What ’s different between Jig and Fixture

Basic Principle of workholder

Identify the types of locators and support
used fro jigs and fixtures
 Hold & support

guide the cutting tool.

•references the cutting tool

Jig
Fixtures
Permanent Jigs and Fixtures
Modular Fixtures
Drill jig and milling fixture.
• Assembly
• Welding fixtures

• Inspection
• Mechanical-inspection fixtures
• Optical-inspection fixtures
• Electronic-inspection fixtures
Go - No go gage
• Purpose and function of work holders
• Consistently position workpiece relative to
the tool
• Hold workpiece in position against tool
forces
• Restrict deflection of the workpiece due to
tool and holding forces
• A locator is usually a fixed part of a fixture, the
purpose of which is to restrict movement of the
workpiece.
• A clamp is a moveable part of a fixture, the
purpose of which is to provide a holding force.
• A support is a fixed or moveable part of a
fixture, the purpose of which is to prevent
workpiece deflection under the action of
imposed cutting forces or clamping forces.
 Clamp Support

Locator
 Degrees of Freedom

Translational Rotational.
 Two objectives when mounting a
part in a fixture for machining:

• 1. Accurately position the part at the

desired coordinates.

• 2. Restrict all six degrees of freedom so

that the part cannot move.
First Plane
TIPS
• Use the largest surface of the part for the
first ("primary") reference plane.
• Position the three support points as far
apart as possible.
• If more than three support points are
required to prevent deflection, make the
additional points adjustable.
Second Plane
Third Plane
If more than one support point
is required to prevent
deflection, make the
additional points adjustable.
Degrees Of Freedom
 Understanding DoF
 There are total 12 DoF of any object which is free in
space to move or rotate.
 Example… The motion of a ship at sea has the six DoF
of a rigid body, and is described as:
 Translation and rotation:
-Moving up and down — (elevating or heaving);
-Moving left and right — (strafing or swaying);
Moving forward and backward — (walking or surging);
Swivels left and right — (yawing);
Tilts forward and backward — (pitching);
Pivots side to side — (rolling).
 3- 2-1, principle of fixturing
• The purpose of Fixturing is.
• 1. Resting — which is stability ?
•
2. Locating — locate the job with respect to datum ?
•
3. Orienting — In which desired direction job should be
orientate secondary datum ?
•
4. Clamping — ensuring above three positions are not
disturbed, clamping may be mechanical, pneumatic,
electrical or hydraulic, that we will learn later
Six-point location method or 3-2-1 method ?

First the three locators, or

supports, are placed under the
work piece.

It will positioned the primary

locating surface also known as
datum.

It will restrict 5 degrees of

freedom,
1) restrict axial movement
downward a long minus Z
axis.(Number 6).
2) Restrict rotation about the X
axis(Nos: 7 and 8)

3) Y axis(no.9).
Secondary Location Surface
The next two locators are normally
placed on the secondary surface,
restricting an additional three degrees
of freedom by arresting:

-The axial movement along the Plus Y

axis ( that is number 3)
- rotational movement about the Z (that
is 11 number and 12 number
respectively).
 The final Locator

• is positioned at the
end of the part.

• it restricts the axial

movement in one
direction along the X
axis

• These 6 locators will

restrict a total of nine
degrees of freedom
as shown in this
drawing.
9 degrees fix
Positioning Locators
 3-2-1 Locating Principle
A workpiece, just like any
free solid body, has six
degrees of freedom (twelve
degrees of freedom by
considering the +/-
movements in each
category)

For locating it is necessary to

arrest all these six degrees
of freedom to ensure the
mechanical stability.
 Plane 1
A single locator in Plane 1 would
arrest the linear motion along the
X-axis.
A second locator in the same
plane would arrest the rotary
motion about the Z-axis.
Another locator placed in the
same plane would arrest the
rotary motion about the Y-axis.
Adding one more locator in Plane
1 would not serve any purpose.
 Plane 2
 So fourth locator is placed in
Plane 2 which is perpendicular
to Plane 1. This would restrict the
linear motion along the Y-axis.
 The fifth locator is placed in the
Plane 2 which can arrest the
rotational motion about the X-
axis.
 The sixth locator placed in Plane
2 would not serve any purpose.
 Plane3
 So, sixth locator is placed in Plane 3
which is perpendicular both the planes
1 and 2.

 This would arrest the linear motion

along the Z-axis.
component with six
locators
 QA
According to the principle of location in jigs and
fixtures, how many degrees of freedom are to be
eliminated to have a body fixed in space?
(a)3
(b)4
(c)5
(d)6
 Considering 12 DOF
 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.
 3 pins arrest 5doF

 Rest the work piece on three

non-collinear points of the
bottom surface (XY),
 This will be arresting the +Z,
 CROT-X,
 ACROT-X,
 CROT-Y and
 ACROT-Y degrees of
freedom.
 2 pins arrest 3dof
Now, rest the work
piece at two points of
side surface (XZ),

 you will be able to fix

the
 +Y
CROT-Z and
ACROT- Z
degrees of freedom.
 1 pin arrest - 1dof

 Now, rest the work piece

at one point of the
adjacent surface (YZ),

 you will be able to fix

the

 +X degrees of freedom
 Points to ponder
When more than one locator is placed on a surface (plane),
they should be distributed as far apart as possible on the
surface.

While selecting the surface for the largest locators,

consideration should be given to the largest area of the
workpiece.
 QUIZ TIME
In the 3-2-1 principle of fixture design, 3 refers to the
number of

(a)Clamps equired

(b)Locators on the primary datum face

(c)Degrees of freedom of the workpiece

(d)Operations carried out on the primary datum face

 BASIC PRINCIPLES OF
LOCATING

• To perform properly, workholders must

accurately and consistently
position the workpiece relative to the cutting tool,
part after part. To accomplish this, the locators
must ensure that the workpiece is properly
referenced and the process is
repeatable.
• Workpiece should automatically come to
rest against locators despite operators skill
or effort.
• Location system must consistently position
all workpieces in relations to the tool
despite the variations in the working
environment.
• e.g. surface irregularities, wear of locators,
dirt, temperatures difference.
• 1. Establishing a locating plane
• Surface should be machined to insure
accurate location
• Choose locating point as far as possible.
• 2. Part size
• Number of locator used to reference a part
normally depends on the part size.
• 3-2-1principle determines the minimum number
required
• When holding force cannot be applied more than
six locators can be used
• Less operator skill is required when placing the
workpiece in the holder
• To Increase center line control
 3. Stability

• Workpiece is unstable when placed on

the locators, the workpiece tends to lift or
rock away from one or more locators.
• Place locators far for more stability and
to minimize the effect of wear of locators
and workpiece irregularity.
• Top heavy workpiece may led to stability
• Poorly placed holding force
• Not enough locators
 4. Cutting pressures

• Try to place locator opposite of the tool

force to avoid deflection of the workpiece.
• Where possible, tool-forces should be
such that they force the workpiece into
contact with the locators.
• Holding forces should not be in the
opposite direction to the tool forces
 5. Fool-proofing

• Process of position locators such that part

will only fit in the proper position. Achieved
by foolproofing pin.
 Chip removal

• Chips and burr on locating surface can

cause wear and disturb proper location.
• 1. Make locators easy to clean
• 2. Make them self cleaning
• 3. Protect them
Controlling Chips
 Sharp locators

• Burr and Chip Relief

 Summary:
• Clamping Rules of Thumb
• Define three reference planes on the
workpiece and fixture.
• Provide one opposing clamping force
opposite each plane to restrict movement
• When in doubt, rely on additional
cylinders to take up uncertainty.
Types of workpiece location
C) Radial Location
 Radial location
• Supplement to the concentric locators to
provide a specified fixed relationship to the
concentric locator.
 Combined location
• Most workholders use a combination of
locational methods to completely locate a
workpiece.
• 1. External locators
• Devices used to locate the part from
external surface.
• Two basic forms of external locators are
fixed or adjustable.
•
 Commercial Locating pins
• easily available in market,
 Adjustable support
• Threaded type adjustable supports
Spring type adjustable support with
locking nut
 Internal locators

• For locating holes and bored diameters –

usually located internal surfaces.
• Fixed locators – machined to suit specific size
when the size variations are not large –
example: base plate
• Compensating locators: conical and self
adjusting
 Integral locators

• Locators which are machined into the

body of the work holder.
• Disadvantage – extra time for machining
and no replacement for wear or damaged
locators
 Assembled locators

• Similar to integral locators

• Replaceable locators
V locators
 Cylinder movements
• Cylinder can come along upward Y (1),
forward X(1) ,
• Backward Z(1) and rotation along Z ( 2) –
5 movement is possible.
 Nests

FULL Partial
 Adjustable locators
• Application: Workpiece surface is irregular; large
variations is the workpiece (Sand Castings)
• Advantage: Cost is reduced as the location is
not critical
 Relieved locators
• To minimize contact between workpiece
and locators – to avoid locator sticking and
jamming in the part.
.
Diamond Pin location
Floating Pin locator
Floating Pin locator
ECCENTRIC LEVELING LUGS
•
Conical locators
14. Spring pins
• Not the locating
device but ensure
that workpiece is in
contact of all locator
• Used for small and
compact parts
 15. Spring stop buttons
Work same like spring pin but are
designed for large workpiece.
Using Spring-Loaded Locators
 Today’s Agenda
• Type of Locator
• Trick of Design
• Clamping Principle
• Jig Design
Avoiding Redundant Location
Preventing Improper Loading
 Determining
Locator Size and
Tolerances
CLAMPING GUIDELINES
 Clamping principles
• 1.Design and use consideration
• Simple clamps should be used
• Quick loading and unloading should be permitted
• Production rate should be considered
• 2.Cutting pressures
• Understanding of cutting forces may eliminate need to
restrain 12 DOF
• Drilling – Torque and upwards force
• Milling operation horizontal force should be directed
towards jaw
• 3.Part damage
• Excessive clamping leads to elastic deformation.
4.Clamping and location
• Tool forces tend to move the workpiece away from the
locators
 B. CAM
A. Screw

D. Toggle Linkage

C. Wedge

E. Lever
F. Combined screw and wedge
 Basic types of clamps

1.Strap clamp
Clamp…
Positioning the Clamps
2.Screw clamp

Direct Pressure screw clamps

3.Hook Clamp
Indirect Pressure (Magnification
is possible by using leverage
 3. Cam clamp
•Fast operating clamping devises

•Direct – tendency to loosen during machining

Indirect – efficient and safest
 4. Toggle clamp
• Fast clamping and release actions
• Move completely clear of the workpiece
• High ratio of holding force to actuation
force
• Limited range of movement
• Inability to compensate for different
thickness (suitable to only slight changes
of workpiece thickness)
A possible tightening with a single
turn is as efficient as screwing 10
turns, but so much faster
Automatic toggle clamp:
• A. Definition
• Jigs are work holders, which are designed to hold, locate, and support a workpiece
while guiding the cutting tool throughout its cutting cycle.
• Drill jigs are – drilling, tapping, reaming, countersinking, counter boring, chamfering,
and spot facing.

• B. Design considerations
• 1. General, machine and process
• General Consideration
• Justification of manufacturing cost reduction
• Machine Consideration
• 1. Size, Type, and Capabilities of machine
• 2. Machine should be capable of handling the part – shape, size and accuracy
• 3. Enough space to mount Workholding device
• 4. Tool designer must know about – table size, “T” slot size, machine travel
axis
•
 Jig Design
• Process Consideration

• 1. Consider all manufacturing steps

• 2. If the part is not pre-processed first-operating
jigs are used to make hole to serve for location
purpose is subsequent steps.
• 3. Multiple jigs and fixtures can be used for one
part
• 4. Chip removal should be considered for each
manufacturing step
•
 •a. Template

• 1. They do not incorporate clamping device

• 2. Plate containing hole or bushings to guide a drill
• 3. Place on parts
b. Plate

• Template jig equipped with clamping device.

 c. Universal or pump
• Universal jigs utilize a handle connected to a cam or
rack and pinion to move either a busing plate or nest
plate. Parts held in the universal jigs have surface
adaptable to fitting against the surfaces of the bushing
plate and nest.
•

•Changing bushings it can be used for different components

Leaf
• Small and incorporates a hinged leaf that carries
bushings, and through which clamping forces is applied.

Can be a box type

 Channel

•Permit drilling in more than

one surface

•Reduces number of setups

but increase in design and
manufacturing cost of jigs
 tumble box
• Tumble jigs permit
machining form all six
sides.
 Indexing jigs

1. Placed on base and bore

2. Locating stud
3. Hex nut
4. C-Washer
5. Drill bushing
6. Index pin
7. Spring
8. Bushing plate

Used to drill hoes located in pattern.

Location for the holes is generally
taken from the first hole drilled.
54.12
%
 P = Pitch = 1/Number of threads per inch (tpi)
H = Angular Depth = 0.866025 x P
H/8 = Shortening of major dia = 0.108253 x P
H/4 = Shortening of minor dia = 0.216506 x P
d = Actual Depth = 0.541266 x P
r = Radius at the Root = 0.1443 x P
Hn = Basic height of Internal Thread = 0.54127 x P
Hs = Basic height of External Thread = 0.61344 x P