Design of Jig

(Problem)
Dr.B.CHOKKALINGAM ME, Ph.D
Associate Professor Department of Mechanical
Engineering
Sri Ramakrishna Institute of Technology
Coimbatore-641010
 Design of Jig
• Design and draw a channel jig for mild
steel component as shown in the figure to
drill a hole of 18 mm diameter.

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Design of Jig

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 Different Steps involved in Design

• Selection of Bush

• Selection of locator

• Design of jig body

• Selection of Clamps

• Bill of Materials

4
 Selection of Bush
• Outside diameter –Push fit or Press fit or
Transition fit
• Inner hole – Running Fit
• Bush Selection
• Fixed bush ,headed type
• (DDB 5.100)

5
 0.034
18  0.016

Selection of Bush

• Given hole diameter is 18mm.

• Tolerance for inner diameter of bush:
• d1F7φ – Running fit
18

• From DDB 3.9,

• d1=
6
 Selection of Bush

• d2=25mm
• Tolerance for push fit- d2h6 φ
• From DDB-3.7

0.000
0.013
• d2 = 25
•
7
 Selection of Bush
• Other dimensions of bush are
• l1= 16mm
• l2= 12mm
• d3= 30mm

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 Selection of locator
• For better rigidity- 2 locators and 2 clamps
on both sides are used
• Select locating pin corresponding to jib
plate thickness

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 Selection of locator
• Width of workpiece = 45 mm
• Therefore the width of jig is selected as
= 45mm
• Use 2 locators for perfect alignment at a width
of 45 mm

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 Selection of locator
• Locator head diameter , (DDB 5.92)
• D= 16mm
• h1=14mm
• Other Dimensions
• d=15mm,
•

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 Selection of locator
• h1=14mm, (DDB 5.92)
• h2=22mm,
• d1=12mm,
• d2=11.5

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 Design of Jig Plate
• Thickness of jig plate must be equal to the
length of the bush o, l2 of the bush= 12mm
or greater than the length of the bush.
• Initial Assumption
• The jig plate thickness =12mm = l2 of the
bush

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 Design of Jig Plate
• The jig plate thickness =15 mm > l2 of the
bush (12mm)
• The length of h1 must be less than or equal
to the thickness of jig plate (h1=14mm)

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Design of Jig Body

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 Design of Jig Body
• Width of the jig plate ,W=45mm ( width of the
workpiece,)
• Length of jig plate = 2tp+lw+h2+Allowance
• = (2X15) + 75 + 22+ 15 =142mm
• tp – thickness of jig plate = 15mm
• Lw – length of work piece = 45mm

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 Design of Jig Body
• Height of jig plate = Hw + tp + clearance for
chip removal
• Hw ,Height of the work piece = 52mm
• Tp, thickness of the jig plate=15mm
• = 52+15+clearance for chip removal

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 Design of Jig Body
• Clearance between work piece and top jig
plate
• = 0.5Xdrill dia – for ductile
• = equal to drill dia – for brittle
• The material is ductile ,
• So,height of jig plate=52+15+9 =76 mm

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 Selection of Clamp
• Pressure pad assembling is used to clamp right
hand side of work piece and
• fixed at the end of clamp.
• 2 clamps are selected for better rigidity
• (DDB 5.104)

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 Selection of Clamp
• Outer dia of pressure pad = d1 = 16mm
• Other dimensions
• d4 = 6.4mm
• f=3.5mm
• h = 9.5mm
•

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 Selection of Clamp
• d5 = 12mm
• d6=7mm
• d7 = 2mm
• Size of screw M8
• Fastening pin= 2m6X8

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Channel jig with work piece

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 Bill of Materials
SL. NO Part Name Material Nos.
1 Bush Gun metal 1
2 Jig Plate Steel 1
Screw clamp
3 with Steel 2
pressure pad
Locator
4 Steel 2

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 Problem-2
• A fixture or jig has to be designed and built for
drilling a through hole of dia 10 mm in pre-
machined mild steel pins of dia 50mm and
length 100mm work piece at a distance of
40mm from one end face as indicated in the
Figure( next slide)

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Problem-2

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Problem-2

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Locating by V – block and
adjustable pin

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Supporting the blank against forces
• Supporting on V - block

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 Complete jig with location and
ejection
• Quick clamping by cam ,Tool guidance

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 Bill of Materials
SL. NO Part Name Material Nos.

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 Problem-3
• Design a jig for drilling two holes of 10mm
diameter on the given work piece

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Work piece

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 Different Steps involved in Design
• Selection of Bush
• Selection of locator,
• Design of supporting element
• Design of jig body,
• Design of jig leaf
• Selection of Clamps
• Selection of jig feet or button, hinges
• Bill of Materials
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Selection of Bush

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 Selection of Bush
• Drill diameter = 10mm
• Bush diameter d1= 10 mm (DDB 5.100)

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 Selection of Bush
• Outside diameter –Push fit or Press fit or
Transition fit
• Inner hole – Running Fit
• Bush Selection
• Fixed bush ,headed type
• (DDB 5.100)

36
 Selection of Bush

• Given hole diameter is 10mm.

• Tolerance for inner diameter of bush:
• d1F7φ – Running fit
18

• From DDB 3.9,

0.028
 0.013
• d1= 10
37
 Selection of Bush

• d2=16mm
• Tolerance for push fit- d2h6 φ
• From DDB-3.7

0.000
 0.009
• d2 = 16
•
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 Selection of Bush
• Other dimensions of bush are
• l1= 20mm
• l2= 16mm
• d3= 20mm
• d4= 13mm

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 Selection of locator
• For better rigidity- v locator and 2 stops on
either side of both ends are used

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 Selection of locator
• Diameter of work piece = 42 mm
• Diameter 40mm standard V locator is
available DDB(5.97)
• Where as the diameter 42mm is to be
fabricated
• Use 2 stoppers on either side of both ends for
perfect alignment at a width of the work piece
30mm.

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 Selection of locator
• V Locator (DDB 5.97)
• Diameter of work piece= 42 mm
• Height of V locator = 42mm
• Other Dimensions
• Width =50 mm,
• Length = 52 mm
•

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 Supporting Element
• Diameter=30 mm,
• Height =42-12
• = 30 mm
•

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 Design of Jig Plate
• Thickness of jig plate must be equal to the
length of the bush o, l2 of the bush= 16mm
or greater than the length of the bush.
• The jig plate thickness =16mm = l2 of the
bush

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Design of Jig Plate

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 Design of Jig Plate
• Length of the jig plate=2tp+lw+ clearance on
both sides
• = (2X16)+95+20= 147 mm= 150 mm
• Width= Width of the V locator
• = 50 mm
• Thickness of jig plate= 16 mm

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Jig Plate with Bushes

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 Design of Jig Body
• a)

• b)

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 Design of Jig Body
• Width of the jig plate ,W=50mm
• ( width of the V locator)
• = 50 mm
• Length of jig plate = 2tp+lw+clearance
• =(2X16) + 95 + 20 =147mm= 150 mm
• tp – thickness of jig plate = 16mm
• Lw – length of work piece = 95mm

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 Design of Jig Body
• Height of jig body = tp + Height of V locator+
clearance for chip removal
• Hw ,Height of the V locator= 42mm
• Tp, thickness of the jig plate=16mm
• Chip Clearance = 20
• = 42+16+20 =78 mm, = 80 mm

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Design of Jig Body

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 Selection of Clamp
• Pressure pad assembly is used to the work
piece at the top
• fixed at the jig plate
• (DDB 5.104)

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 Selection of Clamp
• Outer dia of pressure pad = d1 = 25 mm
• Other dimensions
• d4 = 9.5 mm
• f=6 mm
• h = 15 mm
•

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 Selection of Clamp
• d5 = 18 mm
• d6=10 mm
• d7 = 3 mm
• Size of screw M12
• Fastening pin= 3m6X14

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Jig Plate Holding Cam Rod

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Selection of jig button
(DDB 5.98)

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 Selection of jig button
• In order to place the drill jig on the machine
table, jig buttons are used at the bottom (4
nos).
• (DDB 5.98)
• d1= 25 mm,d2=12 mm
• l=14mm,

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 Jig with Work piece
• Asdsembly

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Jig with Work piece

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 Jig with Work piece
• Front View

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 Jig with Work piece
• Side view

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 Bill of Materials
SL. NO Part Name Material Nos.
1 Bush Gun metal 2
2 Jig Plate MS 1

3 Jig Body MS 1

V Locator
4 CI 1

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 Bill of Materials
SL. NO Part Name Material Nos.
Screw clamp
with
5 MS 1
pressure pad

Supporting
6 MS 1
block
7 Jig feet MS 4
Jig plate
8 holding cam MS 1
rod 63
 Bill of Materials
SL. NO Part Name Material Nos.
9 Stoppers MS 4
Hinge -jig
10 MS 1
plate

Hinge rod-
11 MS 1
cam rod

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