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Chapter 3

The document discusses the design of simple jigs and fixtures including factors to consider in design, common materials used, design principles, and an example of designing a drill jig. Design considerations include locating parts, clamping methods, supports, tool guides, and indexing. Calculations for forces, material removal rate, total depth, and drilling time are also presented.

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Gemeda
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19 views

Chapter 3

The document discusses the design of simple jigs and fixtures including factors to consider in design, common materials used, design principles, and an example of designing a drill jig. Design considerations include locating parts, clamping methods, supports, tool guides, and indexing. Calculations for forces, material removal rate, total depth, and drilling time are also presented.

Uploaded by

Gemeda
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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CHAPTER THREE

Design of simple Jigs


The design of jigs and fixtures is dependent on
numerous factors which are analyzed to achieve an
optimum output. A fixture is a means through which a
part is securely fastened to the machine tool table to
accurately locate, support and hold the part during the
machining operation. A jig is a special class of fixture,
which in addition to provide all the functions as above,
also guides the cutting tool during machining.
 This is generally used for the operations such as drilling,
boring, reaming, tapping, counter boring, etc. Jigs should
be of light construction, consistent with rigidity to
1
facilitate handling, especially when
Tools Jigs jigs have to be
and Die Design

turned over so that holes can be drilled from more than


 Drill jigs provide methods for correctly locate
the workpiece with respect to the tool , Securely
clamp and rigidly support the workpiece during
the operation and Guide the tool Position and/or
fasten the jig on a machine.
While designing the jig we have to take process
considerations like,
 Type of Operations (drilling, reaming, other)
 Number of Operations
• Similar vs. different
 Sequential vs. simultaneous
• Sequence
Tools Jigs and Die Design
2
 Inspection Requirements
 Material Selection
There are a wide range of materials from where jigs and fixtures
could be made, to resist tear and wear, the materials are often
tempered and hardened.
Materials used in Jigs and fixtures are made from a variety of
materials, some of which can be hardened to resist wear. It is
sometimes necessary to use nonferrous metals like phosphor
bronze to reduce wear of the mating parts, or nylons or fibre to
prevent damage to the work piece. Given below are the
materials often used in jigs, fixtures, press tools, etc.
– Hardened steel
– Carbide
– Bronze
– Stainless steel
 Tools Jigs
3 – Mild steel
and Die Design
Design Considerations for Jigs
Jigs and fixtures are manually or partially power operated
devices. To fulfill their basic purposes, jigs and fixtures are
comprised of several elements (as indicated in Fig below ) :
 base and body or frame with clamping features
 locating elements for proper positioning and orientation
of the blank
 supporting surfaces and base
 clamping elements
 tool guiding frame and bushes (for jig)
 indexing plates or systems, if necessary
 auxiliary elements
 fastening parts.
4 Tools Jigs and Die Design
Fig Major elements of jigs and fixtures

5 Tools Jigs and Die Design


6 Tools Jigs and Die Design
Basic Design Steps
1. Method of locating the part – identify the
standard components required for locating
Purpose.
2. Design the clamping method. Make a proper
choice of clamps – C-washer, swing washer, nut,
strap clamp, toggle clamp, etc.
3. Design any supports required
4. Design the jig bushes required.
5. Design the jig body.

7 Tools Jigs and Die Design


The Design Principles for Jigs
 The design of Jigs and fixtures depend on the following factors:

Workpiece and finished component


Size and geometry study,
The machine size and capacity,
The machine’s extent of automation,
Availability of clamping arrangement and locating devices in the
machine,
The accuracy of the available indexing devices,
The machine tools rigidity,
The needed accuracy level in the quality of work to be produced,
etc.
8 Tools Jigs and Die Design
Design of drill jigs
The standard formulae for the various forces
associated with the operations of jigs and fixtures
are explained below:

9 Tools Jigs and Die Design


10 Tools Jigs and Die Design
11 Tools Jigs and Die Design
∗C- Chisel edge length(mm)
12 Tools Jigs and Die Design d-drill diameter
W- web thickness
 Drilling of holes
In drilling, marking and punching are done manually for
drilling desired holes at desired degree.
So, more time is required for marking and punching at
required degree angle and pitch circle diameter.
Also more time required for inspection of bore diameter.
DES IGN PROCESS OF JIG:
RAW MATERIAL:- For a blank of different geometries of
Base plate (Y*X mm)
Square bar (Y*X *Z mm)
Square bar (Y*X *Z mm), where X,Y and Z are dimension
of blank listed below in diagram as sample.

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14 Tools Jigs and Die Design
Calculations
Feed Rate : 0.123 mm / rev
1) Material Removal Rate

MRR = П*D2 *f*N/4, where D- diameter of hole, f- feed


rate, N- rpm
2) Total Depth
Total Depth L = Total height + 2*0.29*D
3) Drilling Time
Drilling Time T = L/N*f, L- total length
4) Total Time = Loading and Unloading Time + Drilling
Time for Drill number of holes.

15 Tools Jigs and Die Design

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