DRILL JIGS

DRILL JIGS

DRILL JIGS

DRILL JIGS

DRILL JIGS

DRILL JIGS

Definition Design Principles Principles of Location and Clamping Degrees of Freedom Six Point Location Principle Elements of Drill Jig Types of Locators Redundant Location

Types of Clamping Devices Tool Guiding Types of Drill Bushes Materials for Drill Bush Drill Classification Fool Proofing

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DEFINITION

A device used to hold work piece during machining operations Has tool guiding elements such as drill bushes Is rarely clamped to machine table to move it on the table to align its bushes with machine spindle This is generally used for the operations such as drilling, boring, reaming, tapping, counter boring, etc.

Drilling

Countersinking

Reaming

Boring

Tapping

Counter boring

Spot-Facing

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DESIGN PRINCIPLES

USE WORK HOLDER CLAMPING MASS PRODUCTION, ACCURACY AND INTERCHANGEABILITY RELATIONSHIP BETWEEN THE WORK AND THE CUTTING TOOL ADVANTAGES

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USE In jig design, its application is to be considered first. If, the piece for which the jig is made is to finally bear a fixed relation to some other machine part, it becomes necessary to consider not only the part being jigged, but also its relation to the other parts with which it is to be assembled. Again, if the piece is of special accuracy, the jig design may be different from that of a machine part, which does not require that much accuracy. In one case, the jig is both a rapid production tool and an interchangeability tool. In the other case, the jig is merely a convenient tool for getting rapid production.

DESIGN PRINCIPLES

DRILL JIGS WORK HOLDER

DESIGN PRINCIPLES

Next to consider is how the piece shall be held in the prospective jig. The points or surfaces, best suited for location points and surfaces are decided upon. The surface machined usually offers the best location to work from. If the surfaces are rough, as in an ordinary casting, the selection of the locating surfaces or surface is more difficult. Some surface or hole will be essentially more important than all the remaining surfaces or holes. In such a case, the jig designer uses location points which will position the important hole or surface, first and afterward considering the points of lesser importance.

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DESIGN PRINCIPLES

WORK HOLDER A flat surface, which is machined, is usually located against a flat surface; if not, a flat surface should be given line or point contact. A curved surface is located against a V or points. CLAMPING This refers to the devices which hold the work piece against the location points or surfaces. The design should be such that the least number of clamping devices are used, to reduce clamping time, as this limits production. All clamping devices should exert their pressure, directly in line with the supporting points, so that the piece clamped will not be sprung out of shape.

DESIGN PRINCIPLES MASS PRODUCTION, ACCURACY AND INTERCHANGEABILITY Mass production methods demand a fast and easy method of positioning work for accurate operations. Jigs and fixtures are production tools used to accurately manufacture duplicate and interchangeable parts. Jigs and fixtures are specially designed so that large numbers of components can be machined or assembled identically, and to ensure interchangeability of components. The economical production of engineering components is greatly facilitated by the provision of jigs and fixtures.

DRILL JIGS

DESIGN PRINCIPLES MASS PRODUCTION, ACCURACY AND INTERCHANGEABILITY The use of a jig or fixture makes the operation fairly simple, which would otherwise require a lot of skill and time. Jigs and fixtures position components accurately; and hold components rigid and prevent movement during working to impart greater productivity and part accuracy. Jigs and fixtures locate, hold or grip a work piece to perform on the work piece a manufacturing operation. A jig or fixture is designed and built to hold, support and locate every component (part) to ensure that each is drilled or machined within the specified limits.

DRILL JIGS

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DESIGN PRINCIPLES

RELATIONSHIP BETWEEN THE WORK AND THE CUTTING TOOL The correct relationship and alignment between the tool and the work piece is maintained. Jigs and fixtures may be large or very small. Their use is limited only by job requirements and the imagination of the designer. The jigs and fixtures must be accurately made and the material used must be able to withstand wear and the operational (cutting) forces experienced during metal cutting. Jigs and fixtures must be clean, undamaged and free from swarf and grit. Components must not be forced into a jig or fixture.

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DESIGN PRINCIPLES

RELATIONSHIP BETWEEN THE WORK AND THE CUTTING TOOL Jigs and fixtures are precision tools. They are expensive to produce because they are made to fine limits from materials with good resistance to wear. They must be properly stored or isolated to prevent accidental damage, and they must be numbered for identification for future use.

DRILL JIGS ADVANTAGES

DESIGN PRINCIPLES

Reduce the cost of production Maintain consistent quality Maximize efficiency Enable a variety of parts to be made to correct specifications

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LOCATING AND CLAMPING PRINCIPLES

Locating and clamping are the critical functions of any work holder. Hence, the fundamental principles of locating and clamping and the numerous standard components must be thoroughly understood. BASIC PRINCIPLES OF LOCATING

To perform properly, work holders must accurately and consistently position the work piece relative to the cutting tool, part after part. To accomplish this, the locators must ensure that the work piece is properly referenced and the process is repeatable.

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BASIC PRINCIPLES OF LOCATING

ACCURACY CONSISTENCY REFERENCING REPEATABILITY

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LOCATING AND CLAMPING PRINCIPLES

REFERENCING AND REPEATABILIY "Referencing" is a dual process of positioning the work piece relative to the work holder, and the work holder relative to the cutting tool. Referencing the work holder to the cutting tool is done by the guiding or setting devices, done by using drill bushings. Referencing the work piece to the work holder, is done with locators. Incorrectly placed part is incorrectly located will be machined incorrectly. Improperly positioned cutter will improperly locate the machined detail. So, in the design of a work holder, referencing of both the work piece and the cutter must be considered and simultaneously maintained.

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LOCATING AND CLAMPING PRINCIPLES REPEATABILITY

Repeatability" is the ability of the work holder to consistently produce parts within tolerance limits, and is directly related to the referencing capability of the tool. The location of the work piece relative to the tool and of the tool to the cutter must be consistent. If the jig or fixture is to maintain desired repeatability, the work holder must be designed to accommodate the work piece's locating surfaces. The ideal locating point on a work piece is a machined surface. Machined surfaces permit location from a consistent reference point. Cast, forged, sheared, or sawed surfaces can vary greatly from part to part, and will affect the accuracy of the location.

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DEGREES OF FREEDOM THE MECHANICS OF LOCATING

A work piece free in space can move in an infinite number of directions. For analysis, this motion can be broken down into twelve directional movements, or "degrees of freedom." All twelve degrees of freedom must be restricted to ensure proper referencing of a work piece.
TWELVE DEGREES OF FREEDOM As shown in Figure 3-1, the twelve degrees of freedom all relate to the central axes of the work piece. Notice the six axial degrees of freedom and six radial degrees of freedom. The axial degrees of freedom permit straight-line movement in both directions along the three principal axes, shown as x, y, and z.

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DEGREES OF FREEDOM

The radial degrees of freedom permit rotational movement, in both clockwise and counterclockwise radial directions, around the same three axes. Twelve degrees of freedom

Figure 3-1. The twelve degrees of freedom

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DEGREES OF FREEDOM

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SIX POINT LOCATION PRINCIPLE

LOCATING FROM EXTERNAL SURFACES

Locating a work piece from its external edges is the mostcommon locating method. The bottom, or primary, locating surface is positioned on three supports, based on the geometry principle that three points are needed to fully define a plane. Two adjacent edges, usually perpendicular to each other, are then used to complete the location.
The most-common way to locate a work piece from its external profile is the 3-2-1, or six-point locational method. With this method, six individual locators reference and restrict the work piece.

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SIX POINT LOCATION PRINCIPLE 3-2-1 PRINCIPLE OF LOCATION

Figure 3-4. Three supports on the primary locating surface restrict five degrees of freedom.

As shown in Figure 3-4, three locators, or supports, are placed under the work piece. The three locators are usually positioned on the primary locating surface. This restricts axial movement downward, along the -z axis (#6) and radially about the x (#7 and #8) and y (#9 and #10) axes. Together, the three locators restrict five degrees of freedom.

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SIX POINT LOCATION PRINCIPLE 3-2-1 PRINCIPLE OF LOCATION

The next two locators are normally placed on the secondary locating surface, as shown in Figure 3-5. They restrict an additional three degrees of freedom by arresting the axial movement along the +y axis (#3) and the radial movement about the z (#11 Figure 3-5. Adding two locators on a side restricts eight degrees of and #12) axis. freedom

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SIX POINT LOCATION PRINCIPLE 3-2-1 PRINCIPLE OF LOCATION

The final locator, shown in Figure 3-6, is positioned at the end of the part. It restricts the axial movement in one direction along the -x axis. Together, these six locators restrict a total of nine degrees of freedom. The remaining three degrees of freedom (#1, #4, and #5) will be restricted by the clamps.

Figure 3-6. Adding a final locator to another side restricts nine degrees of freedom, completing the 3-2-1 location.

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TYPES OF LOCATORS

CONCENTRIC AND RADIAL METHODS OF LOCATING

Concentric and radial locators restrict the work piece moving in nine directions.
The base and the centre pin restrict nine directional movements. Located in this manner, the part is only free to move vertically or radially around Z axis. The radial locator prevents rotation in + and directions around Z axis. The only left out movement in Z + axis is restricted by the clamping force.

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TYPES OF LOCATORS The three forms of location: plane, concentric, and radial

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TYPES OF LOCATORS

1. EXTERNAL LOCATORS External locators locate a part by its external surfaces. They are termed as locators or supports. Locators prevent movement in a horizontal plane. Supports are placed beneath the work piece and prevent downward movement and rotation around the horizontal axes. The two basic forms of external location or supports are fixed and adjustable. 1.1 FIXED LOCATORS They are solid locators that establish a fixed position for the work piece. Typical examples are integral locators, assembled locators, locating pins, V locators and locating nests.

1.1.1 INTEGRAL LOCATORS These are machined into the body of the work holder. In most of the case, this is the least preferred, because of the following disadvantages: - Added time required to machine the locator. - Difficult to replace the locator, in case of wear out. - Additional material required to allow for the machining of the locator.

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TYPES OF LOCATORS

1.1.2 ASSEMBLED LOCATORS These are similar to integral locators but differ in that they both are to be machined. They may be used as locators or supports. Assembled locators are frequently made of Tool Steel and hardened to prevent wear. ADVANTAGES -Replaceable. (Ref. Fig. 4-20) -As they are not part of the major tool body, they do not require additional material for tool body. 1.1.3 LOCATING PINS These are the simplest and basic form of locating element. They may be made in house or purchased commercially, available in several styles and types. (Ref. Fig 4-21). Standard dowel pins are frequently used for this purpose.

LOCATING DEVICES Pins, pads, and recesses used to locate the work piece on the jig

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TYPES OF LOCATORS

1.1.3 LOCATING PINS Because of their simplicity, easy application and replaceability, round pins are the most commonly used form of locating device. The location and the number of pins are decided by the size, shape and configuration of the part. 1.1.4 V - LOCATORS A cylinder has six degrees of freedom. Each freedom is to be restricted. A cylinder is placed in the intersection of two perpendicular planes. The base plane is perpendicular to X and Z axes and the vertical plane is parallel to Y and Z axes. Both these planes restrict the freedom in six directions. The pin serving as end stop restricts one degree of freedom. Rotation around Z axis is restrained by clamping force.

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TYPES OF LOCATORS

1.1.4 V LOCATORS Locating a cylinder in a V places its longitudinal axis in true location. The basic principle of V location can be applied to work pieces that are not true cylinders but do contain cylindrical segments. It is also used to locate parts with cylindrical ends. The cylindrical ends of the part is tangent to both sides of the V. The included angle between the two surfaces of a V locator governs the positions of varying diameters.

DRILL JIGS TYPES OF LOCATORS 1.1.5 LOCATING NESTS This method of locating features a cavity in the work holding device into which the work piece is placed and located. If the cavity is the same size and shape as the work piece, this is an effective means of locating. Such nests can be used to locate cylindrical work pieces. No supplementary devices such as pins are normally required. DISADVANTAGES 1. As the work piece is completely surrounded, removal of the part often becomes difficult. If the work piece and the nest are of the same thickness, the difficult is much more. 2. Even if the jig is turned over to remove the piece part, or even if an ejection system is added, the processing time is increased.

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TYPES OF LOCATORS

3. The burr produced during the operation may lock the work piece in the nest, which may add to the difficulty in the removal of the part. 4. Chips formed by the operation may lodge in the jig which must necessarily be removed. PARTIAL NESTS Partial nests are used to overcome the above disadvantages. Flat members, shaped to fit portions of the work piece are fastened to the work holder. Accurate positioning of the nests is ensured by means of screws and dowels.

Dimensioning Jig Drawings

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TYPES OF LOCATORS

1.2 ADJUSTABLE LOCATORS They are movable locators, frequently used for rough cast parts or similar parts with surface irregularities. Examples are threaded locators, spring pressure locators and equalising locators.

Fig. 8.1.9 Locating by holes (a) locating by two holes (b) locating by one hole

Fig. 8.1.11 Locating by mandrel or plug

Fig. 8.1.8 Locating by (a) flat surfaces and (b) types of pins used for that.

Fig. 8.1.10 Locating by a pin and Vee block.

Method of Using Locating Stubs or Pins.

Diagrams Showing Fixed and Adjustable V's.

Fig. 8.1.15 Supporting (a) by flat surface and (b) by pins

Fig. 8.1.16 Adjustable supporting pins

Fig. 8.1.16 Adjustable supporting pins

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TYPES OF LOCATORS

CAST PLASTIC PLATE TYPE JIG With the development of plastic casting materials, making cavities for locating work piece is simplified. The casting material is poured around the work piece prototype. The resulting cavity becomes the nest for the part. 1.2. ADJUSTABLE LOCATORS They are widely used for irregular work pieces or where large variations between parts make solid locators impractical. The principal type is the threaded style. Some times it is also used as a clamping device. Adjustable locators are used as solid locators simply by adding lock nut or screw.

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TYPES OF LOCATORS

1.2.1 ADJUSTABLE SUPPORTS They are simply adjustable locators positioned beneath the work piece. The primary types are as follows: 1.2.1.1 THREADED SUPPORTS They are used along with solid supports to permit easy leveling of irregular parts in the work holder. 1.2.1.2 SPRING SUPPORTS They are also used along with solid supports to level the work piece. In this type, instead of using threads to elevate the locator, a secondary threaded element such as thumb screw is used to lock the position of the spring support.

DRILL JIGS 1.2.1.3 EQUALISING SUPPORTS They are used to ensure constant contact of the supports and work piece. These supports are normally self adjusting.

TYPES OF LOCATORS

Figure 3-3. Solid, adjustable, and equalizing supports locate a work piece from a flat surface.

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TYPES OF LOCATORS

1.3 INTERNAL LOCATORS Locating a work piece from an internal diameter is the mostefficient form of location. The primary features used for this form of location are individual holes or hole patterns. Depending on the placement of the locators, either concentric, radial, or bothconcentric-and-radial location are accomplished when locating an internal diameter. Plane location is also provided by the plate used to mount the locators. The two forms of locators used for internal location are locating pins and locating plugs. The only difference between these locators is their size: locating pins are used for smaller holes and locating plugs are used for larger holes.

DRILL JIGS 1.3 INTERNAL LOCATORS

TYPES OF LOCATORS

As shown in Figure 3-7, the plate under the work piece restricts one degree of freedom. It prevents any axial movement downward, along the -z (#6) axis. The center pin, acting in conjunction with the plate as a concentric locator, prevents any axial or radial movement along or about the x (#1, #2, #7, and #8) and y (#3, #4, #9, and #10) axes. Together, these two locators restrict nine degrees of freedom. The final locator, the pin in the outer hole, is the radial locator that restricts two degrees of freedom by arresting the radial movement around the z (#11 and #12) axis. Together, the locators restrict eleven degrees of freedom. The last degree of freedom, in the +z direction, will be restricted with a clamp.

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TYPES OF LOCATORS

Figure 3-7. Two locating pins mounted on a plate restrict eleven-out-oftwelve degrees of freedom

JIG BODY While steel may be used for the body or frame of a jig, it is a usual thing to use cast iron. If cast iron is used the jig can be more or less completely worked out in the pattern, and possibilities of alteration in design may show as desirable. When it is realized that many shops use jigs weighing hundreds of pounds in their production work, it is clearly seen why cast iron is largely used for jig bodies.

Diagram Showing Use of Locating Pads

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TYPES OF LOCATORS

LOCATING GUIDELINES No single form or type of locator will work for every work holder. To properly perform the necessary location, each locator must be carefully planned into the design. The following are a few guidelines to observe in choosing and applying locators. Positioning Locators The primary function of any locator is to reference the work piece and to ensure repeatability. Improperly positioned locators cannot ensure this. When positioning locators, both relative to the work holder and to the work piece, there are a few basic points to keep in mind. Whenever practical, position the locators so they contact the work piece on a machined surface.

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TYPES OF LOCATORS

FEATURES: Precision locating pins with a tapered tip for easy part loading, and a shoulder to resist downward forces (superior to standard dowel pins). Round Pins and Diamond Pins are often used together to locate from two holes in a work piece. Diamond pins are relieved, to locate only in 1 axis. Round Pins are also useful as side locators. LOCATING PRINCIPLES: When a Round Pin and Diamond Pin are used together, the Round Pin is the primary, 2-axis locator, while the Diamond Pin is the secondary, 1-axis locator. Diamond Pins are relieved to locate only radially around the Round Pin, avoiding redundant location. This prevents binding while loading and unloading the part, yet still maintains high accuracy.

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TYPES OF LOCATORS

SIZES: Head diameters are available in 1/16" increments from 1/4 to 1" (2mm increments from 6-20mm in metric). Diamond Pins are available in three tolerance ranges see Dimensions page for part numbers: X = Normal Tight Fit Y = Medium Fit Z = Loose Fit SPECIALS: For pins with a special head diameter (A dimension), please contact factory. MATERIAL: 1144 steel, heat treated Rc 50-55, black oxide finish.

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ROUND PIN AND DIAMOND PIN

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POSITIONING LOCATORS

The machined surface not only provides repeatability but usually offers a more-stable form of location. The work piece itself determines the areas of the machined surface used for location. In some instances, the entire surface may be machined. In others, especially with castings, only selected areas are machined. The best machined surfaces to use for location, when available, are machined holes. Machined holes offer the most-complete location with a minimal number of locators. The next configuration that affords adequate repeatability is two machined surfaces forming a right angle. These characteristics are well suited for the six-point locational method. Regardless of the type of locator, the primary requirement in selecting a locating surface is repeatability

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POSITIONING LOCATORS

To ensure repeatability, the next consideration in the positioning of locators is the spacing of the locators themselves. As a rule, space locators as far apart as practical. This is illustrated in Figure 3-12. Both work pieces shown here are located with the six-point locating method. The only difference lies in the spacing of the locators. In the part shown at (b), both locators on the back side are positioned close to each other. In the part at (a), these same locators are spaced further apart. The part at (a) is properly located; the part at (b) is not. Spacing the locators as far apart as practical compensates for irregularities in either the locators or the work piece. Its also affords maximum stability.

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POSITIONING LOCATORS

Figure 3-12. Locators should be spaced as far apart as practical to compensate for slight irregularities and for maximum stability.

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POSITIONING LOCATORS

The examples in Figure 3-13 show conditions that may occur when locators are placed too close together if the center positions of the locators are misaligned by .001". With the spacing shown at (a), this condition has little effect on the location. But if the locating and spacing were changed to that shown at (b), the .001" difference would have a substantial effect. Another problem with locators placed too close together is shown at (c). Here, because the locators are too closely spaced, the part can wobble about the locators in the work holder.

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POSITIONING LOCATORS

Figure 3-13. Positioning locators too close together will affect the locational accuracy

Fig. 8.1.12 Deflection due to force(s) for wide gap in between supports

Force

Force

Fig. 8.1.13 Stability in supporting (a) not correct (unstable)

(b)correct (stable) work piece

Fig. 8.1.14 Recess in long span supporting

LOCATOR SIZE AND TOLERANCES The work piece itself determines the overall size of a locating element. The principle rule to determine the size of the work piece locator is that the locators must be made to suit the MMC (Maximum-Material Condition) of the area to be located. The MMC of a feature is the size of the feature where is has the maximum amount of material. With external features, like shafts, the MMC is the largest size within the limits. With internal features, like holes, it is the smallest size within the limits. Figure 3-20 illustrates the MMC sizes for both external and internal features.

6-75

Locator sizes are always based on the maximum-material condition of the work piece features.

Cylindrical locators Sizing cylindrical locators is relatively simple. The main considerations are the size of the area to be located and the required clearance between the locator and the workpiece. As shown in Figure 3-21, the only consideration is to make the locating pin slightly smaller than the hole. In this example, the hole is specified as .500-.510" in diameter. Following the rule of MMC, the locator must fit the hole at its MMC of .500". Allowing for a .0005 clearance between the pin and the hole, desired pin diameter is calculated at .4995". Standard locating pins are readily available for several different hole tolerances, or ground to a specific dimension. A standard 1/2" Round Pin with .4995"-.4992" head diameter would be a good choice.

Determining the size of a single locating pin based on maximummaterial conditions

THE GENERAL ACCURACY The general accuracy of the work holder must be greater than that of the work piece. Two basic types of tolerance values are applied to a locator: the first control the size of the locator; the second control its location. Many methods can be used to determine the appropriate tolerance values of a work holder. In some situations the tolerance designation is an arbitrary value predetermined by the engineering department and assigned to a work holder without regard to the specific work piece. Other tolerances are assigned a specific value based on the size of the element to be located. Although more appropriate than the single-value tolerances, they do not allow for requirements of the work piece. Another common method is using a set percentage of the work piece tolerance.

THE GENERAL ACCURACY The closer the tolerance value, the higher the overall cost to produce the work piece. Generally, when a tolerance is tightened, the cost of the tolerance increases. A tolerance twice as tight might cost five times to produce. The manufacturability of a tolerance, the ability of the available manufacturing methods to achieve a tolerance, is also a critical factor. A simple hole, if tolerance to .050", can be punched. If, however, the tolerance is .010", the hole requires drilling. Likewise, if the tolerance is tightened to .002", the hole then requires drilling and reaming. Finally, with a tolerance of .0003", the hole must be drilled, reamed, and lapped to ensure the required size.

THE GENERAL ACCURACY One other factor to consider in the manufacturability of a tolerance is whether the tolerance specified can be manufactured within the capability of the tool room. A tolerance of .00001" is very easy to indicate on a drawing, but is impossible to achieve in the vast majority of tool rooms. No single tolerance is appropriate for every part feature. Even though one feature may require a tolerance of location to within .0005", it is doubtful that every tolerance of the work holder must be held to the same tolerance value. The length of a base plate, for example, can usually be made to a substantially different tolerance than the location of the specific features.

Specification of work holder tolerances as a percentage of the work piece tolerances results in a consistent and constant relationship between the work holder and the work piece. When a straight percentage value of 25 percent is applied to a .050" work piece tolerance, the work holder tolerance is .0125". The same percentage applied to a .001" tolerance is .00025". Here a proportional relationship of the tolerances is maintained regardless of the relative sizes of the work piece tolerances. As a rule, the range of percentage tolerances should be from 20 to 50 percent of the work piece tolerance, usually determined by engineering-department standards.

DRILL JIGS Avoiding Redundant Location

REDUNDANT LOCATION

Redundant locators or duplicate locators restrict the same degree of freedom more than once. The work pieces in Figure 3-15 show several examples. The part at (a) shows how a flat surface can be redundantly located. The part should be located on only one, not both, side surfaces. Since the sizes of parts can vary, within their tolerances, the likelihood of all parts resting simultaneously on both surfaces is remote. The example at (b) points out the same problem with concentric diameters. Either diameter can locate the part, but not both.

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REDUNDANT LOCATION

The example at (c) shows the difficulty with combining hole and surface location. Either locational method, locating from the holes or locating from the edges, works well if used alone. When the methods are used together, however, they cause a duplicate condition. The condition may result in parts that cannot be loaded or unloaded as intended.

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REDUNDANT LOCATION

Figure 3-15. Examples of redundant location

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REDUNDANT LOCATION

Always avoid redundant location. The simplest way to eliminate it is to check the shop print to find which work piece feature is the reference feature. Often, the way a part is dimensioned indicates which surfaces or features are important as shown in Figure 3-16, Since the part on the left is dimensioned in both directions from the underside of the flange, use this surface to position the part. The part shown to the right, however, is dimensioned from the bottom of the small diameter. This is the surface that should be used to locate the part.

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REDUNDANT LOCATION

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CONTROLLING CHIPS

The final consideration in the placement of locators involves the problem of chip control. Chips are an inevitable part of any machining operation and must be controlled so they do not interfere with locating the work piece in the work holder. Several methods help minimize the chip problem. First, position the locators away from areas with a high concentration of chips. If this is not practical, then relieve the locators to reduce the effect of chips on the location. In either case, to minimize the negative effects of chips, use locators that are easy to clean, self-cleaning, or protected from the chips. Figure 3-14 shows several ways that locators can be relieved to reduce chip problems.

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CONTROLLING CHIPS

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CONTROLLING CHIPS

Coolant build-up can also cause problems. Solve this problem by drilling holes, or milling slots, in areas of the work holder where the coolant is most likely to build up. With some work holders, coolant-drain areas can also act as a removal point for accumulated chips. When designing a work holder, always try to minimize the chip problem by removing areas of the tool where chips can build up. Omit areas such as inside corners, unrelieved pins, or similar features from the design. Chip control must be addressed in the design of any jig or fixture.

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FOOL PROOFING

Fool proofing prevents improper loading of a work piece. The problem is most prevalent with parts that are symmetrical or located concentrically. The simplest way to foolproof a work holder is to position one or two pins in a location that ensures correct orientation, Figure 3-17. With some work pieces, however, more-creative approaches to fool proofing must be taken.

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FOOL PROOFING

Figure 3-17. Fool proofing the location prevents improper work piece loading.

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FOOL PROOFING

Figure 3-18 shows ways to foolproof part location. In the first example, shown at (a), an otherwise-nonfunctional fool proofing pin ensures proper orientation. This pin would interfere with one of the tabs if the part were loaded any other way. In the next example, shown at (b), a cavity in the work piece prevents the part from being loaded upside-down. Here, a block that is slightly smaller than the opening of the part cavity is added to the work holder. A properly loaded part fits over the block, but the block keeps an improperly loaded part from entering the work holder.

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FOOL PROOFING

Figure 3-18. Simple pins or blocks are often used to foolproof the location.

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FOOL PROOFING

One method to help ensure accurate location is the installation of spring-loaded buttons or pins in the work holder, Figure 3-19. These devices are positioned so their spring force pushes the work piece against the fixed locators until the work piece is clamped. These spring-loaded accessories not only ensure repeatable locating but also make clamping the work piece easier.

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FOOL PROOFING

Figure 3-19. Spring-loaded locators help ensure the correct location by pushing the work piece against the fixed locators.

CLAMPING GUIDELINES Locating the work piece is the first basic function of a jig or fixture. Once located, the work piece must also be held to prevent movement during the operational cycle. The process of holding the position of the work piece in the jig or fixture is called clamping. The primary devices used for holding a work piece are clamps. To perform properly, both the clamping devices and their location on the work holder must be carefully selected. Clamps serve two primary functions. First, they must hold the work piece against its locators. Second, the clamps must prevent movement of the work piece. The locators, not the clamps, should resist the primary cutting forces generated by the operation.

CLAMPING GUIDELINES Holding the Work piece Against Locators. Clamps are not intended to resist the primary cutting forces. The only purpose of clamps is to maintain the position of the work piece against the locators and resist the secondary cutting forces. The secondary cutting forces are those generated as the cutter leaves the work piece. In drilling, for example, the primary cutting forces are usually directed down and radially about the axis of the drill. The secondary forces are the forces that tend to lift the part as the drill breaks through the opposite side of the part. So, the clamps selected for an application need only be strong enough to hold the work piece against the locators and resist the secondary cutting forces.

CLAMPING GUIDELINES The relationship between the locators and clamps can be illustrated with a milling-machine vise. In Figure 3-22, the vise contains both locating and clamping elements. The solid jaw and vise body are the locators. The movable jaw is the clamp. The vise is normally positioned so that the locators resist the cutting forces. Directing the cutting forces into the solid jaw and vise body ensures the accuracy of the machining operation and prevents work piece movement. In all work holders, it is important to direct the cutting forces into the locators. The movable vise jaw, like other clamps, simply holds the position of the work piece against the locators.

Factors in Selecting Clamps

Factors in Selecting Clamps Holding Securely Under Vibration, Loading, and Stress. The next factors in selecting a clamp are the vibration and stress expected in the operation. Cam clamps, for example, although good for some operations, are not the best choice when excessive vibration can loosen them. It is also a good idea to add a safety margin to the estimated forces acting on a clamp. Preventing Damage to the Work piece. The clamp chosen must also be one that does not damage the work piece. Damage occurs in many ways. The main concerns are part distortion and marring. Too much clamping force can warp or bend the work piece.

Factors in Selecting Clamps Surface damage is often caused by clamps with hardened or non-rotating contact surfaces. Use clamps with rotating contact pads or with softer contact material to reduce this problem. The best clamp for an application is one that can adequately hold the work piece without surface damage. Improving Load/Unload Speed. The speed of the clamps is also important to the work holder's efficiency. A clamp with a slow clamping action, such as a screw clamp, sometimes eliminates any profit potential of the work holder. The speed of clamping and unclamping is usually the most-important factor in keeping loading/unloading time to a minimum.

Positioning the Clamps The position of clamps on the work holder is as important as the position of the locators. The selected clamps must hold the part against the locators without deforming the work piece. The clamps need only be large enough to hold the work piece against the locators and to resist any secondary forces generated in the operation. To meet both these conditions, position the clamps at the most-rigid points of the work piece. With most work holders, this means positioning the clamps directly over the supporting elements in the base plate of the work holder, Figure-3-23a. In some cases the work piece must be clamped against horizontal locators rather than the supports, Figure 3-23b. In either case, the clamping force must be absorbed by the locating elements.

Positioning the Clamps

Clamps should always be positioned so the clamping force is directed into the supports or locators

Positioning the Clamps For work holders with two supports under the clamping area of the work piece, two clamps should be used one over each support, Figure 3-24a. Placing only one clamp between the supports can easily bend or distort the work piece during the clamping operation. When the work piece has flanges or other extensions used for clamping, an auxiliary support should be positioned under the extended area before a clamp is applied, Figure 3-24b.

Positioning the Clamps

The number and position of clamps is determined by the work piece and its supports

Positioning the Clamps Another consideration in positioning clamps is the operation of the machine tool throughout the machining cycle. The clamps must be positioned so they do not interfere with the operation of the machine tool, during either the cutting or return cycle. Such positioning is especially critical with numerically controlled machines. In addition to the cutters, check interference between the clamps and other machine elements, such as arbors, chucks, quills, lathe carriages, and columns. When fixturing an automated machine, check the complete tool path before using the work holder. Check both the machining cycle and return cycle of the machine for interference between the cutters and the clamps.

Positioning the Clamps Occasionally programmers forget to consider the tool path on the return cycle. One way to reduce the chance of a collision and eliminate the need to program the return path is simply to raise the cutter above the highest area of the work piece or work holder at the end of the machining cycle before returning to the home position. Most clamps are positioned on or near the top surface of the work piece. The overall height of the clamp, with respect to the work piece, must be kept to a minimum. This can be done with gooseneck-type clamps, Figure 3-25. As shown, the gooseneck clamp has a lower profile and should be used where reduced clamp height is needed.

Positioning the Clamps The size of the clamp-contact area is another factor in positioning a clamp. To reduce interference between the clamp and the cutter, keep the contact area as small as safely possible. A small clamping area reduces the chance for interference and also increases the clamping pressure on the work piece. The overall size of the clamp is another factor to keep in mind. The clamp must be large enough to properly and safely hold the work piece, but small enough to stay out of the way.

Positioning the Clamps

Using gooseneck clamps is one way to reduce the height of the clamps

Positioning the Clamps The primary purpose of a clamp is to hold the work piece against the locators. To do this properly, the clamping force should be directed into the locators, or the most-solid part of the work holder. Positioning the clamping devices in any other manner can easily distort or deform the work piece.

The work piece shown in Figure 3-26 illustrates this point. The part is a thin-wall ring that must be fixtured so that the internal diameter can be bored. The most-convenient way to clamp the work piece is on its outside diameter; however, to generate enough clamping pressure to hold the part, the clamp is likely to deform the ring.

Positioning the Clamps The reason lies in the direction and magnitude of the clamping force: rather than acting against a locator, the clamping forces act against the spring force of the ring resisting the clamping action. This type of clamping should only be used if the part is a solid disk or has a small-diameter hole and a heavy wall thickness.

Positioning the Clamps

Directing the clamping forces against an unsupported area will cause this cylindrical part to deform

Positioning the Clamps To clamp this type of part, other techniques should be used. The clamping arrangement in Figure 3-27 shows the work piece clamped with four strap clamps. The clamping force is directed into the base plate and not against the spring force of the work piece. Clamping the work piece this way eliminates the distortion of the ring caused by the first method. A similar clamping method is shown at Figure 3-28. Here the work piece has a series of holes around the ring that can be used to clamp the work piece. Clamping the work piece in this manner also directs the clamping force against the base plate of the work holder. This type of arrangement requires supports with holes that permit the clamping screws to clamp through the supports.

Strap clamps eliminate deformation by directing the clamping forces into the supports under the part.

When possible, part features such as holes can be used to clamp the part

If the part can be clamped only on its outside surface, one other method can be used to hold the part: a collet that completely encloses the part. As shown in Figure 3-29, the shape of the clamping contact helps control distortion. Depending on the size of the part, either a collet or pie-shaped soft jaws can be used for this arrangement.If the part can be clamped only on its outside surface, one other method can be used to hold the part: a collet that completely encloses the part. As shown in Figure 329, the shape of the clamping contact helps control distortion. Depending on the size of the part, either a collet or pie-shaped soft jaws can be used for this arrangement.

When the part can only be clamped on its outside surface, pieshaped chuck jaws can be used to hold the part and reduce deformation

Positioning the Clamp Size and Force

Calculations to find the necessary clamping force can be quite complicated. In many situations, however, an approximate determination of these values is sufficient. The table in Figure 3-30 shows the available clamping forces for a variety of different-size manual clamp straps with a 2-to-1 clamping-force ratio.

Approximate clamping forces of different-size manual clamp straps with a 2-to-1 clamping-force ratio

Alternatively, required clamping force can be calculated based on calculated cutting forces. A simplified example is shown in Figure 3-31. The cutting force is entirely horizontal, and no work piece locators are used, so frictional forces alone resist the cutting forces.

A simplified clamping-force calculation with the cutting force entirely horizontal, and no work piece stops (frictional force resists all cutting forces).

When work piece locators and multi-directional forces are considered, the calculations become more complicated. To simplify calculations, the worst-case force situation can be estimated intuitively and then treated as a two-dimensional static-mechanics problem (using a free-body diagram). In the example shown in Figure 3-32, the cutting force is known to be 1800 lbs, based on a previous calculation. The work piece weighs 1500 lbs. The unknown forces are:

FR = Total force from all clamps on right side

FL = Total force from all clamps on left side R1 = Horizontal reaction force from the fixed stop R2 = Vertical reaction force from the fixed stop R3 = Vertical reaction force on the right side

= Normal-direction force = FL + FR + 1500

= Coefficient of friction = .19

A more-complicated clampingforce calculation, using a twodimensional free-body diagram

The following equations solve the unknown forces assuming that for a static condition: 1. The sum of forces in the x direction must equal zero. 2. The sum of forces in the y direction must equal zero. 3. The sum of moments about any point must equal zero. At first glance, this example looks "statically indeterminate," i.e., there are five variables and only three equations. But for the minimum required clamping force, R3 is zero (work piece barely touching) and FL is zero (there is no tendency to lift on the left side). Now with only three variables, the problem can be solved:

Solving for the variables, FR = 1290 lbs R1 = 1270 lbs R2 = 2790 lbs

In other words, the combined force from all clamps on the right side must be greater than 1290 lbs. With a recommended safety factor of 2-to-1, this value becomes 2580 lbs. Even though FL (combined force from all the clamps on the left side) equals zero, a small clamping force may be desirable to prevent vibration. Another general area of concern is maintaining consistent clamping force. Manual clamping devices can vary in the force they apply to parts during a production run. Many factors account for the variation, including clamp position on the work piece, but operator fatigue is the most-common fault. The simplest and often-best way to control clamping force is to replace manual clamps with power clamps.

The force generated by power clamps is not only constant but also adjustable to suit work piece conditions. Another benefit of power clamps is their speed of operation: not only are individual power clamps faster than manual clamps, every clamp is activated at the same time.

DRILL BUSHES

FEATURES

1) Material : EN 31 - High Chromium Ball Bearings Steel. 2) Hardness : 62 / 65 HRC [ 740 / 820 HV ] 3) Radius on ID. 4) Internally ground / honed diameters. 5) Double chamfered head. 6) Two-way undercut. 7) Lead for easy entry into jig. 8) Renewable Bushing Heads knurled. 9) Rigid quality control. 10) A wide range of Headed and Headless Jig Bushes available against order. 11) Quick and prompt delivery against Orders. 12) Used by most leading Companies in the Engineering industry around the world.

CLAMPING PINS

HAND-RETRACTABLE PLUNGERS

Knurled Head Standard Plunger (Locking Type)

Radiused Delrin Plunger (Locking Type)

PALM-GRIP HAND KNOBS

Aluminium

Blank

Tapped

Reamed

FLUTED KNOBS

Phenolic Tapped

Phenolic Tapped Through Hole

Phenolic Tapped Short Hub

FLUTED HAND WHEELS

STAR KNOBS

FLUTED HAND WHEELS

Thermoplastic Tapped

Thermoplastic Tapped Through Hole

Cushion Grip Tapped

Phenolic

SPRING PLUNGERS

BALL PLUNGERS

Steel

Delrin

CLAMPS

CLAMPS

HIGH RISE CLAMPS

High-Rise Clamps can be stacked on Narrow Riser Blocks and Spacer Blocks to reach tall work pieces

SWING CLAMP

Automatic Reversible Cam Action Work holding Assemblies

Automatic Reversible Cam Action Work holding Assemblies

Diagrams Showing Cams or Eccentrics Used for Clamping

Fig. 8.1.17 Common strap type clamping

Fig. 8.1.18 Clamping from side for free machining of the top surface.

Fig. 8.1.18 Clamping from side for free machining of the top surface.

Fig. 8.1.19 Clamping by swing plates

Fig. 8.1.20 Quick acting nut for rapid clamping

(a) clamping by cam

(b) screw and cam clamping from distance

Fig. 8.1.22 Quick multiple locating and clamping of cylindrical jobs.

Fig. 8.1.23 Quick acting screw (bayonet type) clamping

DRILL BUSHES

PRESS-FIT BUSHINGS

HEAD PRESS-FIT BUSHINGS

SLIP/FIXED RENEWABLE BUSHINGS

LOCK SCREWS

Fig. 8.1.24 Bushes (a) without head, (b) with head and (c) flange

Fig. 8.1.25 Locking of frequently replaceable bushes.

(a) Two close holes in one bush (b) Two very close holes using eccentric bush

(c) two close holes by two adjacent modified bushes

REST BUTTONS

TYPES OF DRILL JIGS Plate jigs or Channel jigs Angle Plate Jig Box Jigs Leaf or Latch Jig Sandwich Jig Trunnion Jig Jig for multi spindle machines. Template Jig Universal Jig

Box-Type Drill Jig

TEMPLATE JIG

A plain ring-type clamp jig

This is the simplest type of jig; It is simply a plate made to the shape and size of the work piece; with the require number of holes made it. It is placed on the work piece and the hole is drilled, guided through the holes in the template. The template should be hardened to avoid its frequent replacement. This type is suitable only for a few parts.

PLATE TYPE JIG

This is an improvement of the template type of jig. In place of simple holes, drill bushes are provided in the plate to guide the drill. The work piece can be clamped to the plate and holes can be drilled. The plate jig are employed to drill holes in large parts, maintaining accurate spacing with each other.

OPEN TYPE JIG

In this jig the top of the jig is open; the work piece is placed on the top.

Toggle Clamps Toggle Clamp Range: Vertical Clamps, Horizontal Clamps, Telescopic Clamps Locking Clamps. This range of Toggle Clamps are designed to improve engineering and fabrication applications. Improvements are based on the ability to quickly clamp and unclamp work pieces, greatly reducing down-time for machine operators.

Toggle Clamp Properties All steel parts galvanized before assembly Corrosion resistant Stainless steel hinges Safety design prevents injuries Soft Grip handles and ergonomic shapes Application Examples The Metal Industry including, drilling, welding, bending, grinding measuring and assembly lines The Wood and Plastics Industry including adhesives, drilling, milling and assembly lines

Part Foot

Function To support the drill jig. It is adjustable to ensure the leveling of the drill jig

Housing Locator
Locating Pin Drill bush Shoulder Screw Swing plate Clamping plate Clamp screw Swivel pin

To provide the structural main body of the drill jig To locate the horizontal position of the workpiece, To ensure the axial position of the drilled hole
To locate the axis of the workpiece To guide the drilling operation To mount the swing plate, To act as the pivot pin for the swing operation of the swing plate To hold the clamp, To provide a quick release operation To clamp the workpiece To facilitate the clamping action To hold the clamp