JIG&FIX DESIGN Nota

JIGS AND FIXTURES
DESIGN
1
LEARNING OUTCOMES
1)Explain the fundamental of jigs &fixtures.
2)Explain the design concept of jigs & Fixtures.
3) Identify the main components & their functions.
4) Describe the characteristic of jigs & fixtures use in variety of
manufacturing processes.
5) Produce assembly & detail drawings of jigs & fixtures.
6) Apply design procedures in order to improve productivity,
efficiency & cost effectiveness.
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COURSE CONTENTS
1. INTRODUCTION TO JIGS & FIXTURES
2. PRINCIPLES OF LOCATING AND
SUPPORTING
3. CLAMPING AND POSITIONING
4. FIXTURE BODY DESIGN
5. TOOLING FOR NUMERICAL CONTROL
6. MILLING FIXTURE
7. TOOLING FOR DRILLING, REAMING AND
RELATED PROCESS
8. FIXTURE FOR TURNING
9. GRINDING FIXTURE
10. FIXTURE FOR ASSEMBLY AND JOINING
OPERATION
11. INSPECTION FIXTURE AND GAGES
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CHAPTER 1
INTRODUCTION TO JIGS & FIXTURE
Learning Objectives:

• Explain the important of jigs & fixture in the
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production system.
• Identify the benefit of jigs & fixture.
• Explain error proof mechanism.
• Understand and apply the correct procedure to
design jigs & fixture.
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WORK HOLDING DEVICES
Definition
Work holding devices include all devices that hold, grip or
chuck a work piece to perform a manufacturing operation.
The holding force may be applied mechanically, electrically,
hydraulically or pneumatically.
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Q : Name at least 5 work holding devices for metal cutting

operations?
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Special Work Holding Devices
1) Fixtures
- Usually designed for particular work pieces.
- The function of a fixture is to hold and clamp the work piece in a
precise position (Figure a).
2) Jigs
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- A jig is a fixture that guides the tool in addition to holding the work
piece in a precise position (Figure b).
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Part Standardization in Production System (Methods)
1)Jigs and fixtures is introduced to obtain standard products
which are consistent in dimensions.
- By introducing jigs and fixtures, the system is normally known as
machine set up system because the machine is set up in such a way that
the products produce is standardize. This is normally done when mass
production is involved or at least the quantity is sufficient to justify the
cost and to maintain the cost competitiveness of product.
2)Master part system, in which the produced product is made

base on a master part.
- This master part is use as a template in production. This method is
fairly cheaper, but in term of accuracy is not as accurate as jigs and

fixtures. When the product has wide tolerance then it is possible to use
master part system.
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3)Group production system. The group is responsible to

follow up closely and every dimension is measured to ensure
that it is within the specification.
- The process requires a highly skilled manpower and that is costly. This
method is only applicable if the quantity produced is low. As a base of
comparison, a custom made product is always more expensive than the 7
mass produce alternative.
The Benefit of Jigs & Fixtures
- Most manufactured product are produce in mass production
system. Each component is produced independently and at a
later stage these components are assembled together as one
end product. These components must be within a certain
dimensions in order to fit in the final product.
- In the replacement market, in case of damage components,
by specifying the part number the exact component can be
replace and the product can work as normally it would.
- This factor of interchangeability allows product to be mass

produce, and reach the customer at a lower cost. The
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standard components in mass production utilizes jigs and

fixtures to maintain the dimensions.
-Jigsand fixtures benefits,

1) The job can be simplified by introducing error proof
mechanism. This will increase productivity since the job is
being simplified and does not require a lot of thinking 8
3) The amount of scrapped and rework can also be reduced.
4) It will reduce the manpower skill requirement. Highly
skilled manpower requirement can be reduced to skilled or
semi-skilled since with proper instruction, the same quality of
work can also be achieved.
5) In a mass production, set up cost is high and so is the cost
to set up proper jigs and fixtures system. However, due to the
high volume of production, the cost can be amortized over a
larger quantity. Together with the increase in productivity and
the reduction of manpower skilled requirement, the end

products will reach the customer at a much lower cost.
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Pre-Design Procedure
Before any jigs and fixtures design get started, feasibility
studies has to be done and the following 5 areas are normally
covered; Product, Operation, Machine, Operator, and Cost.
Design Procedure
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1. Product Analysis
- During this analysis, not only the product is analyzed but also the
blueprint and the specification sheet need to be well understood.
- The blueprint and the specification sheet actually tell more about
the product than the product itself such as type of material and
properties such as conductivity, durability, hardness, machine ability,
strength, etc. The geometry and its tolerances are also available and
this information is critical for the design of jigs and fixtures.
-For example, ferrous and non ferrous material has different
characteristics and should be treated differently. Even ferrous
material has different type; cast iron, stamped components or forged
has individual characteristics and should not be generalized and
treated in the same manner.
2. Operation Analysis
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- Analyze the operation that is going to be done on the work piece.

- Different type of operation such as machining, assembly, inspection
or simply holding fixture has different requirement.
- For instance, a holding fixture for a plastic part cooling off process
need not be as strong as a milling fixture because there is no force
applies to the work piece. It is also need not be as accurate as an
inspection fixture. A fixture to assemble components by welding
needs to dissipate the heat evenly in order to have uniform cooling
and avoid weld crack, this characteristic may not be required by
other operation. 11
3. Machine and Equipment Analysis
- Analyze the actual machine that is going to be used.
- The machine is very much part of the design since two machines may be
able to accomplice the same task but the orientation or the way the actual
work is carried our may be different. It should also be noted that different
machine has different capabilities and limitations.
4. Operator Analysis
- The ergonomic aspects of the design should not be ignored.
- A jig and fixture is only useful if it achieve its objective of increasing
productivity. If the ergonomic aspect is ignored the design may not be
suitable with the operator and it ended up not being used and defeats the
purpose of introducing it.
- For example, if the jig or fixture is too heavy, maybe proper lifting
equipment must be design as a part of the jig and fixture design.
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5. Cost Analysis
- Finally, once all the above factors are favourable towards the design, only
then the cost analysis Siscarried
KT  (Tout.
/ N The
) cost effectiveness of the jigs and
fixtures can be determined base on the following equation:
where;
S = gross annual saving
K = expected return per year (%)
T = total tool cost
N = estimated life
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- If the cost analysis does not fulfil the above equation, making the jigs and
Cost Reduction Options
There is 2 options can be taken if the design is too costly to be built
or as an improvement practise to minimize the existing jigs and
fixtures cost.
1- By combining jigs and fixtures into multi purpose jigs
and fixtures.
2- By reducing the specification of the jigs and fixtures
itself.
1) Multi Purpose Jigs and Fixtures
- In combining jigs and fixtures these 3 conditions should be
considered:
i) The operation that is being carried out should be similar. Jigs
and fixtures for milling 2 different components can be made into one
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jigs and fixture. However, combining milling and turning jigs and
fixtures may not be a wise decision due to the different nature of the
operation and may require a lot of modification which will involve
higher cost.
ii) The function of the jigs and fixtures must also be the same. The
strength and the accuracy of the jigs and fixtures are dependent on its
function. An inspection jigs and fixture needs higher accuracy but
may not be strong enough to withstand the machining forces as in a
milling operation. 13
2) Reduction of Specification
There are some options to reduce cost by reducing the specifications
for the jigs and fixtures itself, but one must remember that the
quality of the end product must not be jeopardized.
2.1 Use Wider Tolerance

-Jigs and fixtures fabrication requires machining process. The smaller the
tolerance, the more expensive the machining cost will be. By using a
wider tolerance the machining cost will be reduce tremendously.
2.2 Eliminate Unnecessary Machining

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-Only machine the surface of locations that is really necessary. By doing

machining on unnecessary surfaces, the machining time will be increase
and so is the cost.
2.3 Use Informal Drawing or Sketches

- Professionally drawn blueprint can be expensive. In designing a jig
and fixture, simple sketches is sufficient so long that all the required
information is available on the sketches for future reference.
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2.4 Use Standard of the Shelf Components
- Standard of the shelf/ ready made components are normally mass
produced and cheaper. Making the jigs and fixtures using customized
components will not only increase the cost of making it, but also the
cost of maintaining it. This is because all replacements components
have to be specially fabricated when needed. The lead time is normally
longer which can be translated into longer down time if no spare is
always available in the production system.
2.5 Use Alloy

- Alloy is normally softer. If alloy is good enough to be used in the

jigs and fixture, the alloy can help reduce machining cost since
machining time will be lesser.
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2.6 Use Alternative Material

- Alternative material such as plastic or wood can also be used to
reduce cost.
- Wood is cheap and able to absorb impact, will not rust and rather
easy to fasten. However, wood has the tendency to warp and difficult
to form. Plastic, on the other hand, is easier to form, light, will not rust
and is oil free. The shortcomings of plastic are in terms of durability. 15
 Principles of Work Holding
 Objective of Work Holding:

- To position or locate a work piece in definite relation to the cutting
tool and clamp it with a proper force in order to withstand the cutting
forces while maintaining that precise position.
 Elements of Work Holding Device:

i) Locating elements to position the work piece.
ii) Clamping elements to maintain the part in precise location during

operation.
iii) Fixing elements to the machine tool to withstand the operation forces.
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Fixing to machine tool (machine table)
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• A workpiece free in space can move in an infinite number
of directions. For analysis, this motion can be broken down
into twelve directional movements, or "degrees of freedom."
All twelve degrees of freedom must be restricted to ensure
proper referencing of a workpiece.
• As shown in below Figure, the twelve degrees of freedom
all relate to the central axes of the workpiece. Notice the six
axial degrees of freedom and six radial degrees of freedom.
The axial degrees of freedom permit straight-line movement
in both directions along the three principal axes, shown as x,

y, and z. The radial degrees of freedom permit rotational
movement, in both clockwise and counterclockwise radial
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directions, around the same three axes.
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• A workpiece free in space can move in an infinite number of
directions. For analysis, this motion can be broken down into twelve
directional movements, or "degrees of freedom." All twelve degrees
of freedom must be restricted to ensure proper referencing of a
workpiece.
• As shown in below Figure, the twelve degrees of freedom all relate

to the central axes of the workpiece. Notice the six axial degrees of
freedom and six radial degrees of freedom. The axial degrees of
freedom permit straight-line movement in both directions along the
three principal axes, shown as x, y, and z. The radial degrees of
freedom permit rotational movement, in both clockwise and

counterclockwise radial directions, around the same three axes.
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• The devices that restrict a workpiece's movement are the locators.

The locators, therefore, must be strong enough to maintain the
position of the workpiece and to resist the cutting forces. This fact
also points out a crucial element in workholder design: locators, not
clamps, must hold the workpiece against the cutting forces.
• Locators provide a positive stop for the workpiece. Placed against

the stop, the workpiece cannot move. Clamps, on the other hand, 18
rely only upon friction between the clamp and the clamped surface
Flow Chart of New Product Development ( including fixture development for
CNC Milling Machine)
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( in details)
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Steps In Design Jigs & Fixtures
In designing a jig and fixture, 5 steps need to be taken in sequence.

The steps are as follows:
Locating the work piece (points).
Adding the support/ stopper/ locator
Clamping the work piece
Guiding the cutting tool (Jig)
Provide fixture body
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Fixing to machine tool (machine table)
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EXAMPLE OF GANTT CHART FOR NEW
PRODUCT (FIRST ARTICLE)
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GANTT CHART CONTINUE......
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CHAPTER 2
PRINCIPLES OF LOCATING &

SUPPORTING
PRINCIPLES OF LOCATING & SUPPORTING

•Identify suitable locating point and support point
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in designing jigs & fixture by considering all

factors involved.
• Apply nesting application to locate point for
irregular surface.
• Explain jamming phenomenon & identify its
prevention.
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1. LOCATING & SUPPORT POINTS
Definition
• Locator (X & Y datum) is the point or area that is being
used as a reference and it contributes directly towards the
accuracy of the end products.
• Supports (Z datum) help the work piece to be in its free
form to avoid it from twisting or bending. Selections of
support points are not as critical as locating point.
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The best locating surfaces are often determined

by the way that the part is dimensioned.
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• BASIC PRINCIPLES OF LOCATING
To perform properly, workholders must accurately and consistently
position the workpiece relative to the cutting tool, part after part. To
accomplish this, the locators must ensure that the workpiece is
properly referenced and the process is repeatable.
• Referencing and Repeatability

"Referencing" is a dual process of positioning the workpiece relative
to the workholder, and the workholder relative to the cutting tool.
Referencing the workholder to the cutting tool is performed by the

guiding or setting devices. With drill jigs, referencing is accomplished
using drill bushings. With fixtures, referencing is accomplished using
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fixture keys, feeler gages, and/or probes. Referencing the workpiece

to the workholder, on the other hand, is done with locators.
If a part is incorrectly placed in a workholder, proper location of the

workpiece is not achieved and the part will be machined incorrectly.
Likewise, if a cutter is improperly positioned relative to the fixture,
the machined detail is also improperly located. So, in the design of a
workholder, referencing of both the workpiece and the cutter must be 27
"Repeatability" is the ability of the workholder to consistently
produce parts within tolerance limits, and is directly related to
the referencing capability of the tool. The location of the
workpiece relative to the tool and of the tool to the cutter
must be consistent. If the jig or fixture is to maintain desired
repeatability, the workholder must be designed to
accommodate the workpiece's locating surfaces.
The ideal locating point on a workpiece is a machined

surface. Machined surfaces permit location from a consistent
reference point. Cast, forged, sheared, or sawed surfaces can
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vary greatly from part to part, and will affect the accuracy of
the location.
1.1 Locating Point Selection

a) Machine Surface
• Machined surface is the most suitable surface to be selected 28
•It can be a flat or curvature so long as the surface contour is
matched with the surface of the locator it will be more
accurate than unmachined surface.
• Unmachined surface may look smooth but the variation is
always more than machined surfaces.
b) Single/ Multi Locator

• In a jig and fixture, avoid duplicate locator. If there is more

than one locator in a jig and there are cases of product
variation, it is difficult to determine which locator to be used
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as reference.
• The reference points must always be the same point; if it is
different then the variations between work pieces will also
increase and will affect interchangeability.
• In cases where the production requires a series of jigs and
fixture, it is best to use the same points as locating point in
every jigs and fixtures. If different point is used in different 29
c) Position of the locator
• The selected surface and the locator must be able to be
viewed during the operation. This is accommodate easy
checking and to ensure that the work piece is properly
position before the operation begins and remains in position
throughout the operation.
• Locator should also be positioned away from chip locating

surfaces. Besides causing surface damage due to the friction
between the work piece and the locator it can also cause the
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work piece to be stuck to the locator. This will make it more

difficult to dismount the work piece and increase the process
time.

d) Locator Rigidity
Locators will always be in contact with the work piece during
the operation. The designer must design the locator to be 30
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Figure. Locators should be
relieved to reduce locational
problems caused by chips
and coolant build-up.
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Figure . Examples of
redundant location.
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1.2 Support Considerations
In order to balance the work piece, support points should be as
far as possible from center of gravity and evenly distributed
around it. This will ensure that the work piece will not bend or
twisted. It will also minimize the movement of the work piece
because the force that is created by its weight is acting in the
center of the jigs and fixture.
In cases of large work piece where more than 3 supports are
needed, it is suggested that the additional supports to be made
adjustable. This measure is taken to avoid the work piece from
locking inside the fixture.
1.3 General Considerations for Locator & Support

Both the locator and supports should be easily replaceable. This
is important to minimize the cost to maintain the fixture. These
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locator and support will be subject of wear and tear. If the

locator or support is made as integral part of the jig, the cost of
upgrading it will be higher.

Cost will always be a major factor and the following
considerations can be taken to minimize cost;
Use off the shelf or standard components
Use existing in house components 33
Using a realistic tolerance will contribute to cost reduction
since small tolerance will increase the machining cost. Under
normal circumstances a tolerance of 30% to 40 % of the work
piece tolerance is sufficient. However, for inspection jigs a
tolerance of 10 % of the work piece tolerance is
recommended.
The size of the contact areas on the locator and supports
should also be minimized. A larger contact may leave visible
impression on the surface of the work piece.
Fool proofing is another characteristic that can contribute to

increase productivity. It will increase working speed and
reduce scrap.
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Foolproofing
2. RESTRICTING THE WORK PIECE MOVEMENT
An object in its free position is able to move in 12
orientations along X, Y and Z, and these movements are
called degrees of freedom. The 12 movements are 6 linear
movements forward and backward along the 3 axis and 6
rotational movements clockwise and counterclockwise around
these 3 axes. The very purpose of jigs and fixtures are to
minimize these movements. The method to reduce these
movements is known as 3-2-1 Method (but still vibrate –
therefore need for clamping whereas there will no movements

at all) .
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The first step in 3-2-1 method is to introduce 3 pins in the Z-

plane. By doing this, 5 degrees of freedom is restricted. The
5 degrees of freedom are 4 rotational movement around X
and Y axes (balance, not dropping) and downward movement
along Z-axis.
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Next, introduce 2 pins either on X or Y-axis. An additional 3
degrees of freedom are restricted; 2 rotational movements
around Z axis and 1 movement along either X or Y axis.
The last pin is to be introduced on the remaining plane and 1

movement along that particular axis.
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This method restricts 9 degrees of freedom and if more than 9
degrees of freedom is restricted, loading or unloading the
work piece may be problematic ( other 3 degree of freedom
restricted by unfixed items such as clamping, bolt and etc) .
However, 3-2-1 Method is not the only method that can
restrict 9 degrees of freedom; internal concentric locator is
able to serve the same purpose.
The remaining 3 degrees of freedom are rotational
movements around Z axis and one linear movement along the
Z axis.
In actual operation, the number of degree of freedom that
needs to be restricted is very much dependent on the nature of
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operation.
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3. JAMMING & ITS PREVENTION
3.1 Diamonds Pin

When there is 2 holes on the work piece, one cannot use 2
circular pins because it is impossible to handle the variation
of center to center distance between the two holes. To solve
the problem one of the hole should use diamond pins. The
circular side of the pin should be orientated towards stopping
rotational movement around the round pin. The cut off side
should be arranged that it is facing the round pin to allow

center to center distance variation between the two holes. The
illustrations below show some application of diamond pin.
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Question on diamond pin.
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Answer on diamond pin.
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CHAPTER 3
CLAMPING & POSITIONING
• Explain the significant of clamping in designing
jigs & fixture

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• Identify factors to be considered in selecting

clamp
• Identify and explain various types of clamp
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1. FUNCTION OF CLAMPING
• In a jig and fixture, clamping device plays a role to apply
and maintain sufficient counteracting holding force to the
work piece to withstand all tooling forces.
• Clamp design should be as simple as possible so as to
minimize cost. Simple device will also contribute to higher
working speed.
• Poor clamp design or maintenance can cause tool damages
and product variations.
• Clamp selection should be based on the work piece, the
operation and the quantity of parts to be produced. Location

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in the jig should also be properly selected for the clamp to

achieve the followings;
Supply enough pressure to keep the work piece in position
in relation to gauges, locator and tools.
Facilitate easy loading and unloading.
Support rigid portion of work piece and avoid distortion.
Provide minimum hazard to work piece, operator, tools, and 43
2. WORK PIECE TO BE CLAMP
• Clamping force must be determined to avoid over design,
which cost extra, or under design, which is not safe. By
studying the type of material, the cutting tool, cutting speed,
depth and feed the force can be determined.
• Before selecting a particular clamp, the work piece itself
must be studied in areas of configuration or shape, surface
finish and surface variations. The number of clamp required
depends on the size of the work piece and the tool forces. A
large work piece is more difficult to hold and either a fewer,
larger and stronger clamp camp be introduced or a greater

number of smaller clamp. The best choice is the one with the
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least clamping operation and minimal fabrication cost. If the

work piece has a complex contoured surface, equalizing
clamps, hydraulic or pneumatic clamp maybe used instead of
conventional clamps.
• Surface finish may make it necessary to introduce padding
to increase friction and holding force or even to avoid surface
damage. 44
3. SELECTION CHECKLIST
There are some questions need to be answered before selection is
made. Below is some of the checklist that the designer has to go
through before selecting any clamp;
Can the operation be done without clamping?
Is there any jigs and fixture available in house that can be used for the
operation with some modification?
Can standard commercial clamps be used?
Can non-mechanical clamp be used? Operate with machine circuits
whenever possible.
How to make fool proof?
Will it obstruct the cutter?
Will the clamp damage the work piece surface?

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Clamp should be visible.

Clamp should be located on operator side for easy operation.
Locate clamp against rigid supporting surface of fixtures, if not possible
additional support to be introduced to avoid twisting or bending.
If more than 1 clamp is needed, space them out.
Provide clamps with sufficient range to handle variations.
Clamps must be clear of work piece to facilitate loading and unloading.
Clamps must be clear of the cutter before, during and after the
operation. 45
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Figure . Clamps should always be positioned so the clamping force is directed into the supports or locators.
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Figure . The number and position of clamps is determined by the workpiece and its supports.
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Figure. Using gooseneck clamps is one way to reduce the height of the clamps.
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Directing the clamping forces against an unsupported area will cause this cylindrical part to
deform. Strap clamps eliminate deformation by directing the clamping forces into the supports
under the part.
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Figure 3-28. When possible, part features such as holes can be used to clamp the part.
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Figure 3-29. When the part can only be clamped on its outside surface, pie-shaped chuck jaws can be used to hold the part and reduce deformation.
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Analyzing Machining Forces
The most-important factors to consider in fixture layout are the
direction and magnitude of machining forces exerted during the
operation. In Figure 3-8, the milling forces generated on a
workpiece when properly clamped in a vise tend to push the
workpiece down and toward the solid jaw. The clamping action of
the movable jaw holds the workpiece against the solid jaw and
maintains the position of the part during the cut.
Figure 3-8. Cutting forces in a milling

operation should be directed into the solid
jaw and base of the vise.
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Another example of cutting forces on a workpiece can be seen in
the drilling operation in Figure 3-9. The primary machining forces tend
to push the workpiece down onto the workholder supports. An
additional machining force acting radially around the drill axis also
forces the workpiece into the locators. The clamps that hold this
workpiece are intended only to hold the workpiece against the locators
and to maintain its position during the machining cycle. The only real
force exerted on the clamps occurs when the drill breaks through the
opposite side of the workpiece, the climbing action of the part on the
drill. The machining forces acting on a correctly designed workholder
actually help hold the workpiece.
Figure 3-9. The primary cutting forces in a drilling

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operation are directed both downward and radially

about the axis of the drill.
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An important step in most fixture designs is looking at the planned
machining operations to estimate cutting forces on the workpiece,
both magnitude and direction. The "estimate" can be a rough guess
based on experience, or a calculation based on machining data. One
simple formula for force magnitude, shown in Figure 3-10, is based
on the physical relationship:
Please note: "heaviest-cut horsepower" is not total machine

horsepower; rather it is the maximum horsepower actually used
during the machining cycle. Typical machine efficiency is roughly
75% (.75). The number 33,000 is a units-conversion factor.
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Figure 3-10. A simple formula to estimate the magnitude of cutting forces on the workpiece.
Surface Feet Per Minute (SFPM) - The is the cutting speed of the end mill in SFPM = 0.262 x D x RPM
the United States. It is the number of feet per minute that a given point on the
circumference of a cutter travels per minute.
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The above formula only calculates force magnitude, not direction.
Cutting force can have x-, y-, and/or z-axis components. Force
direction (and magnitude) can vary drastically from the beginning, to
the middle, to the end of the cut. Figure 3-11 shows a typical
calculation. Intuitively, force direction is virtually all horizontal in this
example (negligible z-axis component). Direction varies between the
x and y axes as the cut progresses.
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1 kilowatt (kW) = 1.341 horsepower (hp)

Figure 3-11. Example of a cutting force
calculation.
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Selecting Clamp Size and Force
Calculations to find the necessary clamping force can be quite
complicated. In many situations, however, an approximate
determination of these values is sufficient. The table in Figure 3-30
shows the available clamping forces for a variety of different-size
manual clamp straps with a 2-to-1 clamping-force ratio.
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Figure 3-30. Approximate clamping forces of different-size manual clamp straps with a 2-to-1 clamping-force ratio.
1 pounds (lbs)per square foot (psf) = 4.88 kilogram per sq. meter (kgf/m2)
1 kgf = 9.8 Newton

For instance, a 1/4-20 screw has a
1 kilogram exerts a force of approximately 9.81 N down;
1/4-inch major diameter and has 20
or 1 kg*m/s2
threads per inch.
(Due to Gravity)
1Kn =1000 N 54
Alternatively, required clamping force can be calculated based on calculated
cutting forces. A simplified example is shown in Figure 3-31. The cutting
force is entirely horizontal, and no workpiece locators are used, so frictional
forces alone resist the cutting forces.
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Figure 3-31. A simplified clamping-force calculation with the cutting force entirely horizontal, and no workpiece stops (frictional force
resists all cutting forces).
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When workpiece locators and multi-directional forces are considered, the
calculations become more complicated. To simplify calculations, the worst-case
force situation can be estimated intuitively and then treated as a two-dimensional
static-mechanics problem (using a free-body diagram). In the example shown in
Figure 3-32, the cutting force is known to be 1800 lbs, based on a previous
calculation. The workpiece weighs 1500 lbs. The unknown forces are:
FR = Total force from all clamps on right side
FL = Total force from all clamps on left side
R1 = Horizontal reaction force from the fixed stop
R2 = Vertical reaction force from the fixed stop
R3 = Vertical reaction force on the right side
N = Normal-direction force = FL + FR + 1500
µ = Coefficient of friction = .19
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Figure 3-32. A more-complicated clamping-force calculation, using a two-dimensional free-body diagram.
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The following equations solve the unknown forces assuming that for a
static condition:
1. The sum of forces in the x direction must equal zero.
2. The sum of forces in the y direction must equal zero.
3. The sum of moments about any point must equal zero.
At first glance, this example looks "statically indeterminate," i.e., there
are five variables and only three equations. But for the minimum required
clamping force, R3 is zero (workpiece barely touching) and FL is zero (there
is no tendency to lift on the left side). Now with only three variables, the
problem can be solved:
Solving for the variables,

CHAPTER 3
FR=1290lbs
R1=1270lbs
R2 = 2790 lbs
In other words, the combined force from all clamps on the right
side must be greater than 1290 lbs. With a recommended safety factor
of 2-to-1, this value becomes 2580 lbs. Even though FL (combined
force from all the clamps on the left side) equals zero, a small
clamping force may be desirable to prevent vibration. 57

Another general area of concern is maintaining consistent clamping

force. Manual clamping devices can vary in the force they apply to parts
during a production run. Many factors account for the variation,
including clamp position on the workpiece, but operator fatigue is the
most-common fault. The simplest and often-best way to control
clamping force is to replace manual clamps with power clamps.
The force generated by power clamps is not only constant but also
adjustable to suit workpiece conditions. Another benefit of power
clamps is their speed of operation: not only are individual power clamps
faster than manual clamps, every clamp is activated at the same time.
CHAPTER 3
58
Threads Per Inch (TPI)
Metric
US
(Millimeters)
Bolt Size Coarse Thread Fine Thread
UNC UNF 1/16 1.6
1/8 3.2
#0000 - 160 3/16 4.8
1/4 6.4
#000 - 120
5/16 7.9
#00 - 90
3/8 9.5
#0 - 80 7/16 11
1/2 13
#1 64 72
9/16 14
#2 56 64
5/8 16
#3 48 56 11/16 17
3/4 19
#4 40 48
13/16 21
#5 40 44 7/8 22
#6 32 40 15/16 24
1 25
#8 32 36
1-1/8 29
#10 24 32 1-1/4 32
#12 24 28 1-3/8 35
1/4 20 28
Metric
US
(Millimeters)
5/16 18 24
3/8 16 24 1-1/2 38
7/16 14 20 1-5/8 41
CHAPTER 3
1-3/4 45
1/2 13 20
1-7/8 48
9/16 12 18 2 51
5/8 11 18 2-1/4 57
2-1/2 64
3/4 10 16
2-3/4 70
7/8 9 14 3 76
1 8 12* 3-1/4 83
3-1/2 89
1-1/8 7 12
3-3/4 95
1-1/4 7 12 4 102
1-1/2 6 12 4-1/2 114
5 127
* 12tpi is the UNF standard however 14tpi is far more common in actual use. 5-1/2 140
6 152
6-1/2 165
7 178
59
4. TYPE OF CLAMPS
4.1 Strap Clamps
Classes of Levers and Strap Clamps
CHAPTER 3
60
4.2 Sliding Clamps
4.3 Swing Clamps

CHAPTER 3
61
4.4 Hinge Clamps
4.5 Wedge Clamps

CHAPTER 3
62
4.6 Toggle Clamps
Hold Down Action Toggle Clamps
CHAPTER 3
63
Pull Action Toggle Clamps
CHAPTER 3
Straight Action Toggle Clamps
64
Automatic Adjusting Toggle Clamp
CHAPTER 3
Air/Hydraulic Powered Toggle Clamps
65
CHAPTER 4
FIXTURE BODY DESIGN
• Identify factors to be considered in designing the
FIXTURE BODY DESIGN
fixture body
CHAPTER 4
• Select suitable materials for jigs & fixture

• Explain the use of ejector and fool proofing
66
1. DESIGNING THE BODY
• Once the points of locating, supporting and clamping are decided,
the last step is to provide the fixture body. The following points
must be considered in designing the fixture body;
The fixture must fit into the machine or pallet and not interfering
with any machine parts.
The total weight of the fixture and the work piece must not exceed
the maximum weight capacity of the machine.
The fixture base must match the mounting method on the machine
bed.
Adjustment and changing of cutter should be permitted without
disturbing the fixture.
FIXTURE BODY DESIGN
In cases where multiple fixtures are used, make sure that it does not
interfere with one another.
CHAPTER 4
View of cutter’s action must not be obstructed.

Must allow the use of setting equipments such as blocks, dial
indicators or other suitable methods.
Lifting hook to be provided if it is heavy.
 Provide method to establish ‘Program Zero’, where necessary.
Provide sufficient clearance for the fixture to allow any variations,
burrs, fins, or other protrusion that is normal in rough castings and
forgings. 67
Provide support to the free end of the work piece if only a
certain area that is being worked on to avoid bending the
whole work piece.
Loading and unloading must be done easily without any
obstruction.
Provide sufficient areas for the operator’s hand or finger to
maneuver during loading and unloading.
Locator must be protected from damage by cutter over run
or setting it too deep.
Sufficient clearance to provide to allow lifting the work
FIXTURE BODY DESIGN
piece in and out of the locator or centering devices.

CHAPTER 4
Removable locating pins and adjusting device should be

located on operator side to increase working speed.
Fool proofing needs to be done to reduce error and
scrapped.
If the work piece is difficult to remove after the operations,
introduce an ejector.
Fixture body must be properly proportioned to give balance 68
Use commercial fixture and modify it slightly to suit your
requirements.
Fixture body should protect the operator from the cutter.
Minimize cutter travel.
Provide adequate guide for cutting tools.
Provide stowage for loose detail.
Make sure the flow of coolant to the cutting edge is not
obstructed.
Provide easy removal of chips.
Provide channel for the coolant to wash away chips.
FIXTURE BODY DESIGN
Possibility to use compressed air to clean the fixtures.

CHAPTER 4
Protect the operator from coolant splash, flying chips and air
blast.
Provide a datum reference on fixture if necessary.
Balance the fixture if it rotates.
Prevent the work piece from flying out if clamping fail.
Use interlock to avoid clamp loosening if using air or
hydraulics. 69
2. TOOLING MATERIALS
• The physical and mechanical properties of a particular
material that is necessary for an operation is the main
selection criteria for selecting it. Properties such as weight,
conductivity, thermal expansion, strength, hardness, wear
resistance, etc.
• Normally more than one material will meet the requirement
and the final selection, in most cases, are govern by
availability and cost.
• The principal material for tooling can be divided into 3
FIXTURE BODY DESIGN
categories; ferrous, non-ferrous and non-metallic.

CHAPTER 4
• Ferrous material are iron based material while non-ferrous

is materials that have non iron as a based. Nonmetallic are
those materials such as wood, plastic, rubber, and epoxy resin.
70
2.1 Ferrous Material
Ferrous materials can be divided into categories; carbon steel,
tool steels, and cast iron. Carbon steels are widely used in
fixture design and fabrication. It can be divided as in the
following table.
Name Carbon content Properties Utilization
Low carbon 0.05-0.3% Soft & tough Fixture bodies or other areas that
Easily welded where strength and wear resistance is
not required
FIXTURE BODY DESIGN
Medium 0.3 -0.7 % Strong & tough Studs, pins, axles and nuts
CHAPTER 4
carbon Can be heat treated

Difficult to weld
High 0.7- 1.5 % Wear resistance Drill bushings, locators, wear pads
Carbon Difficult to machine
Most hardenable
71
Alloy steels are carbon steels with additional elements added
to it to modify its characteristics. The most common alloying
metals are manganese, nickel, molybdenum and chromium.
Stainless steels are high chromium or high nickel-chromium
steels. These steels can resists high temperature and
corrosives atmosphere.
Tool steels are alloy steels which are produced for cutting
tools, locator or gages.
Cast iron is an alloy of carbon and iron with elements of
silicon, manganese, phosphorus and sulphur.
FIXTURE BODY DESIGN
CHAPTER 4
72
2.2 Non-Ferrous Material
Non ferrous materials are used in areas where magnetism and
tool weight are important factors.
Aluminum has a very good in strength to weight ratio, non
magnetic, easy to machine and form. It is also corrosion
resistance in its pure form but normally its alloys are used due
to its higher strength, even though the corrosion resistance is
slightly reduced.
Magnesium alloys similar to aluminum, has a high strength to
weight ratio. However, it has a disadvantage of being fire
FIXTURE BODY DESIGN
hazard.
CHAPTER 4
Bismuth alloys is normally used as a nesting to hold cast

work pieces for machining. Bismuth, with its low melting
temperature, is melted and poured onto the part and once
hardened, the part is removed and it is used as a nest. It can
also be reused as a nest by repeating the whole process of
melting.
Carbides are tooling materials made from the carbides of 73
2.3 Non Metallic Material
Non metallic material is normally used when cost is too limited
and the volume is also not high.
Wood has the strength but it will warp when exposed to high
humidity. Processed wood such as metal clad plywood, however,
has good resistance to buckling and bending. It is also wear
resistance, lighter than metal, resistance to surface damage unless
being struck by sharp object. Compressed wood also has good
characteristic of excellent machinability compared to other type
of wood.

Plastics are suitable as tooling material where operations are not
severe and low in volume. Plastics are resistance to chemical,
FIXTURE BODY DESIGN
moisture and temperature. They are also inexpensive and

cheaper to maintain. In recent years, newly develop plastics are
CHAPTER 4
able to withstand heat, abrasion, and non stick surface that

facilitate sliding. Some plastics can even match metal in terms of
tensile and shear strength.

Epoxy resins are mainly used for casting and laminating. It is
normally used where a profile has to be copied and the end
product is used as supports, work holders, jig plates, and large
forming dies.
74

3. EJECTORS
As a part of the fixture design is to determine the difficulty of
unloading of the work piece. These work pieces tend to stick
to the fixture once the operation is completed. To improve
this situation, it is possible to include an ejector to push out
the sticking work piece. This will improve the cycle time of
the operation.
Examples of ejectors are shown in the illustration below.
FIXTURE BODY DESIGN
CHAPTER 4
75
4. FOOL PROOFING
Fool proofing must be done for work pieces that can be
placed in more than one way into the fixture. By introducing
fool proofing, scrap will be reduced since the work piece can
only be placed in the fixture only in one way, the correct
position.
A simple illustration of fool proofing is shown below.
FIXTURE BODY DESIGN
CHAPTER 4
76
CHAPTER 5
TOOLING FOR NUMERICAL CONTROL
• Explain 4 areas of concern in CNC fixture namely

1.1. Accessibility
CHAPTER 5
1.2. Accuracy
1.3. Rigidity
1.4. Speed and ease of work piece changing
• Explain the application of modular tooling
77
1. EFFECTIVE CNC FIXTURE
CNC machines are able to various operations in a single cycle.
Similar to other fixtures, it must be able to minimize the cost of
manufacturing or machining the work piece. The fixture must
accommodate quick and precise mounting of work piece onto the
machining center pallet with no loss of accuracy during pallet
change. It locates the work piece quickly and accurately.
Repeatability of the whole process must also be ensured,
otherwise the work pieces will vary from batch to batch.

Clamping should also be quick and easy. Due to the ability of
doing various operations, the fixture must allow all these
CHAPTER 5
operations to be completed in a single cycle. Thus making it

necessary to study the operation more closely and the design is
also more complex that of conventional machines.

With these high complexity fixtures, the cost of the end product
is going to rise due to this higher fixed cost. Thus, making a
dedicated fixture is not advisable due to this increase cost. 78
2. SPECIAL DESIGN CONSIDERATION
Four areas of concern in CNC fixturing are accessibility,
accuracy, rigidity, and speed and ease of work piece
changing.
2.1 Accessibility
The machine is able to accomplish a combination of different
operation such as milling, drilling, taping, turning and boring.
With these many operations, there are also several cutting

tool involved. The path of each cutting tool must be followed
closely to ensure there in no obstruction
CHAPTER 5
2.2 Accuracy
The fixture must be accurate with a very small tolerance.
This type of machine is highly accurate and if the fixture has
a very low accuracy level, it then defeat the purpose of using
this highly accurate machine since the end result is going to
have a large variations. Special attention need to be paid to 79
2.3 Rigidity
These machines normally work with high spindle speed
which directly increases the forces acting on the work piece.
The surface must be strong enough to withstand the machine
forces. The clamping mechanism must also be able to
withstand the forces and disallow the work piece to move or
even vibrate.

2.4 Speed and Ease of Work Piece Changing
The quantity to be produce will dictate the design of the

fixture. The higher the quantity, the easier it is to justify a
CHAPTER 5
more expensive fixture. Even though the cost is slightly

higher the easiness and quickness of loading and unloading
the work piece will cut cycle time. Furthermore, the higher
cost is amortized over a larger quantity giving a smaller
contribution for each work piece towards the cost of the
fixture.
Besides cost, storage problem can also decide whether 80
3. MODULAR TOOLING
Modular tooling is a kit of components which can be used
together in various combinations to locate and clamp work
pieces for machining, assembly, and inspection operations.
The kit may start with a simple step clamp to a accurately
measured block and base plate. An example of modular
tooling set is shown below.
CHAPTER 5
81
• Modular tooling is suitable to be used when order quantity
is too small and no potential of repeat order. When storage
space is a problem in your organization, modular tooling is
the solution. It also add more element to properly locate and
clamp the work piece due to the fact that it has many options
on constructing your fixture.
• No doubt that modular tooling is costly but it is not without
potential for return of investment. Modular tooling allows the
reduction of lead time. Once it is readily available, a job can
start immediately. Unlike conventional tooling which needs

to be ordered, fabricated and tested, modular tooling
eliminates those stages in your production system. Reduced
CHAPTER 5
lead time will give a company a competitive edge over its

competitor.
• Modular tooling also has a very high adaptability, is able to
be used on work pieces, immaterial of the complexity of its
geometry. This modular tooling kit can be used over and over
again and this factor of reusability is an advantage because no
investment is required on other low volume production. 82
• Another advantage is its back up ability. Modular tooling
can be used as a back up in case the dedicated fixture broke
down. While this dedicated fixture is undergoing repair, the
modular tooling can be used. The saving comes from the fact
that the production line keeps running and there is no need to
have another dedicated fixture as a back up. This modular
tooling can act as aback up to one dedicated fixture but to all
that is being used in an organization.
• In constructing modular tooling fixtures one has to select a
base which is large enough for the work piece. Then,

construct the main structure with riser blocks and reinforce
with stop thrust elements. To strengthen the fixture, add more
CHAPTER 5
elements to properly locate and clamp the work piece.
Constructing Modular Tooling Fixtures
83
CHAPTER 6
MILLING FIXTURE
• Explain the working principle of milling
• Identify correct types of milling operation in designing jigs
MILLING FIXTURE
CHAPTER 6
& fixture
• Identify the appropriate fixture design based on work piece
and milling process
(1 HOUR) 84
1. Milling Processes
• Definition: Milling is a process of removing material from a
work piece by relative motion between rotating cutter having
multiple cutting edges and the work piece.
• Milling processes can be divided into 2 categories;

1) Peripheral milling is when the work piece surface that is
going to be removed is parallel to the cutter axis.
2) Face milling, on the other hand, is when it is perpendicular
to the cutter axis.
MILLING FIXTURE
CHAPTER 6

• Peripheral milling can be further divided into 2 groups; up
milling and down milling.
a) Up milling is when the feed direction is against the
direction of cutter rotation.
b) Down milling, the exact opposite of up milling, is when the
feed direction is the same direction as the cutter rotation 85
Figure 6.1: Types of peripheral milling
MILLING FIXTURE
CHAPTER 6
Question : ‘Up milling’ and ‘down milling’conventional

also known as
__________milling
climb and ______milling?
86
Q: WHY DO WE NEED TO KNOW BASIC
PRINCIPLE OF MILLING PROCESS TO DESIGN
JIGS OR FIXTURES?
Answer :
MILLING FIXTURE
• Jigs and Fixtures is used to hold the work piece (part)

CHAPTER 6
when a force is applied on it.

• So, it is important to know before designing the milling
fixture as the forces action on the work piece will be
different between face milling, up milling and down
milling.
87
1.1 Force Exert during Milling Process
A) Tangential Force & B) Feed Force
a) Up-Milling
- There is a tendency of the work piece to be lifted up so in
designing the fixture the clamping force must be strong
enough to withstand this tendency. The tangential force will
cause the work piece to be lifted if the clamp is not strong
enough. It will not only cause variations but may also cause
accidents.
MILLING FIXTURE
CHAPTER 6
- Besides the tangential force of the cutter there is also the

feed force of the work piece needs to be taken into
consideration. In up milling, the feed is in opposite direction 88
b) Down-Milling
- In down milling, the tangential force will push the work
piece down. The requirement on the fixture is then different
compared to up milling. If the work piece’s bottom is not flat
to rest on the milling machine bed, the support that is holding
the work piece is the one that is resisting the milling forces
and need to be stronger compared to up milling.
MILLING FIXTURE
CHAPTER 6
- In down milling the tangential force tends to pull the work

piece into the cutter, thus requires less feed force.
89
B. Cutting Force
-The other two machining parameters needs to be taken into
consideration are the cutting speed (rpm) and the depth of the
cut. These three, feed, speed and depth, determines the
cutting force which is also the force that the fixture needs to
withstand.
• This different requirement of Jigs and Fixtures design will

acquire different cost and the final design is very much
dependent on it.
MILLING FIXTURE
CHAPTER 6
• Selecting the right operation for a job is important because

of the different cost level related to it.
90
2. Jigs & Fixtures for Milling’s work pieces
a) The most important thing to know before actually
designing the fixture is the type of milling machine to be used
for that operation. Different type of milling machine has
different orientation and needs to be taken care of at the
design stage.
b) Once the type of machine is known, the following
information needs to be known;
i.Size, strength, rigidity and locating surfaces of the part
ii.Operation to be performed
MILLING FIXTURE
iii.Required finish and accuracy of the milled surface

CHAPTER 6
iv.Milling method – single piece, string, abreast, progressive,

reciprocal, transfer base, index, rotary, box, or profile milling
v.Stock to be removed and machineability
vi.Number of parts and production rate
vii.Types and design of the fixture
viii.Cutter design and material 91
c) Special attention should be given to fact that the fixture
should be able to handle as many milling operation as
possible. There are many similarities in milling job that it
is actually possible to introduce multi purpose jigs and
fixtures to milling operations. Making it too rigid to hold
only a particular work piece will limit the potential of
minimizing cost in the overall operation of a company.
d) A gauging surface is also required to set the cutter in

relation to the work piece. This point is always used as the
zero point or as the reference point for that particular
MILLING FIXTURE
fixture.
CHAPTER 6
e) Sufficient clearance to change a cutter should also be

provided. If changing of cutter requires the fixture to be
dismounted from the machine, variations will occur since
when setting up machines even though the same procedure
is followed the end result will always vary and the set up
92
time will increase the overall production time. These two
3. Milling Fixture Design
The illustration below shows the essential elements in milling
fixtures.
Essential Elements of Milling Fixture
MILLING FIXTURE
CHAPTER 6
These elements may vary in arrangement and shape but their

purpose are always identical. Vise jaws are the most common
work holding tool for a milling operation. Only for a complex
operation or surfaces contour that a different and more
93
4. First Operation Fixture
• Forge or cast product are often complex and has irregular

finish. These products normally need to be machined to meet
the proper specification. However, with the large variation in
the cast or forge product there is not possible to select any
surface as the locating surface for subsequent operations. The
very first operation that needs to be done is to mill a particular
surface to be used as the locating point.
• The fixture design must be able to hold the work piece

MILLING FIXTURE
CHAPTER 6
firmly without distorting it. Removal of substantial amount of

material from the work piece can cause or relieve internal
stress. The fixture must allow the machined surface to
remains flat after the work piece is being removed from the
fixture, thus making it critical for the work piece to be
supported and clamp but still remain in its free condition with
minimum force applied to it just sufficient to counter the
milling forces. 94
• Forge or cast product are often complex and has irregular
finish. These products normally need to be machined to meet
the proper specification. However, with the large variation in
the cast or forge product there is not possible to select any
surface as the locating surface for subsequent operations. The
very first operation that needs to be done is to mill a particular
surface to be used as the locating point.
• The fixture design must be able to hold the work piece

firmly without distorting it. Removal of substantial amount of
MILLING FIXTURE
CHAPTER 6
material from the work piece can cause or relieve internal

stress. The fixture must allow the machined surface to
remains flat after the work piece is being removed from the
fixture, thus making it critical for the work piece to be
supported and clamp but still remain in its free condition with
minimum force applied to it just sufficient to counter the
milling forces.
95
MILLING FIXTURE
CHAPTER 6
Example of
Gang Milling
96
CHAPTER 6
MILLING FIXTURE
97
CHAPTER 6
MILLING FIXTURE
98
CHAPTER 6
MILLING FIXTURE
99
EXAMPLE OF CASTED PART
FIXTURE
MILLING FIXTURE
CHAPTER 6
100
EXAMPLE OF CASTED PART
FIXTURE
MILLING FIXTURE
CHAPTER 6
101
CHAPTER 6
MILLING FIXTURE
102
CHAPTER 6
MILLING FIXTURE
103
CHAPTER 6
MILLING FIXTURE
104
Q. Design a fixture to milling 2 pieces of key-way 25.4 mm
in one time. State the type of cutter & machine to be used ?
MILLING FIXTURE
CHAPTER 6
105
ANSWER: CNC MILLING MACHINE 3 AXIS & T-SLOT
CUTTER
MILLING FIXTURE
CHAPTER 6
106
EXAMPLE OF
MILLING FIXTURES
MILLING FIXTURE
CHAPTER 6
107
MILLING FIXTURE
CHAPTER 6
Horizontal/Vertical Rotary Table(Rotary

Table)
108
CHAPTER 6
MILLING FIXTURE
109
Summary
 In basic principle of milling operation, there are 2 types of
cutting processes involved which are peripheral and face
milling.
 Tangential, Feed and Cutting force exists during variety of

milling operation need to be considered before designing jigs
and fixtures.
 Type of milling machine used to machined the work piece

influenced the design of jigs or fixtures.
MILLING FIXTURE
CHAPTER 6
 Factors such as multi purpose jigs/ fixtures, gauging

surface, cutter changeable, supported area, design with low
profile etc should be considered on designing milling jigs/
fixtures.
 In some forged and casted parts, a first operation fixture

need to be produced to mill locating surface for subsequent
milling operations. This due to inconsistent of dimension 110
CHAPTER 7
TOOLING FOR DRILLING, REAMING

AND RELATED PROCESS
Identify the advantages of drill Jigs
TOOLING FOR DRILLING, REAMING &
•
• Explain drill jigs application
RELATED PROCESS
CHAPTER 7
•(1 HOUR)
111
1. Drilling and Related Processes
• Drilling, reaming, boring and counter boring, counter
sinking, chamfering and tapping basically uses similar
principle of application or same cutting method. For that
reason, the designs of the fixtures require attentions to be
given to similar areas.
• In all of the above cutting process, the forces involve in

the operations are:
a) Radial forces & b) Thrust forces

RELATED PROCESS
CHAPTER 7
a) Radial force which comes from the spinning effect of

the cutting tool. This force tends to make the work piece
to rotate in the same direction of the direction of rotation
of the cutting tool. However, radial forces in the opposite
direction needs also to be addressed due to the fact that
most tools are able to turn both directions and the counter
clockwise direction is mostly use to extract out the cutting 112
b) The thrust force act on the work piece in the direction
of movement of the cutting tool, most of the time
downward. When the cutting tool is penetrating into the
work piece the radial force is at maximum level and this
must be countered by supports that are strong enough.
The supports must also be located at the right distance
from the hole to avoid any bending or deflection of the
work piece. If the supports are too far apart, bending of
the work piece will tend to happen.

When the cutting tools break through the work piece,

besides the tendency of the work piece to rotate in the
RELATED PROCESS
CHAPTER 7
direction of the cutting tool, it will ‘climb’ to the cutting

tool if the work piece is not heavy enough. This
occurrence of ‘climbing’ can be eliminated by
introducing clamps to force the work piece to remain in
position.
113
2. Advantages of Drill Jigs

•Drill jigs help in producing quality work pieces efficiently
and productively by providing the method to;
 correctly locate the work piece with respect to the
cutting tool.
securely holding and rigidly support the work piece
during the operation
guide the cutting tool.
 position and fasten the jig on the machine.
•Besides of the above, the common advantageous of using

RELATED PROCESS
CHAPTER 7
drill jigs such as;

 minimizing human error.
 allows usage of less skilled labor.
 reduce processing time.
 eliminate retooling for repeat orders.

•Drill jigs will also contribute to minimizing the tool 114
3. Drill Jigs Categories

•Drill jigs can be broadly divided into 2 groups by its type of
construction;
1) Open jig & 2) Closed jig
1) Open jigs - normally used when machining on the work
piece only involves a single surface
2) Closed jigs are used when it involves multiple surfaces.
•More often than not, jigs types are identified by the method used
to construct the jig, as an example, template jigs, plate jigs, leaf jigs,
etc.
RELATED PROCESS
i. Template Drill Jigs

CHAPTER 7

-Template drill jigs an an open jigs.
-Plate containing holes or bushings to guide the cutting tool.
These jigs are normally placed and located directly on a feature of
the work piece to permit holes to be drilled at the desired location.
-There is argument that template drill jigs is not a jig because it
does not incorporate clamping elements in it.
-The advantage of template drill jigs is that they are the simplest
and the least expensive of all other drilling jigs. However, it is
without clamping and the jigs are not properly secured on the work 115
- The other contributing factor is that a feature of the work piece
is used as a reference and in most cases this feature are not the
datum of the work piece. This is against the selection criteria
for selection of locating points.
- Template drill jigs is applicable under the following
situations;
•When the work piece is large and not practical to have a large
fixture to locate the points to be drilled.
• When using 2 or 3 template are cheaper than making one
large jig.
• Accuracy in relation to the reference point or datum is not
highly critical.
RELATED PROCESS
CHAPTER 7
Figure of Flat Plate Template Drill

Jigs
116
ii. Plate Jigs

-Plate jigs are basically template jigs with clamps. The construction
cost is slightly higher but this cost can be recovered. Plate jigs are
more accurate and last longer than the cheaper template jigs. Plate
jigs open construction makes it easier to load and unload the work
piece and allows easy removal of chips. The three variations of
plate jigs; open plate, table plate, and sandwich plate are shown
below. Plate Jigs
RELATED PROCESS
CHAPTER 7
117
-Sandwich plate is applicable when the drilled plate is thin and to
avoid from buckling by the drill thrust force. The bottom plate acts
as support to the work piece.
-Besides flat plate jigs, it can also be modified to drill holes at an
angle. Some example of angle plate jigs are shown below.
Angle Plate Jigs

RELATED PROCESS
CHAPTER 7
118
-An application of the plate jig is shown in the illustration below.
The components of the plate jigs are (1) drill bushings, (2) locator
using dowel pin, (3) clamp, (4) locator block and (5) plate. Three
drill bushings are pressed into the plate while the other two is on the
Jig for Drilling a Channel
locator block.
RELATED PROCESS
CHAPTER 7
119
iii. Universal Jigs

-Universal jigs are commercially available and some of the common
universal jigs are shown below. Usually what needs to be done is
to add locator, supports and drill jig bushings.
Universal Jigs
RELATED PROCESS
CHAPTER 7
120
iv. Leaf Jigs

-A leaf jig incorporates a hinge leaf (plate) that carries the bushings.
The clamping force is applied onto this leaf to hold the work piece
in position. Leaf jigs are limited in size and unable to handle
large work pieces.
-A leaf jig consists of a leaf (drill plate) attached to the body with
precise fitting hinge at one end and a clamp on the other. All that
is required is to add locator, supports and drill jig bushings. By
lifting the leaf, the work piece can be loaded from 3 sides.
However, side plates can also be added depending on the nature of
the operations.
Leaf Jigs If operation is done on more Double
than one side, this jig
Leaf Jig
may also be called tumble jig.
RELATED PROCESS
CHAPTER 7
121
iv. Leaf Jigs

-A leaf jig incorporates a hinge leaf (plate) that carries the bushings.
The clamping force is applied onto this leaf to hold the work piece
in position. Leaf jigs are limited in size and unable to handle
large work pieces.
-A leaf jig consists of a leaf (drill plate) attached to the body with
precise fitting hinge at one end and a clamp on the other. All that
is required is to add locator, supports and drill jig bushings. By
lifting the leaf, the work piece can be loaded from 3 sides.
However, side plates can also be added depending on the nature of
the operations. If operation is done on more than one side, this jig
may also be called tumble jig.
RELATED PROCESS
CHAPTER 7
-Designing the drill jigs can be doneTwoby Approaches

various approaches.
to the Same Job
As an
example, the illustration below shows 2 approaches in drilling and
reaming the drilled holes. In (a) slip bushings on the top plate
were used for both drilling and reaming. In (b) the top side is for
drilling while the bottom is for reaming operation.
122
v. Channel & Tumble Box Jigs

-A leaf jig incorporates a hinge leaf (plate) that carries the
bushings. The clamping force is applied onto this leaf to
hold the work piece in position. Leaf jigs are limited in
size and unable to handle large work pieces.
-If more than one surfaces needs to be drilled, the best option
is to use channel or tumble jigs (more than 3 surfaces).
These two jigs will provide greater accuracy due to lesser
handling compared to a series of separate jigs. Even

though the jig itself will be more costly and complicated,
RELATED PROCESS
CHAPTER 7
but cost effectiveness can still be gain if designed properly.

-Channel jigs allow drilling on 3 surfaces. To minimize cost it
is suggested that a standard U-shaped channel to be used
with pressed fit drill bushings, clamps and locators, all
using standard off-the shelf components. However, the jig 123
Cross Section of a Typical Channel Jig

-Tumble jigs allow drilling in all 6 surfaces or sides. Tumble jig
is commercially available in various sizes. The designer only

needs to specify the locations that need to be machined to fit the
RELATED PROCESS
CHAPTER 7
drill bushings, a means to locate the work piece and clamp the
part.
Tumble Box Jig
124

-For more complicated operations, built up tumble jigs is more
applicable. The illustration below shows a built up tumble jig.
The surface on the opposite side of Hole A is machined flat to
allow the jig to serve as a base when machining hole A. When
drilling Hole B and C, the surfaces on the respective opposite side
are used as the base.
Tumble Jig with Bayonet-lock Clamp
RELATED PROCESS
CHAPTER 7
125
CHAPTER 7
RELATED PROCESS

4. Drill Jigs Bushing
Drill Bushings and Liners
126
Type of Drilling Bushing
•Headless press fit bushings is suitable for permanent installation

with a single size cutting tool. It is also suitable is a jig where
area is limited because it has no head.

• Head press fit is suitable in application similar to headless
press fit but with higher axial load. This axial load will tend to
push the bushing through the jig hole. The head will disallow the
bush from going through the hole.
• Slip renewable and slip fixed renewable bushings are used in

combination with liner L (headless) or HL (with head). Liner is
RELATED PROCESS
CHAPTER 7
utilized when multiple operation are done using the same bushing
such as drilling, reaming, tapping, etc. Liner is also needed in a
situation where the production run is long and the bushings need
to be maintained to ensure its integrity. In this case only the liner
needs to be change without disturbing the press fit bushings. UN-
A-LOC liners do not require bushing locking device but need to
be pressed in using an arbor press. The bushing is locked tight by
the torque of the drill bit.
127
CHAPTER 7
RELATED PROCESS
Accessories
128
5. Installation of Drilling Bushing
• To ensure accuracy of the work piece, the drill bushing
must be properly located and installed. First, the mounting
hole of the bushing must be round and properly sized. This
will avoid bushing closure and jig plate distortion if the
mounting hole is too small. If it is too big than the bushing
will be loose and not properly position due to the free play.

• Chips, as in other operations, will still cause a problem
in drilling jigs if not taken care off in the design stage. Proper
chip clearance is necessary between the bushing and the work

piece to allow easy chip removal. If chip is not able to fall out
RELATED PROCESS
CHAPTER 7
during the operation it will remain in the bushing and the drill
bit will end up stuck in the bushing.

• The clearance will also be determined by the type of
chips produce by the metal. Stringy chips of cold rolled steels
requires a clearance of 1 to 1.5 times of the bushing’s internal
diameter while for cast irons which produces small chips a
clearance of 0.5 times of the bushing’s internal diameter is 129
CHAPTER 7
RELATED PROCESS
inch
Note: All measurements in
130
• An important point to note is that the larger the
clearance between the bushing and the work piece the
lesser the accuracy will be. With the large clearance
the drill bit is allowed to move on a larger angle and
the larger the angle the further the hole will be from the
original intended location. In an application where
accuracy is highly required, minimal clearance should
be allowed. Once the jig is put into operation,
observation should be carried out and if the chip has
the tendency to lift the bushing, it indicates that the
clearance set is insufficient and needs to be increased.

Recommended Clearance between Workpiece and Bushing
If the cutting tool wanders or bends than the clearance
RELATED PROCESS
CHAPTER 7
can be reduce.
131
• If multiple operations are carried out on the same hole, slip
renewable bushings should be used. During the drilling
operation, a larger clearance is needed, but the clearance for
reaming need not be that large anymore because reaming
chips is smaller than drilling chip. This will give greater
accuracy to the work piece. This can be accomplished by
using a different slip renewable busing for the reaming
Chip Clearance for operation with minimal clearance.
Multiple Operations
Burr Clearance

RELATED PROCESS
CHAPTER 7
• Another point in relation to work piece and bushing

clearance, is that the burrs that is created at the top of the
work piece. Without the clearance the burrs will go into the
bushings and lock the drill bit.
• The recommended clearance for burrs is 0.5 times of the
bushing’s internal diameter. Provisions should be made in the 132
• The length of the bushing is also important for a longer
bushing minimize the wandering effect of the drill bit. The
length of the bushings is recommended at 1.5 to 2.5 times of
the internal diameter of the bushing. The jig plate thickness
is also important because a thin plate will deflect when the
thrust force is applied. A plate thickness of 1 to 2 times of
the cutting tool diameter will be sufficient.
• When an irregular surface work pieces is involved, the

bushing must follow the surface profile of the drilled hole
without failing to observe the clearance requirement. The
illustrations below shows examples of jigs for irregular

surface work pieces.
RELATED PROCESS
CHAPTER 7
Drilling Irregular Work surfaces

133
CHAPTER 8
FIXTURE FOR TURNING
• Apply the safe work holding for turning
FIXTURE FOR TURNING
• Explain the operation and application of mandrel, collect, chuck and jaws
CHAPTER 8
•(1 HOUR)
134
8.1 Turning Process
- Turning operations are defined as removal of material from external
surface on a rotating work pieces, rotated about its longitudinal axis on a
lathe machine. Other related operations on external surface are facing,
chamfering, grooving, knurling, threading and parting.
Operations that can be done on internal surface on a lathe machines
includes drilling, reaming, boring, threading and recessing.

8.2 Tool Forces
- The cutting power requirement is dictated by the material, the feed
rate, and depth of cut. Different type of material requires different cutting
force. The unit power, i.e. the power required to remove 1 cm3 of
material in a second, for metals can be obtained in most metal
FIXTURE FOR TURNING
handbooks.
CHAPTER 8
- The unit power will also increase when the feed rate is increased.
Undeformed chips will help reduce the unit power requirement in
turning operations. Additional power is required to change the shape of
the chips. The rake angle will affect the unit power requirement. A
change in rake angle will directly affect the unit power by increasing of
decreasing it, depending on the direction of change. Utilization of a
positive rake angle with positive or positive/negative rake inserts will 135
8.3 Work Holding For Turning

- Work holding for turning needs to be safe, fast, accurate and rigid
in order to get a good work pieces. All the power required will be
transmitted through the work piece holder and this require solid
gripping of the work piece. It is more critical in application where
high speed machining for closer tolerance and smoother surface
finish, which is the current trend.
- The safe work holding and safe maximum speed depend on various
factors including work piece size, geometry, materials and their
properties. The cutting tools used, feed rate, speed, the condition of
FIXTURE FOR TURNING
the work holder and the type of operation.

CHAPTER 8
- The common types of turning work holding devices are faceplates

and fixtures, mandrels, jaw type chuck, step chucks, collets,
magnetic and vacuum chucks.
8.4 Gripping the Work Piece

136
- On selecting the gripping area, the area with the largest diameter
- Magnetic chucks allow rapid loading and unloading with minimum
distortion and leave no marks on the work piece. It also provides
minimal interference with the cutting tool. In some case,
demagnetizer is required to eliminate the residual magnetic field on
the work piece, fixture and the machine.

- Vacuum chucks are suitable for non-magnetic components. It also
leaves no mark to make it suitable for thin-walled and fragile work
pieces.

- In locating work piece for turning, use the holder (gripped surface)
as locator. This will simplify the work compared to locating from
FIXTURE FOR TURNING
any other location, which will also increase the complexity of the jigs
CHAPTER 8

- Problems induced by high speeds should also be taken into
considerations because the high force may cause wok piece distortion
and reduce the chucking pressure.

8.5 Between Center Turning Operations

137
- For cylindrical work pieces, two conical center holes need to be
(a) Typical Driver Plate
(b) Various Types of Dogs used to Rotate
Workpieces held between centers on a lathe
- Face drivers, on the other hand, is design to be mounted on the on

the spindle. Without the lathe dog, operations on the full length of
the work piece can be carried out with a face driver.
FIXTURE FOR TURNING
CHAPTER 8
Face Driver Permits Turning Entire OD of

Workpiece Mounted Between Centers in One
Clamping
138
8.5.1 Mandrels

- Mandrels can be plain or expanding. Plain mandrels have a taper 0.5
mm/m and are force into the work piece. Due to this possible high wear,
plain mandrel is only used for low production situation.
Plain
Mandrel
FIXTURE FOR TURNING
CHAPTER 8
- Expanding mandrels can be of many type and design. Pin type

mandrels are used for gripping cast, forge or rough bores. The pins move
outward when the draw bar is pulled to grip the work piece.
139
Expanding Mandrel and Serrated
Shoes for Gripping Long, Thin-
Walled Workpieces
- Expanding bushing mandrels are generally used in smooth or finished

bore. Some examples of application of expanding mandrels are shown
below.
FIXTURE FOR TURNING
CHAPTER 8
Mandrel for Clamping Stators of Mandrel for Clamping Divider Gear

Various Lengths Housing for Machining
140
8.5.2 Collets

- One of the advantages of collets is high holding power because of the
high contact surface between the work piece and the collets. In addition
to that, collets will not lose its grip due to centrifugal effects. It also does
not leave clamping marks normally left by chucks. The costs of standard
collets are relatively low.
FIXTURE FOR TURNING
Three Basic Styles of Collets (a)

CHAPTER 8
stationary (b) push-out (c) draw-in
141
- Stationary collets seat directly against the spindle nose cap
to prevent outward movement the collets. Surrounding the
collets is a sleeve that is threaded into a push bar. After the
work piece is mounted the sleeve is pushed outward against
the mating tapered surface of the collets head by the push bar.
This forces the collets to close and grip the work piece.

- Push-out collets will hold the work piece accurately if it is
push up to a turret-mounted work piece stop as the turret
closes. The push bar pushes the tapered nose of the collets
against a mating tapered bore in the spindle nose cap. This
FIXTURE FOR TURNING
action forces the collets to close around the work piece and
CHAPTER 8
hold it in place for machining.

- Draw in collets is pulled into the spindle by a draw bar. This
action forces the tapered outside diameter of the collets head
to press against the tapered internal diameter of the spindle
nose cap causing the collets to close and securely grip the
work piece.
142
8.5.3 Jaw Type Chucks
Jaw Type Chuck

FIXTURE FOR TURNING
CHAPTER 8
- The point of contact between the work piece and the chuck
is at the jaw. The jaw needs to be redesigned in order to
properly hold the work piece. Some of examples of good and
poor design of top jaws are shown below.

143
Correct and Incorrect
Designs of Top Jaws
Figure (a) shows that the length

to height ratio should not exceed
1:1 and the height of the top jaw
should not exceed the length of
master jaw. Figure (b) shows
that the gripped diameter should
always be larger than the
diameter that is being machined
while Figure (c) indicated that
FIXTURE FOR TURNING
the work piece should be ac

close as possible to the face of
CHAPTER 8
the chuck. Figure (d) and (e)

indicates that the center line of
the jaw must be in contact with
the work piece and not
otherwise.
144
EXAMPLE OF TURINING
FIXTURES
FIXTURE FOR TURNING
CHAPTER 8
145
CHAPTER 8
FIXTURE FOR TURNING
146
CHAPTER 8
FIXTURE FOR TURNING
147
CHAPTER 9
GRINDING FIXTURE
• Differentiate grinding processes and its application
Identify work holding tools for grinding

GRINDING FIXTURE
•
CHAPTER 9
•(1 HOUR)
148
9.1 Grinding Process

- Grinding can be divided into various types with different machine
configuration. Among the grinding processes that are common are;
Process Description
Surface grinding Produces flat high quality surface
Cylindrical grinding Produce high quality ID or OD surfaces
Jig grinding Generate accurately sized and located hole on hardened material
Center hole grinding Produce precise center hole in a work piece

GRINDING FIXTURE
Abrasive belt grinding Continuous belt with abrasive grains with backing
CHAPTER 9
Abrasive cutoff Uses thin, bonded abrasive wheels to cut up billet
Honing Using bonded adhesives stones to improve surface finish
Special grinding Thread, gear and spline, tool and cutter, cam, crankshaft
149
9.2 Work Holding For Grinding

- Grinding is basically the final process in machining operation.
Grinding determines the work piece’s dimensions are within the
tolerance set in the specification. Normally the other machining
process will machine the work piece and stop while it is still larger
than the specifications and it is the job of grinding to machine it
down to specifications. Due to the small amount of material removal
involve in grinding, it is not justified to have a complex fixture to
hold the work piece. Simplicity in design is important so that the cost
is also minimized to make it comparable to the amount of material
being removed.

GRINDING FIXTURE
CHAPTER 9
- Similar to other fixtures grinding fixture must accommodate easy

loading and unloading. This will contribute to minimizing the
process time. The clamping force in grinding does not have to be too
strong because the force involved is much lower to metal cutting
operations.
- Accuracy is the key to grinding thus making it crucial that the

fixture is of high accuracy. Failure to design an accurate grinding 150

- The most common work holding tools for surface grinding are
magnetic chuck, vacuum chuck, precision vises and modular tooling.
For cylindrical grinding, standard chucks, mandrel and collets are
widely used.

- In general the following considerations have to be taken in
designing grinding fixtures;
•Tolerance must be held closely
•Do not require complex fixture
•Use the same locating surface as other operations
•Avoid deflection
•Control heat build up
GRINDING FIXTURE
CHAPTER 9
•Coolant to be delivered at minimum pressure

•Easy removal of fluid and sludge
•Rotating fixture must be balanced
•Must accommodate wheel dressing without taking the fixture off
151
CHAPTER 10
FIXTURE FOR ASSEMBLY & JOINING

• Identify and explain mechanical assemblies used for joining

• Apply correct mechanical assemblies for different application
• Explain hot joining methods of assembly
CHAPTER 10
• Understand the concept of nesting fixture
•(1 HOUR)
152
Type of Joining

Fixtures for assembly and joining can be classified into two
categories;
I. Mechanical assembly and joining fixtures at room
temperature
II. Fixtures for hot joining methods involving heat

I.Mechanical Assemblies

Mechanical assemblies are the various method of joining one or

more components using mechanical means. Examples of the various
mechanical assemblies are;
CHAPTER 10
i.Riveting – where 2 or more parts are held together in predetermined

positions while the parts are riveted as specified by the part print.
Stationary Riveting Fixture
153
ii. Drilling and pinning – the parts are drilled using a normal drilling
fixture and pinned to assembly specifications.
Drill and Pin Fixture for

Gear and Motor Shaft
iii. Crimping and swaging – used in the assembly of two parts by

crimping a portion of one part over another.

CHAPTER 10
Swaging Fixture for Electrical Connectors
154
iv. Pressing – holding fixtures while an adhesive dries (a means of
applying pressure during drying cycle)
– a fixture to hold 2 parts while one is pressed into
another
Pressing Fixture
v. Tab bending – designed for holding parts together, position them

CHAPTER 10
and forcing tabs of one part over the other.
Tab-Crimping Fixture
155
vi. Wire stitching – hold parts in position for fastening with wire
stitches
vii. Wire stapling - hold parts in position for fastening with wire
staples
viii.Bolting – using bolts and nuts to fasten the components together
Fixture for Screwed Assembly

CHAPTER 10
156
Mechanical assemblies is not only to assemble metal, plastic and the
likes but it can be used to do assembly of wire harness as shown in
the illustration below;
Wire Harness
CHAPTER 10
Boards
Mechanical assemblies can be divided into two main applications.

The first application is positioning. Positioning fixtures are to
precisely assembled components together and later to be assembled
into a larger assembly. For this application, variation allowed in the
sub assembly is minimal in order that the sub assembly to match the
157
larger assembly. Dimension and alignment is critical in positioning
The other application of fixture is for work holding. Work holding fixture
does not require high accuracy. The purpose of work holding fixture is to
facilitate quicker assembly to increase productivity and efficiency.

II.Hot Joining Methods

All type of welding, brazing and soldering fall under this category of hot
joining method of assembly.

i.Welding Fixtures

-Special attention has to be given to these areas in designing welding fixture;
•Should enable all weld to be done in convenient position

•Work piece should be easily and quickly positioned (by one hand where ever
possible)
CHAPTER 10
•Simple and inexpensive with accuracy mo greater than what is required

•Should be built around the work piece
•Only control the essential work piece
•Permit one direction of movement to avoid locked in stresses
•Joints must be readily accessible
•Vertical and overhead welding to be avoided
•To compensate thermal distortion, the components can be bend in the fixture
before welding.
•Heat distortion should release rather than bind the work piece to the fixture
158
•Insulates all location that is touched
- Additional attention should be given to the different type of
welding. In designing gas welding fixture, using acetylene and
oxygen to allow fusion between the filler and the two work piece, no
large heat conducting fixture masses should be close to the weld
area. This will dissipate the heat quickly and may cause crack in the
weld. The heat loss can be minimized and slowed down by using non
heat conducting elements on the point of contact between the work
piece and the fixture.
Workpieces With Simple
Fixturing for Gas
Welding Operations
CHAPTER 10
- Arc welding fixture must be sufficiently strong to avoid

misalignment during welding. In arc welding, backing bars parallel
to the weld line to support the molten weld, govern the weld contour
and protect the weld root from the atmosphere to avoid oxidation.
Heat should also be properly dissipated by properly positioning the
backing bars, locators and supports. 159
Set Block
Locators
- Spot welding uses high force application and proper clamping is

necessary to ensure that the work piece remains properly located.
Spot welding also uses high current, produces high heat and sparks if
the welding gun is not positioned properly. The main requirement of

spot welding fixture is to have clearance above and under the work
piece to allo access for the spot weld gun tip.
CHAPTER 10
Typical Standard Electrode Tips

and Operations
160
- Resistance welding process, in which electric current flows
through the work pieces to be welded ant meets resistance which
heats and soften and later pressed mechanically to make the weld,
should only melt the work pieces and should not melt the fixture.
The resistance is normally provided by magnetic materials because it
cuts down the flow of current. To avoid melting of the jigs the
following can be taken into consideration;

• The electrical conductor part of the fixture is made of material with
very low electrical resistance such as copper, aluminum bronze and
other copper base alloys.

• Provide a cooling system for the jig
• Minimize the number or size of the joints since the more or larger
CHAPTER 10
joints require higher heat.

• Keep materials out of the heated area of the fixture.
- Projection welding utilizes similar concept as resistance welding of

current flow and a cooling system. An example of projection welding
fixture is shown below.
161
Welding Two Stampings
1 Nest for locating the work piece

2 Locating dowels
3 Lower electrodes
4 Locating block
Copper bars with water circulation as cooling
5
system
Copper bars with water circulation as cooling
6
system
7 Copper base plates

8 Copper base plates
9 Insulations
CHAPTER 10
10 Insulations
11 Insulations
162
ii.Brazing and Soldering

Brazing and soldering uses filler material and heat to bond the work
pieces together. However, brazing and soldering does not involve
any welting of the work pieces that are being joined. The following
requirements need to be fulfilled in order to have a good brazing or
soldering fixture;
•High rigidity especially in high stress areas
•Work piece supports must provide alignment
•Located supports as far as possible to avoid heat sink effect
•Fixture in incline position to allow gravity assisted capillary action

•Ample access in working area to allow application of flux, filler
metal, heat and cooling medium
CHAPTER 10
•Work piece hold-down to use mechanical clamps, avoid springs

since it loose resiliency with heat
•Heat the whole joint to ensure uniform flow of the alloy through the
joint
•Easy loading and unloading of work pieces
•Fixture must maintain alignment until filler solidify
163
Simple Nesting Fixture with
Work in Place
Soldering Machine Using Simple Nesting Fixture

CHAPTER 10
Nesting Fixture for Brazing

Nesting Fixture for Brazing with and
with and External Inductor
Internal Inductor
164
CHAPTER 11
INSPECTION FIXTURES & GAUGES

• Identify and explain mechanical assemblies used for joining

• Apply correct mechanical assemblies for different application
• Explain hot joining methods of assembly
CHAPTER 11
• Understand the concept of nesting fixture
•(1 HOUR)
165
1. Basic Principles of Gauging

- Tolerance is required because it is impossible to get 2 working
pieces with exactly the same dimensions. Gage tolerance is
determined by work piece tolerance. The amount of tolerance for a
gage is normally 10% of the work piece tolerance. Gauges that are
used in production by production workers are known as working
gauges.

- Inspection gauges, on the other hand are gauges that are used by
the inspection department. These gauges normally have a tolerance
of 5% of the work piece tolerance.

CHAPTER 11
- Master gauges are gauges that are being used for checking the
accuracy of other gauges and the accuracy tolerance is 10% of that
particular jig that is going to be inspected.
-Deciding the actual tolerance can be divided into two common

systems of unilateral or bilateral tolerancing.
1.1 The Bilateral System

166
The disadvantage of this tolerancing is that oversized and
undersized will go through and pass the inspection.


1.2 The Unilateral System
CHAPTER 11

The unilateral system only allows tolerance that is larger than the
minimum work piece size to a range that is smaller than the
maximum dimension allowed. In this system the work piece, is
always within the maximum and the minimum sized.

167
The disadvantage of this tolerancing is that oversized and undersized
will go through and pass the inspection.

2. Gauge Wear

- Gauges are subjected to friction while being used and this will
CHAPTER 11
resulted in dimension variations even after using it only once. To

overcome this problem, selecting the right material and introducing
allowance to the dimensions will alleviate the problem.

2.1 Gauge Wear Allowance
Gauge wear allowance is a small allowances added to the nominal to
the GO-plug gauge and subtracted on the GO-ring gauge. This will
be used up during operations and once this is used up the gauge
should be replaced.On the NOT GO side, normally no allowance is 168
2.2 Gauge Materials
Selection of materials is important to ensure the gauge will last
longer. Hardened alloy steel is normally used for gauge material. To
increase the life of the gauge the contact surface is usually chromium
plated especially for high volume production run. For operations
where gauge wear is excessive, tungsten carbide contacts can be
used.
In selecting the material, the designer must also ensure that the
contact surface is not too hard that it damages the surface of the work
piece.
CHAPTER 11
169
3. COORDINATE MEASURING MACHINE (CMM)
FIXTURES
- Key Concept : The CMM is the gage, the holding fixture is just
a stage
For the vast majority of CMM inspection applications, the CMM
interrogates the actual part to confirm the orientation of the part on
the machine, and subsequently establish the part datums. This is best
practice as it greatly reduces the influence of part miss-loading in the
holding fixture as a source of error. The holding fixture rarely needs
to be built to gage tolerances, as it serves merely to present the part
to the measuring machine.

CHAPTER 11
- A part holding fixture often simplifies the inspection task, even for
manual inspection systems, simply by holding the part still, and in a
position that facilitates checking it. For automated inspection holding
fixtures are indispensable, as they allow the part to be presented in a
repeatable position, allowing the CMM to execute an automated
inspection sequence without collision into the part. The more
automated the inspection process, the more critical the role of the
holding fixture.
170
- The semi-dedicated fixtures streamline the inspection process,
reduce the inspection cycle time, and the production setup process
down-stream.
- Simple is best for CMM holding fixture construction. The goal is

to give the CMM full access to the part features hence a simple
structure minimizes interference. Similar to the concept of a 3-2-1
part alignment in the CMM software, a 3-2-1 (six point nest) locating
scheme is a very common structure for a CMM fixture.
CHAPTER 11
171
CHAPTER 11
172
- ALUFIX is a set of precision modular components, manufactured
mainly in high tensile strength aluminium that can be easily
interconnected using standard hand tools to construct metrology and
inspection fixtures. The modularity and reusability of the system, as
well as the high accuracy of the individual components, secure a
faster and more efficient way of fabricating the jigs and fixtures
required for the inspection and verification of manufactured goods.
As all the ALUFIX components can be used many times the fixturing
costs can be reduced substantially. The high position accuracy of the
system grid points guarantee a good assembly repeatability as well as
fast and efficient calibration of the contact and datum points on the
fixture.
CHAPTER 11
173
4. ONLINE INSPECTION FIXTURES

CHAPTER 11
Flatness inspection
fixtures for casted part
Part after machining

(CNC milling) & coating
Diameter inspection in
different heights after
CNC Turning process
174

JIG&FIX DESIGN Nota

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JIG&FIX DESIGN Nota

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JIGS AND FIXTURES

INTRODUCTION TO JIGS & FIXTURE

Q : Name at least 5 work holding devices for metal cutting

2)Master part system, in which the produced product is made

fairly cheaper, but in term of accuracy is not as accurate as jigs and

3)Group production system. The group is responsible to

- This factor of interchangeability allows product to be mass

standard components in mass production utilizes jigs and

-Jigsand fixtures benefits,

the reduction of manpower skilled requirement, the end

- Analyze the operation that is going to be done on the work piece.

2.1 Use Wider Tolerance

2.2 Eliminate Unnecessary Machining

-Only machine the surface of locations that is really necessary. By doing

2.3 Use Informal Drawing or Sketches

2.5 Use Alloy

- Alloy is normally softer. If alloy is good enough to be used in the

2.6 Use Alternative Material

 Objective of Work Holding:

 Elements of Work Holding Device:

ii) Clamping elements to maintain the part in precise location during

Fixing to machine tool (machine table)

in both directions along the three principal axes, shown as x,

directions, around the same three axes.

• As shown in below Figure, the twelve degrees of freedom all relate

freedom permit rotational movement, in both clockwise and

• The devices that restrict a workpiece's movement are the locators.

• Locators provide a positive stop for the workpiece. Placed against

In designing a jig and fixture, 5 steps need to be taken in sequence.

Fixing to machine tool (machine table)

PRINCIPLES OF LOCATING &

in designing jigs & fixture by considering all

The best locating surfaces are often determined

• Referencing and Repeatability

Referencing the workholder to the cutting tool is performed by the

fixture keys, feeler gages, and/or probes. Referencing the workpiece

If a part is incorrectly placed in a workholder, proper location of the

The ideal locating point on a workpiece is a machined

1.1 Locating Point Selection

b) Single/ Multi Locator

• In a jig and fixture, avoid duplicate locator. If there is more

• Locator should also be positioned away from chip locating

work piece to be stuck to the locator. This will make it more

1.3 General Considerations for Locator & Support

locator and support will be subject of wear and tear. If the

Fool proofing is another characteristic that can contribute to

therefore need for clamping whereas there will no movements

The first step in 3-2-1 method is to introduce 3 pins in the Z-

The last pin is to be introduced on the remaining plane and 1

3.1 Diamonds Pin

should be arranged that it is facing the round pin to allow

Question on diamond pin.

Answer on diamond pin.

CLAMPING & POSITIONING

jigs & fixture

• Identify factors to be considered in selecting

operation and the quantity of parts to be produced. Location