CHAPTER ONE
Introduction to Jigs and Fixtures:
MACHINING
Machining is an essential process of finishing by which jobs are
produced to the desired dimensions and surface finish by gradually
removing the excess material from the preformed blank in the form
of chips with the help of cutting tools moved past the work surface.
Machining is a removal process.
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Machining aim to;
Fulfill its functional requirements
Improve its performance
Prolong its service.
Drawback in Machining is Loss of material in the form of chips.
Machine tool
A machine tool is a non‐portable power operated and
reasonably valued device or system of device in which
energy is expended to produce jobs of desired size, shape
and surface finish by removing excess material from the
preformed blanks in the form of chips with the help of
cutting tools moved past the work surface.
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Rack Surface and Flank
The surface along which the chip moves upward is called ‘Rack
surface’ of tool.
The other surface which is relieved to avoid rubbing with the
machined surface, is called ‘Flank’.
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Rake angle and Clearance Angle
Rake angle (α): Angle of inclination of rake surface from reference plane i.e. normal
to horizontal machined surface.
Clearance angle (γ ): Angle of inclination of clearance or flank surface from the
finished surface.
Machining: Classification: (According to the number of major cutting
edges (points) involved.):
Single point: turning, shaping, planning, slotting tools etc.
Double point: drilling tools
Multipoint: Milling, broaching, hobbing tools etc.
Types of chips
Continuous chip
Discontinuous chip
Continuous chip with BUE
Serrated chip
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The advent of industrialization in the early decades of the 20th
century has ushered in the concept of providing goods and
services to the common man, like the motorcar, electric motors,
ceiling fans, etc. This enabled the government as well as the
leaders in industry to provide affordable goods to the consumers.
By improving the production techniques and by providing
specialized tooling equipment's, such as jigs, fixtures, special
tools, and gauges, the production cost have reduced considerably
without sacrificing the accuracy and interchangeability of parts
and components.
To achieve the desired quality and quantity of production, the
concept of accuracy and interchangeability go hand in hand.
They play a major role in meeting the present day classes of
engineering production, namely, “flow production” and “batch
production”.
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The jigs and fixtures are the economical ways to
produce a component in mass. So jigs and fixtures are
used and serve as one of the most important facility of
mass production system. These are special work holding
and tool guiding device.
Quality of the performance of a process largely
influenced by the quality of jigs and fixtures used for
this purpose. What makes a fixture unique is that each
one is built to fit a particular part or shape. The main
purpose of a fixture is to locate and in the cases hold a
workpiece during an operation.
A jig differs from a fixture in the sense that it guides the
tool to its correct position or towards its correct
movement
Tools Jigs and Die
during
Design
an operation in addition to locating
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and supporting the workpiece. An example of jig is when
To necessitate the need of jigs, fixtures and special tools, the four main
engineering classes of production are as follows:
Job Production: This involves the manufacture of specialized components
or systems to meet the specific needs of the customers. Examples of job
production are the manufacture of jigs, fixtures and press tools.
Batch Production: Some of the examples of batch production are the
manufacture of aero planes, aero-engines, battle tanks, etc., that use the
concept of intermittent manufacture of large range of products, produced in
batches. Some brands of motorcars like “Benz” and “BMW” may be
classified under “batch production” as they are required to meet specific
requirements.
Flow Production: In flow production, the standardized finished products
are produced in plants, specifically laid out for this purpose. Examples of
flow production are the modern motorcar plants.
Mass Production: In this type of plants, the products are produced in mass
quantities by specialized and repetitive methods, without requiring
specialized layouts as in the case of flow production. Examples are mass
7 production ofDie
Tools Jigs and screws,
Design pins, hand tools, like chisels, spanners, hammers, etc.
1.2. JIGS, FIXTURES AND TOOLING
Jigs and fixtures are manufacturing tools that are
employed to produce interchangeable and
identical components. They are unique tool-
guiding and work-holding devices designed
specifically for machining and assembling large
number of parts.
Jigs and fixtures eliminate the need for a
special set up for every work-piece thereby
facilitating production and also ensuring that
every work piece is manufactured within a
8 predetermined tolerance.
Tools Jigs and Die Design
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As explained earlier the present day trend is to
produce components and systems to meet the basic
specifications of:
(i) Accuracy
(ii) Interchangeability
(iii) Economic production rate.
In order to achieve the above objectives the
following tooling equipments are deployed:
(i) Jigs
(ii) Fixtures
(iii) Special tools like broaching tool, gear shaping
tools, special class of taps and reamers
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(iv) Gauges
Tools Jigs and Die
to
Design
verify if dimensions are within the
limits.
A jig is a device, in which the component is clamped in
a specific location so that cutting tools are guided to
perform one or more operations. The aspect of jigs are:
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Designed to facilitate loading and unloading of components
with ease.
It has locating devices to position a component in a unique
way.
The specification is the gripping of the workpiece through a
clamping device.
Distinguishes from a fixture by guiding bushes which are
fixed/fastened to the jig body or frame and act as guides to the
tools, especially drilling, reaming or face milling cutters.
They enable the tool to be positioned exactly with respect to
the component and more precisely in relation to the location
of the hole to be drilled, or the hole to be reamed.
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A fixture is also a device, which is fastened to the table
of a machine tool, such as milling machine, and in the
case of turning operation in a lathe, the fixture is fastened
to the chuck or a faceplate. The device also enables
loading and unloading of components with ease.
Aspects/ features/
Unique location of workpiece in relation to the fixture
also holds good as in the case of a jig.
clamping is given more emphasis in fixture design as the
clamping force should be able to withstand the cutting
force which may not be along with the direction of
gravity, and hence needs to be analyzed more closely.
The final aspect, which distinguishes a fixture from a jig,
is the absence of bushes to guide the tools.
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How do jigs and fixtures differ!
JIGS FIXTURES
1. It is a work holding device that 1. It is a work holding device that
holds, supports and locates the holds, supports and locates the
workpiece and guides the cutting workpiece for a specific
tool for a specific operation. operation but does not guide the
cutting tool
2. Jigs are not clamped to the 2. Fixtures should be securely
drill press table unless large clamped to the table of the
diameters to be drilled and there machine upon which the work is
is a necessity to move the jig to done.
bring one each bush directly
under the drill.
3. The jigs are special tools particularly 3. Fixtures are specific tools used
in particularly in milling machine, shapers
drilling, reaming, tapping and boring and
operation. slotting machine.
4. Gauge blocks are not necessary. 4. Gauge blocks may be provided
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Tools Jigs and Die Design for