DESIGN OF JIGS & FIXTURES

UNIT 4
(Degrees of freedom, principles of location and clamping, principles of jig
design, fool proofing, elements of jigs, classification of jigs, design of jigs
for drilling and reaming)

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DESIGN OF JIGS & FIXTURES
TOOLS (other than cutting tools)

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PRINCIPLES OF LOCATION
Degrees of Freedom
Degree of Freedom is defined as number of independent motion a body has.
3-2-1 Principle of Clamping Workpiece
It is principle of clamping widely used.
1) 3 Pin are used at Bottom
It will restrict 4 Rotational motion (X,Y Axis) and 1 Translation motion (-Z Direction)
2) 2 Pin
It will Restrict 2 Rotational Motion (Z Axis) and 1 Translation motion in (+X Direction)
3) 1 Pin
It will restrict 1 Translation Motion (+Y)
And Pin 3-2-1 combined will restrict 9 Motion
And Remaining 3 Motion is used to set work-piece at desired location and can be
restricted by Clamp.
(*Notation given i.e +X, -X . Changes according to views)

* Function of a location system is to provide the necessary constraint

so that work piece is correctly located.
* Also should be fool proof so that there is no chance of incorrect
location

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PRINCIPLES OF LOCATION 6-point location principle
THE 3-2-1- PRINCIPLE

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PRINCIPLES OF LOCATION

Extent of location and choice of location system

- Depends on particular operation and upon the shape of the work piece
before that operation
- Location system should eliminate as many DOF as possible to achieve
the necessary accuracy of operation

When there is a choice of location points, the most effective location

system must be selected
Choice depends on
- simplicity
- accuracy
- ease of location
- effect of wear upon the accuracy of the system

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PRINCIPLES OF LOCATION

Redundant location

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PRINCIPLES OF LOCATION

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PRINCIPLES OF LOCATION

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DESIGN OF JIGS & FIXTURES PRINCIPLES OF LOCATION

FOOL PROOFING
• LOCATION SYS SHOULD BE SUCH THAT THE OPERATOR WILL NOT LOAD THE
WORKPIECE IN-CORRECTLY

EG.. 1) USE FOF FOULING PINS FOR STEPPED / COLLARED SHAFTS LOCATION

2) USE OF FOULING AT CORRECT LOCATION W.R.T THE WORKPIECE

SHAPE --- NEAR FLANGE

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PRINCIPLES OF LOCATION

FOOL PROOFING EXAMPLES

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LOCATION METHODS / DEVICES
1) LOCATION FROM PLANE SURFACE

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LOCATION METHODS / DEVICES

2) Location by profile

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3) Location from cylinder LOCATION METHODS / DEVICES

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PRINCIPLES OF LOCATION
LOCATION METHODS / DEVICES

4) Location by spherical surface

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PRINCIPLES OF LOCATION
LOCATION METHODS / DEVICES
5) V - Location

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CLAMPING METHODS

Clamping
Once workpiece is located, then clamping is necessary to
press it against locating surface and hold it against the forces
acting on it

Clamps essential requirements:

1) Must be held rigidly
2) Time of loading / unloading must be shorter as possible
3) Positive even during vibration / chatter
4) Must not damage the workpiece

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CLAMPING METHODS

Types of clamps
1. Plate clamp
2. Strap clamp
1. Simple spring type / knob
2. Dog point clamp
3. Quick acting swinging type

3. Cam clamp
1. Eccentric cam
2. Spiral cam 5. Latch clamp
6. Wedge or key clamp
4. Screw clamps 7. Toggle clamp
1. Set screw 8. Rack and pinion type
2. Screw thread / jack
3. Swing type
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CLAMPING METHODS

- Clamping can use one or more of above devices

- Readily available as std parts (COTS)
• Air operated clamps
• Clamping – spring operated
• releasing by air – wedge / cam

• Hydraulic operated clamps

• Clamping – spring action
• Releasing – hydraulic - lever and cam

• Magnetic clamping
• Only for ferrous workpieces
• Grinding applications

• Vacuum clamping
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DESIGN OF JIGS & FIXTURES TYPES OF CLAMPS

Simplest & most commonly used

clamps; all strap clamps employ
the principle of levers;
Many sizes and shapes are
available as std parts to suit
different applications

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TYPES OF CLAMPS

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TYPES OF CLAMPS
CAM ACTUATED
CLAMPS

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TYPES OF CLAMPS
LATCH CLAMPS

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TYPES OF CLAMPS TOGGLE CLAMPS

LATCH CLAMPS

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TYPES OF CLAMPS
SCREW CLAMPS

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TYPES OF CLAMPS
PUSH TOGGLE CLAMP
HYDRAULIC CLAMPING

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TYPES OF CLAMPS

MAGNETIC CLAMPING

MAGNETIC CHUCK
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VACUUM CLAMPING

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 DESIGN OF JIGS & FIXTURES
UNIT 4
(Degrees of freedom, principles of location and clamping, principles of jig
design, fool proofing, elements of jigs, classification of jigs, design of jigs
for drilling and reaming)

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DESIGN OF JIGS & FIXTURES
DRILL JIGS
❑ IT IS A DEVICE THAT GUIDES THE TOOL DURING CUTTING

❑ ONLY EQUIPMENT THAT NEED NOT BE FIXED TO THE M/C

TOOL TO COUNTERACT THE EFFECT OF CUTTING
FORCES, M/C MOVEMENT OR GRAVITY

❑ SOMETIMES THE JIG IS BOLTED TO THE M/C TABLE DURING

MACHINING OPERATION

❑ THEREFORE A DRILL JIG INCORPORATES MEANS OF

LOCATING & CLAMPING THE WORKPIECE & ALSO
MEANS OF CONTROLLING / GUIDING THE CUTTER
DURING MACHINING

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DRILL JIGS

❑ HARDENED STEEL BUSHES ON GUIDING HOLES -- DRILL

IS GUIDED BY THE BUSHINGS

❑ IF WORKPIECE IS SIMPLE - DRILL JIG IS CLAMPED ON

WORKPIECE

❑ OTHER CASES - WORKPIECE IS HELD BY THE JIG AND THE

JIG IS ARRANGED IN SUCH A WAY THAT
WORKPIECE IS QUICKLY INSERTED AND REMOVED
AFTER MACHINING OPERATION

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DRILL JIGS

❑ DRILL JIGS MAKE IT POSSIBLE TO DRILL, REAM & TAP

HOLES AT GREATER SPEEDS & ACCURACY AS
COMPARED TO CONVENTIONAL HAND METHODS

❑ WHEN JIGS ARE USED – OPERATOR NEED NOT BE

SKILLED

❑ JIGS PHYSICALLY LIMIT AND CONTROL THE PATH OF THE

CUTTING TOOL

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DRILL JIGS
GENERAL CONSIDERATIONS IN DESIGN OF DRILL JIGS

1. RIGIDITY – IS OF PRIME IMPORTANCE

2. SHOULD HAVE PROVISION FOR CHIP REMOVAL / FLOW

3. LOCATION AND CLAMPING

➢ NESTING SHOULD BE PROPER (POCKETS TO REST WORKPIECE IN A JIG)
➢ SHOULD BE EASY TO INSERT & REMOVE FROM JIG
➢ SHOULD BE QUICK TO LOAD NEW PART FOR MACHINING

4. CLAMPING AS FAR AS POSSIBLE ABOVE (OR NEAR) THE BEARING POINT - TO

RESIST THE PRESSURE OF CUTTING TOOL ( PROPER FORCE TRANSMISSION

5. CLAMP SHOULD BOT PROTRUDE EXCESSIVELY BEYOND DRILL BUSHINGS

SINCE THEY MIGHT HINDER TOOL MOVEMENT & DAMAGE THE TOOL

6. SIMPLE CLAMPING DEVICES TO BE USED

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DRILL JIGS
GENERAL CONSIDERATIONS IN DESIGN OF DRILL JIGS

7. HANDLE SHOULD BE INTEGRAL PART OF JIG OR SOULD BE FASTENED TO JIG

BY A SMALL CHAIN SO THAT IT IS NOT LOST WHILE LOADING AND
UNLOADING WORKPIECE

8. USE NYLON CABLE ASSEMBLIES TO FASTEN LOOSE PARTS TO JIG BODY

9. LOCATING POINTS ON JIG SHOULD BE AS FAR AS POSSIBLE FROM EACH

OTHER & SHOULD BE IN VIEW BY OPERATOR

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DESIGN OF JIGS & FIXTURES

Types of drill jigs

1. Plate jigs & channel jigs (template jigs)
2. Leaf jigs
3. Post Jigs
4. Sandwich jigs ( drill plate and workpiece separately located
with different locators)
5. Nutcracker jigs
6. Table jigs (turnover jigs or open jigs)
1. Vertical
2. Horizontal
3. Turned to the face of the drill (inclined)
7. Latch jigs
8. Box jigs
9. Trunnion jigs
[Link] jigs
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PLATE JIG

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LEAF JIG

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LEAF JIG

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BOX JIG

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INDEXING JIG

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INDEXING JIGS

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TRUNNION JIG

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POST JIG
Horizontal Post

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DESIGN OF JIGS & FIXTURES

POST JIG
Vertical Post

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DESIGN OF JIGS & FIXTURES
TYPES OF BUSHES USED IN JIGS
DIFFERENT TYPES OF BUSHES USED BASED ON MACHINING SITUATION

1. FIXED BUSHES (OR PRESS FIT BUSHES)

➢ PLAIN TYPE
➢ HEAD TYPE

2. LINER BUSHES
➢ PLAIN
➢ HEAD OR FLANGE TYPE

3. RENEWABLE BUSHES

4. SLIP-IN BUSHES

5. SCREW OR CLAMP BUSHES

6. SPECIAL BUSHES

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DESIGN OF JIGS & FIXTURES
TYPES OF BUSHES USED IN JIGS

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TYPES OF BUSHES USED IN JIGS

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TYPES OF BUSHES USED IN JIGS

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DESIGN OF JIGS & FIXTURES
TYPES OF BUSHES USED IN JIGS
SPECIAL BUSHES

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DESIGN OF JIGS & FIXTURES
TYPES OF BUSHES USED IN JIGS
SPECIAL BUSHES

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DESIGN OF FIXTURES
FIXTURE - DEFINITION
→A FIXTURE IS A DEVICE FOR HOLDING THE WORKPIECE DURING MACHINING OR
ASSEMBLY OPERATIONS

→ THE NAME IS DERIVED FROM THE FACT THAT THE DEVICE IS ALWAYS FASTENED /
FIXED TO A MACHINE OR BENCH IN A FIXED POSITION

→ DOES NOT GUIDE THE CUTTING TOOL

→ SO ACCURACY OF MACHINING DEPENDS ON M/C TOOL & OPERATOR

→ OTHER TOOLING LIKE BRACKETS / GUSSETS ETC USED FOR POSITIONING PARTS
RELATIVE TO EACH OTHER FOR FABRICATION PURPOSES ARE ALSO COMMONLY
CALLED AS FIXTURES …eg. Assembly fixtures & vibration testing fixtures

→ SOMETIMES MACHINING OPERATION CAN BE COMPLETED BY CLAMPING THE WORK

TO A M/C TABLE W/O FIXTURES – USING T-BOLTS & SMALL PLATES AVAILABLE
ON M/C TABLE – USED WHEN FEW PARTS TO BE MACHINED

→ LARGE QTY PRODN – FIXTURES ARE SPECIALLY DESIGNED AND USED – COST OF
WHICH IS AMORTIZED ON THE TOTAL NO. OF PARTS
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DESIGN OF FIXTURES
TYPES OF FIXTURES

1. VISE FIXTURES
→ PLAIN STRAIGHT SURFACE
→ SPECIAL CONTOUR (V-TYPE)
→ ADJUSTABLE WITH STOP / GUIDE PIN, TONGUE & LOOSE PIECES

2. MILLING FIXTURES
3. BORING FIXTURES
4. TURNING FIXTURES -- CHUCKS, FACE PLATES, MANDRELS &
COMBINATION
5. BROACHING FIXTURES
6. GRINDING FIXTURES -- REGULAR, MAGNETIC (PLAIN & V-BLOCK),
VACUUM
7. MODULAR FIXTURING

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DESIGN OF FIXTURES
VISE FIXTURES

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DESIGN OF FIXTURES
MILLING FIXTURES

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BORING FIXTURES

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DESIGN OF FIXTURES
TURNING (LATHE) FIXTURES – FACEPLATES

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DESIGN OF FIXTRUES
TURNING (LATHE) FIXTURES – FACEPLATES

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DESIGN OF FIXTRUES
TURNING (LATHE) FIXTURES – MANDRELS / CHUCKS

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DESIGN OF FIXTURES
BROACHING FIXTURES

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DESIGN OF FIXTURES
MODULAR FIXTURES (GRID PLATE)
→ AUXILARY BASE PLATE WITH GRID PATTERN OF HOLES
→ HOLES ARE ON 1” CENTERS WITH EVERY ALTERNATE HOLE TAPPED
→ OTHER HOLES ARE DRILLED TO AN ACCURACY OF 0.0002” – USED TO RECEIVE
DOWEL PINS FOR WORKPIECE LOCATORS
→ GRID PLATE BOLTED DIRECTLY TO M/C TABLE
→ UNIVERSAL GRID PLATE ENABLES SPECIFIC LOCATION OF WORKPIECE

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DESIGN OF FIXTURES
MODULAR FIXTURES (GRID PLATE)
ODD SHAPED PARTS THAT CAN’T BE HELD READILY ON GRID PLATE
ARE HELD ON SPECIAL AUXILIARY FIXTURES BUILT ON SMALL BASES
– CONTAIN HOLES THAT MATCH THE GRID PLATE HOLES

GRID SYSTEM OF FIXTURING – BROWN & SHARPE MFG CO.)

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DESIGN OF FIXTURES
MODULAR FIXTURES

A 5-axis milling machine with interchangeable work tables

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DESIGN OF FIXTURES
PRACTICAL PROBLEMS:

This bracket to be placed

on the silencer pipe and
welded in position shown

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DESIGN OF FIXTURES
PRACTICAL PROBLEMS:

Four holes dia 6.0mm, 100 mm apart and 30

degree apart to be drilled on the pipe to
mount this bracket

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