Production & Manufacturing Related Theory for Exercise No 4.1.
159
Fitter - Drill jig
Drilling jig constructional features, types and uses
Objectives: At the end of this lesson you shall be to
• what is jig
• list the different types of drill jig and uses
• state constructionl features of drill jig
Introduction to jigs The design of a particular type of jig will be based on:
A jig is a device in which a work piece/component is - the position wherein the drilling or its allied operation/
held and located for a specific operation in such a way operations are to be performed
that it will guide one or more cutting tools to the same - the shape of the piece part.
zone of machining.
Plate jig
Types of drill jigs
This jig consists of a drill plate which rests on the
Drill jigs may be divided into two types component to be drilled. For correct positioning/locating,
- Open pins and clips are provided. For heavier piece parts,
sometimes clamps are not used. Generally a base
- Closed plate will not be available for this type of jigs. (Figs 1, 2
and 3)
Open jigs are used when the operation is to be done
only on one side of the piece. Closed jigs (Box jig) are
used when the operations are to be done on more than
one side of the piece. Jigs are identified according to
the way they are built. Most commonly used jigs are:
- Template jig
- Plate jig
- Table jig
- Sandwich jig
- Angle plate jig
- Modified angle plate jig
- Box jig
- Channel jig
- Leaf jig
- Indexing jig
- Solid jig
- Post jig
- Trunnion jig
Types of drill jigs
Template jigs
This type of jigs fits over on or into the work and is not
usually clamped. They are simple and cheap. They may
or may not have guide bushes. When bushes are not
used the whole jig plate may be (Fig 1)
Copyright Free Under CC BY Licence
Angle plate jig
These jigs are used to hold work which are to be drilled
at right angles to their mounting locators. (Fig 6)
Table jig (Turnover jig)
This is used when it is necessary to locate the piece
part from its face. For accurate seating of the jig on the
machine table, four legs will be provided on this type of Modified angle plate jig
jig. (Fig 4) These jigs are used for drilling at angles other than 90°.
(Fig 7)
Box jig
This is made in the form of a box or a frame work. The
component is located and clamped at one position but
drilling can be done from different directions as required.
Sandwich jig When a box jig contains bushings on two or more sides
for drilling from different directions, it is called a tumble
This is ideal for thin or soft workpieces which may bend jig. (Fig 8) This jig is meant for small components only.
or warp due to force while machining. In this type of
jigs, the component will be sandwiched between the
base plate and the drill plate. (Fig 5)
2 P & M Fitter (NSQF Level - 5): Related Theory for Exercise 4.1.159
Copyright Free Under CC BY Licence
Channel jig
They are the simplest form of box jigs.
The workpiece is held between two sides and machined
from the third. (Fig 9)
Latch or leaf jig
This type of jig will have a hinged cover with the latch
clamps for easy loading and unloading of components.
The cover with latch must be positively located and
clamped so that the bushes are accurately located with
respect to the component. (Fig 10)
Solid jig
This can be used while drilling small piece parts. The
body of this type of jig is machined from a solid block of
steel. (Fig 12)
Post jig
This is used for location from a bore. The post should
be as short as possible to facilitate loading and at the
same time it must be long enough to support the
workpiece. (Fig 13)
Indexing jig
Indexing jigs are used to accurately space holes on other
machined area around a part. The jig uses the part being
machined as a reference plate. A spring loaded plunger
indexes the part. (Fig 11)
P & M Fitter (NSQF Level - 5): Related Theory for Exercise 4.1.159 3
Copyright Free Under CC BY Licence
Trunnion jig
This can be used when large or awkwardly shaped
workpieces are to be drilled from different directions.
This is a further modification of the box jig which is
carried on trunnions and rotated from station to station
and positioned, using an indexing device. (Fig 14)
A jig is a special device which holds, supports, locates
and also guides the cutting tool during operation. Jigs
are designed to accommodate on or more components
at a time.
Jigs are available for drilling or boring.
Drilling jigs are used to drill , ream, tap and to perform
other allied operations. (Fig 16)
Boring jigs are used to bore holes which are either too
large to drill or of odd size. (Fig 17)
Constructional features of drill jig
Objectives: This shall help you to
• list the different parts of a drill jig and also their uses
• state the different types of drill bushes and their uses
• state the different types of locators and clamps used in jigs.
The basic features of a drill jig are (Fig 1) In some drill jigs like plate and clamp jigs there will be
no base plate.
- base plate or jig body
Drill plate
- drill plate or jig plate
It holds the drill bushes. Cutting tools are guided by
- drill bushes locating pins
means of the drill bushes. Unbushed holes made on the
- clamps. drill plate are sometimes used for small runs.
Base plate
Drill bushes
This provides a rigid support for mounting piece parts,
locating pins etc.
4 P & M Fitter (NSQF Level - 5:) Related Theory for Exercise 4.1.159
Copyright Free Under CC BY Licence
Renewable bushes are divided into two groups.
Slip renewable bushes (slip bushes)
These bushes are used when more than one operation
is performed in the same location. (Eg:drilling and
reaming) These bushes are used with press-fitted liner
bushes and a lock clamp. (Fig 5)
They are used to locate and guide drills, reamers, taps
and any other revolving tools commonly used to make
or modify holes. (Fig 2)
Fixed renewable bushes
These bushes are used where only one operation is to
These are hardened and ground to exact sizes to ensure be performed with each bush, whereas several bushes
the needed repeatability in the jig. Standard size bushes may be used during the life of the jig. These are also
are also available. held in a liner and retained by a screw. (Fig 6)
Types of drill bushes
-
Press fit bushes
- Renewable bushes
- Liner bushes
Press fit bushes are made in two forms.
- Head
- Headless
Liner bushes are used to provide a hardened hole where
These bushes are used where frequent change of bushes renewable bushes are located. Liner bushes are press-
is not anticipated. (Figs 3 and 4) fitted to the jig plate.(Fig 7)
P & M Fitter (NSQF Level - 5:) Related Theory for Exercise 4.1.159 5
Copyright Free Under CC BY Licence
Locating pins or locaters are used
- to restrict the movement of the component
- to position the piece part with respect to the tool
- to facilitate easy loading and unloading of component
piece parts
- to assist the operator for correct loading (fool
proofing).
Different types of locating pins are used according to
the shape of the component and also according to the
hole locators. A few types of locating pins are shown in
Figs 8 to 16.
6 P & M Fitter (NSQF Level - 5:) Related Theory for Exercise 4.1.159
Copyright Free Under CC BY Licence
- cam clamp (Fig 18)
Clamps
Clamps in jigs are meant for holding the component in
position against the cutting force. They also help in rapid
loading and unloading of the components. Clamps are
fitted in such a way that they do not interfere with the
cutting operation.
The commonly used types of clamps are:
strap clamp (Fig 17) - screw clamp (Fig 19)
- latch clamp (Fig 20)
P & M Fitter (NSQF Level - 5:) Related Theory for Exercise 4.1.159 7
Copyright Free Under CC BY Licence
- wedge clamp (Fig 21) - hook clamp (Fig 23)
- toogle clamp (Fig 22)
8 P & M Fitter (NSQF Level - 5) Related Theory for Exercise 4.1.159
Copyright Free Under CC BY Licence
Production & Manufacturing Related theory for Exercise No 4.1.160
Fitter - Drill jig
Fixtures - constructional features,types and uses
Objectives: At the end of this lesson you shall be to
• what is fixture
• list the different type of fixture and uses
• state the constructional features of fixtures
• state the functions of setting blocks and blancinng weight in fixture.
Introduction to fixture Angle plate fixture
A fixture is a production tool used to locate accurately This fixture is used for machining the part at right angle
and to hold securely one or more work- pieces so that to the locator. (Fig 2)
the required machining operations can be performed.
A fixture should be securely fastened to the table of the
machine upon which the work is done. The main purpose
of a fixture is to locate the work quickly and
accurately,support it properly ,and hold it securely.
Classification of fixtures
Fixtures are classified by the type of machine on which
Modified angle plate fixture
they are used. If a fixture is made for a milling machine
it is called a milling fixture. Some of the most commonly This fixture is used for machining the part at angles
used fixtures are turning fixture, milling fixture, welding other than 90°. (Fig 3)
fixture, boring fixture, assembly fixture, inspection
fixtures etc.
The elements of jigs and fixtures are
- location
- clamping
- tool guiding or setting
- body base or frame
Types of fixtures
Types of fixtures are determined mainly by how the tool
is used. Because of the increased tool forces, fixtures
are built stronger and heavier than jigs. The most
common type of fixtures are Vice jaw fixture
Plate fixture This fixture is used for machining small parts. The
These are the simplest form of fixtures. It is made from standard vice jaws are replaced with jaws that are made
a flat plate which has locater and clamps to locate and to suit the work. (Fig 4)
hold the part (Fig 1).
Copyright Free Under CC BY Licence
Indexing fixtures fixture is a production tool that locates and holds the
work-piece. It does not guide the cutting tools, but the
These fixtures are used for parts that require machining
tools can be positioned before cutting with the help of
on evenly spaced surfaces. (Fig 5)
setting blocks and feeler gauges etc. (Fig 8)
Use of fixtures
Fixtures of different types are made for:
A great deal of importance is placed today on improving
- milling
productivity in manufacturing processes. Application of
jigs and fixtures has contributed a lot towards this - turning
direction.
- grinding
Jigs and fixtures (Figs 6 and 7) are devices used in - welding
manufacturing or assembling. They also facilitate in
carrying out special operations accurately. - assembly
- bending etc. (Fig 9)
10 P & M Fitter (NSQF Level - 5) Related Theory for Exercise 4.1.160
Copyright Free Under CC BY Licence
Constructional features of a fixture
Objective: This shall help you to
• define various constructional features of a fixture.
common types of fixtures used for the machining
operations are:
- milling fixture (Fig 1)
- turning fixture (Fig 2)
- grinding fixture etc.
These fixtures consist of a base plate, standard clamps
and locators, setting blocks and balancing weights.
workpieces with the fixture as in the case of drill jigs.
The clamps used in the fixtures are very rigid and sturdy.
The setting blocks
These are used to position the fixture and work relative
to the cutter before machining.
A feeler is introduced between the cutter and the setting
faces of the block for correct positioning of the cutter
with the fixture. (Fig 4)
Base plate
The base plate for a milling fixture is provided with
tenons at its bottom for proper location of the fixture
with the machine table through Tee slots. (Fig 3) Two or Balancing weight
four hold-down slots are provided in the base plate for This is used dynamically balancing the irregular
rigid clamping of the fixture with the machine table. workpiece fixed to the turning or cylindrical grinding
fixture.
Standard clamps and locators
These are provided for clamping and locating the
P & M Fitter (NSQF Level - 5) Related Theory for Exercise 4.1.160 11
Copyright Free Under CC BY Licence
In the case of a turning fixture, normally the base plate Vice fixture
of the fixture is clamped to the face plate. (Fig 5)
Standard machine vices, attached with special jaws,
provide an easy method of holding parts for machining.
(Fig 6)
Other types of tooling used for positioning parts relative
to each other for fabricating purposes are also commonly
referred to as fixtures. Bending fixtures, assembly
fixtures and welding fixtures are examples of this type.
The construction of a fixture depends upon the
machining and fabricating methods employed.
Difference between jigs and fixtures
Jigs Fixtures
jig holds and positions the work piece, guides Fixture only hold and position the work piece,
the cutting tool does not guide the cutting tool
Fixture is usually fixed to the machine table
Jig is not fixed to the machine table
Fixtures are used in grinding, milling, turning,
Jigs are used in drilling machine for drilling, tapping,
bending and assembling.
counter boring, and countersinking etc.
12 P & M Fitter (NSQF Level - 5: ) Related Theory for Exercise 4.1.160
Copyright Free Under CC BY Licence