in the same plane would arrest the
rotary motion about the Z-axis.
— Another locator placed in the same plane would arrest
the rotary motion about the Y-axis.
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IES - 2007
— Adding one more locator in Plane 1 would not serve any
According to the principle of location in jigs and
purpose.
fixtures, how many degrees of freedom are to be
— So fourth locator is placed in Plane 2 which is eliminated to have a body fixed in space?
perpendicular to Plane 1. This would restrict the linear
Fig. A (a) 3
motion along the Y-axis.
component with (b) 4
— The fifth locator is placed in the Plane 2 which can
six locators (c) 5
arrest the rotational motion about the X-axis.
— The sixth locator placed in Plane 2 would not serve any (d) 6
purpose.
— So, sixth locator is placed in Plane 3 which is
perpendicular both the planes 1 and 2. This would
For 2023
arrest the(GATE, ESE &along
linear motion PSUs)the Z-axis. Page 2 of 7 S K Mondal (Ex. IES) (GATE Topper, IES Topper)
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 Considering 12 DOF Points to ponder GATE - 2005
— You must fix all the 12 degrees of freedom except the three When 3-2-1 principle is used to support and locate a
transitional degrees of freedom (-X, -Y and -Z) in order to — When more than one locator is placed on a surface
three dimensional work-piece during machining,
locate the work piece in the fixture. So, 9 degrees of (plane), they should be distributed as far apart as
freedom of the work piece need to be fixed. the number of degrees of freedom that are
— Rest the work piece on three non-collinear points of the possible on the surface. restricted is
bottom surface (XY), and you will be able to fix (a) 7
the +Z, CROT-X, ACROT-X, CROT-Y and ACROT- — While selecting the surface for the largest locators, (b) 8
Y degrees of freedom.
— Now, rest the work piece at two points of side surface (XZ), consideration should be given to the largest area of the (c) 9
and you will be able to fix the +Y and CROT-Z and ACROT- workpiece. (d) 10
Z degrees of freedom.
— Now, rest the work piece at one point of the adjacent
surface (YZ), and you will be able to fix the +X degrees of
freedom. 19 20 21

GATE - 2001 GATE-2013 (PI) IES 2011

3-2-1 method of location in a jig or fixture would In the 3-2-1 principle of fixture design, 3 refers to the In the 3-2-1 principle of fixture 3 refers to number of
collectively restrict the workpiece in n degrees of
freedom, where the value of n is number of (a) Setups possible
(a) 6 (a) Clamps equired (b) Clamps required
(b) 8
(c) 9 (b) Locators on the primary datum face (c) Positions on primary face
(d) 12 (c) Degrees of freedom of the workpiece (d) Locating positions
(d) Operations carried out on the primary datum face

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Duplex Fixture Milling fixtures Milling fixtures

— It is a type of multi-station fixtures used primarily for — Milling fixtures are the most common type of fixtures — Whenever possible, the tool should be changed to suit
high speed, high volume production runs where the that are in general use today. the part. Moving the part to accommodate one cutter for
machining cycle must be continuous. — The reason for this is the geometric complexity of the several operations is not as accurate or as efficient as
— It uses only two stations. Once the machining operation workpieces that are milled. changing cutters.
is complete at station one, the fixture is revolved and the — The simplest type of milling fixture is a milling vise — Locators must be designed to resist all tool forces and
machining is started at mounted on the machine table. thrusts. Clamps should not be used to resist tool forces.
station two. During this — However, as the workpiece size, shape, or complexity — Clearance space or sufficient room must be allotted to
period, the machined part becomes more sophisticated, so too must the fixture. provide adequate space to change cutters or to load and
is unloaded from station There are a variety of milling fixtures that are in use. unload the part.
one and a fresh part is — For Design: The design should permit as many surfaces — Milling fixtures should be designed and built with a low
loaded there, and so on profile to prevent unnecessary twisting or springing
For 2023 (GATE, ESE & PSUs) of the part to be machined
Page as possible
3 of 7 without removing S K Mondal (Ex. IES) (GATE Topper, IES Topper)
25 the part. 26 while in operation. 27

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— Cylindrical Locators: Used for locating components
having drilled holes.
— The cylindrical component to be located is gripped by a
cylindrical locator fitted to the jig’s body and inserted
in the drilled hole of the component.
31
— Drill Bush Locator : Used for holding and locating
cylindrical workpieces.
— The bush has conical opening for locating purpose
and it is sometimes screwed on the jig’s body for
the adjustment of height of the work.
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Different methods used for Location
IES-2015 Conventional — Flat Locator : Used for location of flat machined
surfaces of the component.
Explain salient design principles of milling
fixtures with a typical milling fixture diagram.
[10 Marks]
29 30
— Conical Locator : Used for locating the workpieces
— Jack Pin Locator : Used for supporting rough
having cylindrical hole.
workpieces.
— It is superior as it has a capacity to accommodate a
slight variation in the hole diameter of the component —A suitable method to accommodate the
without affecting the accuracy of location.
components which are rough and un-machined.
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Diamond Pin Locator
— Vee Locators: Quick and effective method of locating
— Diamond pins are often used for radial location .
the workpiece. — One cylindrical locator (Pin A) arrests five degrees of
freedom, second cylindrical locator at the position B
— Used for locating the circular and semi-circular type of will arrest the sixth degree of freedom.
— If the two holes are identical in size then any pin can be
workpieces.
made the principal locator. However, if one of the holes
is larger then the principal locator will be placed in the
larger hole.
— The second locator is made slightly smaller than the
hole and relieved from both sides to take care of the
variation in the X direction. The cylindrical surfaces
will locate the part in the Y direction.
Page 4 of 7 S K Mondal (Ex. IES) (GATE Topper, IES Topper)
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Setting Blocks
— After the fixture has been securely clamped to the
machine table , the work piece which is correctly located
in the fixture , has to be set in correct relationship to the
cutters.
— This is achieved by the use of setting blocks and feeler
gauges.
— The setting blocks is fixed to the fixture.
— Feeler gauges are placed between the cutter and
reference planes on the setting block so that the correct
depth of the cut and correct lateral setting is obtained.
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Ejectors
— Used to remove work from close-fitting locators, such
as full nests or ring nests.
— These devices speed up the unloading of the part from
the tool, which reduces the in-tool time and increases
the production rate.
For 2023 (GATE, ESE & PSUs)
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IES – 1998, 1999 IES - 2009
Diamond pin location is used in a fixture because A lever having two precisely drilled holes, one
(a) It does not wear out smaller than the other, has to be located in a fixture
using hardened and ground plugs for further
(b) It takes care of any variation in centre distance machining in relation to the holes. Select the
between two holes correct method of locating the lever from the given
(c) It is easy to clamp the part on diamond pins alternatives.
(d) It is easy to manufacture (a) Using two hardened and ground plugs, the smaller
one having flats machined on each side
(b) Using two hardened and ground plugs
(c) Using one hardened and ground plug and one V-
block
(d) Using two V-blocks
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IFS 2018
Describe any two types of locators used in
jigs.
[ 5 Marks]
41 42
Clamping Strap Clamps
— To restrain the workpiece completely a clamping device — Based upon the lever principles to amplify the
clamping force required.
is required. — By tightening the stud the clamping force is transferred
— Holds the workpiece securely in a jig or fixture against to the part.
— Heel pin is the fulcrum about which the lever acts while
the forces applied over it during on operation. the clamping force is applied at the stud by tightening
— Device should be incorporated into the fixture, proper the screw.
— The actual amplification of the applied force depends
clamp in a fixture directly influence the accuracy and upon the distance between the stud and the heel pin
quality of the work done and production cycle time. (B), and that between the stud and the part (A).
Page 5 of 7 S K Mondal (Ex. IES) (GATE Topper, IES Topper)
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 Screw Clamps
— A much faster way of applying clamping is to make use
of either a swing washer or a cee-washer if the
workpiece has a bore for clamping.
— A swing washer can be used to clamp a part having a
hole.
— This helps in loading and unloading the part quickly.
— The only condition is that the hole used for clapping
should be larger than the nut used for clamping.
— A cee-washer is similar to a swing washer, which
remains loose unlike a swing washer. Other-wise,
application is very similar.
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Cam Clamps
— Provide clamping force because of the contour of the cam
surface that comes into contact with the plate used for the
clamping.
— Plate is pushed down by the cam against the spring
pressure to hold the part in place.
— Cam clamps are quick in operation.
— Cam clamps are of three types, eccentric cam, flat spiral
cam and cylindrical cam.
— The design shown in Fig. is flat spiral and is the most
commonly used clamp.
— The design shown is indirect pressure clamping where
the pressure is transmit to the part through the plate.
This is more stable and the vibrations during
machining do not affect the a part clamping.
Toggle Clamps
— A toggle clamp is a quick acting mechanical linkage where
two of the elements make up a toggle action.
— Toggle clamps are mainly used because of their fast action
for clamping and unclamping, their ability to completely
clear the work piece and the force Fixture amplification
possible for clamping.

Fig. A cam clamp used

Fig. A push-pull
for quick and easy type toggle
Fig. An example of a
clamping a part clamp
fixture held by a cam
49 clamp 50 51

Equalizers IES - 1996

— When the clamping force is to be applied at more than Assertion (A): A workpiece with rough un-machined
one location then an equalizing clamp is useful. In this surface can be located in a jig or fixture on three
type of clamp the link arm system is being used to supporting points.
apply an equally divided clamping force to a pair of Reason (R): Indexing is made accurate by
clamps acting on the same component. It is also supporting on three points.
possible to use this system of clamping to clamp two
(a) Both A and R are individually true and R is the
parts. correct explanation of A
— This is particularly useful in a condition where the
(b) Both A and R are individually true but R is not the
operator may be denied easy access to one or other of correct explanation of A
the clamps.
(c) A is true but R is false
Fig. An equalizing clamp
For 2023 (GATE, ESE & PSUs) Page 6 of 7 (d)SAKisMondal
false but(Ex.
R isIES)
true (GATE Topper, IES Topper)
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 IES - 1996
Consider the following statements:
The cutter setting block in a milling fixture
1. Sets the cutting tool with respect of two of its surfaces.
2. Limits the total travel required by the cutter during
machining.
3. Takes location from the location scheme of the
component.
(a) 1,2 and 3 are correct (b) 1 and 2 are correct
(c) 2 and 3 are correct (d) 1 and 3 are correct

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For 2023 (GATE, ESE & PSUs) Page 7 of 7 S K Mondal (Ex. IES) (GATE Topper, IES Topper)
 Jigs and Fixtures: Answers Key

GATE- 1999 PageNo. 1 Slide No. 9 Ans.(b)

IES-2007 Page No.2 Slide No.18 Ans.(d)

GATE - 2005 Page No.3 Slide No. 21 Ans.(c)

GATE-2001 Page No.3 Slide No.22 Ans.(c)

GATE-2013(PI) Page No.3 Slide No.23 Ans.(b)

IES-2011 Page No.3 Slide No.24 Ans.(d)

IES-1998,1999 Page No.5 Slide No.38 Ans.(b)

IES-2009 Page No.5 Slide No.39 Ans.(a)

IES-1996 Page No.6 Slide No.54 Ans.(c)

IES-1996 Page No.7 Slide No.55 Ans.(d)

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