UNIT 6

JIGS AND
FIXTURES
SYLLABUS
INTRODUCTION
 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
JIGS
 Device that holds, supports, or is placed on a part to
be machined.

 locates and holds the work piece

 Guides the cutting tool

 For repeatability and exact duplication of a part for

reproduction
JIGS
FIXTURE

 Strong and rigid mechanical devices which attaches to

a machine

 For quick and consistently accurate locating,

supporting and clamping, blanks against cutting tools

 Much-wider scope of application than jigs

 Common fixtures include milling fixtures, lathe

fixtures, sawing fixtures, and grinding fixtures
MATERIAL FOR JIGS AND FIXTURES

 Materials used in Jigs and fixtures are made

from a variety of materials, some of which can be
hardened to resist wear.
 Given below are the materials often used in jigs,
fixtures, press tools etc. Some common materials
are as following:

 Hardened Steel.
 Carbide.
 Bronze.
 Stainless Steel.
BASIC ELEMENT
 A sufficiently rigid body (plate, box or frame
structure) into which workpiece is loaded.

 Locating elements

 Clamping elements

 Tool guiding elements (for Jigs), Tool setting

elements (for Fixtures)

 Elements for positioning or fastening the jig or fixture

on the machine on which it is used
 THREE TWO ONE LOCATING PRINCIPLE
 All possible movement of an object in space can be
describe with reference to linear motions along three
perpendicular axes defining space and three rotational
about these axes.
 These six basic movements can take place in a total of
12 different direction.
 The location system must stop movement in six
directions of movement and the clamping forces must
stop the others in the opposite directions.
 A definite pattern of placement of locators should be
developed to constrain the movement of a body in
space.
 To illustrate the system of location the movement
of the cube in space are considered. The pattern of
arrangement is called the 3-2-1 location system. A
triangle symbol is used to schematically represent a
locator.
 Considering the six degree of freedom of a rectangular
block
 It is made to rest on several points on the jig body.
Provide a rest to workpiece on three points on the
bottom x-y surface.

 This will stop the movement along z-axis, rotation with

respect to x-axis and y-axis.

 Supporting it on the three points is considered as

better support then one point or two points.

 Rest the workpiece on two points of side surface (x-z),

this will fix the movement of workpiece along y-axis
and rotation with respect to z-axis.
 Provide a support at one point of the adjacent surface
(y-z) that will fix other remaining free movements.

 This principle of location of fixing points on the

workpiece is also named as 3-2-1 principle of fixture
design as number of points selected at different faces
of the workpiece are 3, 2 and 1 respectively.
 For a fixture designer, the major portion of design
time is spent deciding how to locate the work piece in
the fixture.
 You know that any free body has a total of twelve
degrees of freedom as below:
 6 translational degrees of freedom: +X, -X, +Y, -Y,
+Z, -Z
And 6 rotational degrees of freedom:
 Clockwise around X axis (CROT-X)

 Anticlockwise around X axis (ACROT-X)

 Clockwise around Y axis (CROT-Y)

 Anticlockwise around Y axis (ACROT-Y)

 Clockwise around Z axis (CROT-Z)

 Anticlockwise around Z axis (ACROT-Z)

 You must fix all the 12 degrees of freedom except the
three transitional degrees of freedom (-X, -Y and -Z) in
order to locate the work piece in the fixture. So, 9 degrees
of freedom of the work piece need to be fixed.

 But, how? By using the 3-2-1 method as below:

 Rest the work piece on three non-collinear points of the

bottom surface (XY), and you will be able to fix
the +Z, CROT-X, ACROT-X, CROT-Y and ACROT-
Y degrees of freedom.

 Now, rest the work piece at two points of side surface

(XZ), and you will be able to fix the +Y and ACROT-
Z degrees of freedom.
 Now, rest the work piece at one point of the
adjacent surface (YZ), and you will be able to fix
the +X and CROT-Zdegrees of freedom.

 So, you can successfully fixate 9 required degrees

of freedom by using the 3-2-1 principle of fixture
design.
 IMPORTANT CONSIDERATIONS WHILE DESIGNING JIGS
AND FIXTURES
 Study of workpiece and finished component size and
geometry.
 Type and capacity of the machine, its extent of
automation.
 Provision of locating devices in the machine.

 Available clamping arrangements in the machine.

 Available indexing devices, their accuracy.

 Evaluation of variability in the performance results of the

machine.
 Rigidity and of the machine tool under consideration.

 Study of ejecting devices, safety devices, etc.

 Required level of the accuracy in the work and quality to

be produced
 MEANING OF LOCATION
 The location refers to the establishment of a desired
relationship between the workpiece and the jigs or fixture
correctness of location directly influences the accuracy of
the finished product.
 The jigs and fixtures are desired so that all undesirable
movements of the workpiece can be restricted.
 Determination of the locating points and clamping of the
workpiece serve to restrict movements of the component
in any direction, while setting it in a particular pre-
decided position relative to the jig.
 Before deciding the locating points it is advisable to find
out the all possible degrees of freedom of the workpiece.
 Then some of the degrees of freedom or all of them are
restrained by making suitable arrangements. These
arrangements are called locators.
PRINCIPLES OF LOCATIONS

 Any rectangular body many have three axis along x-

axis, y-axis and z-axis.
 It can more along any of these axes or any of its
movement can be released to these three axes.
 At the same time the body can also rotate about these
axes too.
 So total degree of freedom of the body along which it
can move is six.
 For processing the body it is required to restrain all
the degree of freedom (DOF) by arranging suitable
locating points and then clamping it in a fixed and
required position.
PRINCIPLE OF LOCATION

 The principle of minimum locating points

 The principle of mutually perpendicular planes
The principle of extreme position of pins
 Relief should be provided where burr or swarf
will get collected
 Locating surface should be raised above the
surrounding surfaces of J/F so that chips can be
swept off readily.
 Sharp corners in the locating surfaces must be
avoided
 Adjustable type locators to be used for rough
surfaces
LOCATING PRINCIPLE

 To position the work piece w.r.t. to tool, to ensure

precision in machining

 Locating: dimensional and positional relation-

ship b/w work piece and tool

 Locator: device to establish and maintain position

of a part in a jig or fixture
 PRINCIPLE OF CLAMPING
 1)The clamping pressure applied against the workpiece
must counteract the tool forces

 2) The clamping pressure should not be directed towards

the cutting operation. Wherever possible it should be
directed parallel to it.

 3) The clamping pressure must not damage/deform the

work surface.
 4) Clamps should be arranged directly above the points
supporting the work, otherwise distortion of work may
occur.
PRINCIPLE OF CLAMPING

 5) Clamping pressure should be directed towards the

points of support, else the work will tend to rise from
support

 6) Clamping should be simple, effective and foolproof.

 7) Fibre pads should be riveted to clamp faces to avoid

damage to fragile workpieces
TYPES OF JIGS

 Jigs may be divided into two general classes: Boring jigs

and Drill jigs

 Boring jigs are used to bore holes that either is too large
to drill or must be made an odd size.

 Drill jigs are used to drill , ream, tap, chamfer, and

counter bore, countersink .

 Basic jig is almost the same for either machining

operation. The only difference is in the size of the
bushings used
 CHANNEL JIG
 The work-piece is mounted against the top and one side
of the jig.
 It is clamped from the third side

 It’s a type of box jig

 Provides better stability and support for workpiece

 This type is limited to work-pieces of simple

symmetrical shapes
 It mainly consist of the jig body, jig bush and screws
and w.p is clamped inside the channel with the help of
screw.
CHANNEL JIG
TEMPLATE JIGS
 Template jigs are normally used for accuracy rather
than speed.
 This type of jig fits over, on, or into the work and is not
usually clamped.
 Least expensive and simplest type of jig to use.
 PLATE JIGS
 It is the modified form of the template jig with jig bushes
incorporated on the temple

 Consist of a single bush plate with a provision for

locating and clamping of w.p.

 They have built-in clamps to hold the work

 They use a flat plate containing bushing as their main
structural member
 All the details are attached and referenced to this plate

 May or may not have legs

 Easy part loading and unloading, chip removal by

providing clearance b/w plate and the w.p.
PLATE JIGS
 Similar to templates, The only difference is that plate
jigs have built-in clamps to hold the work.

 Made with or without bushings, depending on the

number of parts to be made.
 BOX JIGS
 Surround the part totally

 Shape resembles a box

 In the figure, for loading, the cam rod is taken out of

the jig and the w.p placed in position inside the jig.

 The cam rod is then replaced and rotated to its locking

position

 This holds the work-piece firmly so that the drilling

operation can be performed
 Such jigs are generally used for components having
irregular shapes or that cannot be held by common
methods.

 Number of holes can be drilled economically with box

jig.

 One side is open for loading and unloading the w.p

and provided bushing arrangements.

 The box jig can permits drilling of holes in three sides

of the work-piece and saves times and increase
production.
BOX JIGS
 TEMPLATE JIGS
 It is the form of jig consisting of a suitable material
having holes for correct location.
 The plate serve as a template which is fixed on the
component to be drilled.
 Temple jigs are normally used for accuracy rather than
speed.
 Used for locating hole pattern on large workpieces.

 Usually not clamped (self-clamping).

 It is the least expensive .

 Simplest type of jigs.

 They may or may not have bushings. When the

bushings are not used, the whole jig plate is normally
hardened.
ANGLE-PLATE JIGS
 Used to machine parts at right angles to their locators.

 Pulleys and Gears use this type of jig.

The locators are generally fixed to the vertical wall of

the angular body.
 The central locator has groove for the passage of the
drill after passing through the workpiece.

 The cylindrical locator and diamond pin locator are

fixed to the vertical wall.

 C Washer and hexagonal screw is provided for

clamping.
LATCH TYPE JIGS
 Leaf jig has hinged jig plate.
 Drill bushes are fitted on the jig plate which is hinged
at one end.
 The jig plate can be swung aside to provide clear path
for workpiece loading and unloading.
 Clamping screw and drill bushes are accommodated
in jig pate.
 The jig plate must have positive resting surface.

 The jig plate is clamped against the resting face by an

eyebolt.
 Quick clamping and unclamping of the jig plate is
possible.
 Handknob is provided to facilitate clamping
TYPES OF FIXTURE
TYPES OF MILLING FIXTURES

 Milling Fixtures can be classified in a variety of

ways:

(1) According to the way the workpiece is clamped,

such as hand-clamping fixtures, power-clamping
fixtures, toggle fixtures etc.

(2) According to the way the workpiece is located, such

as center fixtures, V-block fixtures etc.
3)According to the method of presenting the
workpiece to the cutter, as rotary fixtures where the
workpiece is rotated under the cutter. Indexing
fixtures where the workpiece is indexed into the next
position during the machining cycle.

(4) According to the milling operation performed on

work, such as face-milling fixtures, slabmilling
fixtures, slotting fixtures, string-milling fixtures etc.
STRING or LINE MILLING FIXTURES:
 A number of components strung behind each
other in a line
 The fixture moves relative to the cutters
HYDRAULIC CLAMPING FIXTURE:
SPRING TYPE FIXTURE:
CLAMP TYPE FIXTURE:
WELDING FIXTURE
 The welding fixture is used where two or more parts
needed to be welded with high accuracy.

 The fixture should be strong enough to withstand the

welding.
ASSEMBLY FIXTURE

 The assembly fixture is used to assemble many

parts of a component with ease.
 The processes can be carried on the part and
desired component can be achieved.
POKA YOKE IN JIGS AND FIXTURE

 Poka yoke is quality management concept

developed by shigeo shingo to prevent occurrence
of human error in the production line. It means
avoiding inadvertent errors.

 It is one of the many component of shingo’s zero

quality control which aims at elimination of
defective products.

 Poka yoke is implemented by using simple devices

that should prevent the people from committing
mistakes.
POKA YOKE IN JIGS AND FIXTURE
 Shigeo Shingo defined poka-yoke as POKA-
‘Inadvertent mistake that anyone can make’ and
YOKE- ‘To prevent or proof’

 Poka-yoke is a tool to have “zero defects” and even

reduce or eliminate quality control.

 Poka-yoke is a Japanese name for “fool-proofing”.

 Poke-yoke represents the intelligence of the operator

by excluding repetitive actions that require a thinking
process.
CHARACTERISTIC OF DEVICES THAT ARE
USED FOR POKA YOKE

 Poka yoke are expected to have the following

characteristics
 Useable by everybody

 Simple in design

 Low cost

 Should not require continuous attention from the

operations
 should provide instantaneous , response, prevention
or corrections.

 Poka yoke is best when it prevents mistakes not

when it identifies the occurrence of a mistakes
APPLICATION OF POKA YOKE
 Jigs and fixtures in which components cannot be loaded wrongly.

 Pins, screws dowels placed non symmetrically so that a component

cannot be assembled incorrectly.

 Plugs that can be inserted only in right type of holders and in

correct direction.

 Interlocked controls so that a machine will not start unless both

hands of the operator are not out.

 button covers so that the button can not be pressed accidently.

 Simplicity of design so that minimum effort is necessary for loading

and unloading

 Design for safety.