Jigs

and
Fixtures
Introduction

The successful running of any mass production depends upon

the interchangeability to facilitate easy assembly and
reduction of unit cost. Mass production methods demand a
fast and easy method of positioning work for accurate
operations on it.

Jigs and fixtures are production tools used to

accurately manufacture duplicate and interchangeable parts.
Jigs and fixtures are specially designed so that large numbers
of components can be machined or assembled identically, and
to ensure interchangeability of components.
 Definitions
• Jig: A device that holds
the work and locates
the path of the tool.
• Fixture: A device fixed
to the worktable of a
machine and locates
the work in an exact
position relative to the
cutting tool.
 What are Jigs and Fixtures

• Anything used to hold

a work piece in a
desired location
– Locate parts for
precision
– Repeating process on a
series of parts
– Holding parts for
machining, painting,
assembly
 • JIG

It is a work holding device that holds, supports and

locates the workpiece and guides the cutting tool for a
specific operation. Jigs are usually fitted with hardened
steel bushings for guiding or other cutting tools. a jig is a
type of tool used to control the location and/or motion of
another tool. A jig's primary purpose is to provide
repeatability, accuracy, and interchangeability in the
manufacturing of products. A device that does both
functions (holding the work and guiding a tool) is called a
jig.
An example of a jig is when a key is duplicated, the
original is used as a jig so the new key can have the same
path as the old one.
A jig guides the cutting tool, in this case with a bushing
 FIXTURE

It is a work holding device that holds, supports and locates the

workpiece for a specific operation but does not guide the cutting tool. It

provides only a reference surface or a device. What makes a fixture

unique is that each one is built to fit a particular part or shape. The main

purpose of a fixture is to locate and in some cases hold a workpiece

during either a machining operation or some other industrial process. A

jig differs from a fixture in that a it guides the tool to its correct position

in addition to locating and supporting the workpiece.

Examples: Vises, chucks

A permanent workholder used for a drilling operation.
Modular workholders combine ideas and elements of both
permanent and temporary workholding to make inexpensive-yet-
durable workholders.
 Two main
types of jigs:
• For machining purposes
– Locates the component,
holds it firmly in place,
and guides the cutting
tool.
• For assembly purposes
– Locates separate
component parts and

Northwestern Tools
holds them rigidly in their
correct positions while
they are being connected.
 Drill jig terms
• Open jig (also called plate jig or drill
template)
– The simplest type of drill jig
– Consists of a plate with holes to guide the
drills, and may have locating pins that
locate the workpiece on the jig
 Drill jig terms

• Drill bushings
– Precision tools that
guide cutting tools
such as drill and
reamers into
precise locations in
a workpiece.
Accurate Bushing Co.
 Drill jig components
• Jig body
– Holds the various parts of a jig assembly.
• Cap screws and dowel pins
– Hold fabricated parts together
 Drill jig components
• Locating devices
– Pins, pads, and recesses used to locate
the workpiece on the jig.
 Drill jig components

• Clamping devices
 Drill jig components
• Locking pins
– Inserted to lock or
hold the work piece
securely to the jig
plate while
subsequent holes
are being drilled.
 Uses of Jig and fixture
• Reduce cost of production.
• Increase the production.
• To assure high accuracy of parts
• Provide for interchangeability
• Enable heavy and complex parts to machine
• Reduced quality control expenses.
• Increased versatility of machine tool.
• Less skilled labour.
• Saving labour.
• Partially automates the machine tools
• Use improve the safety, accidents low
 Elements of Jig and fixture
• Sufficiently rigid bodies (plate, box or frame
structure
• Locating elements.
• Clamping elements.
• Tool guiding elements.
• Elements for positioning or fastening the jig or
fixture.
Dimensioning Jig Drawings
 Designing jigs

• Jigs can also be

designed as per
requirement of the
workpiece for
holding and other
machining
operations.
Northwestern Tools
Fixtures

Standard Parts Co.

 Fixture components

Standard Parts Co.

• Fixture base
– Fixture components and the workpiece are
usually located on a base, which is
securely fastened to the milling machine
table.
 Fixture components

American Drill Bushing Co.

• Clamps
– Clamps counteract forces from the feed of
the table and rotation of the cutter.
 Fixture components

• Set blocks
– Cutter set blocks are mounted on the
fixture to properly position the milling cutter
in relation to the workpiece.
 Basic Categories of Jigs
• Clamps
• Chucks
• Vises
• Bushings
• Modular Fixtures
Clamps
Chucks
Vises
Bushings
Modular Fixturing
 V-location
• In V-location, work pieces having circular or
semicircular profile are located by means of
a Vee block. The block should be used
accurately so that the variation in the work
piece size are not detrimental to location.
• Vee can be used for both locating and
clamping purpose for this two Vee can be
used, one fixed other sliding one. Fixed Vee is
used for locating and sliding one for clamping.
• The sliding Vee block may be actuated by
means of a hand operated screw.
 Bush location
• Shaft type work pieces can be easily locate in a
hardened steel bushes. The bushes can be plain or
flanged type. A flange straighten the bush and also
prevent it from being driven into the jig body if it is
left unlocked.
 Design principles of location purpose

The following principles should be followed

while locating surfaces.
1.At least one datum or reference surface
should be established at the first opportunity.
2. For ease of cleaning, locating surfaces should
be as small as possible.
3. The locating surfaces should not hold swarf
and thereby misalign the workpiece
4.Locating surfaces should be raised above
surrounding surfaces of the jigs or fixture.

5. Sharp corners in the locating surfaces must be

avoided.
6. Adjustable type of locaters should be used for
the location on rough surfaces.
7. Locating pins should be easily accessible and
visible to the operator.
LOCATING PRINCIPLES

3-2-1 PRINCIPLE

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Fig. 1 The maximum number of degrees of freedom for a component

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 Fig. 2 A component with a single locator

• A single locator in Plane 1 would arrest the linear motion along X-

axis.
• A second locator in the same plane would arrest the rotary motion
Z axis.
• Another locator placed in the same plane would arrest the rotary
motion about the Y axis.
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 Fig. 3 A component with six locators

• The fourth locator can be place in Plane 2 would restrict the linear
motion along the Y – axis.

• The fifth locator can arrest the rotational motion about the Y-axis.

• The sixth locator placed in Plane 3 would arrest the linear motion
along the Z-axis.
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Fig. 4. The effect of position the locators apart on a given space

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Fig. 5 Mechanical stability of the component can be achieved by locating
the largest number of locators on the largest surface area.

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Fig. 6 Locating method for a disc-type (short cylindrical) component

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Fig. 7 Locating method for a long cylindrical component

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Fig. 8 Three types of locators used in various features

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Fig. 9 The round locator used in locating a workpiece with an already
finished hole.

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Fig. 10 Three locators are used in a fixture to locate a planar surface

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Fig. 11 Relieved locator showing the reduction in the contact area
between the locator and the workpiece surface

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Design a jig for a
part shown in Fig. 1

Fig. 1 Required part

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The following are some steps that are
indentified to help in designing a jig
1. Method of locating the part – identify the
standard components required for locating
purpose.
2. Design the clamping method. Make a proper
choice of clamps – C-washer, swing washer,
nut, strap clamp, toggle clamp, etc..
3. Design any supports required.
4. Design the jig body.

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Drill jig for locating 16 mm hole

Locating arrangement for part shown in Fig 1

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Based on the preliminary examination of the part, the
following points emerge:

• Method of locating the part – the central hole, which is

already finished can be used for locating as well as indexing
for holes to be drilled.
• Clamping can be done with a nut and a C-washer since the
central hole is large enough.
• Indexing can be done with a retracting – type plunger going
into the previous hole drilled.
• The jig can be simple indexing jig with a post for locating the
part.

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Indexing arrangement by using retractable plunger
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The next step is indentifying the type and sixe
of jig bush required.

Headless type does not serve the purpose,

since it has to go beyond the jig plate.

Hence, a standard head type jig bush is

selected.
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Jig bush location for the part shown in Fig 1

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Next step there fore is to add the jig base to
keep all these elements in their respective
position.

For this purpose, an L-shaped structure is

sufficient.

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Completed jig with a sample part loaded in the jig for the part
shown in Fig. 1 83
A few principle are enunciated below that could be
adhered will ensure better designed drill jig

1. Drill jigs should be as light as possible can

consistent with rigidity to facilitate handling.
2. A jig, which is not bolted to the machine table,
should be provided with feet, preferable four,
opposite all surfaces containing jig bushes.
3. Make the jig foolproof so that the component
cannot be loaded in the wrong way.
4. Clearance holes or burr slots should be provided
in the jig to allow for burr formed when the drill
breaks through the component and for scarf
clearance, particularly from locating faces.
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5. Make all component – clamping devices as quick
acting as possible.
6. Locate clamps so that they will be in the best position
to resist the pressure of the cutting tool when at
work.
7. Avoid complicated clamping and locating
arrangements, which are liable to wear or need
constant attention.
8. Make, if possible, all locating points visible to the
operator when placing the component in position in
the jig so that a component can be seen to be
correctly loaded. The operator should also be able to
have an unobstructed view of the clamps.

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9. Clamps should be positioned above the points
supporting the component, in order to avoid
distribution and should be strong enough to hold the
component without bending.
10. The process of inserting and withdrawing the
component from the jig should be as easy as possible.
Ample space should be left between the jig body and
component for hand movements.

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A typical milling fixture
Some of principles to be considered while designing the
milling fixtures are the following:

1. The design should permit as many surfaces of the part to be

machined as possible without removing the part.
2. Whenever possible the tool should be changed to suit the
part. Moving the part to accommodate one cutter for several
operations is not as accurate or as efficient as changing
cutters
3. Locators must be designed to resist all tool forces and thrust.
Clams should not be used to resist the cutting forces.
4. Clearance space or sufficient room must be allotted to
provide adequate space to change cutters or to load and
unload the part.
5. Milling fixture should be designed and built with a low profile
to prevent unnecessary twisting or springing while in
operation
6. The entire workpiece must be located within the area of
support of the fixture. In those cases where this is either
impossible or impractical, additional supports, or jacks, must
be provided.
7. Chip removal and coolant drainage must be considered in the
design of fixture. Sufficient space should be permitted to
allow the chips to be easily removed with a brush.
8. Set blocks or cutter-setting gauges must be provided in the
fixture design to aid the operator in the properly setting up
and tool in the production
 Some principles to be considered while designing
lathe fixtures are the following:

1. A tool designer must deal with centrifugal force. The complex

fixture must be designed and constructed to resist the effects
of the rotational or centrifugal forces present in the turning.
2. Sine lathe fixtures are designed to rotate; they should be as
lightweight as possible.
3. Lathe fixtures must be balanced. While perfect balance is not
normally required for slow speed turning operations, high
rotational speeds required the fixture to be well balanced.
4. Projections and sharp corners should be avoided since these
areas will become almost invisible as tool rotates and they
could cause serious injury.
5. Part to be fixtured should, whenever possible, be gripped by
their largest diameter, or cross section.
6. The part should be positioned in the fixture so that most of
the machine operation can be performed in the first fixturing.
7. Clamp should be positioned on surfaces, or areas, which are
rigid before and after machining.
8. As with other fixtures, some means of cutter setting should
also be incorporated into design. However, since the work
holder will be rotating, this setting device should be removed.