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Manufacturing Tooling5. Jig Design
Nageswara RaoPosinasetti
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Fixture
A fixture is a means through which apart is securely fastened to themachine tool table to accurately locate,support and hold the part during themachining operation.
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Jig
A jig is a special class of fixture, whichin addition to provide all the functions
as above, also guides the cutting toolduring machining.
This is generally used for theoperations such as drilling, boring,reaming, tapping, counter boring, etc.
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Typical jig used for boring operation
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Drill Jigs
Provide methods forCorrectly locate the workpiece with
respect to the tool
Securely clamp and rigidly support theworkpiece during the operation
Guide the tool
Position and/or fasten the jig on amachine
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Drill Jigs
Advantages
Minimize tool breakage
Minimize the possibility of human error
Permit the use of less skilled labor
Reduce manufacturing time
Eliminate retooling for repeat orders
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Machine Considerations
Horsepower
Size limitations
Weight limitations
Cutting Tools
Special Machinery
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Process Considerations
Type of Operations (drilling,reaming,other)
Number of Operations
Similar vs. different
Sequential vs. simultaneous
Sequence
Inspection Requirements
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Jig Bushes
To position and guide the cutting toolfor cutting.
Materials
Hardened steel
Carbide
Bronze
Stainless steel
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Headless Bush
Most popular andleast expensive
Light axial load isexpected
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Clearance between Bush and Part
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Headed Drill Bush
Jig plate can be thinner
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Slip Renewable Bush
Used for multipleoperations such asDrilling followed by
reaming
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Drill bushing position for angular drill entry
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Fig. 5.43 Drilling irregular work surfaces
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Jig Components
Locators
Clamps
Jig plate with bushes
Jig body
Other elements as required
Supports
Jig feet
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Types of Jigs
Template jigs
Plate jigs
Universal jigs
Leaf jigs
Channel and tumble jigs
Indexing jigs
Miscellaneous jigs
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Template jigs
No clamping arrangement
Plates with bushing to guide the tool
Directly placed on the part
Simple
Least expensive
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Nesting Template Drill Jigs
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Template jigs
Disadvantages
Not as foolproof as other types
Orientation of the hole pattern toworkpiece datums may not be as accurateas other types
They are usually not practical whenlocating datums are dimensioned
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Plate jigs
A template jig with workpiece clampingsystem
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Plate Jig
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Plate Drill Jig
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Fig. 5-7 Plate jigs
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Fig. 5-7 Plate jigs
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Fig. 5-7 Plate jigs
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Fig 5-8 Angle plate jigs
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Fig 5-8 Angle plate jigs
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Universal jigs
Also called as Pump jigs
Universal that can be used for anygiven part by adding the necessarylocators and bushes
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Leaf jigs
Small
Hinged leaf with bushes which alsoapplies the clamping force
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Channel and tumble jigs
For drilling in more than one surface
Complicated and expensive
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The example illustrated was designed to drill 4holes equi-spaced around the tapered hub of ahand-wheel at right angles to the hub diameter.
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Indexing jigs
To drill holes in a pattern
Indexing arrangement
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Miscellaneous jigs
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Drill Jig with R H Component
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Drill Jig with L H Component
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Drill Jig with R H Component unassembled
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Drill Jig with R H and L H Componentssimultaneously
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Pot Drill Jig
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Pot Drill Jig
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Jig Design Guidelines
Drill Jigs should be of lightconstruction, consistent with rigidity tofacilitate handling, especially when jigshave to be turned over so that holescan be drilled from more than one side.
All unnecessary metal should be coredout of the jig body.
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Jig Design Guidelines
A jig which is not bolted to the machine tableshould be provided with feet, preferably four,opposite all surfaces containing guidebushings, so that it will 'rock' if not standingsquare on the table and so warn theoperator.
Clearance holes or burr slots should beprovided in the jig to allow for the burrformed when the drill breaks through thecomponent and for swarf clearance,particularly from locating faces.
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Jig Design Guidelines
Make all component clamping devices asquick acting as possible.
Design the jig fool-proof by the use of foulpins and similar devices, that is arrange it sothat the component, tools or bushes cannotbe inserted except in the correct way.
Make some locating points adjustable whenthe component is a rough casting and maybe out of alignment.
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Jig Design Guidelines
Locate clamps so that they will be in the bestposition to resist the pressure of the cuttingtool when at work.
If possible, make all clamps integral parts ofthe jig and avoid the use of loose parts.
Avoid complicated clamping and locatingarrangements which are liable to wear orneed constant attention.
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Jig Design Guidelines
Place all clamps as nearly as possibleopposite some bearing point of thecomponent to avoid springing thecomponent and in accessible positions.
All sharp edges should be removed from thevarious detail parts of the jig.
Provide handles or other devices whereverthese will make the handling of the jig more
convenient.
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Jig Design Guidelines
If possible, place all tool guide bushingsinside the geometrical figure formed by
connecting the points of location of the feet. Make, if possible, all locating points visible to
the operator when placing the component inposition in the jig so that the component canbe seen to be correctly located. The operatorshould also be able to have an unobstructedview of the clamps.
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Jig Design Guidelines
Before using the jig in the machine shop forcommercial purposes, test all jigs as soon asthey are made.
The location points, which are hardened ifnecessary, are established withconsiderations to machining operations, ifany, to follow and that any mating parts arelocated from the same datum surface.
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Jig Design Guidelines
Locating and clamping arrangements aredesigned to reduce idle time to a minimumby using simple clamps which are easy andquick to operate and also operate withoutdamaging the component.
Springs should be used whenever possibleto elevate the clamps clear of the componentwhilst being loaded or unloaded.
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Jig Design Guidelines
Clamps should be positioned abovethe points supporting the component,
in order to avoid distortion and shouldbe strong enough to hold thecomponent without bending.
Generally clamps should not be reliedupon for holding the work against the
pressure exerted by the cutting tool.
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Jig Design Guidelines
Locating and supporting surfacesshould, whenever possible, berenewable.
Such surfaces should be of hard material.
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Jig Design Guidelines
The process of inserting andwithdrawing the component from the jigshould be as easy as possible.
Ample space should be left between thejig body and the component for handmovements.
Some means of ejection should exist torelease the component if it sticks in the jig.
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Jig Design Guidelines
The design of the jig must be safe.
Handles or levers should be large enough
to clear adjacent parts so that pinchedfingers are avoided.
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Jig Design Guidelines
If necessary, make provision for theuse of coolant.
Position locations at places wherethere is no flash or burr on thecomponent.
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Jig Design Guidelines
If possible, eliminate spanners by theuse of levers.
If spanners have to be used, make onespanner fit all the clamp operating boltsand nuts.
Consideration should be given at thedesign stage to the use of standardisedjig components.
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Power requirement for Drilling
d = drill diameter, in
K, A, B, E - Constants
8.18.0, dfAKMTorque =
28.08.02, dEKdfBKTThrust +=
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Basic Design Steps
1. Method of locating the part identify thestandard components required for locatingpurpose.
2. Design the clamping method. Make aproper choice of clamps C-washer, swingwasher, nut, strap clamp, toggle clamp, etc.
3. Design any supports required
4. Design the jig bushes required.
5. Design the jig body.
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Design Study Drill Jig
1. Method of locating the part Thecentral hole which helps in locating aswell as indexing for the hole.
2. Clamping can be done with a nut
and a C-washer
Indexing will have to be done with aplunger type retracting.
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For locating 5/8 inhole
Forlocatingin the jigbody
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For locating 5/8 inhole
Forlocatingin the jigbody
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