JIGS AND FIXTURES

Jigs and Fixtures are Production-work holding devices used to manufacture duplicate parts accurately

A Jig is a special device that holds the workpiece but also guides the cutting tool as the operation is performed

A Fixture is a production tool that locates, holds, and supports the work securely so the required machining operations can be performed

Elements of Jigs and Fixtures

1. Locating Elements: These position the workpiece accurately with respect to the tool guiding or setting elements in the fixture. 2. Clamping Elements: These hold the workpiece securely in the located position during operation. 3. Tool Guiding and Setting Elements: These aid guiding of the tool in the correct position with respect to workpiece.

Advantages of Jigs and Fixtures

1. Productivity

2. Interchangeability

3. Skill Reduction

4. Cost Reduction

Jigs and Fixture Design Factor

1. Study of the component. 2. Study of the type of the capacity of the m/c. 3. Study the locating elements. 4. Study of the clamping arrangement. 5. Study of clearance between jig and the component. 6. Study of the indexing devices. 7. Study of the fool-proofing arrangement. 8. Study of the ejecting devices. 9. Study of the swarf removal arrangement. 10.Study of rigidity and the vibration problems. 11.Study the safety devices. 12.Study the methods of manufacture of jigs and fixture.

Supporting and Locating Principles

Basic Rules for Locating 1. Positioning the Locators: Whenever possible, locators should contact the work on a machined surface. This permits accurate placement of the part in the tool and ensures the repeatability of the jig or fixture.

PART

WRONG METHOD

RIGHT METHOD

2. Tolerance: When designing a tool, the designer must keep the part-tolerance in mind. As a general rule, the tool tolerance should be between 20 and 50 percent of the part tolerance.

3. Fool proofing: Fooling proofing is means by which the tool designer should ensures that the part will fit into the tool only in its correct position.

Locating Methods
1. Location from Plane surface:

2. Location from Profile:

3. Location from Cylinder

Recess for burr and dirt

Prevention of Jamming

Diamond Pin Locator

Diamond pins are the two way locating devices, because they only locates in one axis. Diamond locating pins are used in conjunction with a round locating pin. The round pin holds the workpiece in position to the fixture, and the diamond pin holds the workpiece to keep it from rotating around the round pin.

Restricting Movements
Six-point Location by 3-2-1 Method

Three-pin base restricts six directions of movement

Five-pin base restricts ten directions of movement

six-pin base restricts twelve directions of movement

Clamping and Positioning

The function of any clamping device is that of applying and maintaining sufficient counteracting holding force to a workpiece to withstand all tooling forces

Types of clamp

Strap clamp

Swinging clamp

Hinge clamp

Spherical washers for equalizing clamping forces.

Pivoted strap clamp

Edge strap clamp

Edge jaw clamp

Quick acting screw clamps.

Swinging strap clamp

Swinging hook clamp

T-Slot clamp

Edge clamp

Method of clamping a small crankshaft by use of a sliding clamp and equalizing pivoting clamp.

Quick acting clamps

Hinge clamp

Vice

Rack and pinion

Magnetic work holding devices

Universal chuck

TYPES OF JIGS

CLAMP JIG

DIAMETER JIG

CHANNEL JIG

LEAF JIG

PLATE JIG

JIG FOR MULTISPINDLE MACHINE