Jigs and Fixtures

AGENDA
Introduction
Research Objectives
Methodology
Taxonomy
Welding Jigs & Fixtures
Design Consideration
Advantages
Conclusion
INTRODUCTION
 DEFINITION
 FIXTURE: a device used to hold, position
and/or align a work piece for an operation or
process. Shipyard uses include assembly,
subassembly, foundation and part fabrication.
 JIG: a device used to guide a tool; a template.
Shipyard uses include pin tables and other
devices for assembly of foundations,
bulkheads, assemblies and parts. Jigs are often
incorporated into fixtures.
 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
interchange ability of components.
 jigs and fixtures position components
accurately and hold components rigid and
prevent movement during working in order to
impart greater productivity and part accuracy
 DIFFERENCE BETWEEN JIGS AND
FIXTURES
 JIGS: Jigs are used to hold the work piece and
also to guide the tool while performing the
operation.
Jigs are mostly used for drilling operation
 FIXTURES: Fixtures are used only to hold the
work piece and it won’t guide the tool.
Fixtures are mostly used for milling operation
 ELEMENT OF JIGS AND
FIXTURE
Jigs and fixture consist of three elements :
 Locating element
 Clamping element
 Tool guiding and setting element
 Contd…
 LOCATING ELEMENT : These position the work piece
accurately wrt. the tool guiding or setting element in the
fixture
 CLAMPING ELEMENT : These hold the work piece
securely in the located position during operation.

 TOOL GUIDING AND SETTING ELEMENT :

 These guiding or setting the tools in the correct position with
respect to the work piece .
 Drill bushes guide the drill accurately to the work piece.
 Milling fixture use setting for correct positioning of milling
cutters with respect to the work piece.
RESEARCH OBJECTIVES
 Research Objectives
 Increased 1st time quality = Lower Costs
 accuracy
 fairness
 gap minimization
 Increased Productivity = Lower Costs
 less man-hours
 increase throughput
 lessen skilled labor requirement
METHODOLOGY
 Methodology
1. Survey and Classify
2. Preliminary Design New System of Jigs or
Fixtures
3. Economic Analysis
4. Final Design New System of Jigs or Fixtures
5. Documentation and Dissemination
TAXONOMY
 Why Complete a Taxonomy ?
 It involves a relatively exhaustive search
 Relationships between different jigs and
fixtures are highlighted
 Through understanding
 Plan for Improvement
 Taxonomy

Jigs & Fixtures

Portable Fixtures

Stationary Fixtures

Guiding Jigs

Restraining Jigs
 PORTABLE FIXTURES

Portable Fixtures

Portable Platen

Shaft Fixture w/ Rollers

 Portable Platen

This platform can be

relocated by truck.

It is metal and creates a non

permanent workspace.
 Shaft Support with Rollers

This fixture supports

the shaft in position
and
occasionally rotates to
prevent sagging of the
shaft.
 STATIONARY FIXTURES

Stationary Fixtures

Burn Table

Cradle

Metal Columns

Mocks
 BURN TABLE

This metal table made

of a grid framework
allows slag to fall
through the spaces.
CRADLE

Large wooden cradles are used

to support and maintain the
shape of the hull during the
erection stage.
 METAL COLUMNS

Round Pipe supports, fixed in

height provide adequate room
for a crawler to drive under.

Wooden chocks and wedges

are used where necessary to
level the unit.
Threaded Adjustable Rudder Mock

Support for the Rudder unit has

been constructed to match the
unit shape. It is used only once
for a single hull design.

This fixture holds the rudder

while bearings are installed
during assembly of the rudder.
 SHELL MOCK

This mock resembles

a mold of the inner
bottom shell plating.
The shape is
maintained while
stiffeners are welded.
 GUIDING JIGS

Guiding Jigs

Pin Jigs

Pipe Jigs

Wireways
 PIN JIGS

Unique shaped panels can be

formed over the Pin Jigs.

Threaded pipes are positioned

in a grid and pins are used to
adjust their heights.
 PIPE SUPPORTS

Pipe supports are used to hold

irregular shaped units in
position while being outfitted.

They may also be used

during unit erection.
 WIREWAYS

These trees help to

guide ductwork or gas
lines so that access
can be maintained
during construction.
 RESTRAINING JIGS

Restraining Jigs

Cable and Stay

Chains

Clamps

Pipe Supports
 CABLE & STAY

Cable and stays are used to

maintain vertical alignment prior
to welding.

This cable and stay is

adjustable via the use of a
ratcheting come along.
 GRIPPING CHAIN

Chains are used in

the Pipe shop to
restrain or fasten
pipes to the work
table.
 CLAMPS

Clamps are used to

hold the work piece
in fixed position for
the intended work to
be performed.
ADJUSTABLE PIPE SUPPORTS

Pipe support on wheels help

make the work piece movement
easier than use of a crane and
hold the work piece in position.
 DOWN SELECT PROCESS

 Translate Discussions to Participants

Customer Requirements • Planning
 Establish Production • Mold Loft
Needs • Pipe Shop
 Translate to Required • Machine Shop
 Attributes • Unit Assembly
• Accuracy Control
• Ship Erection
• Package Units
• Maintenance
 PIN JIG CONCERNS
Rust and Corrosion
Desire Manual Adjustment
Must Manage Horizontal Component
Jig Must Not Distort Work Piece under
Load
WELDING JIGS & FIXTURES
 WHY ???
 To minimize distortion caused by heat of
welding.
 To permit welding in a more convenient
position.
 To increase welding efficiency and
productivity.
 To minimize fit-up problems.
 WELDING JIGS
 Welding jigs are specialized devices which
enable the components being welded to be
easily and rapidly set up and held.
 QUALITY REQUIRED:
 Rigid and strong since it has to stand
contractional stresses without deforming.
 Simple to operate, yet it must be accurate.
 Designed such that it is not possible to put the
work in it the wrong way.
 Faced with wear-resistant material to stand
continual wear.
 WELDING FIXTURES
 A welding fixture serves the same purpose as a
welding jig; but, in addition, it permits the
changing of the position of the work during the
actual welding, so as to place the welds in a plane
convenient to the operator at all times
 This increases welding speed.
Fixture Characteristics
 Supporting
 Clamping
 Grounding and
 Imparting movement (usually referred to as travel
or traveling) to name but a few
 Welding Fixture Classification
 Those that act on the work being welded: clamp the
parts together while simultaneously supporting them, the
objective being to effect a weld in the flat position. hold
the work stationary in which case the welding equipment
moves or is traveled over it or may be mechanized and
move the work under the stationary welding equipment.
Includes rotating positioners, power turning rolls, lathes,
and mill type setups etc.
 Those that act on the welding equipment:
provide only stationary support or both support and
travel to the welding equipment. include the beam with
carriage, the self-propelled tractor, the spud welding unit
and a variety of boom type welding manipulators.
 Fixture Selection
 In selecting fixtures for mechanized welding,
the engineer must evaluate considerations
such as
 Production volume
 Joint geometry
 Movability of the welding head.
 Design of Good Welding Jigs and Fixtures
 The fixture should be strong and light but rigid enough to
ensure accurate alignment.
 Whenever possible, a fixture should be positioners, enabling all
welds to be brought to a convenient welding position.
 The fixture should permit quick and easy positioning (by one
hand, if possible). Thus, balancing of the fixture may be
necessary.
 Design should be as simple and inexpensive as possible;
accuracy and elaboration should be no greater than required.
Only essential dimensions should be controlled in a fixture.
Appearance should be disregarded.
 The use of light alloys for moving parts reduces weight. Air or
electric motors should be used for revolving, and air or
hydraulic rams for tilting the fixture assembly.
 CONTD…
 should be built around the work and should locate and
clamp components in position so that assembly,
tacking, and welding may be carried out in one fixture.
 should permit freedom of movement in one plane to
avoid residual stress in the completed weldment.
Design should permit heat dissipation to release,
rather than bind, the assembly being welded.
 Joints must be readily accessible for welding. By slots
or other means, the fixture should readily present
seams on the reverse side of the object
 Fixtures should be kept cool enough to handle air,
water, fins or insulated handles can be used.
 Parts should be prebent in the fixture, if necessary, for
final accuracy.
 CONTD…
 Clamps must operate quickly. Screws and moving parts
should be protected against weld spatter.
 Either integral or separate copper backing bars should
be used in cases of poor fit or for light plate.
 Use of nuts and bolts, wrenches, C-clamps, wedges and
hammers and hand screws should be minimum.
 Methods of grounding the work are important
considerations in fixture design, since they affect arc
action, quality of weld, and speed at which welds are
produced. The ground must make good contact with the
work through the medium of copper, copper graphite
brushes, sliding shoes etc.
 CONTD…
 A good fixture design avoids the problem of arc blow by
taking following measures:
(a) All steel other than being welded should be kept .at
least 25 mm from the arc.
(b) Clapping fingers may be made from a non-magnetic
material.
(c) The ground connection should be made directly with
the work and not with the backing bar. The point of
connection should be as far from the arc as possible. The
ground can be split to offset arc blow.
(d) When possible, the fixture should be built from low
carbon steel, large masses of steel should be normali-zed
to minimize residual magnetism.
(e) When horn type fixtures are used, the welding should
be toward the closed end.
 CONTD…
 The fixture should be designed for ease of
accessibility to the welding head when
procedure adjustments and servicing are
necessary. Accessibility is also necessary in
the positioning of welding controls.
 The design of fixture should be such that the
weldment can be easily and quickly removed
from the fixture.
 TYPES OF JIGS AND FIXTURES
 A C-clamp is good enough for most welding jobs. It can
be quickly and cheaply made in the shop.
 A simple, but effective ‘V’ rest for supporting short bars
or pieces of pipe for tacking or welding on the bench
 Rotating fixtures for making circumferential welds or for
building up rollers, rings, valves, drilling bits and axles
are very valuable, as they speed up the job and make for
neater welds with less waste.
 A few clamps for sheet or plate joints
 To turn over very large pieces of work for positioning in
welding, it is often useful to build adapters which bolt or
clamp to the work and contain the trunnions.
 A roller bed for welding pressure vessels, containers
and other cylindrical objects.
DESIGN CONSIDERATION
 DESIGN PRINCIPLE
The 3-2-1 Principle of Jig Fixture Design
 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
 6 rotational motion(3 clockwise & 3 anticlockwise)
about respective axes.
 It must required to 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?
 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-Z degrees of freedom.
 So, you can successfully fixate 9 required degrees of
freedom by using the 3-2-1 principle of fixture design.
DESIGN CONSIDERATION FOR JIGS AND
FIXTURE
 Design consideration for jigs and fixture
depends upon following three factors.
 Tooling cost
 Tooling detail and
 Tooling operation
 These design consideration are independent of
each other.
 TOOLING COSTS
 The total cost of any jig or fixture is frequently the
major area of consideration many work holder
designs.
 Permanent fixtures have distinct advantages in the
production of high-volume and high-precision parts.
 It reduce machine setup time, machine cycle time and
the level of operator skill required to produce
satisfactory quality output
 General-purpose work holders are more expensive
than temporary tools in most cases, but their utility
and flexibility often allow these work holders to be
regarded as a capital cost to be amortized over a
period of time without regard to actual usage.
 CONTD…
 Modular fixturing is typically a capital investment to
be amortized over a set lifespan, with an average cost
assigned to usage for each anticipated job.
 Modular fixturing is typically a capital investment to
be amortized over a set lifespan, with an average cost
assigned to usage for each anticipated job.
 General-purpose tools are reused extensively, but
still incur some costs for maintenance and storage.
 Modular fixtures will be disassembled, and the
components maintained, stored, and reused
frequently.
 TOOLING DETAILS
 It is the overall construction characteristics and
special features incorporated into the jig or fixture.
 depends upon the type and complexity of the
individual tooling elements, the extent of secondary
machining and finishing operations on the tool, the
tool-design process, and the amount of detail in the
work holder drawings. Permanent work holders are
designed and built to last longer than temporary
work holders.
 Permanent work holders contain different
commercial tooling components based on expected
tool usage.
 Contd….
 Permanent jigs intended for a high-volume drilling
operation.
 The secondary operations normally associated
with tooling include hardening, grinding, and
similar operations to finish the work holder
 permanent work holders are hardened and
ground to assure their accuracy over a long
production run.
 TOOLING OPERATIONS
 The performance of any work holder is critical
to the complete usefulness of the tool.
 he performance of a permanent, modular, or
general-purpose work holder is considered,
several factors about the machine tools must
be known.
 These factors include the type, size, and
number of machine tools needed for the
intended operations.
 Figure 1-6 shows a typical temporary work
holder for drilling and milling operations on the
same part
ADVANTAGE
 ADVANTAGES OF JIGS &
FIXTURES
 cost savings
 precise and accurate
 increase productivity
 Interchangeability
 less skill requirement
 Time saving
 Alignment of a part or work piece.
 Securing the part or work piece.
 Duplication of a process.
 Contd…
 Maintain or improve part quality.
 Reduce cost of production.
Improve overall safety to the part, the operator,
and the machine.
CONCLUSION
 CONCLUSION
 Both the jigs and the fixtures are used to
reduce the nonproductive time of any mass
production process.
 The 3-2-1 method is the fundamental principle
for all types of fixture design.
 There are varieties of jigs & fixtures are used in
shipyards for different purposes
 It should be standardized at part and assembly
level to reduce tooling and manufacturing
costs.