Design of Jigs, Fixtures and Press Tools UNIT 1: Jigs and Fixture

DESIGN OF JIGS, FIXTURES and PRESS
TOOLS
UNIT 1: Jigs and Fixture
Subject Code: ME8095
VARTHINI RAJAGOPAL
ASSISTANT PROFESSOR
DEPARTMENT OF MECHANICAL ENGINEERING
GOVERNMENT COLLEGE OF ENGINEERING SRIRANGAM
TIRUCHIRAPALLI
Turning Fixture
Design Considerations in Turning Fixture
• The fixture along with the component should be perfectly balanced to avoid
undesirable oscillations.
• The fixture should be free of any projections, so that interference with the tool post or
cutting tool is avoided. In view of this specific criterion, sliding ‘V’ clamps are used.
Wedge-type edge clamps are used so that they do not protrude outside. However, in
certain cases where the component itself has a larger length, heel-type clamps can be
adopted.
• Wherever fixtures are used in more than one machine, backplates must be used.
Backplates are just intermediate devices, positioned in-between the headstock and the
fixture, and are either fastened to the flange of the spindle or screwed to the spindle
directly.
• The clamping arrangement should be capable of withstanding the various forces

developed during operation- cutting force tangential to the cutting circle, axial and
radial forces due to the feed of the tool and bending forces due to pressure of tool on
the workpiece.
Turning Fixture
• It consists of workpiece locating and clamping elements.
• These fixtures are commonly used for facing, turning and boring operation.
• The workpiece should be positioned correctly with respect to rotating machine spindle
for all these operations.
• For boring and turning, the axis of the bore or the outside diameter to be machined must
be aligned with the machine spindle axis.
• Generally, turning machine spindles have accurately machined spigots for location and
threads for clamping of locators and work holders.
Turning Fixture
• Most of machines are given with back plate
that is permanently mounted on the machine
spindle.
• This plate is used to locate and clamp turning
fixtures.
• Commonly, outside diameter of the back plate
is super finished.
• Locating spigot is used for aligning axis of
rotation of fixtures with machine spindle.
• Back plate is given with three or more equi-
spaced holes for clamping turning fixtures.
• Turning fixtures provide quick loading,
locating & clamping of workpieces in mass
production.
Standard work holders in Turning Fixture
5. Faceplate
Face Plate Turning Fixture
Face Plate Turning Fixture
Collet Turning Fixture
• Collet chucks or collets are used mainly to
hold bar stock, especially in the smaller sizes.
• A collet is a circular steel shell having three
or four equally spaced slits extending the
greater part of its length.
• These slits impart springing action to the
collet.
• That is why, collets are also known as “spring
collets”.
• The collet nose is made thicker to form the
jaws.
• The outside surface of the nose fits in the taper
hole of the hood.
• The inside of the collet is made according to
the shape of the work to be held.
• They are usually classified according to the
method of closing the collet.
• Push-out collet: The collet being closed by
pushing it against a taper in the hood. It gives
a good control of length. The hood must be
removed when the collet is changed.
• Pull-in collet: The collet is closed by pulling
it into a taper in the hood. It gives a poor
control of length. The hood does not need to
be removed when the collet is changed.
Dead length collet:
For accurate positioning of
the bar, both the push out and draw in type collet
present some error due to the movement of the bar
along with the collet while gripping.
• This difficulty is removed by using a stationary
collet on the bar.
• Dead length collet has two conical seats.
• The tightening of the spindle nut squeezes the
collet between the two conical seats to clamp the
stock.
• Consequently, dead length collets do not move the
stock inwards or outwards like pull-in or push-out
collets.
• This type of collet is less economical as
manufacturing of two conical mating surface
increases machining cost.
• Also, manual tightening or loosening of nut takes
more setup time than pneumatic operated
pull/push type collet
Mandrel
 Mandrels are internal locators used for
machining the outside diameter of the
workpieces concentric with finished bores.
Boring Fixture
 The bore to be machined should be aligned with the axis of the machine spindle.
 The boring fixture should have the locator and clamps/studs well clear of the tool path.
 Balance weights should be added to the face plate so that even and symmetrical distribution of
mass around the centre line of the fixture is achieved.
 In an example, the workpiece to be bored rests on angle plate face A and its boss is centralized
with the machine axis by a sliding V block which can be operated with knurled screws S.
 The workpiece is clamped in this position by two clamps C.
Boring Fixture
 The height of the angle pate, sliding V and other parts is kept less than workpiece thickness to
prevent obstruction to facing tool F.
 The workpiece is bored through, and one side of the boss is faced on this fixture.
 The eccentric masses due to the workpiece, angle plate, and clamps are counterbalanced by
balance weight B.
Grinding Fixture- Surface Grinding
 Surface grinding is widely used in industry to finish lengths and thicknesses of the workpieces
within precise tolerances.
 The standard magnetic furnished with surface grinding machines can be used satisfactorily for
workpieces having resting surface parallel to the surface to be ground.
 Solid plates can be ground under magnetic clamping alone and no other fixtures are necessary.
 However, light workpieces having lesser resting area tend to tilt and fly off the magnetic table
due to the high speed of the grinding wheel and the high feed used in grinders with
reciprocating or rotating tables.
 As lesser magnetic clamping force is not sufficient to secure the workpiece during the
grinding operation, it is necessary to provide additional supports by nesting the workpiece.
 This can be done by placing solid plates around the workpiece.
 With more weight and resting area, the nest plates are held firmly by the magnetic force of the
table.
 The nest plates siege the workpiece from outside and arrest its movement in the horizontal
plane, thus preventing it from flying off or tilting due to high speed and feed inherent in the
grinding operation.

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DESIGN OF JIGS, FIXTURES and PRESS

• The clamping arrangement should be capable of withstanding the various forces

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