Tool Engineering

Part 1 – Jig and Fixture Design

A.Senthil Kumar
Assoc Professor
Dept of Mechanical Engineering
EA-05-26 / 6516 6800
mpeask@nus.edu.sg
 Course Outline
•  Introduction
•  Principles of Location
•  Principles of Clamping
•  Drill Bush and Jigs
•  Milling Fixture
•  Turning Fixture
•  Indexing and Miscellaneous Fixtures
•  Modular Fixtures and CAD of Fixtures
 Learning Outcome
•  Identify the types of locators and clamps
used for jigs and fixtures
•  Specify the location of locators and clamps
•  Design a jig or a fixture for a given part
 Assessment
•  Examination – 50 marks from my section –
two questions

•  Term paper – 20 ~30 %

 Reference Materials
•  Handbook of Jigs and Fixture Design
–  by SME
•  Jig and Fixture Design
–  by Hoffman
•  Fixture Design Manual
–  by Henriksen
•  An Introduction to Fixture Design
–  by Kempster
•  Tool Design
–  by Donaldson
 Lecture Details
•  11th Jan – Introduction / Location
•  14th Jan – Location / Problem solving / Clamping
•  18nd Jan – Clamping /Problem Solving
•  21st Jan – Jig
•  25th Jan – Jig
•  28th Jan – Problem Solving
•  1st Feb – Milling Fixture
•  4th Feb – Turning Fixture
•  8th Feb - Holiday
•  11th Feb – Indexing fixtures
•  15th Feb - Modular Fixture
•  18th Feb – Fixture review
 Definition
•  JIG
–  A structure or a box which holds the
components, locates and guides the cutting tool
–  It is mainly used in drilling, reaming, tapping
and boring
•  Fixture
–  A structure or a box that holds the component
or held to the component, locates and does not
guide the cutting tool
–  It is mainly used in milling, turning, planning,
grinding, welding and assembly operations
 Introduction to Work holding
n  Work holders should be strong enough to
withstand the machining forces and weight of the
workpiece.
n  Also, in addition to normal cutting forces, the
designer should consider large momentary
loads.
n  Work holders should be designed considering
many factors like the nature of the workpiece,
cost, and safety.
n  It is cheaper to use the standard work holders.
Effect of Process on Work Holding
Sequence of Machining Operation?
 Referencing
A dual process of positioning the workpiece relative
to the work holder, and the work holder relative to
the cutting tool.
This is to ensure precision in any machining
operation.
q  Referencing the workpiece to the workholder, is done with locators
and supports.
q  Referencing the work holder to the cutting tool is performed by the
guiding or setting devices.
v  With drill jigs, referencing is accomplished using drill bushings.
v  With fixtures, referencing is accomplished using fixture keys,
feeler gages, etc.
 Referencing
If a part is incorrectly placed in a workholder, proper location of
the workpiece is not achieved and the part will be machined
incorrectly.

Workholder Cutting tool

Workpiece

Toolholder

If a cutter is improperly positioned relative to the fixture,

the machined detail is also improperly located.
 Referencing
Locators: The devices that restrict a workpiece's movement.

•  must be strong enough to maintain the position of the workpiece and to

resist the cutting forces. Hence, locators must hold the workpiece against
the cutting forces.
•  are used to properly position the part.
•  and make sure that the tool is easily loaded and unloaded.
•  Make the tool foolproof.
Supports: The devices which provide support for the part.
•  Properly designed locators serve as supports.
 Difference between locators and clamps
n  Locators provide a positive
stop for the workpiece.
n  While placed against the stop,
the workpiece cannot move.

•  Clamps, on the other hand, rely only upon friction between

the clamp and the clamped surface to hold the workpiece
(Sufficient force could move the workpiece).

•  Clamps are only intended to hold the workpiece against the

locators.
 Workpiece Surfaces

n  Flat surfaces have flat bearing area, such as: edges, flanges,
steps, faces, shoulders, and slots.

n  Cylindrical surfaces are located on a circumference or diameter.

Examples are: internal (concave) surfaces or holes or external
(convex) surfaces of turned cylinders.
n  Irregular surfaces provide neither a flat nor cylindrical locating
surfaces, such as cast or forged workpieces.
The Mechanics of Locating
 The Mechanics of Locating 2
5
4

•  A workpiece free in space can have 1

twelve directional movements, or
"degrees of freedom (DOF)." 6
3 6 DOF in the space
•  There are 6 rotational and 6 axial If you consider positive
directions
movements.
•  All twelve degrees of freedom must Rotational:
be restricted to ensure proper cw & ccw
referencing of a workpiece.

In some tool design books,

rotational movement has
been named as radial Axial:
movement, which is not a
Positive and negative
correct term mathematically! 12 DOF in the space directions
If you consider positive &
negative directions
 Six-point locational method
or 3-2-1 method
n  Three locators, or supports, are placed under the workpiece
(positioned on the primary locating surface, restricting five degrees of
freedom). This restricts axial movement downward, along the -z axis
(#6) and rotationally about the x (#7 and #8) and y (#9 and #10) axes.

Primary locating surface

9 10 8 7
 3-2-1, or six-point, locational method
•  The next two
locators are
normally placed on
the secondary 12 11

locating surface, 3
restricting an
additional three
degrees of freedom
by arresting the
axial movement
along the +y axis
(#3) and the
rotational
movement about
the z (#11 and #12)
axis.
 3-2-1, or six-point, locational method
Pins restricted
n  The final locator, is 3pins 5DOF
positioned at the end
of the part. It 2pins 3DOF
restricts the axial 2 1pins 1DOF
movement in one 9DOF
direction along the -x
axis (restricting one
more degree of
freedom). Together,
these six locators
restrict a total of nine
degrees of freedom.

n  The remaining three degrees of

freedom (#1, #4, and #5) will be
restricted by the clamps.
 Forms of location
n  Plane locators
n  Concentric locators
n  Radial locators
n  Combined locators

Plane locators locate a workpiece from any surface. The surface may
be flat, curved, or have an irregular contour. In most applications,
plane-locating devices locate a part by its external flat surfaces.

workpiece

locators locators
 Forms of location
Concentric locators, locate a workpiece from an internal or external
diameter. The most-common type of concentric location is the use of a
locating pin.
Some workpieces, however, might have a cylindrical projection that
requires a locating hole in the fixture.
workpiece

workpiece Concentric
locators

Concentric
locators
 Forms of location
Radial locators restrict the movement of a workpiece around a
concentric locator.

Concentric Radial
locators workpiece locators

•  Combined locators: In many cases, locating is performed by a combination

of the three locational methods (Most work holders use a combination of
locating methods to completely position a workpiece).
 Locating from External Surfaces

•  The three major forms

of supports are solid,
Solid Supports (fixed)
adjustable, and
equalizing (These are
briefly explained here, but
will be studied in detail
later).
Adjustable Supports

Equalizing Support

Figure 3-3, Carr Lane

 1- Solid Supports

•  Solid supports are fixed-height locators.

•  They precisely locate a surface in one axis.
•  Though solid supports may be machined directly into a tool
body, a more-economical method is using installed
supports, such as rest buttons.

Solid Supports (fixed)

 2- Adjustable Supports
n  Adjustable supports are Threaded adjustable supports
variable-height locators.
n  Like solid supports, they will Knurled collar
also precisely locate a surface
in one axis.
n  These supports are used where
workpiece variations require
adjustable support to suit Adjustable Supports
different heights.
n  These supports are used
mainly for cast or forged
workpieces that have uneven or
irregular mounting surfaces.
 3- Equalizing Supports
•  Equalizing supports are a form of adjustable support used when
a compensating support is required.
•  Although these supports can be fixed in position, in most cases
equalizing supports float to accommodate workpiece variations.
•  As one side of the equalizing support is depressed, the other
side raises the same amount to maintain part contact.
•  In most cases adjustable and equalizing supports are used along
with solid supports.

Equalizing Support
 Locating from Internal Surfaces
•  Locating a workpiece from an internal diameter is the most-
efficient form of location.
•  The primary features used for this form of location are
individual holes or hole patterns.
•  Either concentric, radial, or both-concentric-and-radial location
are accomplished when locating an internal diameter.
•  The two forms of locators used for internal location are locating
pins and locating plugs.
–  The only difference between these locators is their size: locating pins are
used for smaller holes and locating plugs are used for larger holes.
 Locating from Internal Surfaces
How many degrees of freedom are restricted in this system?

n  The base restricts any y

downward movement
x
and rotation around
the X and Y axes
(5DOF restricted).
n  The pin prevents any
movement along X z
and Y directions (4
DOF restricted).
n  The part is restricted
from moving in nine
directions.
Location from Cylindrical Surfaces

Restricts all degrees of freedom

except rotation about YY

Recessed so that dirt/chips can

fall into it

Lead must be long

•  Fragile workpiece
must be supported
over a long length
•  Long lead must be
provided
•  Relief must be
provided to avoid
redundant location

•  Special Lead is designed to

avoid jamming while loading
the workpiece
•  Long post may cause
jamming and hence
use short post.
•  Provide long lead for
easy loading of the
workpiece
 Clamping on Location Post
•  This is used when
clamping is done on
location post

•  Used to retain the

location pin
•  Used for locating
cylindrical shafts

•  Bush can be easily

replaced when there is
wear due to repeated
loading and unloading
of the workpiece
•  Position 2 has more
accurate rotational
accuracy than position
1 for the same error.
•  Conical Locators are used to
locate from the axis of a
cylindrical feature, when the
diameter of that feature is not
accurate
•  Locator is adjustable to
compensate for the variations in
the workpiece diameter
•  Vee locators are used
for locating on
cylindrical or partially
cylindrical surfaces
•  Movable Vee locators
–  Screw operated is slow
compared to the cam
operated devices
 Test yourself!
How many degrees of freedom are restricted in this system?
How do you answer this question in 2 seconds?!
…ok in 10 seconds?

Answer: Always think of the

possible ways that you can
quickly remove the part and
consider how many possible
movements are existed.

Here you can remove the part

by raising it (one movement
along z). So the other
degrees of freedoms are
restricted=11.
 Test yourself!

•  How many degrees of

freedom are restricted
here in this drill jig?
n  Ten degrees of freedom are
restricted. The part can have
two possible motions
(sliding along the jig (toward
right) + rotation about the
axis perpendicular to the Locating from External Surfaces
support surface).
 Test yourself!
•  How many degrees of
freedom are restricted here
in this drill jig?
n  Nine degrees of freedom
are restricted. The part can
have 3 possible motions as
shown in red.
 Test yourself!
•  How many degrees of freedom are
restricted for this rocket?

9 degrees of freedom are

restricted, since the rocket
might have 3 possible
movements as shown.
Basic Rules for Locating
 2- Tolerance
•  The workpiece itself determines the
overall size of a locating element.

•  locators must be made to suit the

MMC (Maximum-Material
Condition) of the area to be located.
(The MMC of a feature is the size of the
feature where is has the maximum amount of
material).

–  With external features, like shafts, the

MMC is the largest size within the
limits.

–  With internal features, like holes, it is Carr Lane, Fig 3-20. The MMC sizes for both
external and internal features.
the smallest size within the limits.
 2- Tolerance
•  Tool tolerance should be between 20 and 50 percent of
the part tolerance.
Question:
If a hole in a part must be located within ±0.010 mm, then the tolerance
of the hole in the jig must be between ……mm ……mm

Answer: ±0.002 mm and ±0.005 mm

From10.0±.002
10.0±.010 To 10.0±.005

From 5.0 ±.002

5.0 ±.010
To 5.0 ±.005

Part Jig
 2- Fool proofing
•  A means by which the tool designer ensures that the part will fit
into the tool (only in its correct position).
•  The simplest and most cost effective method is positioning a
foolproof pin.

Carr Lane- Fig 3-17: an otherwise-

nonfunctional fool proofing pin
ensures proper orientation.
 3- Fool proofing
–  Prevents improper loading of a workpiece

Fool proofing pin

Block
block

Three locating pins used to

establish location of part Block used to foolproof the
on large diameter location of the part
Diamond locating pin
Carr lane, Fig 3-18: a cavity in the
workpiece prevents the part from
being loaded upside-down.
 4- Duplicate locators
•  Redundant, or duplicate, locators should be avoided.
b) Problem with
concentric
diameters: Either
a) Flat surface diameters can
can be locate the part, but
redundantly not both!
located. The
part should be
located on
only one, not
3 round pin locators locating
both, side of the part by its edges
surfaces.
c) Difficulty with combining
hole and surface location:
Either locational method
(locating from the holes or
locating from the edges)
2 round locators locating works well if used alone.
the part by the holes
Question:
4- Duplicate locators
How do we avoid the redundant location (How do we find out
which side is the reference side and which side is the redundant
side) ?
Answer:
simplest way to eliminate
is to check the shop
print to find which
workpiece feature is
the reference feature.

Carr Lane, Figure 3-16. The best locating surfaces are often
determined by the way that the part is dimensioned.
 5- Using Spring-Loaded Locators
One method to help ensure accurate location is the installation of
spring-loaded buttons or pins in the work holder.
–  spring force pushes the workpiece against the fixed locators
until the workpiece is clamped.
–  not only ensure repeatable locating but also make clamping
the workpiece easier

Carr Lane, Figure 3-19. Spring-

loaded locators help ensure the
correct location by pushing the
workpiece against the fixed
locators.
 5- Using Spring-Loaded Locators
•  Spring-stop buttons:

Contact Button –
Steel or polymer Flat Face Flat Face with Tang
 6- Controlling Chips
•  Chips are an inevitable part of any machining operation and
must be controlled so they do not interfere with locating the
workpiece in the work holder.
•  Chip control must be addressed in the design of any jig or
fixture.
•  Position the locators away from areas with a high
concentration of chips.
•  If this is not practical, then relieve the locators to reduce the
effect of chips on the location.
•  To minimize the negative effects of chips, use locators that
are easy to clean or protected from the chips.
 6- Controlling Chips
•  Coolant build-up can also cause problems.
•  Solve this problem by drilling holes, or milling slots, in areas of the
work holder where the coolant is most likely to build up.
•  With some work holders, coolant-drain areas can also act as a
removal point for accumulated chips.
•  When designing a work holder, always try to minimize the chip
problem by removing areas of the tool where chips can build up.
•  Omit areas such as inside corners, unrelieved pins, or similar
features from the design.
 Test yourself!
•  Which locating is appropriate?

Locators should be spaced as far apart as practical to compensate

for slight irregularities and for maximum stability.
 Test yourself!
•  Which locating is appropriate?
Locator Types
 Locator Types
1.  External (Fixed and Adjustable):
1.  Integral,
2.  Assembled,
3.  Pins,
4.  Commercial Pin (Plain and Shouldered),
5.  V-type,
6.  Locating nests,
7.  Sight.
2.  Internal:
1.  Machined internal,
2.  Relieved,
3.  Diamond pins,
4.  Floating locating pin,
5.  Conical,
6.  Self-adjusting locators,
7.  Spring locating pins,
8.  Spring-stop buttons.
 External locators
•  External locators are used to position a part by their external surfaces.

Fixed locators:
n  Solid locators that establish a fixed position for the part.

Adjustable locators:
n  Movable locators,
n  Used for rough-cast mainly,
n  Used for parts with surface irregularities,
n  Used in conjunction with fixed locators to permit variation in part sizes.
Fixed External Locators
 Fixed Locators
•  Integral locators:
–  Machined into the body of the workholder,
–  Least preferred type of locators because of:
•  Additional material required to allow for the machining of the locator
(wasted material),
•  the time which takes to machine the locator,
•  The problem of replacing the locator if it wears or becomes damaged.

Fig 4-19, SME

 Fixed Locators
Assembled pins:
•  Made of tool steel,
•  Hardened to prevent wear,
•  Similar to integral locators but:
–  they are replaceable,
–  Using them does not require additional material for the tool body.
•  May be used as locators or supports.
 Fixed Locators
Pins:
•  Simplest and most basic form of locating element (specially round pins),
•  Either made from steel drill rod or purchased commercially,
•  Location and number of the pins are determined by following the 3-2-1
principle.

Locating pins without shoulders: Locating pins with shoulders:

(Round, bullet, plain, conical) (plain, round, bullet, dowel)
 Y

Fixed Locators
•  V-type: X

–  Suitable for a cylinder as well as a prism.

Z
–  Made up of two perpendicular plates.

How many DOF are restricted by this v-type locator?

Y
The workpiece has 5 DOFs as shown in blue color, 5 DOFs for the part,
so 7 DOFs are restricted: 7 DOFs are restricted
1- Small pin restricts the part in z direction,
2- Horizontal plane limits the motion in –Y direction -Z
as well as rotations about X axis,
3- Vertical plane limits the motion in –X direction as X
well as rotations about Y axis.
Hence, the pin takes 1 DOF,
The horizontal plane takes 3 DOFs,
The vertical plane takes another 3 DOFs.
 Test yourself!
•  In the following figure, a workpiece with two cylindrical ends is
confined by means of two V locators. How many DOFs are
restricted?
Just the upward motion is possible, so 11 DOFs are restricted.

Fig 4-26 SME

 Fixed Locators
part

Locating nests:
Feature a cavity in the workholder
device into which the workpiece is
placed and located,
No supplementary devices such as pins
are normally required.
 Fixed Locators
Locating nests part
Disadvantages:
1.  Since the workpiece is completely
surrounded, It is difficult to lift out of the nest.
n  Solutions 1: the workholder can be turned over and
the part shaken out.
n  Solution 2: ejector pins can be used (which will add
time to the processing).

2.  The operation performed may produce burrs that tend to lock the part
into the nest.
3.  Chip from the operation may lodge in the nest and must be removed.
4.  In case of polymer or low-melt alloy, a prototype of the part is required
to make the locators or jig.
Adjustable External Locators
 Adjustable Locators
Adjustable locators:
–  Movable locators,
–  Used for rough-cast mainly,
–  Used for parts with surface irregularities,
–  Used in conjunction with fixed locators to permit variation in
part sizes.

•  Types:
–  Threaded,
–  Spring pressure,
–  Equalizing.
•  Adjustable locators as well as adjustable supports are available.
• 
Adjustable Locators
Adjustable supports are positioned beneath the workpiece.

Threaded
adjustable
supports
Adjustable Locators

•  Spring-type adjustable
supports are used to level the
workpiece.
•  Rather than using threads to
elevate the locator a
secondary threaded element
(such as thumbscrew) is used
to lock the position of the
spring support.

Fig 4-36, SME

 Adjustable Locators
•  Adjustable locators also can be used as a clamping device. (The position of
the locator is not critical and this reduces the cost).

Threaded adjustable locator

Internal Locators
 Internal Locators
They are Locating features, such as holes or bored diameter.
Types:
Fixed size workpiece
–  Made to a specific size to suit a certain hole diameter
–  Include machined, commercial pin, and relieved locators
Compensating (types are Conical and self adjusting)
–  Used to centralize the location of a part or allow larger variations
Fig 4-39, SME
in hole sizes.
Relieved (Example: Diamond pin)
–  Provide minimum contact between the workpiece and locating
pin.
–  This reduces the chance of the locator jamming or sticking in the
part.

Fig 4-41, SME

Internal Locators
Diamond pins:
•  Used for radial location in conjunction
with round locating pins,
•  Provides more accurate radial location,
•  The bearing surface of the diamond pin
must be positioned to restrict movement
of the part.
•  In some cases, the part is completely
located using two diamond pins.

Diamond Pins are relieved, to locate only radially

around the round pin, avoiding redundant location.
 Internal
Conical locators (cone locator pin):
Locators
•  Medium-accuracy tapered locating pin,
•  Centralized locators that compensate for variations in part sizes
as well as centering a part in the workholder.
Types (Fig 4.46 SME):
•  Spring loaded (a)
•  Threaded (b)
•  Used as external locator with a conical cup (c)

See also Fig 4.46, SME

 Internal Locators
Self-adjusting locators:
•  Used in applications such as sand casting (great variation in the size of
the holes to be located),

Fig 4.4, SME

 Rotation of the pin

Spring Locating Pins Spring inside

the pin

•  Applies spring force to hold the work

piece against its locators.
•  This will ensure proper contact during the
clamping operation.
•  Their small size and compact design
make them useful for smaller parts.
•  Protective rubber seal around the contact
pin helps seal out debris and coolant.
Carrlane link
 Spring Locating Pins

1 2 3

1.  The part is positioned over the workholder,

2.  The part is placed against the solid locator and pushed down
against the spring pin,
3.  When seated, the spring locating pins push the workpiece
against the solid locator.
Spring Locating Pins
•  Some spring locating pins are mounted in an
eccentric liner.
•  The liner permits pin adjustment to suit parts with
looser tolerances.
 Drill bushing
Question (v-type locators)
•  A cylindrical workpiece is placed in a V locator so
a hole can be drilled perpendicular to the
longitudinal axis. Any variation in the diameter of
the workpiece will cause a displacement in the
location of the vertical axis. How can you design o
this locator, so it is not dependent to the diameter of
the workpiece?
c
Displacement (error)

n  The v locator could be positioned so its

axis is parallel to that of the drill bushing.
In this case, variation in the diameter of
the workpiece will cause no
displacement of the vertical axis, and
the drilled hole will not deviate from its
No displacement
required position.
 Question (adjustable locators)
•  If the workpiece has an inclined
side, how to you locate it?

n  In such cases, an adjustable-stop

locators with a movable pad
(leveling pad) is used. Using
adjustable locators allows the
part to be positioned exactly.
n  Swivel contact bolts are also
useful.
 Locating Elements for Flat Surfaces

Supports Stops

Fixed Adjustable Fixed Adjustable

Fixed – Spring Self

Pads Pins adjustable loaded adjustable

Spherical Jack Wedge-type

top
Flat top Screws Jack Screws