Advanced Production Process 1 Module II

BROACHING
Broaching is a machining process for removal of a layer of material of desired width and depth
usually in one stroke by a slender rod or bar type cutter having a series of cutting edges with gradually
increased protrusion.

Broaching tool consists of a series of distinct cutting edges called cutting teeth along its length.
Feed is accomplished by the increased step between any two successive teeth on the broach. The total
material removed in a single pairs of the broach is the cumulative result of all the teeth in the tool in
action (it is not necessary that all the teeth available in the broach in action at a time). The cutting speed
of the broach is decided by the linear travel of the tool with respect to the work piece. The shape of the
cut surface (machined surface) is determined by the contour of the cutting edges on the broach. Generally
broaches are made of high speed steel (HSS). In some cases the broaches are made of cast iron and their
cutting edges are made of cemented carbide inserts.

NOMENCLATURE OF BROACHING TOOL

Pull End: Pull end is made to attach the broach to the broaching machine through the puller head. Pull
end for engaging the broach in the machine
Neck of shorter diameter and length, where the broach is allowed to fail, if at all, under overloading
Front Pilot: This centers the broach in the hole to be finished just before start of processing. Front pilot
for initial locating the broach in the hole
Roughing Teeth: These are the cutting edges which remove larger amount of stocks during cutting.
Larger amount removal generates poor quality of surface finish but makes the operation faster. Roughing
and finishing teeth for metal removal
Finishing Teeth: These are cutting edges removing smaller stocks of material. These are used for final
finishing of the surfaces and their accurate sizing. Finishing and burnishing teeth for fine finishing
Rear Pilot and Follower Rest: This is a supporting device to the broach when it is likely to complete its
operation of broaching. Rear pilot and follower rest or retriever
 Advanced Production Process 2 Module II

Land: It is the width of flank face of the broach normally it is kept slightly inclined to give relief angle to
the flank face of broach.
Pitch: It is the distance between two corresponding points on two successive teeth of a broach. Normally
pitch of finishing teeth of a broach is kept comparatively smaller than the rough cutting teeth.
Height of the Teeth: Height of the roughing and finishing teeth gradually increases from the shank to the
finishing teeth. This increment is called the cut per tooth; it depends on the material being machined.
Normally the cut per tooth is taken from 0.01 or 0.2 mm for the finishing teeth and it may go up 0.2 mm
for the cutting teeth.

Types of Broaches
According to the type of operation (nature of work )
• Internal broach
• External broach (surface)
According to method of operation
• Push type
• Pull type
According to configuration
• Horizontal
• Vertical
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According to type of construction

• Solid broach
• Built up broach
• Inserted tooth broach
• Progressive cut broach
According to operation
• Hole broach
• Surface keyway broach
• Spline broach
• Spiral broach
• Burnishing broach
Pull Broaching: Work piece is clamped to the broaching machine in stationary position and the broach is
pulled through the work. Broaches are usually long and are held in a special head. Pull broaching is
mostly used for internal broaching. During operation a pull type broach is subjected to tensile force,
which helps in maintaining alignment and prevents buckling. Pull type broaches are generally made as a
long single piece and are more widely used, for internal broaching in particular.

Push Broaching: Work piece is held in the broaching machine in stationary position and broach is
pushed through the portion of work piece to the machined. Normally push broaching is done by hand and
arbor presses (hydraulic press). This method is also recommended for internal broaching like for sizing
and finishing the holes, cavities, and key ways. Push type broaches are essentially shorter in length (to
avoid buckling) and may be made in segments. Push type broaches are generally used for external
broaching, preferably, requiring light cuts and small depth of material removal.

Surface Broaching: Any one of two, either work piece or the broach (tool) is kept moving and other is
kept stationary. The method is widely used as surface finishing operation. In case of surface broaching,
the broaching tool is specifically designed for the shape to be finished.

Continuous Broaching: In continuous broaching the broach is held stationary in the broaching machine
and work piece is moved continuously. The teeth of movement of the work piece may be straight,
horizontal or circular. This is generally used for broaching a large number of similar work pieces at a
time.

Types of Broaching Machine

• According to purpose of use
– general purpose
– single purpose
– special purpose
• According to nature of work
– internal broaching
– external (surface) broaching
• According to configuration
– horizontal
– vertical
• According to number of slides or stations
– single station type
– multiple station type
 Advanced Production Process 4 Module II

– indexing type
• According to tool / work motion
– intermittent (one job at a time) type
– continuous type
Horizontal broaching machines, typically shown in Figure, are the most versatile in application and
performance and hence are most widely employed for various types of production. These are used for
internal broaching but external broaching work is also possible. The horizontal broaching machine is
usually hydraulically driven and occupies large floor space.

Vertical broaching machines, typically shown in Figure,

Occupies less floor space, are more rigid as the ram is supported by base, mostly used for external
or surface broaching though internal broaching is also possible and occasionally done.
Continuous broaching machine
Broaching operation and broaching machines are as such high productive but its speed of
production is further enhanced by;
– incorporating automation in tool – job mounting and releasing
– increasing number of workstations or slides for simultaneous multiple production
– quick changing the broach by turret indexing
– continuity of working
Continuous broaching machine is a different type of classification. These machines can be
horizontal or vertical type. The concept of continuous broaching machine is concerned with continuity.
This continuity of operation can be maintained by keeping the broach stationary and moving workpiece
through the tool (broach) to perform cutting. In case of horizontal continuous broaching machines two
sprockets, one on each side of the machine, are maintained. On the sprockets, there is continuous travel
of an endless chain having a series of fixtures mounted on it. The broaches are rigidly hold on the
machine in horizontal position over the chain. Work pieces are loaded on the fixtures on one side of the
machine and unloaded on its over sides shown.
In case of vertical type continuous broaching a number of platens are mounted on a continuous
chain. Broaches holders are mounted on these platens to carry the broaches work pieces are clamped on
the horizontal table of the machine which is are kept stationary. Broaches are moved across the work
pieces by the chain.
 Advanced Production Process 5 Module II

Broaching operations
Broaching operations are used for processing of various internal and external surfaces. This is also
recommended for processing of round and irregular shaped holes ranging from 6 to 100 mm size which
may have flat or contoured surfaces. Some of the cavities and holes are directly machined by broaching
operations, the example is spline hole. Sometimes execution of broaching operation requires more than
one pairs. The teeth of a gear or spline may be broached altogether or one or a few at a time. Normal
indexing operation (see milling machine operation for details) is done for cutting teeth by broaching.
After completion of broaching of one tooth indexing action is performed and another tooth is broached
and this continues till all the teeth are broached.

Merits of Broaching
(a) It gives high rate of production so recommended for mass production.
(b) Production run time in case of broaching is very large as a broach has very long life. The whole
processing load is shared by so many teeth.
(c) Due to faster operation and longer tool life, it is relatively cheaper.
(d) Both rough cutting as well as finished cutting can be completed in a single pairs of tool.
(e) Little skill or employment of semi-skilled manpower is sufficient to perform broaching operation.
(f) Broaching provides accurate and excellent quality of surface finish. It is capable to maintain tolerance
of the order of ± 0.007 mm and surface finish value up to 0.8 µ.
 Advanced Production Process 6 Module II

(g) It is also capable to process internal and external surface including intricate shaped cavities.
(h) Broaching makes the effective use of cutting fluids as it facilitates the flow of cutting fluid into the
cuts.
 Very high production rate (much higher than milling, planing, boring etc.)
 High dimensional and form accuracy and surface finish of the product
 Roughing and finishing in single stroke of the same cutter
 Needs only one motion (cutting), so design, construction, operation and control are simpler
 Extremely suitable and economic for mass production

Merits of broaching
(a) Broach is a multipoint cutting tool having multi cutting edges. Preparation of cutting edges is a costly
affair. Its initial cost is quite high.
(b) There is a limitation of size of workpiece in case of broaching. Very large sized workpieces can not be
subjected to broaching operation.
(c) Broaching is not possible for the surfaces having obstructions.
(d) Application of broaching is restricted upto finishing and accurate sizing as it can remove only small
stocks of material. Removal of larger stocks is not possible in broaching operation.
(e) There is a urgent need of rigid clamping of workpiece in broaching operation to maintain its accuracy
and finish. Clamping devices require frequent maintenance and cost.
Limitations
 Only through holes and surfaces can be machined
 Usable only for light cuts, i.e. low chip load and unhard materials
 Cutting speed cannot be high
 Defects or damages in the broach (cutting edges) severely affect product quality
 Design, manufacture and restoration of the broaches are difficult and expensive
 Separate broach has to be procured and used whenever size, shape and geometry of the job
changes
 Economic only when the production volume is large.
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GEAR MNUFACTURING
Gear terminology (Nomenclature of gear)

Gear Blank: The metallic workpiece accurately sized and shaped which is used as workpiece for gear
cutting is called gear blank. The diameter of gear blank is called gear blank diameter.
Addendum Circle: It is an imaginary circle which passes through top of all gear teeth and represents
maximum diameter of a gear. This maximum diameter is equal to gear blank diameter.
Addendum: Addendum of a gear is the radial distance between addendum circle and pitch circle of the
gear.
Pitch Circle: This is an imaginary circle along which thickness of a gear tooth becomes equal to spacing
between them.
Deddndum: It is the radial distance between pitch circle and root circle of a gear.
Root Circle: Root circle is an imaginary circle which is supposes to pass through root of all gear teeth.
Tooth Clearance: This is the distance between the top of a tooth of one gear and the bottom of the
corresponding tooth of other mating gear is known as clearance or tooth clearance.
Pressure Angle: The angle made by the line of action with the common tangent to the pitch circle is
called pressure angle.
 Advanced Production Process 7 Module II

Face: It is the portion of the tooth lying between top of the tooth and pitch circle.
Flank: This is portion of the gear tooth between its pitch circle and root circle.
Thickness of a Gear Tooth: It is also called chorodal thickness of gear tooth. It is width of two gear tooth
measured along the pitch circle. At the pitch circle width of gear tooth becomes equal to the width of
spacing between two consecutive gear teeth.

Backlash: It is difference between actual tooth thickness and the width of space at which it meshes with
other gear.
Circular Pitch: It is the distance between corresponding points of adjacent teeth measured along the
pitch circle.
Diametral Pitch: It is number of teeth of a gear per unit of pitch circle diameter.
Module: It is reciprocal of diameteral pitch. It is linear distance in mm that each tooth of the gear would
occupy if the gear teeth were spaced along the pitch diameter.
 Advanced Production Process 8 Module II

Methods of gear making

• Casting
– Sand casting
– Permanent mould casting
– Die casting
• Powder metallurgy
• Plastic moulding
• Stamping (Forming on power press)
• Extruding
• Coining
• Rolling
• Machining
o Form cutting
o Template method
o Generating
 Gear hobbing
 Gear Shaping
 Gear planning
GEAR SHAPING METHOD
This process uses a pinion shaped cutter carrying clearance on the tooth face and sides and a hole
at its center for mounting it on a stub arbor or spindle of the machine. The cutter is mounted by keeping
its axis in vertical position. It is also made reciprocating along the vertical axis up and down with
adjustable and pre-decides amplitude.
 Advanced Production Process 9 Module II

GEAR PLANING
In this method, gear cutting is done by a rack shaped cutter called rack type cutter. The principle is
illustrated in Figure. The working is similar to shaping process done by gear type cutter. The process
involves rotation (low rpm) of the gear blank as the rack type cutter reciprocates along a vertical line.
Cutting is done only in the downward stroke; the upward stroke is only a return movement. The main
difference of this method with the previous one is that once the full length of the rack is utilized the gear
cutting of operation is stopped to bring the gear blank to its starting position so that another pass of gear
cutting can be started. So this operation is intermittent for cutting larger gears having large number of
teeth over their periphery.

GEAR HOBBING
In this process, the gear blank is rolled with a rotating cutter called hob. Gear hobbing is done by
using a multipoint cutting tool called gear hob. In gear hobbing operation, the hob is rotated at a suitable
rpm and simultaneously fed to the gear blank. The gear blank is also kept as revolving. Rpm of both, gear
blank and gear hob are so synchronized that for each revolution of gear bob the gear blank rotates by a
distance equal to one pitch distance of the gear to be cut. Motion of both gear blank and hob are
maintained continuously and steady.

 Hobbing is a process of generating a gear using a rotating tool called “Hob”.

 The hob has helical threads
 The threads have grooves cut parallel to the axis to provide cutting edges.
 The gear teeth are cut into the workpiece by a series of cuts made by the hob.
 It is the most widely used gear cutting process for creating spur and helical gears.
 Gear hobbing is a multipoint machining process in which gear teeth are progressively generated
by a series of cuts with a helical cutting tool (hob).
 Both the hob and the workpiece revolve constantly as the hob is fed across the face width of the
gear blank.
 They rotate in a timed relationship
 A proportional feed rate is maintained between the gear blank and the hob
 Several teeth are cut on a progressive basis
 It is used for high production runs
 Advanced Production Process 10 Module II

Gear Generating comparison

 Advanced Production Process 11 Module II

FINISHING OF GEARS
Surface of gear teeth produced by any of the generating process is not accurate and of good quality
(smooth). Dimensional inaccuracies and rough surface generated so become the source of lot of noise,
excessive wear, play and backlash between the pair of gears in mesh.
For smooth running, good performance and long service life, the gears need
• to be accurate in dimensions and forms
• to have high surface finish and
• to be hard and wear resistive at their tooth flanks
which are achieved by some gear teeth finishing work after near accurate preforming and
machining. Small gears made by cold rolling generally do not require further finishing. If a rolled gear
needs further surface hardening only then little finishing by grinding and or lapping is done after
hardening. Gears produced to near-net-shape by die casting, powder metallurgy, extrusion, blanking etc.
need little finishing. But machined and hardened gear teeth are essentially finished for accuracy and
surface finish.
GEARS FINISHING METHODS

• Gear shaving
• Roll finishing of gear tooth
• Gear burnishing
* Gear grinding
• Lapping of a gear
• Gear honning
GEAR SHAVING
The teeth of straight or helical toothed external spur gears and worm wheels of moderate size and
made of soft materials like aluminum alloy, brass, bronze, cast iron etc. and unhardened steels are mostly
finished by shaving process. The different types of shaving cutters which while their finishing action
work apparently as a spur gear, rack or worm in mesh with the conjugate gears to be finished. All those
gear, rack or worm type shaving cutters are of hard steel or HSS and their teeth are uniformly serrated to
generate sharp cutting edges.
While interacting with the gears, the cutting teeth of the shaving cutter keep on smoothening the
mating gear flanks by fine machining to high accuracy and surface finish. For such minute cutting action,
the shaving teeth need an actual or apparent movement relative to the mating teeth along their length.
ROLL FINISHING OF GEAR TOOTH
This process involves use of two hardened rolling dies containing very accurate tooth profile of
the gear to be finished. The gear to be finished is Yet in between the two dies.

GEAR BURNISHING
In this method the machined gear is rolled under pressure with three hardened master gears of
high accuracy and finish. The minute irregularities of the machined gear teeth are smeared off by cold
plastic flow, which also helps in improving the surface integrity of the desired teeth.
 Advanced Production Process 12 Module II

GEAR GRINDING
In this operation abrasive grinding wheel of a particular shape and geometry are used for finishing
of gear teeth. Gear to be finished is mounted and reciprocated under the grinding wheel. Each of the gear
teeth is subjected to grinding operations this way.

LAPPING OF A GEAR
The process of lapping is used to improve surface finish of already made teeth. In this process the
gear to be lapped is run under load in mesh with cast iron toothed laps. Abrasive paste is introduced
between the teeth. It is mixed with oil and made to flow through the teeth. One of the mating members
(either gear or lapping tool) is reciprocated axially along with the revaluations.

GEAR HONNING
It is used for super finishing of the generated gear teeth. Honing machines are generally used for
this operation. The hones are rubbed against the profile generated on the gear tooth. Gear lapping and
gear honing are the lost finishing operations of a gear generation process.

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PRESS TOOLS
Metal forming is one of the manufacturing processes which are almost chip less. These operations
are mainly carried out by the help of presses and press tools. These operations include deformation of
metal work pieces to the desired size and size by applying pressure or force. Presses and press tools
facilitate mass production work. These are considered fastest and most efficient way to form a sheet
metal into finished products.

PRESS
The press is a metal forming machine tool designed to cut metal by applying mechanical force or
pressure. The metal is formed to the desired shape without removal of chips.
The working operation is completed by a single stroke of the punch, and finished part may be
produced in less than one second. The machine used to apply the required pressure or force in a
short duration is called press. The press consists of a frame, supporting bed and ram. The ram is
equipped with special punches and moves towards and into the die block which is attached to the
rigid body. The punch and die block assembly are generally referred to as a die set or simply
die.
 Advanced Production Process 13 Module II

Press selection
• Work material
• Thickness of stock
• Type of operation
• Size and shape of the work
• Rate of production
• Type of drive

Classification of Presses

1. According to source of power

a. Manual operated press
b. Power operated press
i. Mechanical press
ii. Hydraulic press
2. Method of power transmission
a. Crank press
b. Eccentric press
c. Cam driven press
d. Toggle press
e. Knuckle press
f. Rack and pinion press
3. Number of slides
a. Single action press
b. Double action press
c. Triple action press
4. Types of operation
a. Punching press
b. Blanking press
c. Drawing press
d. Bending press
e. Coining press
5. Types of frame
a. Gap or open fram
i. Bench press
 Advanced Production Process 14 Module II

ii. Open back inclination (OBI) press

b. Closed frame press
i. Arch press
ii. Straight side press

PRESS WORKING NOMENCLATURE

1: Bed: The bed is the lower part of the press frame that serves as a table to which a Bolster plate is
mounted.
2: Bolster Plate: This is a thick plate secured to the press bed , which is used for locating and supporting
the die assembly. It is usually 5 to 12.5 cm thick.
3: Die Set: It is unit assembly which incorporates a lower and upper shoe, two or more guide parts and
guide part bushings.
4: Die Block: It is a block or a plate which contains a die cavity
5: Lower Shoe: The lower shoe of the a die set is generally mounted on the bolster plate of a press. The
die block is mounted on the lower shoe, also the guide post are mounted on it.
 Advanced Production Process 15 Module II

6: Punch: This is male component of a die assembly, which is directly or indirectly moved by and
fastened to the press ram or slide.
7: Upper Shoe: This is the upper part of the die set which contains guide post bushings.
8: Punch Plate: The punch plate or punch retainer fits closely over the body of the punch and holds it in
proper relative position.
9: Back up Plate: Back up plate or pressure plate is placed so that intensity of pressure does not become
excessive on punch holder. The plate distributes the pressure over a wide area and the intensity of
pressure on the punch holder is reduced to avoid crushing.
10: Stripper: It is a plate which is used to strip the metal strip from cutting a non-cutting
Punch or die. It may also guide the sheet.

Types of dies
• Simple die
• Progressive die
• Compound die
• Combination die
• Inverted die
Simple die
1. Cutting die: used for cutting operations such as Piercing, blanking, etc
2. Forming die: Used for forming (non-cutting) operations such as Drawing, bending, etc
 Advanced Production Process 16 Module II

Progressing Dies
These dies are able to do progressive actions (operations) on the work piece like one operation followed
by another operation and so on. An operation is performed at one point and then work piece is shifted to another
working point in each stroke of ram.
Progressive die (or follow on die) is used for batch production progressive of small die two to
medium size components. In cutting operations (piercing and blanking) are performed at different stations’
by using separate punch and die for each operation. The cost of progressive die is high and is used
for high rate of production. The scrap produced is high in progressive dies. The strip is fed to the
first station where the piercing is done. When the ram ascends the strip is then fed to the second station
under blanking punch. During the stroke of press, blanking is performed at second station
while piercing at the first station. From then on, each stroke of the press will produce a complete
component (washer) and the strip is fed across by the same amount.
Compound Dies
In these dies two or more cutting actions (operations) can be executed in a single stroke of the ram.
In compound die two or more cutting operations are performed at single station in a single stroke
of the ram. When the ram descends, the blanking and piercing operations are performed
simultaneously. For blanking operation, the punch used for piercing becomes a die. i.e blanking is
done in opposite direction to that of piercing. This die is very economical. If leads to savings in floor
space and power, and the accuracy of the parts prod used is higher.

Combination Dies
As indicated by their names these dies are meant to do combination of two or more operations
simultaneously. This may be cutting action followed by forming operation. All the operations are done in a
single action of ram. The combination die is similar to compound die, except that in combination die the
cutting operation is combined with forming operation. These operations are performed in a single stroke of
ram at different stations
 Advanced Production Process 17 Module II

Inverted die
In inverted dies, the die is attached to punch holder and the punch is carried on to the die
shoe attached to the bolster. As the ram descends, the blank is cut off from the strip. On the
upward stroke of the ram, the shedder pushes the blank out of the die opening and
the stripper forces the scrap strip off the punch. Design of inverted dies is complicated and its cost is
high. However, there is little possibility of thin blanks being bent, and the cutting edges need less
regrinding.

PRESS TOOL OPERATIONS

1. Cutting operations
a) Blanking
b) Piercing
c) Lancing
d) Cutting off and Parting
e) Notching
f) Shaving
g) Trimming
2. Shaping operations
a) Forming (embossing, beading and cutting, bulging, etc)
b) Drawing
c) Bending

CUTTING OPERATIONS
These are the processes of separating a piece of metal from stock with a punch and
die. Some of cutting operations are explained below
Blanking: Blanking is a process of cutting out desired shape from the strip or sheet by a single blow of the
punch. The product of blanking (part cut out from sheet) is a finished product or may be used for
subsequent cold forming process. The sheet left with a hole on the dies goes as waste. The size of die
determines the size of blanked part and the clearance should be given to the punch.
Piercing: Piercing or punching is a process of making a desired hole by using a punch and die. The
blanked part is a waste and a sheet with a hole left on the dies is a desired product. The size of the punch
determines the size of hole and the clearance should be given to die.
Lancing: Lancing is a cutting operation in which hole is partly cut (i.e. no metal is actually removed) and
bending down the cut portion.

Cutting and parting: Cutting off is the process of severing a piece from a strip by cutting along a single line
i.e. the width of cut is neglected. Parting is a process of separating a piece from a strip by removing
the scrap, the width of cut is equal to the thickness of scrap removed.
 Advanced Production Process 18 Module II

Notching: Notching is the process of cutting out the edges of the strip to obtain the desired outer contour of the
work piece.
Shaving: Shaving is a process of finishing the edge of the blank to an accurate size. The clearance
provided for die is very small to give the required tolerances.
Trimming is the process of finishing the edges of a part by removing the flash or excess metal around it.

SHAPING OPERATIONS:
In shaping operations the metal is deformed into required shapes by using punch and die.
Embossing: Embossing is a shallow forming operation which uses a matched punch and die. The
thickness of work piece is uniform, and is intended for duplicating of the pattern on either sides of
the sheet metal. It is used for decorative sheet work and to obtain the impressions of desired
form.
Coining: Coining is squeezing the metal flows into the cavity operation between in which the
punch and die. It is employed for making coins, medals and similar articles.
Beading and curling: These operations involve forming of edges into a roll to increase
the strength and appearance. Also, they eliminate exposed sharp’
edges. These are used in manufacture of hinges, pans and similar items
Bulging: Bulging is a forming operation in which the portions of a drawn shell or tube are
expanded. The force required to expand the shell is transmitted through media such as oil
or water
Hole flanging: Hole flanging or extruding is the process of forming a flange around
a hole.
Swaging: Swaging operation is similar to coining operation except that the metal is not
confined in the die. Flash as a result of over flow of unconfined metal is removed in the
subsequent operations.

DRAWING:
Drawing is the process of producing hollow shapes such as cups and dishes from a flat
sheet metal. Drawing processes can be classified into two types.
(i) Deep drawing, and
(ii) Shallow or 'box drawing
In deep drawing the height of the component is greater than the diameter or width.
In shallow or box drawing the height of the component is less than the diameter or width.
BENDING:
Bending is a cold working process which consists of uniformly straining flat sheet
or strip of metal around a linear axis. Metals on the outside of the bend is stressed in
tension while the inside is compressed, and the metal tends to become slightly thinner at
the bend.
 Advanced Production Process 19 Module II

V-Bending: In this method, a metal strip is placed on a die of wedge shaped cavity and
is forced into the cavity by wedge shaped punch. The bend angle may be less
than 900, 900 or more than 900.

Edge bending: In edge bending, the strip is held in the form of cantilever on flat die, and
unsupported length is forced against the vertical face of the die by a flat punch.

SPRING BACK
The deformation which has been accompanied by bending Is partly plastic and partly
elastic. When bending force is removed, there is some elastic recovery, resulting In a slight
decrease in bent angle, This is known as spring back.
 Advanced Production Process 20 Module II

JIGS AND FIXTURES

• Jigs and fixtures are production tools
• Used to accurately manufacture duplicate and interchangeable parts.
• When large numbers of components can be machined or assembled identically
• Jig: A device that holds the work and locates the path of the tool.
• Fixture: A device fixed to the worktable of a machine and locates the work in an exact
position relative to the cutting tool.

Uses of Jigs & Fixtures in Manufacturing Industries

1) To reduce production cost
2) To increase production rate
3) To ensure high accuracy in part manufacture
4) To enable heavy and complicated complex shaped parts to be machined by being held
rigidly to a machine
5) To provide interchangeability
6) Reduce quality control expenses
7) Less skilled labour & save labour costs
8) Improve work safety
Basic Elements
1) A sufficiently rigid body (plate, box or frame structure) into which workpiece is loaded.
2) Locating elements
3) Clamping elements
4) Tool guiding elements (for Jigs), Tool setting elements (for Fixtures)
5) Elements for positioning or fastening the jig or fixture on the machine on which it is
used
6) Safety to operator

JIGS
A jig is a special device that holds, supports, or is placed on a part to be machined. It is a
production tool made so that it not only locates and holds the work piece but also guides the
cutting tool as the operation is performed. Jigs are usually fitted with hardened steel bushings
for guiding drills or other cutting tools.

FIXTURES
A fixture is a device for locating, holding and supporting a work piece during a
manufacturing operation. It is a production tool that locates, holds, and supports the work
securely so the required machining operations can be performed.
Jigs Fixtures
1. Hold the work piece in position and guide the 1. Hold the work piece in position, but not guide the
cutting tool. cutting tool.
2. Usually movable on machine table. 2. Clamped in a fixed position on machine table.
3. Used for drilling, reaming tapping and counter 3. Used for milling, turning, grinding, welding etc.
boring.
4. Lighter in construction. 4. Heavy in construction.
 Advanced Production Process 21 Module II

PRINCIPLES OF LOCATION
A body in a space has six degree of freedom; three of these are line? along X, Y, Z, and three are
rotary about X Y, Z. The plate shown in Fig. 8.1, can move along three aXes - X, Y and Z and it
can also rotate around these axes.
A locating system should eliminate degree of freedom so as to complete the operation with
required quality.

Pins 1, 2, and 3 prevent linear motion along 'Y—Y' and rotation about 'Z-Z' and 'X-X'.
Pins 4 and 5 prevent linear motion along 'Z—Z' and rotation about 'Y-Y', and
Pin 6 prevents linear motion along 'X-X'. Thus, all the six degrees of freedom have been
removed. This is generally referred as 3-2-1 principle of location.
 Advanced Production Process 22 Module II

PRINCIPLES OF CLAMPING:
One of the most important features of any jig and fixture is to clamp the work piece in a
fixed position. The following factors are to be considered for efficient clamping of work piece.
 Use rapid action clamping devices to minimize clamping time.
 Must have positive clamping action to prevent undue movement.
 Clamps should withstand rough usage.
 Clamps should be simple to handle and easy to
 Control without danger to the operator.
 Clamping force should be exerted on positively
 Supported points of work piece.

LOCATING METHODS

LOCATORS
The most commonly used locating elements are pins, buttons, pads rest plates and V-blocks.
The buttons are shorter than pins and are generally used for vertical locations. Pins are
usually employed for horizontal location. Pads Support the vertical surfaces and used for
larger work pieces. Pads with larger bearing area are called rest plates and used to support
the previously, machined surfaces of larger part. V-blocks are generally intended for
cylindrical parts. Work pieces may also be located by cavities made on jigs and fixtures, and
such cavities are called rest.

TYPES OF CLAMPS
Screw clamp: These are threaded parts with knurled collar or head (square or hexagonal) for
rotating and tightening the screw to increase the clamping area pads are provided. This
clamping applies pressure directly on the side faces of the work piece.
 Advanced Production Process 23 Module II

Strap clamp: This is also called edge clamp. This type clamping is done with the help of a lever
pressure acting as a strap on the work piece. Strap or plate clamps are most popular devices
for clamping.

Cam clamp: Cam clamps are quick action devices for clamping, but they tend to l6ose due to
vibration. A simple cam-operated clamp. It is operated by actuating the handle.
Toggle clamp: Toggle clamps-are quick action clamps and their operation depend upon the
movement of rigid link. They are widely used for holding sheet-metal parts in position. Toggle
clamps gives a clearance for loading and unloading of work pieces, and provide heavy
clamping force.
Hydraulic and Pneumatic clamps: Hydraulic and pneumatic clamping devices are widely used
in mass production and ensure reliable clamping of work pieces with uniform and equalized
clamping pressure.
 Advanced Production Process 24 Module II

TYPES OF JIGS
Drill jigs may be divided into two general types, open and closed. Open jigs are for
simple operations where work is done on only one side of the part or sometimes two sides of
a work piece. Closed jigs, on the other hand, operate on two or more sides. The most-common
open jigs are template jigs, plate jigs, table jigs, sandwich jigs, and angle plate jigs.

DIFFERENT TYPES OF JIGS

Drilling Jigs
Drilling jigs are used for large number of operations. Different types of drilling jigs are
described below.
Template Jig: This is a simple plate of metal or wood which carries correct locations of holes
to be made in the work piece. Size of template jig should be same as that of the work piece. It
is overlapped with the work piece and drilling is done quickly. Use of this jig avoids the
marking operation completely.

Plate Type Jig: If the work is to be done on very large scale, an improvement can be made to
template jig that is plate type jig. This uses a plate having drill pushes and suitable means to
hold and locate the works that it can be clamped to the plate and holds drilled directly
through the bushes in correct positions.

Table jig: Plate jigs are sometimes made with legs to raise the jig off the table for large work.

Open Type Jig: In this jig the top is kept open and work piece is placed on the base of the jig
and the drill plate. Carrying the drill bushes is placed on the top to guide the tool. After the
operation is over, the drill plate is removed and work piece is replaced.

Channel jig: The body of channel jig is in the form of standard channel. The component is
located in a channel and is clamped by screw. It is used for drilling simple symmetrical shapes.
 Advanced Production Process 25 Module II

Swinging Leaf Type Jig: This type of jig carries a leaf or plate, arranged at the top or on one
side, which is capable of swinging about a fulcrum. It is normally the drill plate itself which is
pivoted about a point at its one end. A swinging leaf type jig is shown in Figure 4.15. The work
is loaded and unloaded with the help of swinging bolt.

Box Type Jig: Its construction is like a box and it is used for the components having irregular
shape and to be operated at different places. This type of jig provides rigid support, so
machining on the various places of work piece becomes comfortable.

Solid Type Jig: This is also used for drilling holes in articles of simple shapes and relatively
smaller sizes. This is made of standard section of rolled steel.

Pot Type Jig :This jig is used for drilling holes in hallow cylindrical components having smaller
size. Here the body of the jig is like a pot that is used to accommodate the work piece
comfortably. Location on the inside surface of the component is provided by the clamp
projecting from the bush plate located over the top of the work pieces.

Index Jigs: This type of jig is equipped with the facility of indexing, which creates positional
division of the work piece suitably. This jig is used for quick drilling of equidistant holes on
the circular surface of the work piece. By means of indexing device a hole is drilled then the
work piece is moved (indexed) to next position under the drill bush for drilling automatically.

Multi-station Jigs: These jigs are designed for multi-spindle machine where many operations
can be performed simultaneously. Each spindle of the machine carries a different tool to
perform a different operation. Tools and spindles are arranged in the sequence in which
operations are to be performed.
 Advanced Production Process 26 Module II

Universal Jig : As indicated by the name universal jigs are meant to do large number of operations. These
may have replaceable elements on them. Selection and mounting of an element depends on the type of
operation to be performed.

TYPES OF FIXTURES:
All fixtures used in industry; can be divided into two groups
1. Universal fixtures
a. Machine vices
b. Three jaw self-centering chuck
c. Universal dividing head
d. Magnetic chucks, etc.
2. Special fixtures for specific operations
a. Milling fixture,
b. Boring fixture,
c. Grinding fixture,
d. Welding fixtures, etc.

Machine Vices: The machine vice is the simplest form of fixtures used to hold the parts for
machining. Special jaws are designed to accommodate odd-shaped work pieces and at the
same time to prevent damage to machined surfaces.

Milting fixture: The cutting force induced in milling is heavy and therefore, the fixture is rigidly attached
to the table. Cast iron fixtures are more efficient than steel and is recommended for accurate work. The
milling fixture essentially consists of base, tenon strips, setting blocks, T-bolts, clamps and locating pins.
The work piece is located on fixture base which is bolted in position on the machine table. The cutter is
set in a correct position by mounting a feeler gauges (0.4 to 0.5 mm thick).

Boring fixture: Boring is the operation of enlarging the hole, and is achieved by rotating the boring bar in
the work or by rotating the work piece around the boring bar. The purpose of boring fixtures is to guide
the boring bar as in drilling or to hold the work piece in position with respect to boring bar, as in milling
fixture.
 Advanced Production Process 27 Module II

Grinding fixture: The following fixture is used for different grinding operations.
1. Mandrels for external grinding
2. Magnetic chucks for surface grinding, and
3. Special jaws chucks for internal grinding
Design characteristics of grinding fixture are similar to milling fixture. However, a setting block is not
necessary, but the fixture directly bolted to the machine table. It is common practice, in surface grinding,
to use suitable fixtures directly with magnetic chucks. In such cases bolting of fixture to machine table is
not necessary.

Welding fixture: The basic purpose of welding fixtures is to locate and hold the parts together
in their position during welding. The welding fixtures comprise usual locators and clamping
devices and are positioned such that the welding heat does not damage them. The provision
for titling or rotation of the fixtures should be made for ease welding from various sides.

DRILL BUSHES:
In drill jig, the tools are guided properly by using drill bushes in a jig plate. They are usually
made for case hardened steel. For easy entrance of the tool, an adequate chamfer should be
made at the top of the bore, and also chamfer should be made at the bottom of their external
diameter to facilitate entry into the bush plate.

The following types of bushes are widely used in drilling

1. Fixed bushes
(i) Plain
(ii) Headed (or flange),
(iii) Shaped end
2. Slip bushes
3. Liner bushes.
Fixed bushes: Fixed bush is 'pressed' to fit into the jig plate and is used mainly when hole is
produced with one tool. Headed bushes are preferred to headless (plain) bushes because it
controls the hole depth, and chances of bush getting loose and sliding axially with the tool are
lesser in headed (collar) bushes. Sometimes the bottom end of the bush is shaped to suit the
profile of work piece to prevent deflection of tool.

Slip bushes: Slip bushes are used when two or more tools are necessary for completing a hole.
They should be prevented from rotating during drilling by using a retaining screw. The head
of slip bushes is knurled to facilitate handling.

Liner bushes: The main functions of liner bushes are to act as hardened guide for slip or
renewable bushes and to guide the tool. Liner bushes are 1forced' to fit into jig plate.
 Advanced Production Process 28 Module II

Liner bushes: The main functions of liner bushes are to act as hardened guide for slip or renewable bushes and to guide
the tool. Liner bushes are 1forced' to fit into jig plate.

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JIG BORING MACHINE

Boring is a process of enlarging an existing drilled or cored hole with a single point cutting
tool. Jig boring machine is the most accurate of all machine tools. Its accuracy is obtained by rigid
construction, use of low expansion metal and the use of precise methods of measuring the
movement of the table in two coordinate directions.

WORKING PRINCIPLE OF JIG BORING PROCESS

The jig boring is a special type of boring process; hence its working principal is just similar
to the boring process. In this process rotating tool is passed over the stationary work. This principal
is used for large work pieces, while for small size work pieces tool is kept stationary and work is
moved by applying force. The feed in this process is given with respective to the vertical axis of the
hole and its radius.

CONSTRUCTION &MAIN FEATURES

• Jig boring machine generally consists of a heavy base and a column.
• A spindle head is provided at the top of this column, which is fixed on the guide ways of the
column. The spindle is fixed using preloaded antifriction bearings.
• The table is arranged on the saddle. It can move in different on the guide ways of the saddle.
• Table provides longitudinal motion to the work piece & saddle cross movement to the work
piece.
• By moving the spindle head up and down, the vertical movement of the spindle is obtained.
 Advanced Production Process 29 Module II

MAIN COMPONENT OF JIG BORING MACHINE

• BED:-the component which base to the machine is called bed it us made from C.I. it support
the column, saddle, control penal and whole machine.
• COLUMN:-it is also a hollow component made from cast iron. It is supporting the head
stock , guide ways and vertical head provides axis for positioning.
• head-stock:-it is also called spindle-head.it is fixed on column in front side. Spindle is
supported in quill. As this quill is moving up and down side becomes like a telescopic
mechanism.
• TABLE AND SADLE:- table helps to clamp and hole the work piece in a fixture in required
position. Hence t-shaped slots are made in it. The saddle provides possibility of longitudinal
motion of the work piece.
• PICK-UP DEVICES:- it is attached on the table and saddle. It is helping in controlling
various machine operations automatically. Again devices are necessary for accurate
measurements.

TYPES OF JIG BORING MACHINE

Depending on the design features, jig boring machines are classified into two basic types.
1. Open front Jig boring machine (vertical milling machine type) or Single column jig boring
machine
2. Cross rail jig boring machine (Planer type) or Double column jig boring machine

SINGLE COLUMN JIG BORING MACHINE

• Single column jig boring machine is used for small size of component.
• It is made of plain rotary table, inclined table and square table
• It looks like a vertical milling machine, hence it is called vertical milling type jig boring
machine.
 Advanced Production Process 30 Module II

DOUBLE COLUMN JIG BORING MACHINE

The vertical columns are provided at two sides of this machine. This construction looks like a planer
hence it is called a planer type jig boring machine. It is used for the large weight work pieces.

HOLE LOCATION PROCEDURE

The accuracy of a hole involves both size and location.
1. Layout method
2. Transfer method
3. Button method
4. Coordinate method
1. Layout method: Layout method consists of drawling lines on a work piece, and marking
the centers of hole with a punch. The drill is started in center punch mark.
 Advanced Production Process 31 Module II

2. Transfer method
The transfer method consists of drilling or reaming through a hole already existing a master
plate (template). The master plate is used as a jig and is clamped with the work piece. This method
is employed in production work where the relative position of hole location is known.

3. Button method
The button method or buttoning is a common method of locating the position of
hole. In this method tool maker buttons are used. These are accurately sized hollow cylinders
and are available in different size.

In this method, button is clamped by a screw to the work piece and adjusted with
precision measuring tools to the position desired for a hole. The work piece is mounted
on the face plate of a lathe with the button protruding. The work piece is shifted
until the button is running true. This can be achieved by using a dial indicator. Thus the axis
of button is concentric to the hole to be made. The work piece is clamped firmly, then button is
removed. The hole is made on the same spot.

4. Coordinate method
In this method the position of location is achieved by moving the work piece
from a reference point through measured distance along perpendicular axes (coordinate
axes). Movements are commonly made through cross-slide screw or lead-screw and graduated
dials.

SYSTEM OF MEASUREMENT FOR LOCATIONS

The more accuracy is required in measurement taken by jig boring machine and in position,
generally different measuring mechanisms are used for taking measurements.

1. Lead screw method

2. Gauging method
a) Mechanical gauging method
b) Electrical gauging method
3. Optical measuring method

2. Lead screw method

It is the most common and quick system of locating the holes. The lead screw is rotated in a
nut to obtain both longitudinal and cross feed. The micrometer dials are provided on the lead screw,
so that every movement is controlled and measured. If there is backlash or wear on lead screw may
cause errors, this can be eliminated by suitable devices.
 Advanced Production Process 32 Module II

2.a. Mechanical gauging methods

Mechanical gauging method or end measuring system is used for locating the holes. The end
measures are placed against a stop on the table and a dial indictor is fitted at the outer end. The table
is moved in longitudinal and crosswise direction to locate the hole accuracy, and its travel is
governed by the length of the end measures.

2.b. Electrical gauging method

It is an electromagnetic system used for locating the holes.

3. Optical measuring method

4. Microscopic Attachment to the spindle