DESIGN OF JIGS, FIXTURES, PRESS TOOLS AND MOULDS UNIT I LOCATING AND CLAMPING PRINCIPLES 1. What is Locator? 2.

What are the basic rules for Locating? 3. What do you know about Fool proofing? 4. What are the locating methods? 5. What are the types of Locator / Support? 6. Differentiate Pin and Button Locator. 7. What are the principal of secondary locators? Explain with example. 8. What are the disadvantages of nesting type locators? .9. If two or more holes to be drilled are very close, what is the method used in providing bushing? 10. What is the clearance provided between the drill bush and the drill bit? 11. What are the general classifications of drill bushes? 12. Why should the drill feet be ground after the assembly with the jig frame, rather than before the assembly? 13. What is the general rule to decide the length of a drill bush? 14. Generally, it is a practice to have four legs for the drill jig instead of three. Give your explanation. 15. What are the principles of Locators? 16. What are the types of production? 17. What are the types of Clamp? 18. What is the use of Ejectors? 19. What are the specific advantages of conical locators? 20. What are the principles of clamping? 21. What is six point principle /3-2-1 principle? 22. What are the types of clamping methods? 23. What type of locator used for Circular and Cylindrical surface? 24. What do you know about Nesting Locator/ Cavity Locator? 25. Write the common types of nesting locators. 26. What are the types of Sight locators? 27. What are the types of mechanical actuation clamps? 28. What are characteristics of good location? 29. What is repeatability? 30. What are the major constraints of locator? 31. How many planes of movement for rectangular and cylindrical surface? UNIT II JIGS AND FIXTURES 1. What is Jig? 2. What is Fixture? 3. Differentiate Jigs and Fixture. 4. Write the advantages of Jig and Fixtures. 5. What are the essential features of Jigs and Fixtures? 6. General rules for designing Jigs and Fixtures. 7. What are the material used in Jigs and Fixtures? 8. List the factors to be considered for Jigs and Fixtures. 9. Tabulate the material list for various parts of Jigs and Fixture. 10. What is the difference between a drill jig and a fixture?

11. Distinguish between a drill jig and a drill fixture. 12. What forces does a drill bit exert on a workpiece? 13. Is it correct to locate drill bushes in the leaf of a leaf-type drill jig? 14. State the reasons for avoiding the clamping of a component with a hinged plate of a leaftype jig? 15. Why small projections that project outside the drill jig are avoided? 16. Complex clamping devices are avoided. State True or False. Give reasons for your answer. 17. The locating points in a drill jig should be visible. State True or False. State the reason for your answer. 18. What is the distance between the bottom of a drill bush and the workpiece? 19. What are the methods employed for removal of chips form the jig? 20. Why stress relieving is done for the jig bodies, which are fabricated through welding process? 21. What is the hardness of a drill bush? 22. What are the main advantages for choosing cast-constructed jig body? 23. What is the type of fit between a jig body and a liner bush? How is a liner bush of outside diameter of 20 mm dimensioned in a drawing to take care of the tolerances? How does the hole in the jig frame into which the liner bush is fitted, is dimensioned? 24. What is the type of jig used for drilling a number of holes in more than one orthogonal plane of a component? 25. How does an indexing jig work? 26. What are the cost considerations in the use of a fixture? 27. Why are keys/tenons mounted at the base of the milling fixture? 28. What are the various types of production milling? 29. What are the classifications of broaching fixtures? 30. What are the basic differences between a lathe fixture and a milling fixture? 31. How are components clamped to the fixture in a surface-grinding machine? 32. What are the advantages of jig and fixtures? 33. What are the elements of jig? 34. What are the two types of Jig? 35. What are the components of milling fixtures? 36. Write the classifications of milling fixtures? UNIT III PRESS WORKING TERMINOLOGIES & ELEMENTS OF CUTTING DIES 1. How is the stock guided in press tools? 2. What does an OBI press mean? 3. What is a double-action press? 4. How does a stock stop function in a manually-fed press tool operation? 5. What is meant by a compound die? 6. What is the difference between strippers, ejectors and knockouts? 7. What is the difference between coining and embossing? 8. What is the advantage of air-bend dies? 9. What is meant by centre of pressure? 10. What is the difference between direct and indirect piloting? 11. What causes the burnished surface (often referred to as cut hand) that appears on walls of the pierced hole and slug? 12. What is the function of a knockout rod? 13. What is the type of force coming on the punch? How are the punches designed?

the

14. What is the difference between a fixed and a floating stripper? 15. What is the function of the air-vent provided on the punch of a drawing die? 16. What is an automatic stop? 17. What is an inverted die? What as its advantage? 18. What is notching? 19. What is the difference between parting and cutting? 20. What is the effect of excessive clearance between the punch and die cutting operations? 21. What is triple-action press? 22. What are the different methods of attaching pilots to punches? 23. What are the elements of mechanical presses? 24. What are the types of common presses? 25. What are the press working operations? 26. Mention the principle accessories of common press. 27. What is bending? 28. What is mean by Swaging? 29. What is Drawing? 30. What do you know about Planishing? 31. What is mean by Coining? 32. What is Embossing? 33. What are types of Fixtures? 34. What is modular fixtures? 35. Write the advantages of modular fixture. 36. What are the disadvantages of modular fixture? UNIT IV BENDING FORMING AND DRAWING DIES 1. What is the difference between bending, forming and drawing? 2. What is the function of draw die ring? 3. What is a disappearing pin? Where is it used? 4. What are the methods of reducing spring back? 5. What is meant by air-bending? 6. What is the purpose of primary stops? 7. What is meant by curling? 8. What is meant by a wiping die? 9. In sheet metal piercing and blanking, what is meant by penetration? 10. What is a trigger stop? 11. What is an air-cushion? What is the advantage of air-cushion? 12. What is the force required for channel bending? 13. What type of press is used for air-bending? 14. What is meant by lancing? 15. What is a combination die? 16. What is meant by shut height of a press? 17. What is mean by angular clearance? 18. What is meant by stretch forming? 19. What is meant by fool proofing of a die block? 20. What is meant by a finger stop? 21. What is the difference between direct and indirect knockout? 22. What is meant by fine blanking? 23. What are advantages of bottoming dies compared to air dies? 24. What are the advantages of compound die compared to progressive die?

25. How do you determine the number of stations required for a progressive die? 26. What is the difference between swaging and bulging? 27. What is the type of press used for drawing? Why? 28. What are the defects in drawn components? 29. What is ironing with respect to drawing operation? 30. What is meant by reverse redrawing? 31. What is the effect of insufficient clearance between the punch and the die in a cutting operation? 32. What is the advantage of reversed redrawing? UNIT V DESIGN OF MOULDS 1. What is the use of Moulds and dies? 2. Name few molding techniques. 3. What is Die casting? 4. Why die castings used in manufacturing? 5. What are the Die Casting Advantages? 6. What are the Benefits of die casting vs. plastic molding techniques? 7. What are the Benefits of die casting vs. sand casting? 8. What are the Benefits of die casting vs. permanent mold techniques? 9. What are the Benefits of die casting vs. forging? 10. What are the Benefits of die casting vs. stamping techniques? 11. What are the Benefits of die casting vs. screw machine products? 12. Choose the proper alloy for die casting. 13. Discuss the Die casting process. 14. What do you know about Die construction? 15. What is Die casting Design? 16. List the types of Molds for Aluminum Casting. 17. What is Sand Casting Mold? 18. What is Casting Molds? 19. What is Shell Mold? 20. What is Ceramic Mold? 21. What is Permanent Mold Casting? 22. What is Plaster Molds? 23. What is Graphite Casting Molds? 24. What is Chill? 25. What is the need of Core? 26. What are the types of sand molding? 27. What is Mechanized sand molding? 28. What is automatic high pressure sand molding lines? 29. What is Horizontal sand flask molding? 30. What is Vertical sand flask less/ Disa molding? 31. What is Match plate sand molding 32. What is Vacuum molding?

PART-B UNIT-I 1. Explain briefly with neat sketch cylindrical and adjustable locators. 2. Explain briefly non-conventional clamping. 3. Explain briefly with neat sketch latch and wedge clamping. 4. Explain briefly magnetic clamping. 5. With a neat sketch explain pneumatic and hydraulic clamping. 6. What is meant by vacuum clamping? Explain. 7. Explain the types of locating devices. 8. Explain the types of clamping devices. 9. Explain the latch clamp with suitable example. 10. State the significance of clamping force in relation to cutting force. 11. Mention the various locating methods with suitable example. 12. What is the use of dowel pins? Explain with example? UNIT-II 1. Mention the advantages disadvantages of jigs and fixtures 2. Describe the design principles for jigs and fixtures. 3. Explain briefly materials used in jigs and fixtures. 4. Describe the elements of jigs and fixtures. 5. Describe the accessories of jigs and fixtures. 6. Explain briefly 3-2-1 location of principle. 7. Explain the functions of jig bushes? 8. Explain the condition of using plain and flanged bushes in jigs. 9. Explain the different types of jigs? 10. Explain the different types of fixtures? 11. Sketch the channel jig with an example. 12. Explain indexing jig with suitable example. 13. What are the design factors to be considered while designing a lathe fixture? 14. Briefly explain the construction and working of faceplate turning fixture. 15 Explain any one type of lathe mandrel. 16. List out the various types of milling fixtures and explain any two in detail. 17. Define the tennon and setting block in milling fixture. 18. Explain with a neat sketch the working of a gang milling fixture and compare with straddle milling fixture. 19. Differentiate straddle milling fixture and key-way milling fixture. 20. Define broaching and explain the types of broaching fixtures with neat sketch. 21. Design a milling fixture to make a slot of 120 X 120 X 15. 22. What are factors to be considered while designing milling fixture? UNIT-III Describe briefly the various press working operations. Write short notes on terminology. What are the factors to be considered while selecting a press? Explain briefly the functions of following parts in press tool. (i) Stripper (ii). Pilots (iii). Shedder. 5. Explain fixed stripper and spring loaded stripper with sketch. 6. Sketch complete die- set assembly. 1. 2. 3. 4.

7. Describe with neat sketches any two dies used in press working operations. 8. Describe with a neat sketch a compound die and compare its merits and demerits with combination die. 9. Explain with example center of pressure. 10. Differentiate between compound die, combination die and progressive die. 11. Write short notes on the following. (i) Bending and forming die (ii). Combination and compound die. (iii). Calculation of center or pressure with example. UNIT-IV 1. Write short notes on bending, forming and drawing. 2. Write down the step by step design procedure of cutting dies 3. Write down the step by step design procedure of drawing dies 4. Design for drawing die as shown in figure from medium carbon steel take ft = 36 KN/CM2 5. Sketch and design a drawing die as shown in figure from medium carbon steel 3600 Kg/CM2 6. Explain with example to estimate the number of draws in drawing process. 7. Write short notes on types of forming dies, 8. Sketch and design a blanking die to make 30mm diameter part from 1.6mm thick mild steel metal. Take 320 N/mm2 9. Sketch and design a blanking die to make 25mm diameter part from 2mm thick medium carbon steel metal. 10. Sketch and design a blanking die to make diameter 30mm part from 3mm thick carbon steel sheet metal. Take fs = 32 Kg/mm2 11. How to calculate bending allowance in bending process? Explain. 12. What is spring back? And how is it controlled in bending die? 13. Write short notes: (i) Design of drawing die (ii). Design of bending die. (iii).Types of cutting operations. 14. Calculate the developed length of part as shown in figure. 15. Explain modern press tool with application.