JIGS & FIXTURES

Jigs
Jigs are provided with tool guiding elements such as drill bushes. These direct the tool to the correct position on the workpiece. Jigs are rarely clamped on the machine table because it is necessary to move the jig on the table to align the various bushes in the jig with the machine spindle.

Fixtures
Fixture hold the workpiece securely in the correct position with respect to the machine / cutter during operation. There is sometimes a provision in the fixture for setting the tool with respect to the workpiece / fixture. But, the tool is not guided as in the jig. Fixtures are often clamped to the machine table.

Elements of Jigs and Fixtures

Locating elements: position the workpiece accurately with respect to the tool guiding or setting elements in the fixture. Clamping elements: These hold the workpiece securely in the located position during operation. Tool Guiding and Setting elements: These aid Guiding (drill bushes) or Setting (setting pieces) the tools in correct position with respect to the workpiece.

Advantages of Jigs and Fixtures

Productivity Interchangeability Skill Reduction Cost Reduction

Presentation of workpiece

Materials used in Jigs and Fixtures

High speed steels:
18% W for toughness and strength. 4.3% Cr for better hardenability and wear resistance 1% V for retention of hardness at high temperatures Air or oil hardened to RC 64-65.
contd.

Materials used in Jigs and Fixtures

Die Steels: Also called High Carbon (1.5 to 2.3 %) High Cr (12%), Cold working steels and are used for press tools and thread forming rolls. Hot die steels with lesser carbon (0.35%) and Cr (5%), but alloyed with molybdenum (1%) and vanadium (0.3 1%) for retention of hardness at high temperature are used for high temperature applications like forging, casting and extrusion. contd.

Materials used in Jigs and Fixtures

Carbon steels:
0.85 to 1.18% C and can be oil hardened to RC 62-63. Used for tools for cutting softer materials like wood work, agriculture, etc. and also for hand tools such as files, chisels and razors. Bushes and locators are also made up of carbon steels contd.

Materials used in Jigs and Fixtures

Collet steels (Spring steels):
1 % C and 0.5 % Mn. Usually tempered to RC 47.

Mild steels:
Cheapest and most widely used material in Jigs and Fixtures. Contains 0.3 % C. Used for parts which are not subjected to much wear and are not highly stressed.
contd.

Materials used in Jigs and Fixtures

Cast iron:
It contains 2 to 2.5 % C Used in milling fixtures as it absorbs vibrations well. Self lubricating properties make CI suitable for machine slides and guide-ways. High machinablity.
contd.

Materials used in Jigs and Fixtures

Nylon and Fibre:
Used as soft lining.

Phosphor bronze:
Widely used for replaceable nuts in screw operated feeding and clamping systems

Case hardening steels High Tensile steels Steel castings

Principles of Location

Six degrees of freedom

Principles of Location

Twelve degrees of freedom

Principles of Location

Three pins arrest Five degrees of freedom

Principles of Location

Five pins arrest Eight degrees of freedom

Principles of Location

Six pins arrest Nine degrees of freedom

Principles of Location

Workpiece Requirements

Principles of Location

Accuracy

Principles of Location

Motion Economy

Principles of Location

Redundant Locators

Principles of Location

Workpiece distortion due to redundant location

Principles of Location

Adjustable support

Principles of Location

Fool proofing

Principles of Location

Distance between locators