Jigs & Fixtures

Jigs & Fixtures

Fixture : Mechanical device (Strong & Rigid) designed and used in M/c shops to enable
easy, quick & consistently accurate locating , supporting and Clamping Workpiece against
tool for higher productivity and quality in batch Production.

Jig : Jig is a fixture having additional system of tool guidance.

Advantages of Jigs and Fixtures :
1. Minimize tool breakage, guidance of cutting tool, drill, reamer
2. Minimize the possibility of human error, partially automates the M/c tool.
3. Permit the use of less skilled labor
4. Reduce manufacturing time, cost
Design of Jigs & Fixtures :
Major Parts comprising jig & fixtures // elements to be designed :
1. Base and Body or Frame : Strong and rigid
2. Locating elements /System : for positioning and orientation of the blank
3. Supporting System
4. Clamping System/elements
5. Tool guides- bushings
6. Indexing Mechanism –plates / systems
7. Auxiliary elements : fasteners
12 : Degrees of Freedom
3-2-1, 4-2-1,Principle of Location:
D E
8
A

F
F B C

Pins A, B, C : Restrict 1,2,3,4,7 , no of D.O F. ( Rotation about X and Y axis and translation along -ve Z- Axis)
Pins D, E : Restrict 5,6, 12 , no of D.O.F. (Rotation about Z axis and , Translation along +ve Y – axis )
Pin F : Restrict 10 , no of D.O.F. ( Translation along –ve X-axis)
Remaining D.O.F are : 8 ,9,11, Which can be arrested by Locating and Clamping
(Translation along +ve, Z-axis, +ve , X-axis, -ve , Y-axis)
Design of Jigs : Element / Part-1: Base Body or Frame
Design of Jigs : Element / Part-2 & 3,
Locating & Supporting Devices Rules / Principles :

 Locating :
1. One or more surfaces preferably machined are to be taken for reference.
2. Locating should be easy , quick and accurate
3. The locating pins should be as far as possible
4. System should be Fool proof and redundancy should be avoided
5. Vee block and cones should be used for self locating solid and hollow
cylindrical jobs
 Supporting :
1. Supporting should be provided at least at three points
2. Unsupported span should not be large to cause sagging
3. Proper recess should be provided for supporting large flat area
4. If more than three pins are required for supporting large work pieces then the
additional pins are to be spring loaded or adjustable
Locating & Supporting Devices Rules / Principles :
Locating & Supporting Devices Rules / Principles :
Locators / Methods :
 Locating by Flat surfaces:
Solid Supports : Easiest and Cheapest, Less accurate, used where m/c surface act
as locating point.
Locators / Methods :
Locators / Methods :
Adjustable Supports :
Locators / Methods :
 Locating by Hole one or two :
Locators / Methods :
 Locating on mandrel or plug :

 Nesting / Profile Locators :

Locators / Methods :
 Nesting / Profile Locators :

 Used for Cylindrical W/p

 No need of supplementary locating devices
 But it is difficult to lift out of the cavity
 Some time finger slots are provided
 It encloses the w/p fully
Locators / Methods :
 Nesting / Profile Locators :

 Full Nest for work pieces other than cylinders

Encloses the work completely
 For large W/p , partial nests are used to
Enclose certain contours of the W/p
Design of Jigs : Element/Part -4, Clamping Principles :
 Clamping must be strong , rigid and Stable, unaffected by vibrations, easy, quick.
 Should not hinder loading and unloading work, interfere with operator of m/c tool.
 Clamping force should act against rigid part and not damage the job.
 Use minimum Standard parts , Use pads of softer material such as nylon or fiber
 Wearing parts have to be hard and replaceable
 Clamping should be fool proof, Reliablity, safety and low cost
Clamping Principles :
Clamping Methods ; Ordinary Clamping:
Clamping Methods ; Ordinary Clamping:
Clamping Methods ; Quick acting Clamping:

Cam Operated Clamp

Clamping Methods ; Quick acting Clamping:
Clamping Methods ; Quick acting Clamping:

Button Clamps
Clamping Methods ; Quick acting Clamping:
Design of Jigs : Element /Part-5, Tool Guides Bushings :
Tool Guides / Bushes are Provided :
(0.00025 to 0.0025 larger than drill size , can drill 10,000 to 15, 000 holes )
1. To eliminate elastic spring back ,to locate & guide tool relative to the work.
2. No need of marking,
3. Reduce tool run out, off
4. No hole expansion ovalisation
5. Reduces tool breakage
Types of Bushes :
1. Press Fit Bushings : Installed directly in jig body, Less Accuracy.

2. Liner Bushings : Master Bushings, Permanently fixed to jig body. guide to

renewable type of bushings:
Types of Bushes :
3. Renewable Bushings :
 For periodic replacement
 In large production , due to wear
 Sliding fit into liner bush
 Retaining screw for preventing rotation lift
 Can be removed only after removing retaining screw

4. Slip Bushings:

 For two or more tools to cut

 On same axis, different diameter
 Drilling followed by reaming
 Slip bush is used for each tool
 Retaining screw for preventing rotation lift
Types of Bushes :

Screw Bush
Holds the bush in place
Makes bush adjustable
Can be used for locating
Can be used to clamp
Design of Jigs : Element/Part-6, Indexing Mechanism
 Used to move the work piece relative to machine table or spindle.
 Used for quick, accurate location of work piece in number of specific positions.
Design of Jigs : Element/Part-6, Indexing Mechanism
Design of Jigs : Element/Part-6, Indexing Mechanism
Types of Jigs : Template Jig :
Based on construction and method of operation Drill Jigs are Classified as
 Simple plate of metal or wood which carries correct location of holes to be
made in the workpiece. Size of template should be same as that of workpiece.
 Directly placed on the part , No Clamping arrangement
 Eliminates marking need completely, Least expensive
Types of Jigs : Plate Jig :
 A Template jig with work piece clamping system
 Located and Clamped directly on the work piece and bolted in position
Types of Jigs :
Types of Jigs :
Design of Jigs :
Principles :
1. Should allow easy and quick loading and unloading of work piece
2. Should be as open as possible to minimize chip or burr accumulations
3. Fool proofing provision should be there.
4. The use of ejection devices to force the work piece out from the jig or fixture
5. Design for safety : avoid sharp corners , bolts and nuts should be inside the
body of jig or fixtures.
Design of Jigs : Example -1
Design of Jigs : Element 2 &3, Locating & Supporting
Design of Jigs : Element -4, Clamping
Design of Jigs : Element-5, Tool Guidance
Design of Jigs :
Design of Jigs :
Design of Jigs : Example -3
Design and draw a Template drilling Jig for the mild steel component to drill four
holes of 5 mm, dimeter at 70 P.C.D.
Design of Jigs : Example -3
Design of Jigs : Example -3

Nest Locator

Template
Design of Jigs : Example -4
For a C.I. component in which a 3 holes of 12 mm diameter are to be drilled. Design
and draw a drilling Jig.
Design of Jigs : Example -4

1. Body
2. Jig Plate
3. Stud
4. C- Washer
5. Pin
6. Plain Washer
7. Drill Bush
8. Stud Bush
9. Nut
10. Work piece
Design of Jigs : Example -4

Body Jig Plate

Design of Jigs : Example -5
Design and draw a box drilling Jig t drill 4 holes in mild steel component.

1. Jig Body 6. Clamping Screw

2. Conical Locator 7. Pin
3. Locking Screw 8. Pin
4. Clamp Plate
5. Drill Bush
Design of Jigs : Example -5
Design of Jigs : Example -5
 Design of Jigs : Example -6
It is required to drill 4 holes in a mild steel component. Design and draw an Indexing
Jig for drilling hole.
Design of Jigs : Example -6
1. Strip
2. Flat Screw
3. Jig plate
4. Support plate
5. Bush
6. Work piece
7. Locating Stud
8. C- Washer
9. Hex. Soc. Hd Screw
10. Pin
11. Holder
12. Hex Nut
13. Base Plate
14. Hex. Soc. Hd screw
15. Hex Soc. Hd Screw
16. Dowel
Design of Jigs : Example -6
1. Strip
2. Flat Screw
3. Jig plate
4. Support plate
5. Bush
6. Work piece
7. Locating Stud
8. C- Washer
9. Hex. Soc. Hd Screw
10. Pin
11. Holder
12. Hex Nut
13. Base Plate
14. Hex. Soc. Hd screw
15. Hex Soc. Hd Screw
16. Dowel
Design of Jigs : Example -6

13, Base Plate 4, Support Plate

Design of Jigs : Example -6
Design of Fixtures :
Fixtures name is derived /fact /it is always fastened to a m/c or bench
Fixtures are designed specifically for an operation and so named like
 Milling Fixtures
 Turning Fixtures
 Tapping Fixtures
 Assembling Fixtures
 Fixtures for grinding
 Fixtures for broaching
 Fixtures for boring/ drilling
 Fixtures for welding
Difference between Jig and Fixtures
1. A fixtures holds and position the work but does not guide like jig
2. Fixtures are heavier in construction, Jigs are lighter in construction
3. Bolted rigidly on machine table, Jigs are not bolted
4. Subjected to higher cutting forces, Clamping must be big, Hexagonal
nuts used to clamp, Jigs to lighter forces, Hand nuts used.
5. Fixtures can be used for all machining applications, Jig not for all.
Design of Fixtures : Milling Fixtures
Fixture components :
• Base : Securely fastened to milling machine table

• Setting Block :
 Motion of cutting tool is more complex, movement in two different axes
 Used for tool setting/ locating cutting tool in relation to w/p surface
Design of Fixtures : Milling Fixtures
 Setting block fixed to the fixture, feeler gauges are placed between the cutter and
reference plane on the setting block so that the correct depth of cut and correct
lateral setting is obtained.
Design of Fixtures : Milling Fixtures/ Example-1 & 2
Design a String milling fixture to cut slot 3*3 mm in a cylindrical mild steel
component
Design of Fixtures : Milling Fixtures/ Example-1

1. Base Plate 6. Thrust Plate

10. Work Plate
2. Support Block 7. Stepped V- Block
11. Allen Screw
3. Support Block 8. Std V- Block
12. Allen Screw
4. Spindle 9. Guide Block
13. Handle
5. Holding Block
Design of Fixtures : Milling Fixtures/ Example-1
Design of Fixtures : Milling Fixtures/ Example-2
Design of Fixtures : Milling Fixtures/ Example-3
Design of Fixtures : Milling Fixtures/ Example-4
References :
1. Introduction to Jigs and Fixtures , 3rd Edition, M.H.A. Kempster, The
English Language Book Society and Hodder And Stoughton, London.
2. Jigs and Fixtures, 3rd Edition, P. H. Joshi, Tata McGraw Hill Education
private limited, New Delhi.
3. Tool Engineering and Design, G.R. Nagpal, Khanna Publishers, Delhi
4. A Text Book of Production Technology, P.C. Sharma, S. Chand &
Company Ltd. Ramnagar New Delhi.
5. Jigs and Fixture Design, Fifth Edtion, Edward G. Hoffman, Thomson
Delmar Learining, a division of Thomson Learing Inc.