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Jigs and Fixture
Introduction
• Fixture is a work-holding device utilised to securely position,
support, and affix a workpiece in a stable position
• It comprises of different work holding devices, which are
clamped on the machine table to hold the work in requisite
position.
• Unlike jigs, fixtures do not guide the tool.
Fundamental Differences
• A jig guides the tool in addition to holding the workpiece
but the fixture only position the workpiece.
• A fixture is heavier in construction and bolted on the
machine table, whereas the jigs are lighter for quicker
handling.
• The fixtures are employed for holding the work in case
of milling or turning operations, whereas jigs are used
for holding the work & guiding the tool in drilling, taping
operations. Fig: Jig (L) and Fixture (R)
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Advantages
• It increases machining accuracy, as the workpiece is properly located and tool is guided.
• It reduces the operator’s labour and consequent fatigue as handling operations are
minimized.
• It increases production capacity by enabling a number of workpieces to be machined in a
single set up.
• It reduces expenditure on the quality control of the finished products.
• It reduces the overall cost of machining by fully or partly automatizing the processes.
Elements of Jig & Fixture
• Body: It is a plate, box or frame type
structure where components are located
for machining. The body should be quite
sturdy and rigid.
• Locating elements: These elements
locate the workpiece in a proper
position with respect to the cutting
tool.
• Clamping elements: These elements Fig: Elements of Jig and Fixture
firmly secure workpiece in the located
position.
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Elements of Jig & Fixture
• Positioning elements: These have different types of fastening devices and it is used to
secure Jig or Fixture to machine at the proper position.
• Grinding and setting elements: These elements guide the cutting tool in case of jig and
help in proper tool acting in case of the fixture.
Location
• The location refers to the establishment of a desired relation between the
workpiece and jig or fixture.
• The jigs and fixture must be designed in such a way that all possible movement
of the workpiece must be restricted.
• The locating points are determined by first finding out the possible degree of
freedom of the workpiece, which are then restricted by a suitable arrangement
termed as locators.
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Principle of Location
• In the fig, it can be observed that the rectangular block is free
to move along the three axis X, Y and Z.
• The body can also rotate about this three axis as well,
thus the total DOF six.
• In order to locate the block accurately, this six movements
has to be restricted by arranging suitable locating points
and then clamping the block in position.
Fig: DOF of a rectangular
block in space
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Six point / 3-2-1 location of a rectangular block
• To made the block rest on the jig body, it has to be located by using locating points, 3 base
pins, 2 pins in vertical plane, and 1 pin perpendicular to first two planes.
• The bottom of the block is supported against three points, the rear face against two points
and the side of block rests against single points, all protruding from jig body.
Fig: Side,
front and
top view
of the
locating
pins
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Continuation
• The three supporting pins restricts the downward movement of block along Z-axis.
• The movement along X and Y-axis are restricted by using double and single pins
respectively.
• The rotary movements of block about Y, Z and X-axis are also restricted by bottom, back,
and side pins.
• Thus these six points serves to locate the block correctly while restraining all the
movements.
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Six point location of a three legged object
• The object is resting on pointed legs on a flat surface.
• It is thus prevented to move along CD axis, and rotating
about EF & AB axis.
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• In the fig, it can be observed that front legs are made
ball ended and are made to rest on a V-groove.
• The spherical balls makes perfect mating surface
with V-groove.
• Thus the object is restrained to move along AB and
rotation about CD.
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• In fig, it can be observed that the rear leg also
made ball ended and is made to rest on a
separate V-groove set at right angle to first one.
• The body is now perfectly restrained against any
movement.
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Methods of Location
• There are different methods of locating a • Types of locators:
workpiece.
1. Flat Locator
2. Cylindrical Locator
3. Conical locator
• A particular locating arrangement is selected only 4. Jack pin Locator
after careful study about the type of work, type of 5. Drill bush Locator
operation, amount of accuracy required etc.
6. Fixed V Locator
7. Sliding Locator
8. Outside pin Locator
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Flat Locator
• Flat type locators are used for locating flat
surfaces of component.
• An undercut clearance is provided at the
bottom for collecting small metal chips or
the dust particles.
• Horizontal button flat locator is better than
the Vertical button flat locator as it has the
capacity to handle more end loads and
have provision for clearance.
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Cylindrical Locator
• The cylindrical locators are used in case of
components having drilled holes.
• Undercut is provided around the locator along the
work table for having proper clearance.
• The working surface of the locator is inserted
inside the drilled hole of the component to locate it
in the position.
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Conical Locator
• Conical locators are used locating components
having drilled holes.
• This locator is superior compared to the
cylindrical one because of its ability to
accommodate variation in hole diameter of the
component.
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Jack pin Locator
• Jack pin locators are used for supporting workpiece
from the bottom, while locating it.
• Mainly rough and unmachined components are
located by jack pin locator.
• The height of the pins are adjustable to
accommodate the variation in surface texture of the
component.
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Drill bush Locator
• It is used to locate the cylindrical workpieces.
• The drill bush and jig body have conical
openings for locating purpose.
• The drill bush sometimes serves the purpose of
guiding the tool.
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V Locator (Fixed/Sliding)
• These locators are used for components having
circular and semi circular profiles.
• This locator can be of two types fixed V locator
and adjustable V locator.
• The fixed type locator is normally fixed on the jig
and adjustable locator can be moved axially.
• The standard included angle for V-block is 90˚.
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Outside pin Locator
• These are used for locating components having
odd and irregular surface profiles.
• The pins are provided on the contours of the
outer profile of the workpiece.
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Clamping
• The clamps serves the purpose of holding the work pieces securely on the jigs or fixtures
against the cutting forces.
• The principles of clamping are as follows:
Types of Clamps:
1. Screw clamp
1. Hold the work rigidly against the disturbing forces. 2. Flat clamp
2. Keep the work firmly in contact with the locating pins. 3. Pivoted clamp
3. Quicker loading and unloading consideration. 4. Equalizing clamp
4. Should not distort or loosen when subjected to vibrations. 5. Latch clamp
6. Swing plate clamp
5. Should not damage the work.
7. Double acting clamp
6. Should be simple and fool proof. 8. Wedge clamp
9. Cam clamp
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Screw Clamp
• It is used to clamp the workpieces on the edges of the
jig or fixture.
• To clamp or unclamp any work, longer duration is
required.
• Large amount of effort has to be made to clamp or
unclamp a particular work.
• After clamping, a mark is left on the surface of the work.
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Flat Clamp
• It is used to clamp any work by its flat face.
• Mainly flat workpieces are clamped by using flat
clamps.
• By tightening the provided nut, the work is clamped
while using this nut.
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Pivoted Clamp
• This clamps eliminates the need of using the
spanner for clamping purposes.
• The work can be gripped quickly by rotating the
screw.
• The rotating screw actuates the pivoted on the face
of the work.
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Equalizing Clamp
• These clamps are used to clamp any work by exerting
equal pressure at two spots on the work face by the two
legs of the clamp.
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Latch Clamp
• Latch clamp is used to clamp any work by using a
latch and a pivoted leaf.
• The clamping or unclamping happens very quickly
by pushing the latch.
• The clamp does not exert high pressure on the
workpiece.
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Swing Plate Clamp
• Swing plate clamp is used to clamp or unclamp lighter
workpieces in quick duration.
• The clamp is operated by swinging the plate and locking it
in the required position by using a turning screw.
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Double Acting Clamp
• This clamp is employed to grip the work by rotating the
central screw.
• The rotating screw actuates two clamps at two works to
operate simultaneously.
• Sufficient gripping pressure by these clamps.
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Wedge Clamp
• This clamp is used to grip the work by using the
wedge block by rotating the screw.
• The wedge block grips the work against the fixed
surface fitted on the jig body.
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Cam Clamp
• It is used to clamp any work by actuating the cam handle
up or down.
• This type of clamp is not recommended where vibration is
present as it can slack the clamp.
• This clamp is extensively used in jig & fixtures due to its
rapid and convenient action.
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Fool Proofing
• The fool proofing means designing of jig and fixture with such devices so as to make it
impossible for the for an operator to insert the incorrect component in the required
position.
• This arrangement prevents the accidental error of the operator from spoiling the work.
• This is accomplished by using fouling pegs, cross frames, pins arranged within the jig or
fixture in such a way that it does not create interfere with the correct location of the work.
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Indexing
Indexing in jigs and fixtures is a process of rotating a workpiece to a precise, repeatable position to
perform operations like drilling or milling at specific intervals
Computer-Aided Design (CAD)
CAD is the use of computer systems to assist in the creation, modification, analysis, and optimization
of a design. It replaces manual drafting with an automated system that offers numerous advantages.
Function:
• 2D and 3D Modeling: Creating detailed geometric models of parts and products.
• Analysis and Simulation: Testing the design for stresses, fluid dynamics, or assembly fit
before a physical prototype is made.
• Documentation and Drafting: Generating precise technical drawings with dimensions and
specifications.
Computer-Aided Manufacturing (CAM)
CAM uses computer systems to plan, manage, and control manufacturing operations through
either direct or indirect computer interfaces with production resources. It translates the CAD
model into instructions for machines.
Function:
•Tool Path Generation: Creating the specific paths for computer numerical control (CNC)
machines to cut or shape material.
•CNC Programming: Generating the machine code (e.g., G-code) that controls machine tools
and industrial robots.
•Quality Control: Assisting with automated inspection processes.
Computer-Aided Process Planning (CAPP)
CAPP is the crucial link that connects CAD and CAM. It uses computer technology to assist process planners
in defining the sequence of operations required to manufacture a product.
Function:
•Process Plan Development: Determining the sequence of machines, tools, and operations needed to
create a part.
•Material and Tool Selection: Recommending appropriate materials and cutting tools based on the
part's design and manufacturing rules.
•Cost and Time Estimation: Providing estimates for production time and costs.
Product Cycle (Design and Manufacturing)
Product Cycle revised with CAD/CAM overlaid
Numerical Control (NC)
• Numerical control refers to the operation of machine tools from numerical data.
• Data for the operations may be stored on paper tape, magnetic tape, magnetic disks, etc.
Because numerical information is used, the concept is called numerical control.
• Numerical control is the operation of machine tools and other processing machines by a series of
coded instructions.
• With a built-in computer controlling the machine tool functions and the system is known as
computer numerical control (CNC).
Figure: Basic components of the NC system.
Classification of Numerical Control Machines
Type of motion
1. Point-to-point systems
2. Contouring or continuous systems.
Programming method
1. Absolute positioning
2. Incremental positioning (or Chain positioning).
Control system
1. Open loop system
2. Closed loop system.
Figure: The procedure of production through Numerical Control
Figure: A NC Machine Tool System, showing a NC Knee-type Vertical Milling Machine
CONVENTIONAL NUMERICAL CONTROL (NC)
It is a hard-wired NC system, employing integrated circuits which are permanently wired and arranged on
printed circuit boards (PCBs). Also, this NC system is purely a hardware based system. It is not easy to
change the main features of its control unit as well, because it is also hard wired.
COMPUTER NUMERICAL CONTROL (CNC)
It is a software based system, in which the computer replaces the control unit of the conventional NC. lt
does not carry the hard-wired logic systems and all their functions for controlling the machine tool are
performed by the software programme of the computer. That is why it is known as a software based
system.
G-code (Geometry)
Governs the movement of the machine's axes to create the part's geometry.
M-code (Miscellaneous)
Controls auxiliary machine functions, including starting/stopping, tool changes, and coolant.
Example 1
CNC milling machine part programming example
G21 G94 G90
M03 S800 M08 G42
G00 X0 Y0 Z5
G01 X0 Y0 Z-5 F150
G01 X0 Y50 F150
G01 X10 Y60 F150
G01 X65 Y60 F150
G01 X65 Y5 F150
G02 X60 Y0 R5 F150
G01 X0 Y0 F150
G01 Z5 F150 M09
G28 X0 Y0 Z0 Plate thickness: 5 mm
Feed: 150 mm/min
M05 Speed: 800 rpm
M30
Example 2
Plate thickness: 20 mm