JIGS AND FIXTURES

Productivity is the prime concern of a Production Engineer. He wants to ensure maximum quantity of production, without sacrificing the specified quality products. In mechanical production, jigs and fixtures form an important category of equipment that plays a major role in achieving productivity. What are jigs and fixtures? Jigs and fixtures are work-holding devices. What is the difference between them? JIGS are work-holding devices with tool guiding elements such as drill bushes. They are rarely clamped on machine table, because it is often necessary to move the jig on machine table to align various bushes with machine spindle. FIXTURES are work-holding devices without tool guiding elements. Some times they may have tool or cutter setting elements. They hold the work-piece securely in the correct position with respect to the machine / cutter during operation. They are always clamped on the machine table. Elements of Jigs and Fixtures 1. Locating elements or Locators. These elements position the work-piece accurately with respect to tool. 2. Clamping elements or Clamps. These elements hold the work-piece securely in the located position during the machining operation. The claming system holds the work piece against the cutting forces without damaging it. 3. Tool guiding or tool setting elements. These elements guide the tool or set the tool or cutter in correct position with respect to the work-piece (as located by locating elements).

Figure 1(a)

Figure 1(b)

Locators Locating elements are provided so that the operation being performed or the surface being generated by that operation, should bear desired positional relationship with some other surface on the component. For example, when a flat piece is held tight on the

magnetic table of the surface grinder, the top surface generated by the grinding wheel is perfectly parallel to the bottom surface, which was held flat against the magnet. A perfect V-block ensures that the cross-centre line of any perfectly round job passes through its own centre line (dividing the included angle of the V). For locating on holes, locating pins, plungers or mandrels are used. [SKETCHES OF V_BLOCK, PINS, etc ] The locators or locating elements on a Jig or a Fixture are required to fulfill the following requirementsi) Locators should meet dimensional requirements of the work piece as indicated on the component drawing. ii) A locator should locate the work piece with reference to the most accurate surface of the work piece. iii) Locators should constrain the work piece in such a way that it should not be free to rotate about or move along any axis. iv) Locators should facilitate easy loading and unloading of components. Some examples of locators Clamps The purpose of clamping elements is to provide an invariably stable position of the work piece as located by locators in the jig or fixture. For this, displacement is prevented by tightly holding the work piece against the work holding support. Strap or plate type clamps in conjunction with screw or studs are most simple and common devices. Clamping elements should have following featuresi) Clamps should be positioned to direct the clamping force on the strongly supported portion of the work piece. ii) Clamps should be strong enough to withstand the forces developed during operation. But at the same time a clamp should not dent or damage work piece. iii) Clamping time should be minimized by using hand knobs, tommy bars, knurled screws, handles, etc. iv) Clamps should be convenient for the operator to handle. Faulty application of clamping may spoil a satisfactory method of location. The common faults observed in clamps are: (a) The component gets lifted away from the surface. (b) Due to poor design considerations, the swarf (Chips) has a tendency to get accumulated or clogged on the locating surface which results in errors and rejections. (c) Due to excessive clamping force, the clamp or even the work support or location may get temporarily or permanently deformed. Some examples of clamps

Tool Guides

Figure 2(a)

Figure 2(b) Advantages of jigs and fixtures 1. Productivity: - A Jig or a Fixture reduces operation time and increases productivity by eliminating marking, positioning and frequent checking of individual components. 2. Interchangeability: - Jigs and fixtures ensure the uniform quality of manufactured parts which in turn eliminates the need for selective assembly. Any randomly selected part would fit into the assembly. 3. Reduction in skill requirement: - Jigs & Fixtures eliminate manual locating of work-piece and setting or guiding tool. This reduces the skill-requirement on the part of operator. 4. Cost reduction: - Higher production, reduction in scrap, easy assembly and savings in labour costs together result in substantial cost reduction.