SYLLABUS

For the trade of

JIGS AND FIXTURE MAKER

UNDER

Apprenticeship Training Scheme

Government of India
Ministry of Labour & Employment
Directorate General of Employment & Training
New Delhi-110001
 GENERAL INFORMATION

Name of the Trade : Jigs and Fixtures Maker

N.C.O. Code No. : 7222.30

Entry Qualification : Passed 10th class examination

under 10+2 system of education or
its equivalent.

Duration of the Apprenticeship Training : 02 years

Rebate allowed in Apprenticeship Training : One year and six months for
trainees completed Broad Based
Basic Training in Production and
Manufacturing Sector under Centre
of Excellence Scheme and
Advanced module of Centre of
Excellence Scheme in
Manufacturing Jigs and Fixtures.

Ratio of apprentices to workers other than : 1:2

unskilled workers

Course Outline :

The training shall comprise of –

a) On the job training
The actual training shall be dependent on the facilities available in the
establishment, with an idea to expose the trainees to as many activities as possible.
The trainees shall maintain a daily work dairy for a job training, which shall be
periodically authenticated by the supervisor.

b) Project
Each apprentice shall under take a project in any of the areas depending on his/ her
interest and facilities available in the establishment. The duration of the project shall
be two Weeks.
 Syllabus for the trade of Jig & Fixture Maker
Under
Apprenticeship Training Scheme

1. Reading & understanding of Jigs & fixtures, drawing etc.

Use of limits fits & tolerances.

2. Measurement of surface finish.

Measuring straightness, flatness circularity & roundness, cylindricity, profile of any line
or surface, parallelism, perpendicular & squareness, angularity, position concentricity
& coaxially symmetry.

3. Revision of metal cutting

To do drilling, reaming, boring & its sub types like counter bore, counter sinking
Reaming, taping, boring, etc.
Understand the tool geometry

4. Turning processes, working on milling machine. Types of milling.

5. To identify different types of cutters

6. Use of heat treatment processes

Working on grinding machine.
Selection of grinding wheels and standard marking system as per IS 551
To understand wheel balancing, turning and dressing

7. Factors infusing surface quality. Grinding allowance, hardness requirement

Working on surface finishing processes like broaching, honing & lapping
To work on jig grinding machine.
Jig boring machine

8. Electrical discharge machine (EDM)

Understand the use of Jigs and Fixtures

9. Locations, clamps, bushes.

10. Use of fasteners.

Study of fastening methods

11. Use of dowels and doweling

12. Steps in manufacturing jigs & fixtures.
Process planning

13. Use of drill bushes

14. Location principals and degree of freedom
15. 3-2-1 principals of location and choice of location surface

16. Use of clamping principles

Hydraulic clamping, pneumatic clamping, vacuum clamping & magnetic clamping
Indexing devices - linear indexing devices & rotary indexing devices.
Template jigs & pot jigs-description of parts & function

17. Use of indexing jig, turn over jig, leaf jig & latch jig
Milling fixtures

18. Direction & intensity of forces in milling

Essential of milling fixtures
Straddle milling fixture
Reciprocal milling fixture
Modular jigs fixture (Universal tool kit)

19. Use of turning fixture

20. Use of grinding fixture

21. Use of broaching fixture

22. Use of welding fixture

23. Modern jigs and fixtures using hydraulics and pneumatics

Cost estimation of jigs and fixtures

24. Study of SEAMS

25. Project work

26. Project work

Related instructions

1. Cores of objective & safety rules to be observed in shop floor.

Brief outline of various subject to be revealed & scope for employment
Methods of production & importance of Jigs & fixtures in batch production, and
continuous production.
Review of engineering drawing –sheet size, layout planning lines & lettering,
method of projection, section dimensioning conventional representation of screw
threads & gears.
2. *Limits, fit & tolerances as per IS:919-2002-Necessity of specifying limits of size,
basic size & deviation types of fits & application hole basic & shaft basic system,
advantages of hole basic system over shaft basic system, fundamental deviation &
IS tolerance, unidirectional & bilateral tolerance and interpreter of fit designation for
different sizes.
* Surface roughness- Necessity of finish on engineering components, unit of surface
roughness, interpreter of surface roughness, interpreter of surface roughness
symbols in drawing, surface roughness expected form various manufacturing
process and methods of measuring surface finish.
3. Geometric features as peer IS 8000-1985-straightness, flatness circularity &
roundness, cylindricity, profile of any line or surface, parallelism, perpendicularity &
squareness, angularity, position concentricity & coaxially symmetry maximum
material condition & representation of geometric feature in engineering drawing.
Principal of metal cutting –orthogonal & oblique cutting, chip formation temperature
on cutting edges, necessity of coolant, tool were & tool life. Cutting tool material-
properties & application of carbon steel alloy steel high-speed steel & tungsten
carbides.
4. Drills- drill material, drill types & used. Helix angle point & clearance angle according
to depth of hole, material to be drilled & drill sizes. System of drill size, standard
designation influence of symmetry of point angle & lip length on size of holes
selection of center drill size according to diameter of work piece, carbide tipped drills
and use.
Reamers- types of reamers and use reaming allowance care & entrance.
Taps – hand tapes machine tap and calculation of drill size for 60° metric threads.
Counter bore, counter sink, sport face and boring tools.
Drilling Machine – types, specification, tool holding and work holding device.
Drilling machine operations- Drilling center drilling, reaming, tapping, boring, counter
boring.
Counter sinking and spot facing producer, Spindle speed and feeds for these
operations.
5. Signal point’s tool- geometry of rough turning to finish turning tool- parting tool,
boring tool & threading tool. Carbide tipped tools with disposable inserts, influence
of tool angel on cutting efficiency tool life & surface finish.
Turning processes – lathe types specification attachment & accessories tool holding
& work holding device, lathe operation, tool setting, cutting speed feed, depth of
cutting.
6. Milling Machine- types, specification. Attachment and accessories, tool holding and
work holding device.
ii) Milling process- face milling and peripheral milling (up-milling and down milling.
iii) Milling cutters – cylindrical cutting side & face cutter with index able carbide
inserts & uses. Tip geometry of milling cutters.
iv) Selection of cutting speed & depth of cut milling operation- plain milling, face
milling, side milling, straddle milling, angular milling, gang milling, from milling,
profile milling, end milling, saw milling, key way milling, groove milling, slot milling,
helical milling and cam milling.
 7. Universal dividing head- parts & function. Indexing methods – direct indexing,
simple indexing, different indexing, angular indexing and linear indexing,
calculations.

i) Materials used for jigs & fixtures and related specifications.

ii) Classification of steel, effect of alloying elements, necessity of
treatment and heat treating equipments.
iii) Iron carbon equilibrium diagram, TTT diagram quenching media.
iv) Heat treating process, Annealing, Normalizing, Hardening and tempering and
stress relieving.
v) Surface Harding and cryogenic treatment.
vi) Distortion of components during heat treatment defects and remedies.

8. Grinding processes- principle of grinding process.

Grinding machine- cylindrical and surface grinding machines, specification and work
holding device
Grinding wheels – abrasive types, grain sizes, grades, structure and bonds.
Selection of grinding wheels and standard marking system as per IS 551.
Grinding parameters – wheels speeds, work speed, downfeed or in feed and
traverse feed. Wheel balancing, turining and dressing.
Factors infusing surface quality. Grinding allowance, hardness requirement and
coolants.
Procedure of grinding parallel, right angled, stepped and angular surface.

9. i) Broachingmachine types, broaching techniques and application.

ii) Lapping and honing process – working principal, types of machine and
surface finish obtainable.
iii) Jig boring machine parncipal parts, accessories, tools, works holding
devices, methods of locating and edge, co-ordinate locating system, co-
ordinate factor, measurement and inspection of holes.
iv) Jig grinding machine- part working principal application.
v) Electrical discharge machining (EDM)- types of machine working principal
and application.
vi) Co-ordinate measuring machine application.

10. Definition of Jigs and Fixtures.

Difference between Jigs and Fixtures.
Advantages of Jigs and Fixtures
Basic elements of drill Jigs body, feet, locations, clamps , bushes and their function.
Chip removal abnd swarf disposal arrangement.

11. Presentation of work piece in the assembly drawing of Jigs and Fixtures.
Types of jigs and fixtures bodies-rabricated, we;ded and cast.
Standerd fasteners used in jigs and fixtures and fasterning methods:- types of
threaded fasteners-size of clearance hole with respect to dowelds-counter boar and
 counter slink hole size method of applying socket cap screws-shoulder scrws and
application socket head screws-socket flat head screw and application.

12. Dowels and doweling: purpose of doweling, material and nardness of dowels
regular and oversize dowels-shapes of dowels-indian standard for dowels-reaming
dowels holes-proportion of through, semi blind and relived dowels-dowels for multi
parts-Richard brothers dowels of blind applications-positioning prinicipals of dowels
holes in jigs and fixtures.
Standard commercial sizes of steel plants, odes, bars sheets and channels.

13. Steps in manufacturing Jigs & Fixtures.

Process planning: Establishment of reference datum surface, choosing cheapest
machine process which can accomplish the tolerance specified, positioning the
finishing operation, economic/logical sequencing of operation, tooling, man power
requirement, degree of skill necessary, operation time and machine tool setting
time.
Working out the requirement of raw meterial sizes of manufacturing the jigs and
fixtures elements.

14. Drill bushes-press fit bushes (headed & headless) Renewable bushes, slip bushes,
slip bushes, threaded bushes, special bushes and bushes for drilling at curved and
tapered surface, Standard Manufacturing steps of drill bush.

15. Location prinipals and degree of freedom.

3-2-1 principals of location and choice of location surface
Redundant location, motion eclonomy and profing.
Location from plane surface-fixed and adjustable support for rectangular work piece,
equalizer rocker locators, location pads, for large fixtures and recess for burr and
dirt.
Loction from a profile-sighting location with finger slot, profile location by pin,
exocentric location and location nets.
Location from cylinder-cylindrical locators, jamming prevention lead, dimaond pin
application and design, conical locators and V-locators.

16. Clamping principles-positioniongof clamps ofn the work piece, strengh of clamp
according to cutting force, productivity requirement operator fatique and work piece
variation. Tapes of clamps-screw clamp, flat strap clam, pivoted strap clamp, edge
strap clamp & edge jaw clamp.
Equalizing clamps latch clamp, swing plate clamp & double ecting clamp.
Quick action clamps, hinged clop, swing clamp, wedge clamp, cam clamp, hook
clamp & toggle clamp.
Hydraulic clamping, pneumatic clamping, vacuum clamping & Magnetic clamping.
Indexing devices-lineart, indexing devisees & rotary indexing-devices. Template jig
& pot jig-description of parts & function.
17. Indexing jig, turn over jig, leaf jig & latch jig. Description of parts and functions of:
1) Milling fixtures-description & types
 2) Manufacturing steps of milling fixtures.

18. Direction & intensity of forces in milling according to types of machine kind of cutter
& direction of feed in up milling & down milling.
Essentials of milling fixtures - strengh, thrust cutting seating, and machine location
tendons, rigid clamping, motion ecomomy & scarf disposal.
Straddle milling fixture, kay way milling fixture & gang milling fixture-description of
part of functions.
Reciprocal milling fixture - description of part and functions of
Modular Jigs Fixture (universal to kit) - Description advantages and applications.

19. Turning fixture-chucks with special jaws, use of faceplate and balancing
requirement. Spring collects and lathe mandrels-types and applications.

20. Grinding fixture-Nesting of components for surcace grinding, epoxy resin nest, use
of sine vices and industrial adhesive taps.

21. Broaching fixtures-types and applications.

22. Welding fixtures-thermal expansins and contraction due to welding, clearance

between locators nd work piece to permit expansion ande contraction use of C-
clamps and toggle clamps, spatter grooves, tilting and rotating arrangement for
welding in down hand position. Typical examples of welding fixtures.

23. Modern jigs and fixtures using hydrayulics and pneumatics.

Cost estimation of jigs and fixtures Revision and Test.

24. Study of SEAMS.

25. Project Work.

26. Project Work.