Jigs and Fixtures For Machine Shop: by Abhishek Tevatia MAE, MAIT, Delhi

Metal Cutting and Tool Design (ETME-310)
Topic - Tool Design
Lecture on
Jigs and Fixtures for Machine Shop
By Abhishek Tevatia MAE, MAIT, Delhi
Abhishek Tevatia, Mechanical & Automation Engineering Department
Topic - Tool Design
This lecture will cover
(i) Definition of Fixture and Jig (that aid machining) (ii) Conceive the purposes of use of jigs and fixtures (iii) State the design considerations for jigs and fixtures (iv) I illustrate the methods of (a)locating (b)supporting and (c) clamping of jobs in jigs and fixtures (d) guidance of cutting tools by bushes in jigs
Topic - Tool Design
DEFINITION
Fixtures Mechanical (strong and
rigid) devices and used (in machine shop) to enable easy, quick and
consistently supporting
accurate and clamping,
locating, blanks
against the tool for higher productivity and product quality in batch
production Jig is a fixture having an additional feature of tool guidance.
Topic - Tool Design
Steps usually followed in machining without fixture

Marking & Punching Mount and fix the blank on the machine bed or in a vise with proper alignment, support and clamp Adjust the tool-work position by shifting job, vice or tool Initiate machining and check/correct tool work position, Complete machining Inspect / measure the machined features
Abhishek Tevatia, Mechanical & Automation Engineering Department 4
Topic - Tool Design
BASIC PURPOSES OF USING JIGS & FIXTURES
To eliminate tedious marking, punching, mounting trialpositioning and repeated checking

Easy, quick and consistently accurate locating, and clamping blank against the tool Guidance of cutting tool (drill, reamer etc) To raise productivity and maintain quality consistently To reduce operators labour and skill requirement To attain close tolerances and interchangeability To reduce rejection and overall cost
base
mounting
Topic - Tool Design
Economic application of jigs and fixtures
Mode of machining
in ordinary machine without fixtures
in ordinary machines using jigs and fixtures
In automatic machine without or with special fixturing
Topic - Tool Design
DESIGN OF JIGS & FIXTURE
Salient elements to be designed

Base and body Locating elements/ system Supporting system Clamping system/ elements Tool guides framing & bushing Indexing system, if needed Auxiliary elements (fasteners etc)
Topic - Tool Design
Factors essentially considered during design of jigs and fixtures

Easy, quick & consistently accurate locating Provide strong, rigid and stable supporting Quick , strong and rigid clamping Tool guidance for accuracy and safety Easy, quick and uninterrupted loading and unloading Use of minimum and standard parts Adjustable locating for part size variation Chip removal Simple but accurate indexing, if required Ergonomics and safety Manufacturability Service life and cost
Topic - Tool Design
DESIGN OF FIXTURE AND JIGS

Major functions requiring proper design
(a)
(b)
Locating Supporting Clamping of blank Tool guidance in jigs
There may be several methods of locating etc depending upon

job-shape, size, material
machining requirement
cutting tools-type, size & shape
But some basic rules are followed during design

Topic - Tool Design
Fundamental requirements for locating, supporting and clamping
10
Topic - Tool Design
Locating Blanks in Jigs or Fixture

Design Principles or Rules o o o o o o one or more pre machined surface holes are to be used for reference The reference surface or holes should be important features based on which other dimensions are laid Locating should be easy, quick and accurate Locating pins should be strong, rigid and hard. Locating pin should be wide apart V-block and cones are preferable for cylindrical jobs.
11
Topic - Tool Design
Design Locating cont

o Sight location for jobs of irregular surfaces
o o
Pivoted arms may be used for locating and supporting large jobs adjustable pins or screws are to be used to accommodate the part size variation
Topic - Tool Design
General methods of locating

Locating work piece for machining in lathes
o o By fitting into self centering chuck By fitting into collets
o o o
Mounting in between centers Mounting on mandrel held in spindle Fitting in a fixture mounted on faceplate
13
Topic - Tool Design
General methods of locating cont..

Locating work piece for machining in other than lathes
14
Topic - Tool Design

Locating by holes
Locating by holes and V-block

Topic - Tool Design

Locating by mandrel or plug
16
Topic - Tool Design
SUPPORTING PRINCIPALS AND METHOD Design principals or rules for supporting

o o o Minimum 3 point contact required to support at flat surface Supporting pins or plugs should be strong, rigid and hard Unsupported span-should not be much wide
17
Topic - Tool Design
SUPPORTING Cont..
o supporting should keep job stable under forces
o Recess to be provided within wide contact area.
18
Topic - Tool Design
SUPPORTING Cont..
o cylindrical jobs are to be supported (and located) on V block o additional (over 3) pins are to be used
to compensate part size variation to support large and heavy jobs to prevent deformation of job by forces
o additional pins should be adjustable
o Mandrel may be used to support land (and locate) ring type blanks
Topic - Tool Design
SUPPORTING Cont..
Common methods of supporting
Supporting on vices Supporting at flat surfaces Supporting by fixed pins or plugs
Topic - Tool Design
SUPPORTING Cont..
Common methods of supporting
Extra supporting by additional adjustable pins.
Supporting (& locating) on V-block and mandrels

Topic - Tool Design
Design for Clamping

Design principles or rules of clamping
Clamping must be strong, rigid and stable Should be easy, quick and adequate.
Should not hinder loading and unloading work Clamping force should act against rigid part and not damage the job
Minimum and standard parts are to be used for clamping Wear parts have to be hard and replaceable
Clamping should be fool-proof Reliability, safely and low cost.
Topic - Tool Design
Methods of clamping in fixtures

(a) Ordinary (b) Quick acting Ordinary (Slow) Methods
Topic - Tool Design
Ordinary Methods Cont.. Clamping from side for through machine of top surface
Topic - Tool Design
Ordinary Methods Cont.. Clamping using swing plates
Other common clamping methods Vice, magnetic chucks, chucks and collets
Topic - Tool Design
Quick Clamping Method Quick acting nut
Topic - Tool Design
Quick Clamping Cont..
Clamping using Cam
Topic - Tool Design
Multiple clamping of cylindrical jobs
Topic - Tool Design
Quick acting screw (bayonet type)
Topic - Tool Design
DRILL JIG BUSHING

Purposes of using bush
To reduce or eliminate runout To locate the tool in position To prevent buckling and breaking of tools To attain and maintain accuracy, safety and economy
Desired characteristics
Material - hard or hardened steel (Rc >= 60) Finishing inside and outside by grinding Bushes length >= 2d and diameter d+ (d is drill diameter) Quick fitting, removal and replacement Do not slip unwantedly
Topic - Tool Design
Types of bushes
According to fitting
press fit slip type with liner screw type with/ without liner
According to head
without head with head with flange
Topic - Tool Design
Types of bushes Cont
Frequently replaceable bushes
Topic - Tool Design
Types of bushes Cont
Special types of bushes

Jigs and Fixtures For Machine Shop: by Abhishek Tevatia MAE, MAIT, Delhi

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Metal Cutting and Tool Design (ETME-310)

Topic - Tool Design

Abhishek Tevatia, Mechanical & Automation Engineering Department

Metal Cutting and Tool Design (ETME-310)

Topic - Tool Design

This lecture will cover

Abhishek Tevatia, Mechanical & Automation Engineering Department

Metal Cutting and Tool Design (ETME-310)

Topic - Tool Design

accurate and clamping,

production Jig is a fixture having an additional feature of tool guidance.

Abhishek Tevatia, Mechanical & Automation Engineering Department

Metal Cutting and Tool Design (ETME-310)

Topic - Tool Design

Steps usually followed in machining without fixture

Metal Cutting and Tool Design (ETME-310)

Topic - Tool Design

BASIC PURPOSES OF USING JIGS & FIXTURES

To eliminate tedious marking, punching, mounting trialpositioning and repeated checking

Metal Cutting and Tool Design (ETME-310)

Topic - Tool Design

Economic application of jigs and fixtures

In automatic machine without or with special fixturing

Abhishek Tevatia, Mechanical & Automation Engineering Department

Metal Cutting and Tool Design (ETME-310)

Topic - Tool Design

DESIGN OF JIGS & FIXTURE

Salient elements to be designed

Abhishek Tevatia, Mechanical & Automation Engineering Department

Metal Cutting and Tool Design (ETME-310)

Topic - Tool Design

Factors essentially considered during design of jigs and fixtures

Abhishek Tevatia, Mechanical & Automation Engineering Department

Metal Cutting and Tool Design (ETME-310)

Topic - Tool Design

DESIGN OF FIXTURE AND JIGS

Locating Supporting Clamping of blank Tool guidance in jigs

There may be several methods of locating etc depending upon

But some basic rules are followed during design

Metal Cutting and Tool Design (ETME-310)

Topic - Tool Design

Fundamental requirements for locating, supporting and clamping

Abhishek Tevatia, Mechanical & Automation Engineering Department

Metal Cutting and Tool Design (ETME-310)

Topic - Tool Design

Locating Blanks in Jigs or Fixture

Abhishek Tevatia, Mechanical & Automation Engineering Department

Metal Cutting and Tool Design (ETME-310)

Topic - Tool Design

Design Locating cont

Metal Cutting and Tool Design (ETME-310)

Topic - Tool Design

General methods of locating

Abhishek Tevatia, Mechanical & Automation Engineering Department

Metal Cutting and Tool Design (ETME-310)

Topic - Tool Design

General methods of locating cont..

Abhishek Tevatia, Mechanical & Automation Engineering Department

Metal Cutting and Tool Design (ETME-310)

Topic - Tool Design

General methods of locating cont..

Locating by holes and V-block