Introduction to Jig & Fixture Design

Outcomes After completing this topic student should be able to:Identify the jigs & fixtures. Objective of tool design Define the elements consist in the jigs & fixtures. Identify limits and fits Define the material used in jigs & fixtures.

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Jigs & Fixtures

General definitions Jigs and fixtures are production-work holding devices used to manufacture duplicate parts accurately. The correct relationship and alignment between the cutter, or other tool, and the workpiece must be maintained. To do this, a jig or fixture is designed and built to hold, support, and locate every part to ensure that each process of drilled or machined within the specified limits.
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FGB40103 - Jigs & Fixtures Design

Jigs? Cutting tool guided(x fix kt machine table) It provided with tool guiding elements such as drill bushes. These direct the tool to the correct position on the work-piece. Fixtures? Work-piece guided(selalu fix kt machine table) To hold the work-piece securely in the correct position with respect to the machine/cutter during operation.
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Objective
The main objective of tool design is to lower manufacturing costs while maintaining quality and increased production. To accomplish this, the tool designer must satisfy the following objectives:
Provide simple, easy to operate tools for maximum efficiency Reduce manufacturing expenses by producing parts at the lowest possible cost. Design tools that consistently produce parts of high quality Increase the rate of production with existing machine tools Design the tool to make it foolproof and to prevent improper use. Select materials that will give adequate tool life, Provide protection in the design of the tools for maximum safety of the operator.
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Elements of Jigs & Fixtures

Generally all the jigs and fixtures consist of:
Locating Elements: these position the workpiece accurately with respect to the tool guiding or setting elements in the fixture. Clamping Elements: these hold the workpiece securely in the located position during operation. Tool Guiding and Setting Elements: these aid guiding or setting of the tools in correct position with respect to the workpiece.

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Advantages of Jigs and Fixtures

Productivity: jigs and fixtures eliminate individual marking process, positioning and frequent checking. This reduces operation time and increases productivity Interchangeability: jigs and fixtures facilitate uniform quality in manufacture. There is no need for selective assembly. Any parts of the machine fit properly in assembly, and all similar components are interchangeable.

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Skill Reduction: jigs and fixtures simplify locating and clamping of the workpieces. Tool guiding elements ensure correct positioning of the tools with respect to the workpieces. There is no need for skillful setting of the workpiece of tool. Cost Reduction: higher production, reduction in scrap, easy assembly and savings in labor costs result in substantial reduction in the cost of workpieces produced with jigs and fixtures.
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Limits and Fits

The largest and the smallest of the shaft (or hole) are called the high and low limit, respectively. The difference between these limits, i.e. the permission variation, is called tolerance. If tolerance is allowed only on one side of the nominal dimension it is called unilateral. For example, 20.00 +0..02 has got 0 00 unilateral tolerance. If tolerance is allowed on both sides of the nominal dimension (e.g 20.00 +0..01 it is called bilateral. 0 01
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Classification of Fits
Running fits: this provides for easy rotation as well as axial movement of shaft (male part) in hole (female part). It is used for bearing diameters of rotating shafts. Locators in production devices are made running fit with workpiece for quick loading and unloading. Push fit: this fit requires light hand pressure or tapping for assembly of the mating parts. It is used mainly for precise assembly of replaceable locators in jigs and fixtures.
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Press Fit: the mating parts are assembled y hammering or with a press. There is a positive interference between the hole and the shaft. This prevents rotary as well as axial movement between the assembled parts. Force Fit: this is used for permanent assemblies such as wheels and hubs on shaft force fit parts require heavy pressure for assembly.
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The clearance or interference provided for obtaining the various fits is called allowance.

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In shaft basis of fits the diameter of the shaft is kept constant while that of the hole is varied. In hole basis, the hole size is kept constant and the shaft size is varied to obtain the various fits. The tolerance depends upon the mating diameter sizes. The distribution of the tolerance is specified by alphabets. Holes are specified by capital letters A,B,C,D, etc. whereas shafts are specified by small letters a,b,c,d, etc.
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The alphabets are suffixed by digits 1,2,3,4,5 .16 showing the grade of accuracy. Digit 1 signifies the highest accuracy and digit 16 the least.

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In tool making accuracy grades 7 to 11 have been found most convenient. Generally unilateral H type tolerance distribution is preferred. Most of the accurate holes are made to H7 limits which can be obtained by careful reaming. For mass production, the less accurate H8 holes are used.
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The following combinations are widely used in tool making.

For example for a 20 H7 hole, the shaft should be:

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Materials used in Jigs and Fixtures

Jigs and fixtures are made from a variety of materials, some of which can be hardened to resist wear. Given below are the materials often used in jigs, fixtures, press tools, collects, etc.
High Speed Steels (HSS) Die Steels Carbon Steels Collet Steels (Spring Steels) Oil hardening Non-Shrinking Tool Steels (OHNS) Case Hardening Steels High Tensile Steels Mild Steel Cast Iron Steel Castings Nylon and Fibre Phospher Bronze

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Materials used in Jigs and Fixtures

Common materials used in jigs and fixtures construction; Cast iron It used for tool bodies and some commercial of jig and fixture components. The advantages of this material, it can absorb vibration during machining operations. Carbon Steel Carbon steel is the primary material of jig or fixture tooling. Its ease of fabrication, low cost, availability and versatility have made it popular for tool construction. There 3 types of this steel as follows: Low Carbon Steels Medium Carbon Steels High Carbon Steels
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Materials used in Jigs and Fixtures

Low Carbon Steels Low Carbon Steels are used mainly for structural part of a jig or fixture. They should only be used in areas where mass is required and no wear or stress will occur such as base plate or support plate. The carbon contents of this steel is between 0.05 to 0.30 percent, which is allow cast hardening to resist wear for low production tools. Medium Carbon Steels It used in much the same way as low carbon steels, but in areas of tooling require more strength. It works well as clamps, studs, and nut and in almost any area where toughness is required. The carbon contents are between 0.3 to 0.50 percent. It can be hardened by case hardening or other conventional hardening processes.
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Materials used in Jigs and Fixtures

High Carbon Steels High Carbon Steels are generally limited to tool constructions in areas that are subject to most wear. Parts such as drill bushings, locators for clamp, wear pads, and supports can be made of this material. The carbon contents are between 0.50 to 2.0 percent and easily hardened by conventional hardening process.

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Basic Type and Function of Jig & Fixture

Outcomes After completing this topic student should be able to:Identify the classes of jigs & fixtures. Identify the types of jigs and fixtures. Choose a class and type of jig and fixture for selected operations on sample parts.

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Classes of Jigs
Divided into 2 classes: - boring & drill Boring jigs are used to bore holes that either are too large to drill or must be made an odd size Drill jigs are used to drill, ream, tap, chamfer, counterbore, countersink, reverse spotface or reverse countersink. The basic jig is almost the same for either machining operation. The only difference is in the size of the bushings used.
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Classification of Fixtures
Fixtures are normally classified by the type of machine on which they are used. Fixtures can also be identified by subclassification. For example, if a fixture is designed to be used in a milling machine, it is called a milling fixture.

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Template Jig

Workpiece

Template Jig

Normally used for accuracy rather than speed. This type of jig fits over, on, or into the work and is not usually clamped. Least expensive and simplest type of jig.
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Plate Jig
Similar to templates The difference is that plate jigs have built-in clamps to hold the work. This jig can be made with or without bushing, depending on the number of parts to be made. Sometimes made with legs to raise the jig off the table for large work.
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FGB40103 - Jigs & Fixtures Design

Sandwich Jig

A form of plate jig with a back plate. Ideal for thin or soft parts that could bend or warp in another style of jig.
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Angle - plate Jig

Used to hold parts that are machined at right angles to their mounting locators. Pulley, collars, and gears are some of the parts that use this type of jig.
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Box Jig

Usually totally surround the part. This style of jig allows the part to be completely machined on every surface without the need to reposition the work in the jig.
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Channel Jig
The simplest form of box jig. The work is held between two sides and machined from the third side.

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Leaf Jig
A small jigs with a hinged leaf to allow for easier loading and unloading. The differences between leaf jigs and box jigs are size and part location. Leaf jig normally smaller than box jigs Usually equipped with a handle for easier movement
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Indexing Jig
A jig that is specifically designed to locate a part in multiple positions, one after another. Indexing jigs are often used to drill holes around the surface of a cylindrical workpiece.
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Plate Fixture with hydraulic Swing clamps

Simplest form of fixture. The basic fixture is made from a flat plate that has a variety of clamps and locators to hold and locate the part.
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Angle-plate fixture
Is a variation of the plate fixture. With this tool, the part is normally machined at a right angle to its locators.

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Vise-Jaw Fixture
Used for machining smalls parts. With this type of tool, the standard vise jaws are replaced with jaws that are formed to fit the part.

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Indexing Fixture
Similarly to indexing jigs. These fixtures are used for machining parts that must have machined details evenly spaced.

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Multi-station Fixture
Used primarily for high speed, highvolume production runs, where the machining cycle must be continuous.

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Profiling Fixture
Used to guide tools for machining contours that the machine cannot normally follow. Since the fixture continuously contact the tool, an incorrectly cut shape is almost impossible.
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