Page 1 of WEB CHAPTER 5- JIGS AND FIXTURES

WEB CHAPTER 5 - JIGS AND FIXTURES

Jig is a structure to locate and clamp a component for guiding the cutting tool in
operationslikedrilling,reaming,etc.Theyareusedforinspectionalso.

The work is located for machine operations by different types of locating devices.
Clampingforcesduetofrictiononlycannotberelieduponcompletely.Acylindricalpin
is the cheapest and easy locator. Cylindrical bush locators are used for solid work
pieces,butconicallocatorsarepreferred,becausetheyofferselfcentering.Vblockscan
beusedforcylindricalaswellasrectangularobjects

Clamping of the work piece is necessary in addition to location, otherwise it may move
duetocuttingforces.Toreducethewearofclampingdeviceswithcontinuoususe,they
arehardened.Iftherearechancesofdamagingthesurfaceoftheworkpiece,asoftnose
canbeprovidedontheclamp.Thevarioustypesofclampingdevicesare:
Abarclampusesasimplebarhavingaholeinthemiddle.Onesideofthebarisplaced
ontheworkpieceandtheotheronaheel.Astudpassesthroughtheholeofthebar,anda
nutoveritclampstheworkpiece.
Athreadedheelhastheadvantagethatitcanbeadjustedtoanyheightaccordingtothe
heightoftheworkpiece.
Aswingingclampusesanarmwhichishingedononesideandslottedontheotherside.
Theworkpieceislocatedbelowthisarm;aswingingboltisfittedintheslotofthisarmto
clamptheworkpiecewithanut.
In a side clamp, the bar clamps the work piece from one side while the other side rests
againstthebodyofthejig.Anarmhavingapinjointatthemiddleandaboltontheother
endclampstheworkpiece.
Inthesideclamp,theclampingforceisproducedbyrotatinganeccentricwiththehelpof
alever.It pushestheVblockandworkpieceisclampedbetweenthejigbodyandblock.

Clampingforceontheclampingdevicecanbegivenbyanyoneofthefollowingmethod:
Thewingnutorknurledknob,studandnut,camsareusefulwheretheclampingforceis
tobeprovidedjustbyrotatingahandleby90degreesorso.Helicalcamcanalsobeused
asanalternate arrangementtotheeccentric.Hydraulicpistonsareusedwhereaheavy
clampingforceisused.

Guides to the cutting tools for the jigs are called as bushings; generally for drilling and
reaming.

Page 2 of WEB CHAPTER 5- JIGS AND FIXTURES

Jigbodyisthemainbody,whichsupportsthebushings,locatingandclampingdevices..
Therearetwocommontypesofjigbodies:opentypeandclosedtype

TypesofJigsarethefollowing:

PlatejigThejigplateisclampedovertheworkpiece.
SwingingleafjigThejigplatecontainingthebushingisswungaboutapin,justforeasy
placementandwithdrawalofthecomponent.
Indexingjigusesanindexingplatetodillholesinpredefinedangularpositions.

Fixture is an aid for manufacturing which is used to hold and locate the job for some
manufacturingoperationbutdoesnotguidethecuttingtool.Fixturescanbeusedforany
machineandareclassifiedaccordingly.
TurningfixtureAlathefixturemaybetoholdatypicalcomponent,whichmaynotfitin
thejawsofachuckinnormalway.
MillingfixtureItmayholdatypicaljobtogethertoreduceclampingandmanufacturing
time.
WeldingfixtureItistolocatetwostructuralmembersforweldingatspecificpositionto
eachother.

W5.1JIG
JigisastructuretoLOCATEandCLAMPacomponentforGUIDINGthecuttingtoolin
operationslikedrilling,reaming,etc.Theyareusedforinspectionalso.

Suppose ahole is to be drilled inclined at 45 degrees in a cylindrical workpiece (Figure

W5.1).Itmaynotbepossibletodrill thisholewithoutthehelpofajig,becausethedrill
bitwillhaveatendencytoslip.Soajigdoesthreethings:

a.Locateandalignthepartattherequiredposition.
b.Clampthepartsothatitdoesnotmoveduetocuttingforceswhilemachining.
c.Guidethetooltoworkontheobject.

Page 3 of WEB CHAPTER 5- JIGS AND FIXTURES

FigureW5.1Adrillingjig

W5.2LOCATIONDEVICES
Theworkpiecehastobelocatedformachineoperations.Theseoperationsimpartcutting
forces and try to move the work piece from its original position. Clamping forces are
generally due to friction only and cannot be relied upon completely. Hence surfaces to
givethereactiontothecuttingforcesshouldalsoformapartoflocationdevices.Various
typesoflocatingdevicesareshowninFigureW5.2.

Theshape oftheworkpiecedecidesthetypeoflocator to beused.Finishedsurfacesare

generallyusedtolocatetheworkpieceagainstthefinishedsurfaceofthejig.Ifthere isno
finishedsurfaceoftheworkpiece,thenanunfinishedsurfacecanbeused.

Acylindricalpinisthecheapestandeasylocator.Numberofpinscanbeoneormanyfor
accuratelocation.Thesepinsaremadeoftoolsteel,hardenedandground(FigureW5.2A).
Cylindrical bush locators can also be used for solid work pieces (Figure W5.2B), but
conicallocators are preferred,becausethey offer selfcentering (Figure W5.2C). V blocks
canbeused(FigureW5.2D)forcylindricalaswellasrectangularobjects(FigureW5.2E).

Page 4 of WEB CHAPTER 5- JIGS AND FIXTURES

FigureW5.2Locationdevices
W5.3CLAMPINGDEVICES
As described earlier, clamping of the work piece is necessary in addition to location,
otherwise it may move due to cutting forces. There are a number of clamping devices.
OnlyafewcommonlyusedareshowninFigureW5.3.

Clampingforceshouldbeappliedatapointwhichdoesnotobstructthemanufacturing
process and will offer reaction so as to withstand the forces developed. To reduce the
wearofclampingdeviceswithcontinuoususe,theyarehardened.Iftherearechancesof
damagingthesurfaceofworkpiece,asoftnosecanbeprovidedontheclampwhichcan
bereplaced,whenwornout.Thevarioustypesofclampingdevicesare:

Barclamps(FigureW5.3A)
Adjustablebowclamp(FigureW5.2B)
Swingingbarclamp(FigureW5.3C)
Sideclamp(FigureW5.3D)
Vslide(FigureW5.3E)

Page 5 of WEB CHAPTER 5- JIGS AND FIXTURES

FigureW5.3Clampingdevices
Barclampusesasimplebarhavingaholeinthemiddle(FigureW5.3A).Onesideofthe
barisplacedontheworkpieceandtheotheronaheelapproximatelyofthesameheight
astheworkpiece.Astudpassesthroughtheholeofthebar.Whenthenutistightened,it
clampstheworkpiece.

Insteadofusingaheeloffixedsize,onecanuseathreadedheel(FigureW5.3B).Ithasthe
advantagethatitcanbeadjustedtoanyheightaccordingtotheheightoftheworkpiece.

Aswingingclamptypejig(FigureW5.3C)usesanarmwhichishingedononesideand
slotted on the other side. The work piece is located below this arm, by lifting it. A
swinging bolt is fitted in the slot of this arm. The nut is tightened over it to clamp the
workpiece.

In a side clamp (Figure W5.3D), the bar clamps the work piece from one side while the
othersiderestsagainstthebodyofthejig.Anarmhavingapinjointatthemiddleanda

Page 6 of WEB CHAPTER 5- JIGS AND FIXTURES

boltonotherendclampstheworkpiecewhentheboltistightened.

FigureW5.3Ealsoshowsasideclamp,buttheclampingforceisproducedbyrotatingan
eccentricwiththehelpofalever.Itclampstheworkpiecequickly.It pushestheVblock
andtheworkpieceisclampedbetweenthejigbodyandblock.

Theforceontheclampingdevicecanbegivenbyanyoneofthefollowingmethods:

Wingnutorknurledknob(FigureW5.4AandB)
Studandnut(FigureW5.4B)
Camsareusefulwheretheclampingforceistobeprovidedjustbyrotatinga
handleby90degreesorso.Useofspiralcamandaneccentricisshowninfigures
W5.4CandW5.4Drespectively.
Helicalcamcanalsobeusedasanalternate arrangementtotheeccentric(Figure
W5.4E).
Hydraulic pistons are used where a heavy clamping force is required
(FigureW5.4F).

Page 7 of WEB CHAPTER 5- JIGS AND FIXTURES

FigureW5.4Clampingforcemethods
W5.4GUIDES
Guides to the cutting tools for the jigs are called BUSHINGS; generally for drilling and
reaming.Bushesareusedtoguide thecuttingtool.Thesebushesarepressedinto a plate
whichisscrewedtothebodyofthejig.Various typesofbushingsareusedasshownin
FigureW5.5.

FigureW5.5Bushingsforjigs

Page 8 of WEB CHAPTER 5- JIGS AND FIXTURES

Basically bushes are of two types: headless and head type. If the centre between the
adjacent holes is small, then a headless bushing is preferred. Sometimes a liner
is used inside thebushing, whichcanbereplacedwhenthebushiswornandone hasnot
toreplacethecompletebush.
Slip busingisused,ifitistobereplacedfordifferentsizesofdrillsorreamingoperations
afterdrilling.

W5.5JIGBODY
It is the main body, which supports the bushings, locating and clamping devices. There
aretwocommontypesofjigbodies:

Opentype(FigureW5.6A)
Closedtype(FigureW5.6B)

Ifdrillingistobedoneinoneplaneonly,anopentypeofbodycanbeused,butifthejig
is to be used from different directions and planes, a closed type of the body is to be
provided. Figure W5.6 shows two such types of the jig bodies; one open type and the
other,closedtype.

FigureW5.6Jigbodies

Ajigbodyismadeofcastironorsometimesfabricatedbyweldingsteelparts.Thebody
hastoberigidformaintainingtheaccuracy.Sharpcornersandedgesshouldbeavoided
forthesafetyoftheoperator.Smallsizeofthejigscanbefixed onthetable,butlargejigs
shouldbeprovidedbymeansoffixingonthemachinesecurely.

Page 9 of WEB CHAPTER 5- JIGS AND FIXTURES

Opentypeofjigscanbefurtherclassifiedas:

A.PlatejigThejigplateisclampedovertheworkpiece(FigureW5.7A)

B.SwingingleafjigThejigplatecontainingthebushingcanbeswungaboutapin,just
foreasyplacementandwithdrawalofthecomponent(FigureW5.7B).

C. Indexing jig It uses an indexing plate to dill holes in predefined angular positions
(FigureW5.7C).Theindexingplate iskeptinpositionbyaspringloadedplunger.

FigureW5.7Typesofjigs

Page 10 of WEB CHAPTER 5- JIGS AND FIXTURES

W5.6FIXTURES
It is an aid for manufacturing which is used to HOLD and LOCATE the job for some
manufacturingoperationbutdoesNOTGUIDEthecuttingtool.Fixturescanbeusedfor
anymachineandareclassifiedas:

Lathefixture
Millingfixture
Weldingfixture

W5.6.1LATHEFIXTURE
A lathe fixture may be to hold a typical component, which may not fit in the jaws of a
chuckinthenormalway.Turningfixturescanbeheldinthejawsofthechuckorcanbe
mountedonthefaceplateofthelathe.

A bracket is shown in Figure W5.8 in which two holes are to be drilled at the position
indicated in the figure. It can be seen, that this component cannot be put on a lathe
chuck easily. A special fixture to hold it is shown in Figure W5.8B. An angled block is
bolted on the front side of the face plate and then the work piece is clamped on it. A
balanceweightismounted to avoidunbalancedforcesonthelathespindle.

Page 11 of WEB CHAPTER 5- JIGS AND FIXTURES

FigureW5.8Alathefixture.

W5.6.2MILLINGFIXTURE
A milling fixture may hold a typical job together to reduce clamping nda manufacturing
time. A setting block is used in conjunction with the holding device to achieve correct
alignment of the tool with respect to the component and accuracy of machining. Figure
W5.9 shows a milling fixture to make slots on a component as shown in Figure W5.9A.
Fourpiecescanbe positionedsimultaneouslytomilladiagonalslot.

Page 12 of WEB CHAPTER 5- JIGS AND FIXTURES

FigureW5.9Amillingfixture

W5.6.3WELDINGFIXTURE
FigureW5.10showsaweldingfixturetolocatetwostructuralmembers(angleirons)for
weldingat30toeachothertoagussetplate.

FigureW5.10AWeldingfixture

Page 13 of WEB CHAPTER 5- JIGS AND FIXTURES

THEORYQUESTIONS
Q.1.Differentiatebetweenajigandfixture.
Q.2.Whatistheimportanceofalocator? Describedifferenttypesoflocators.
Q.3.Whyisclampingnecessaryinajig?Explainanyfourtypesofclampingdevices.
Q.4.Whatisthefunctionofabushinajig?Discussvarioustypesofbushesusedinajig.
Q.5.Explainthedifferenttypesofjigbodies.Givethetypicaluseofeach.
Q.6.Sketchanyturningfixtureandexplainitsconstruction.
Q.7.Explaintheconstructionanduseofamillingfixture.
Q.8.Describeandsketchaweldingfixtureforanytypicalwork.

FILLUPTHEBLANKQUESTIONS
Q1 Ajigisusedfor__________._____________and___________.
Q2. Fixtures__________tofixajob.
Q3. Swingingbarisa______________device.
Q4. ____________areusedwhereaheavyclampingforceisrequired.
Q5. Aneccentriccanbeusedasaclampingdevicefor____________clamping.
Q6. Bushingsareusedas____________injigs.
Q7. ____________isusedifitistobereplacedfordifferentoperations.
Q8. Twoimportantjigbodiesare:____________and____________.
Q9. ____________jigisusedtolocateangularpositions.
Q10.Fixtureholdsandlocatesthejobbutdoesnot____________.
Q11. Millingfixturecanbeusedtohold____________simultaneously.
Q12. Weldingfixturehelpsto____________thepartstobewelded.

MULTIPLECHOICEQUESTIONS
Q1Ajigisusedto

a.drillahole

b.locateandclampaworkpiece

c.locate,clamptheworkpieceandguidethecuttingtool

d.settheworkpieceformeasurement

Q2.Commonfeaturebetweenjigandfixtureisthatbothareusedfor

a.cuttingtheworkpiece

b.holdingtheworkpiece

c.locatingtheworkpiece

d.testingandinspectionoftheworkpiece

Page 14 of WEB CHAPTER 5- JIGS AND FIXTURES

Q3.Slipbushisusedinjigwhere

a.thedrillbitcanslipontheworkpiece

b.holesaretooclose

c.thebushistobereplacedeverytime

d.alinerisusedalongwithbush

Q4Linerinabushofajig

a.savesthebushfromwear

b.strengthensthebush

c.offerslubrication

d.alignsthebushinahole

Q5Acamisusedinajigto

a.locatetheworkpiece

b.liftaheavyworkpiece

c.movetheworkpiecefrequently

d.toclamptheworkpiece

Q6Aturningfixtureisusedonthelathe

a.toturnanonsymmetricjob

b.sothatthesurfacefinishoftheworkpieceisnotspoiled

c.toturntheworkpiecewhichotherwisecannotbefittedonthelathe
d.toturnlongjobs

Q7Anindexingjigisusedto

a.planesurfaces

b.oneangularsettings

c.multiangularsettings

d.multiplanesettings

Q8Afixtureisusedto

a.savetime

b.fixoddshapedjobs
c.easymachining

d.noneofabove

Page 15 of WEB CHAPTER 5- JIGS AND FIXTURES

Q9Thequickestclampingdeviceisa

a.wingnut

b.knurlednut

c.cam/eccentric

d.Conventionalnut

Q10Aconicallocaterhastheadvantageof

a.easylocation

b.selfcentering

c.easylocationandselfcentering

d.offersgoodgrid

AnswerstoFilluptheblankquestions
1Locate,fix,andguidethetool 2helps

5quick

6toolguide
8Open,closed9Indexing
12locate

Answerstomultiplechoicequestions
1c
2a
3c
4a
8b
9c
10c

3clamping 4Hydraulicpistons
7Slipbushings
10guidethetool 11many

5d

6c

7c

Page 16 of WEB CHAPTER 5- JIGS AND FIXTURES

PROBLEMSFORPRACTICE

Q15SketchasuitablejigtodrillaholeintheworkpiecesasshowninfiguresW5P.1to
W5P.5.
.

FigureW5P.1

FigureW5P.2

FigureW5P.3

Page 17 of WEB CHAPTER 5- JIGS AND FIXTURES

FigureW5P.4

FigureW5P.5

Q68SketchafixtureforlathefortheworkpiecesshowninfiguresW5P.6toW5.P8.

Page 18 of WEB CHAPTER 5- JIGS AND FIXTURES

FigureW5P.6

FigureW5P.7

FigureW5P.8

FigureW5P.5FigureW5P.6Partsarematingwitheachother

Page 19 of WEB CHAPTER 5- JIGS AND FIXTURES

Q9 Draw a milling fixture for the work pieces (shown in Figure W5.P9) to a suitable
scale.

FigureW5P.9

Q 10 Draw a suitable jig for welding the steel sections to the gusset plate as shown in
FigureW5P.10.

FigureW5P.10