Design for Manufacturing: Jigs & Fixtures in Aircraft Industries

Author: Leicester College Date created: Date revised: 2009

HNC Year 1 Boeing 767-400 Case Study

Abstract; The use of jigs and fixtures plays a major role in modern production engineering. The basic methods for determining the requirements and configuration of these devices is described . Examples of common practice are also given.

Leicester College 2009. This work is licensed under a Creative Commons Attribution 2.0 License.

Design for Manufacturing Principles of Producibility Design Tools and Manufacturing What is a Fixture? What is a Jig? Jigs & Fixtures Advantages Jig & Fixture: Construction methods and materials Jig & Fixture: different types Jigs & Fixtures: Step by Step Using jigs to build the Boeing 767-400 Credits

Contents

These files support the Edexcel HN unit Design for Manufacture (NQF L4) File Name FMS Unit Outcome 2.2 Key Words Models, work cycles, volume, machine utilisation, automation, flexible, systems

Industrial Robots
Jigs and Fixtures Kinematics

2.2,2.3
2.1,2.3 2.1,2.3

Robot, industrial, robot arm, Cartesian, polar, cylindrical, jointed arm

Efficiency, production, jigs, fixtures, tooling, production, Machines, kinematics, Degrees of freedom, configuration, space, work space, robot, joints, forward, inverse

For further information regarding unit outcomes go to Edexcel.org.uk/ HN/ Engineering / Specifications Jigs & Fixtures in Aircraft Industries

Design for Manufacturing

Design and manufacturing are successive phases of a single operation, the ultimate objective: an acceptable final product. In aerospace context, such acceptability has several components: Market viability, Operational efficiency, Capability for further development, Structural integrity.
Jigs & Fixtures in Aircraft Industries

Design for Manufacturing (Cont.) Other

Maintainability: Civil airliner, Military aircraft Producibility: A structure must not be so complex or difficult in concept that its realisation will Create great difficulties or Increase the cost of the manufacturing process; Tooling: Low cost production is possible only by accounting for every possible manufacturing advantage.
Jigs & Fixtures in Aircraft Industries

Principles of Producibility Design

(1) General Configuration
(2) Major breakdowns (3) Structure and Equipment

Jigs & Fixtures in Aircraft Industries

Principles of Producibility Design

General Configuration: Rectangular vs. tapered wing sections, flaps and control surfaces, Minimum number of major structures, Cylindrical, straight, or conical surfaces vs. compound curvature, Extend of fairing and filleting required; Interchangeability is difficult because of tolerance accumulation, should be used only when essential!
Jigs & Fixtures in Aircraft Industries

Principles of Producibility Design (Cont.)

Major breakdowns Adequate access for assembly, Ease of handling and transportation, Completeness of master breakdown units, Assembly joints, Effectiveness: Improved producibility does not necessarily follow an increase in degree of breakdown!
e.g.; Centre wing-box assembled as a single part rather Jigs & Fixtures in Aircraft Industries than more subsections

Principles of Producibility Design (Cont.)

Structure and Equipment: Simplicity: Adequate access for fabrication and subassembly, etc. Parts Multiple use and Min. number of different parts Min. total number of parts Min. amount and types of attachments Effective use of standard parts, material shape and sizes Detail design:
Interchangeability, Adjustment, Tolerances, Adequate Jigs & Fixtures in edge distances, Machining clearances and fastener Aircraft Industries economy, etc. ...

Tools and Manufacturing

An aircraft is conceived as a complete structure, but for manufacturing purposes must be divided into Sections, or main components ==> split into Sub-assemblies of decreasing size, resolved into Individual detail parts. To build every single part, special tools are required!
Jigs & Fixtures in Aircraft Industries

What is a Fixture?

A Fixture is a special tool used for Locating the work, Clamping the work, Supporting the work, Holding all the elements together in a rigid unit during a manufacturing operation. The most important considerations are: Accuracy and rigidity, followed by ease of use, and economy in construction.
Jigs & Fixtures in Aircraft Industries

What is a Jig?

A Jig is a type of Fixture with means for positively guiding and supporting tools. For both Jigs & Fixtures: Origin: traced back to Swiss watch and clock industry! Objective: to provide interchangeability, reduction of cost, and accuracy of the manufactured Individual detail Parts, Sub assemblies, Sections, or main components, and finally the complete structure.
Jigs & Fixtures in Aircraft Industries

Jigs & Fixtures Advantages

Ensure the interchangeability and accuracy of parts manufactured, Minimize the possibility of human error, Permit the use of medium-skilled labour, Reduce the manufacturing time, Allow the production of repeat orders without retooling.

Jigs & Fixtures in Aircraft Industries

Jig & Fixture: Construction methods and materials

Cast in iron, Fabricated from steel plates, sections and machined parts by welding, Built-up by bolting etc. Materials such as Magnesium, Resin, Wood, Plastics and Composite materials, are also used.
Jigs & Fixtures in Aircraft Industries

Jig & Fixture: different types

Assembly Fixtures, Machining Jigs & Fixtures, Drilling Jigs, boring Jigs, etc. Welding Fixtures, Trim Jigs, Control or Master Jig, Apply Jig; attaching to a larger jig or an assembly of parts, etc. ...
Jigs & Fixtures in Aircraft Industries

Jigs & Fixtures: Step by Step

For every part of structure, A mockup is first designed and is made from material such as wood, plaster, etc., The mockup is used to design and to build the fixtures ensuring the contours and the external form of the structure, The Master Jig is then designed in order to complete the fixture providing the important reference points, Jig and pin points, and to provide a Reference for the regular checks of the fixture, Thermal expansion of fixtures is important!
Jigs & Fixtures in Aircraft Industries

Design for Manufacturing: Jigs & Fixtures in Aircraft Industries

HNC Year 1 Boeing 767-400 Case Study Shane Payne
Jigs & Fixtures in Aircraft Industries

This resource was created Leicester College and released as an open educational resource through the Open Engineering Resources project of the Higher Education Academy Engineering Subject Centre. The Open Engineering Resources project was funded by HEFCE and part of the JISC/HE Academy UKOER programme.

2009 Leicester College

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