Design of Jigs, Fixtures and Press Tools UNIT 1: Locating and Clamping Principles

DESIGN OF JIGS, FIXTURES and PRESS
TOOLS
UNIT 1: Locating and Clamping Principles
Subject Code: ME8095
VARTHINI RAJAGOPAL
ASSISTANT PROFESSOR
DEPARTMENT OF MECHANICAL ENGINEERING
GOVERNMENT COLLEGE OF ENGINEERING SRIRANGAM
TIRUCHIRAPALLI
Course Reference
Joshi, P.H. “Jigs and Fixtures”, Second Edition, Tata McGraw Hill
Publishing Co., Ltd., NewDelhi, 2010.
Venkataraman. K., “Design of Jigs Fixtures & Press Tools”, Tata McGraw
Hill, New Delhi, 2005.
PSG College of Tech., “Design Data”
2 Tuesday, October 26, 2021

Tool VS Tooling
Machine Tool
Machine tools refer to the cutting/ shaping aids that are required to make a
product of desired shape and size.
Example: single point cutting tool, end mill cutter, drill bit, etc.
Tooling
Tooling refer to the accessories/ hardware that aid tools in producing a
component.
 Tooling can be classified into three types depending on scale of production
Prototype tooling: For low volume test run production
Bridge tooling: for mid range production run
3 Production tooling: for mass production Tuesday, October 26, 2021
ProductionTooling
Production devices/tooling are generally work holders with or without
tool guiding/ setting arrangement.
These includes cutting tools, Press tools, Dies, Jigs and Fixtures and
Gauges
These toolings are used for mass production with the aim of promoting
interchangeability, save production time, maintaining dimensional
accuracy and reducing tolerance errors.
These tooling make sure that the final part and other components are
manufactured within a certain tolerance as specified by design engineer.
Tuesday, October 26, 2021
4
Tool design
Tool design is the process of designing and developing the tools methods
and techniques necessary to improve the manufacturing efficiency and
productivity.
The objectives of tool design
To lower manufacturing costs while maintaining quality and increased
production by cutting down the time between the different machining
operations.
To provide simple, easy-to-operate tools for maximum efficiency.
To reduce manufacturing expenses by producing parts at the lowest possible
cost.
 To design tools which consistently produce parts of high quality.
To increase the rate of production with existing machine tools.
To design fool-proof tool that prevents improper use .
To select material that will give adequate tool life.
Jigs Jigs and Fixture
Functions: A jig is a work holding device which locates and holds the component for a
specific operation.
It is also provided with tool guiding elements.
It is usually lighter in construction.
 These direct the tool to the correct position on the workpiece.
It is rarely clamped to the machine table because it is necessary to move on the table to
align the bushes in the jig with a machine spindle .
Jigs are used on drilling, milling, reaming, tapping and counter boring operations.
Fixture
Functions: A fixture is a work holding device which only holds and positions the
workpiece.
Sometimes there is a provision in the fixture for setting the tool with respect to the
workpiece but it does not guide the cutting tool as in jig.
Fixtures are most often clamped to the machine table and are heavier in construction.
6 Fixtures are used in turning, milling, grinding, shaping, planning and boring operations.

Representation of workpiece and tooling
A jig or fixture drawing shows the
workpiece in position with the jig and
fixture.
The workpiece is drawn in chain-dotted
line preferably in colour (red, green or
blue) which can be easily distinguished
from the black line work of the fixture or
jig drawing.
 The workpiece drawn in fixture object
drawing is considered transparent.
 As a result locators, studs or other parts
of the fixture passing through the
workpiece are drawn in full lines instead
of dotted .
7 Tuesday, October 26, 2021
Similarly the parts of the fixture placed
Elements of Jigs and Fixtures
Locating elements:
The workpiece to be machined must be easily loaded and quickly unloaded from the
jig or fixture and each workpiece in a batch or flow production should be accurately
positioned with respect to jig/ fixture to achieve precision.
The locating elements enable in the establishment of a proper relationship between
the workpiece and the jig or fixture.
Locating elements are used to position the workpiece accurately with respect to the
tool guiding or setting elements in the fixture.
The locating elements also supports the workpiece and constraints or restricts the
degree of freedom of the workpiece.

Location
Clamping elements:
The clamping elements hold the workpiece securely in the located position during
the operation and hold it against the action of cutting forces.
The main purpose of the clamping element is to exert force on to the workpiece
against the locating surfaces thereby constraining the degrees of freedom of the
workpiece.

Tool guiding and setting elements:
These elements guide or set the tool in correct position with respect to the work
piece.
In drilling jigs, the tool guiding elements include the hardened bush that is fastened
into the sides of the jig to guide the tool to a proper position in the workpiece.
In fixtures, setting pieces are used for correct positioning of the milling cutter with
respect to the workpiece.

Body:
The jig body is generally made of cast iron by casting process or fabricated by
welding together various slabs and bars of mild steel.
 It may be heat treated to relief the stresses.
Body is the most prominent feature of the jig. Its main purpose is to support and
house the job.

Location
Dimensions of a product in a drawing sheet can be of two types.
Size dimension provides overall length of the part or the diameter of the hole or the
size of a feature.
Location dimension provides the relative position of a feature in the component
with respect to datum (represemted by a shaded triangle with an alphabet in a box)
which can be a centre line or base line or a finished surface.

Location
Common types of location:
Plane location is the act, or process, of locating a
flat surface. Plane location is simply locating a
workpiece with reference to a particular surface or
plane
Concentric location is the process of locating a

workpiece from an internal or external diameter.
Radial location normally is a supplement to

concentric location. With radial location, the
workpiece is first located concentrically, then a
specific point on the workpiece is located to
provide a specific fixed relationship to the Tuesday, October 26, 2021
concentric locator
Locators
Determination of the locating points and clamping points in the workpiece is an
important consideration in the design of tooling.
Locators are the elements that ensure that the component is loaded correctly with
respect to the jig/fixture as well as in relation to the tool and constraints all/some
degrees of freedom of the workpiece
Principle of locators:
Principles of Six point Location
Principle of least point
Principle of Extreme positions
Principle of mutually perpendicular planes
Principle of fool proofing
The two main aspects of locators in jigs or fixtures are
To constraint the degrees of freedom of the component by supporting the component.
To avoid any reductant feature in the locating scheme by serving as datum.
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Principles of Six point Location
Parallelopiped has 12 degrees of freedom in space namely six translations along X-X,
Y-Y and Z-Z axes and 6 rotational movements about the 3 axes namely pitch, yaw
and roll.
In order to provide constraints to the body which has parallel and right angled plane
faces, in this principle, the three adjacent locating surfaces of the blank (workpiece)
are resting against 3, 2, and 1 pegs (locators) respectively, which prevent 9 degrees of
freedom.
The rest three degrees of freedom are arrested by three external forces usually
provided directly by clamping.
Three pegs in the X-Y plane, 2 pegs in the X-Z plane and one peg in the Y-Z plane
are provided and hence, this principle is also known as 3-2-1 location principle

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Three Pegs A,B and C in X-Y plane
 Supporting/balancing a workpiece on 3 points
is considered to be better than the one or two
points. Hence 3 pegs A,B and C are used along
X-O-Z plane.
 These three pegs should form an isosceles

triangle at the horizontal plane and should be
placed as far as possible from each other;
thereby achieving absolute constraint in
rotation.
 The three pegs A,B,C arrest 5 degrees of

freedom motion.
1)Peg C arrests the Motion 5 (Z-Z translation
down) in the fig. Tuesday, October 26, 2021
7 2)Peg A arrests the Motion 1-2 in fig (rotation
Two pegs D and E in X-Z plane
The two pegs D and E in the X-Z plane should
be provided midway in the height of the
component ensuring absolute constraint in
rotation.
Two locating pins D and E arrest 3 Directions
Pin D would arrest the translation motion along
the y-axis (Left) i.e. Motion 8 in the fig
Pin E would arrest the rotary motion about the z-
axis (Motion 6 -7 in the fig.).
One peg F in Y-Z plane
Peg F in Y-Z should be provided midway in the
height of the component so that the translation
motion along the X axis is constrained
Principle of Foolproofing
The main objective of designing a jig/
fixture in mass production is to employ
semi skilled labour instead of skilled
labours.
When semi skilled labours are deployed, the
design has to be made fool-proof such that
the locators used should always correctly
load the component with respect to the
jig/fixture and also in relation to the tool or
cutter.
For example, in case of unsymmetric
components in order to ensure an unskilled
or semi skilled worker to load the
component correctly, certain locators or
9 pins are introduced such that there is only Tuesday, October 26, 2021
one unique way of loading.
Principle of Least Points
According to this principle only minimum locating points should be used to secure
the location of workpiece in any one plane.
Providing additional locators which are redundant will not only increase the cost of
manufacture but also increase the chance of errors in locating a component.
Principle of Extreme positions
Locating Points should be placed as far as possible to minimize the inaccuracies and
for better stability.

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Principle of Mutually Perpendicular Planes
Locating surfaces must be perpendicular. Otherwise, 1. The workpiece tends to rise
due to wedge action. 2. The chips or dirt may clog between the pin and locating
surface, that can further magnify the error.

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DESIGN OF JIGS, FIXTURES and PRESS

2 Tuesday, October 26, 2021

8 Tuesday, October 26, 2021

9 Tuesday, October 26, 2021

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Concentric location is the process of locating a

Radial location normally is a supplement to

Tuesday, October 26, 2021

 These three pegs should form an isosceles

 The three pegs A,B,C arrest 5 degrees of

Tuesday, October 26, 2021

Tuesday, October 26, 2021

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