Design of Jigs

UNIT 3 DESIGN OF JIGS

Structure
3.1 Introduction
Objectives

3.2 Design of Jigs

3.2.1 Elements of Jig
3.2.2 Design Consideration in Jigs
3.2.3 Presentation of Workpiece
3.2.4 Location
3.2.5 Principles of Location
3.2.6 Location Methods
3.2.7 Clamping
3.2.8 Drill Bushes
3.2.9 Jig Feet and Legs
3.2.10 Chip Control

3.3 Types of Jig and Examples

3.4 Summary
3.5 Key Words

3.1 INTRODUCTION
Mass production targets on increasing productivity and increasing accuracy by reducing
the setup cost and manual fatigue. One of the common practices to achieve the goals of
mass production is to use jigs. Let us consider an example that one gets an order of 1000
product in such a way that three holes are to be drilled in a workpiece. In such situations,
designer will lay out the position of each hole with the help of square, straightness,
scribers, centre punch etc. Generally, trial and error method is practiced until the axis of
hole is properly aligned with the axis of drill. Thus, a lot of time will be consumed to
maintain the accuracy. Ultimately it increases operator’s fatigue. Thus, instead of laying
out the position of each hole on each workpiece with the aid of square, straightness,
scribers, centre punch etc., the operator uses a jig to position and guide the drill into
proper place. Drill jig increases productivity by eliminating individual marking,
positioning and frequent checking. Interchangeability is one of the advantages of jigs.
There is no need for selective assembly. Any of the parts will fit properly in the assembly
and all similar components are interchangeable. In addition, a jig reduces the repetitive
nature required for drilling a hole, as the locating, clamping and guiding are done by jig
itself. The tool-guiding element helps in setting of tool in correct position. Hence, skilled
workers are not required. Drill jig makes it possible to drill, ream and tap holes at much
faster speed and with great accuracy as compared to holes produced by conventional
hand methods. The responsibility for accuracy of hole location is taken from the operator
and given to the jig.
Jig can be defined as a workpiece holding and locating device that positions and guides
or controls the cutting tool. Drill jig is device to ensure a hole to be drilled, tapped or
reamed in the workpiece at proper place.
Drill jig consists of a clamping device to hold the part in the position under hardened
steel bushings. Drill passes through the steel bushings during drilling operation. The drill
is guided by these bushings. Generally workpiece is held by jig and the jig is arranged in
such a way that the workpiece can be quickly loaded and unloaded.

35
Design of Cutting Objectives
Tools and Holding
Devices After studying this unit, you should be able to
• know different types of locating elements,
• know different types of clamping elements,
• know different guiding elements,
• design various types of jigs, and
• differentiate various types of jigs.

3.2 DESIGN OF JIGS

3.2.1 Elements of Jig
Jig generally consists of locating element, clamping element and tool guiding or setting
element.
Locating Elements
Locating elements position the workpiece accurately with respect to tool guiding
elements in the jig.
Clamping Elements
Clamping elements hold the workpiece securely in the located position during
operation.
Tool Guiding Elements
Tool guiding elements help in guiding the tools in correct position with respect to
the workpiece. Drill bushes guide the drills accurately to the workpiece.
3.2.2 Design Consideration in Jigs
(a) The main frame of jig must be strong enough so that the deflection of jig is
as minimum as possible. This deflection of jig is caused due to the forces of
cutting, clamping of the workpiece or clamping to the machine table. The
mainframe of the jig should have the mass to prevent vibration and chatter.
(b) Frames should be built from simple sections so that frames can be fastened
with screws or welded, whenever necessary. Those parts of the frame that
remain intact with the jig may be welded. The parts needing frequent
changing may be held with the screws. Where the body of jig or fixture has
complex shape, it may be cast from good grade of cast iron.
(c) Clamping should be fast enough and require least amount of effort.
(d) Clamps should be arranged so that they are readily available and may be
easily removed.
(e) Clamps should be supported with springs so that clamps are held against the
bolt head wherever possible.
(f) If the clamp is to swing off the work, it should be permitted to swing as far
as it is necessary for removal of the workpiece.
(g) All locators, clamps should be easily visible to the operator and easily
accessible for cleaning, positioning or tightening.
(h) Provision should be made for easy disposal of chip so that storage of chips
doesn’t interfere with the operation and that their removal during the
operation doesn’t interfere with the cutting process.
36
 (i) All clamps and support points that need to be adjusted with a wrench should Design of Jigs
be of same size. All clamps and adjustable support points should be capable
of being operated from the fronts of the jig.
(j) Workpiece should be stable when it is placed in jig. If the workpiece is
rough, three fixed support points should be used. If workpiece is smooth,
more than three fixed support points may be used. Support point should be
placed as farthest as possible from each other.
(k) The three support points should circumscribe the centre of gravity of the
workpiece.
(l) The surface area of contact of support should be as small as possible without
causing damage to the workpiece. This damage is due to the clamping or
work forces.
(m) Support points and other parts are designed in such a way that they can be
easily replaced on failure.
3.2.3 Presentation of Workpiece
The representation of workpiece is shown in Figure 3.1. The workpiece is shown by
chain dotted line. This is because workpiece is assumed to be transparent. The elements
of jig such as clamps, locators, supports etc. are shown by continuous line.

Workpiece

Locator

Figure 3.1 : Representation of Workpiece

3.2.4 Location
One of the most important requirements of a successful jig design is that when workpiece
is machined and removed from the jig, the operator should be able to put another
workpiece quickly into jig, clamp it and machine it to the dimensions with given
tolerance.
3.2.5 Principles of Location
(a) Relate the location to dimensional requirements of workpiece.
(b) It is preferable to use most accurate machined surface for location. If there is
variation on the selected surface, the new surface will also contain variations
and one can get workpiece with defects. If most accurate machined surface
is not available, select better machined surface out of available machined
surfaces. Figure 3.2 shows how to select accurate surface for location.
(c) Prevent motion along and around X, Y, Z.
(d) Location system should provide easy and quick loading and unloading of
workpiece with minimum motions.
37
Design of Cutting (e) Avoid redundant locators. Redundant locator means more locators are
Tools and Holding provided than required for support. If three supports are sufficient and one
Devices
places four supports also, then fourth support is redundant. There are stool
stands on four legs. But stool can also stand comfortably on three legs. In
this case fourth leg is redundant one.
(f) Prevent wrong loading of workpiece by fool-proofing.

Z Z

X X

(a) (b)

Figure 3.2 (a) and (b) : Principle of Location

In order to locate the workpiece successively in holding device in the same plane, the
device should provide control through six degrees of freedom in space. Six degrees of
freedom refers to three linear motions and three rotational motions in the space. The
movement along and around three mutually perpendicular axis is shown in Figure 3.2(a).
When these six motions are controlled then only design of jig is said to be good. The
steel block floating in the space is shown in Figure 3.2(b). Here the block is free to move
or rotate in any direction along or around three axes. If obstruction is placed in path of
these motions, it will eliminate degrees of freedom. The steel block is resting on three
supports as shown in Figure 3.2(c). Hence, block is unable to move along z-axis. Also,
block is unable to rotate about x- and y-axis. But, the block moves along x- and y-axis
while rotate about z-axis only.

Pin
Workpiece

Figure 3.2(c) : Principle of Location

Similarly by adding two buttons (marked 2 as shown in Figure 3.2(d)), it is possible to

prevent linear motion of block along y-axis and also rotational motion around z-axis. In
addition, adding pin (marked 3) as shown in Figure 3.2(e), it is possible to prevent the
motion of block along and around three mutually perpendicular axes.

38 2 Pins
Workpiece
Pin
 Design of Jigs
F
E

B C 3 Pins

(d) (e)
Figure 3.2 (d) and (e) : Principle of Location
Figure 3.2(e) also explains 3-2-1 principle of location. This 3-2-1 principle states that “a
workpiece will be completely confined when placed against three points in one plane,
two points in another plane and one point in third plane if the planes are perpendicular to
each other”. Workpiece should be supported on three buttons support for any holding
device.
To achieve dimensional requirement, proper surface for location is selected. Figure 3.3
shows how to select surface to achieve dimensional requirement. Here hole C is at larger
distance from surface B as compared to surface A. Also hole depends upon one
parameter from surface A, i.e. on distance D while hole depends upon two parameter
from surface A i.e. on distance D as well as distance L. If surface B (if it has some errors)
is selected as a reference surface, error will accumulate on final dimension. Hence, best
choice is to select surface A for location.
A

Hole C D

Figure 3.3 : Dimensional Requirement

It is preferable to use most accurate machined surface for location. If there is variation on
the selected surface, the new surface will also contain variations and we get workpiece
with defects. If most accurate machined surface is not available, select better machined
surface out of available machined surfaces. Figure 3.4 shows how to select accurate
surface for location.

Figure 3.4 : Accurate Surface

39
Design of Cutting Loading and unloading should be easy and quick. Figure 3.5 shows principle of motion
Tools and Holding economy. Principle of motion is selecting surface for location with minimum motions.
Devices
Here we will have to drill two holes namely A and C. We can drill hole by two ways:
First drill hole A and then drill C. Here as the axis of hole A and B is same, our first task
is to align the axis of A with B. By locating hole B by pin (restricts the movement along
the axis), we can first drill hole A. Then hole A is used for location to drill hole C. And
by removing the pin the work is completed. Hence there is only one motion to complete
the work.

Figure 3.5 : Motion Economy

In the second case, Drill hole C first and then drill hole A. If we drill hole C, we will
have to lock its movement. Hence, here movement is more. Thus, we will go for drilling
of hole A first and then hole C. Therefore, first select the surface which gives minimum
motion in order to reduce loading and unloading time that will automatically reduce
operator’s fatigue.
If the workpiece is like as shown in Figure 3.6(a), we will get different orientation. The
other orientation is shown in Figure 3.6(b). Reorientation is very difficult to avoid even
after locating the workpiece. In such situation, pin is provided to obstruct the movement
of workpiece. This pin is shown in Figure 3.6(c).
Support Pin for Fool Proofing

Workpiece

(a) (c)

Support

(b)

Figure 3.6 : Foolproofing

3.2.6 Location Methods

A workpiece can be located from
(a) Plane surface
(b) Profile surface
(c) Cylindrical surface
40
Plane Surface Design of Jigs

A plane surface can be located by three pins. The pin locator is shown in
Figure 3.7. A rough surface can be located by means of location pads having point
contact. This is achieved by providing spherical surface at the locating point on
locating pins. Pins should be located as wide as possible from each other. The
height of pins should be equal so that the located surface is parallel to the base
plate. This base plate is rested on machine table.

Figure 3.7 : Pin Locator

If workpiece is undersize or oversize, the fixed pin should not provide adequate
support. Adjustable locator can take care of variation in workpiece. This adjustable
pin locator is shown in Figure 3.8. An adjustable pin takes care of uneven surface
also. There should be provision for collection of chips. Sometimes 3-2-1 principle
is not useful for larger workpiece. Hence, extra workpiece should be used to
maintain stability and rigidity.

Adjustable

Locator

Figure 3.8 : Adjustable Pin Locator

Profile Surface
The profile is generally located by means of sighting plate. Sighting plate is
slightly greater than workpiece. The workpiece is located by means of sighting
plate and is shown in Figure 3.9. There is generally uniform clearance in between
workpiece and sighting plate. Sighting plate provides visual justification of surface
of workpiece.

Clearance

Sighting Plate

Figure 3.9
41
Design of Cutting The profile is also located by means of pin as shown in Figure 3.10. These pins act
Tools and Holding as a restriction to the movement of the workpiece.
Devices
Pin Acts as a Restriction

Pin

Figure 3.10 : Pin Locator for Profile

Cylindrical Surface
Location for cylindrical surface is the most common and convenient form of
location. When cylinder is located on its axis and base, it can rotate only about its
axis and all other motions are constrained. Cylindrical locator is shown in
Figure 3.11. The length of locator should be small to prevent jamming. As large
area comes in contact with workpiece surface, friction may occur. Hence, more
force is required to remove the locator. By providing relief, the force is minimized
to great extent. Also, recess will help in removing burr.

Pin
Lead

Recess for Burr

Press Fit
Figure 3.11 : Diamond Locator

Diamond Locator
Diamond shaped pin should be used to constrain pivoting of the workpiece around
principle locator. The principle locator should be longer than diamond pin so that
workpiece cannot be located and pivoted around it before engaging with diamond
pin. This will help in removing of the workpiece quickly. Figure 3.12 shows
locating the workpiece with diamond shaped pin. If two fixed pins are provided, it
will not accommodate the variation in the central distance of hole. This problem is
avoided by using diamond pin. Also one diamond pin is sufficient to position the
hole in the workpiece while other hole is positioned with the help of fixed pin.
Fixed Pin
Diamond Pin

Figure 3.12 : Locating Workpiece by Diamond Locator

The diamond locator should be positioned in smaller hole. As the width of

diamond pin is less than the diameter of diamond pin, the variation in the hole is
accommodated by diamond pin. The diamond pin locator is shown in Figure 3.13.
42
 Width Design of Jigs
Workpiece

Width < Diameter

Diameter
Diameter

Figure 3.13 : Diamond Pin Locator

V Locator
V locators are widely used for locating cylindrical surfaces from outside. Fixed
v-locator is shown in Figure 3.14. It is used for approximate location. It is
generally fixed by screws to jig body and dowelled to avoid any shift during
operation.

Align Screw

Dowels

Figure 3.14 : Fixed V Locator

By making V-locator adjustable along its axis, one can decide accurate location.
The position of V-block is adjusted by a screw to take care of the variation in the
size of the workpiece. An adjustable V-block is guided by a guide plate to control
its motion along the axis of V-block. The guide should be dowelled to avoid
shifting during the operation.

Screw

Guide Plate

Figure 3.15 : Adjustable V Locator

Conical Locator
Conical locators are extensively used for locating rough unmachined cylinders
generally made from castings and forgings. Cored holes and bosses are centralized
by conical locators. Conical locator is shown in Figure 3.16. 43
Design of Cutting
Tools and Holding
Devices

Guiding

Diameter

Cored Holes

Figure 3.16 : Conical Locator

Conical locators have axial adjustment with a screw, which is also used to clamp
the located workpiece in position. When casting has a single boss, which is to be
drilled, a bush is made integral bush with locator to help in drilling of the
workpiece in the desired position.
3.2.7 Clamping
Clamping is accomplished by clamps. Clamps hold the workpiece, which is firmly
engaged with locators during operation. The clamping system should be strong enough to
withstand forces developed during operation. At the same time, clamping force should
not damage the workpiece. The timing required for loading and unloading must be as
minimum as possible. Clamping must be positive when subjected to vibration, chatter
etc.
Clamp

Unclamped
Workpiece

Bending of Unsupported
Workpiece Due to Clamping

Figure 3.17 : Distortion of Unsupported Part

Principles of Clamping
(a) Clamps should be positioned in such a way that clamping force shall act as a
strong, supported part of the workpiece. Clamping on unsupported part
bends the workpieces as shown in Figure 3.17. This will affect the accuracy
of the operation. A vertical hole drilled in bent workpiece will become
angular when the unclamped workpiece come back to original shape as
shown in Figure 3.17 by dotted line.
(b) Clamping system should not obstruct the path of loading and unloading.
(c) Clamping system should be capable of holding the workpiece securely
against the forces developed during the operation. Also clamping system
should not damage the workpiece with excessive pressure. For clamping
weak workpiece, the clamping force should be distributed over larger area of
the workpiece. While clamping soft workpiece, clamp should be fitted with
pads of softer material such as nylon or fibre to prevent damage to the
workpiece.

44
 (d) Clamping time should be minimized by using handles, hand wheels, hand Design of Jigs
knobs, tommy bars, knurled screws etc. Clamp can be loosened or tightened
manually without using spanners because spanner will increase the motion
of picking, aligning etc.
(e) If the number of clamps are to be loosened or tightened repeatedly, then it is
preferable to use hydraulic or pneumatic clamping. This will reduce
operators fatigue and saves clamping time also. Power clamping provides
loosening and tightening simultaneously.
(f) The clamping points should be provided with sufficient radius. This radius
will take care of variation in the workpiece. Sphere heel pin is used to allow
tilting of the clamp. Clamping variable workpiece is shown in Figure 3.18.

Radius at a
Clamping Point Spherical
Washer

Workpiece
Spherical
Heel Pin

Figure 3.18 : Clamping Variable Workpiece

Spherical washers between clamp and nut will take care of the misalignment
between clamp surface and clamping nut due to tilting of nut. Two pairs of
washers have matching male female spherical seats. The spherical bearing permits
the washer to tilt with respect to each other. As the lower female washer tilts with
the clamp, upper male washer below the nut can remain square with the nut. The
clamping pressure from the nut to the clamp is transmitted by the spherical seat.
Types of Clamp
Strap Clamp
Strap clamp is simple and easy to operate, hence it is used extensively
everywhere. It is rectangular in shape and acts as a lever. The clamp is
tightened by rotating hexagonal nut on a central screw. Strap clamp is
shown in Figure 3.19. One end of clamp presses against the workpiece and
other on the heel pin, thus loading the clamps like simply supported beam.
The clamping face of the clamp is curved while press face of the heel pin is
of spherical shape to take care of variations in workpiece. The spherical
washers between the clamp and hexagonal nut provide a spherical joint,
which permits clamp to tilt with respect to the screw and the nut. Thus,
clamp will take care of variations in the workpiece. Generally, strap clamps
are provided with washer and a spring below the clamp.
Pin

Supporting
Pin

Figure 3.19 : Strap Clamp

45
Design of Cutting The spring lifts the clamp as the nut is loosened. The workpiece becomes
Tools and Holding free from even the gravitational load due to clamp weight. The spring holds
Devices
the clamp in a raised position during loading and unloading of the
workpiece.
Screw Clamp
Screw clamp has a screw thread to clamp a workpiece. The screw clamp has
knurled collar, head knob, tommy bar or spanner flats for rotating and
tightening the screw. Screw clamp is shown in Figure 3.20. Screw clamp
exerts adequate force. It also resists tendency of loosening set up by
vibration. But the disadvantage is that they are slow and may not be suitable
for high production. The screw clamp with pad is shown in Figure 3.20.
Bolt

Cover Plate

Figure 3.20 : Screw Clamp

Cross Pin

Pad

Figure 3.21 : Screw Clamp with Pad

C-Washer
C-washer is a strap clamp with open slot. This clamp is simple and quick in
operation. The slot permits removal of C-washer after a slight loosening of the
hexagonal nut. The pivot shoulder screw makes the C-washer captive. The cross
corner distance of the hexagonal nut should be less than the bore of the workpiece so
that it can permit the passage of the nut through bore during loading and unloading
the workpiece.
Cams
Cams are also easy to operate and quick in operation. Cam tends to shift their mating
faces. There is a risk of the cam clamp getting loose due to vibrations. The
coefficient of friction between the cam and mating surface must be taken into
account while determining the eccentricity of the cam. The eccentric pivoting of a
cylinder converts it to a cam. The eccentricity of the cam should be more than
1.5 times the variations in the workpiece. The outside diameter of eccentric depends
upon the coefficient of friction between eccentric and mating surface.
46
Toggle Clamp Design of Jigs

Toggle is also quick action clamps. Toggle cam is shown in Figure 3.22. These can
be withdrawn by considerable distance for loading and unloading of the
workpiece. These depend upon the movement of rigid links for their movement.
These clamps are used extensively to hold the sheet metal parts in position while
they are being welded or otherwise being fastened. They provide heavy clamping
pressure.

Guide

Workpiece

Figure 3.22 : Toggle Clamp

3.2.8 Drill Bushes

Jigs uses drill bushes for guiding the drill, reamer and other cutting tool to the workpiece.
Generally, these are made up of tool steel and are hardened to RC60 to 64 to provide
wear resisting surface. They are precision made, i.e. outside being ground and inside
either ground or lapped within 0.008 mm concentricity. Generally, the length of bush
should be twice the diameter of the bushing hole. The bushing hole should be very close
to the diameter of the drill but should not be so tight that drill will drag into the bushing.
There are three types of drill bushes.
Press Fit Bushes
These are the most common type of bushes and are pressed interference fit in the
bush plates, i.e. jig plates. The press fit bushes are further categorized into two
types: headed bushes and headless bushes. Figures 3.23(a) and (b) shows the
headed bushes and headless bushes. Headed bushes are generally preferred over
headless bushes because collar provides the stops against the jig plate. Also it is
found that chances of the bush getting loose in the jig plate and sliding axially with
the drill are lesser in collared bushes. But, when spacing of bushes is close,
headless bushes are preferred over headed one. In addition, as the top surface of
the jig plate is required free from projecting collars, the headless bushes are used.
The press fit bushes are also used as a liner for renewable bushes.

Precision Running Fit

Chamfer with Drill F7
Radius Precision
Running Fit
F7

Press Fit
in Jig
Press
Plate p6
Fit p6

Figure 3.23 : (a) Headed Press Fit Bush; and (b) Headless Press Bush

Renewable Bushes
The inside diameter of bush is subjected to severe wear due to continuous contact
with hard cutting tool for continuous or large batch production. The guide bushes
require periodic replacement. The replacement is avoided by making outside 47
Design of Cutting diameter precision location fit. The renewable bushes are shown in Figure 3.24. By
Tools and Holding providing flat on the collar the renewable bush should be prevented from rotating
Devices
and causing axial movement with the cutting tool. The flat arrests with the collar of
the retainer shoulder screw to avoid rotation. Also bush flange below collar of
shoulder screw avoids the bush getting lifted with cutting tool. The liner used in
the jig plate provides hardened wear resistant mating surface to the renewable
bush.

Retainer
Shoulder Screw
Renewable Bush

Figure 3.24 : Renewable Bush

Plate Bush
In plate bushes drilled hole themselves act as a bush. As shoulder is not provided,
holes can be placed as close as possible. Liner bushing is also called master
bushing. These are with head or without head. The liner bushing is shown in
Figure 3.25. This bushing eliminates the need for locking device.

Dowel

Plate Bush

Allen Screw

Figure 3.25 : Plate Bush

3.2.9 Jig Feet and Legs

A drill jig should stand on four legs instead of flat surface. If the jig stands on flat
surface, chips will get under flat surface and imbalance the jig. To avoid imbalance, jigs
stand on four legs. Jig legs may be built into the jig body or purchased as a standard part.
They should be placed on these legs so that all bushings are within the area covered by
legs, which are placed on extremes of the jig. Legs should be ground so that they all lie in
one plane after they are mounted on jig base.
• Coolant should reach to the drill. Sometimes coolant will come out from
sides instead of through drill bushing. There should be holes for escape of
coolant.
• Sharp corners and projection should be avoided.
• Jig should be large enough to enable the operator to hold the jig against the
torque of drilling machine.
• Jig should be as light as possible.

48
 • If the operators hands are covered with coolant then it is very difficult to Design of Jigs
hold the jig. Hence gripping surfaces should be knurled.
3.2.10 Chip Control
Two types of chip generally occur in drilling operation, viz. segmental and continuous
chip. Segmental chips are in the form of small particles. Segmental chips are produced
while drilling cast iron. Segmental type of chip is easy to remove from the drill jig.
Continuous chips are long and stringy and tend to take the form of long coils. These
chips are produced while drilling ductile steel. Enough space should be provided between
work and bottom of drill bushing. It will allow chips to pass between the workpiece and
bushing plate instead of through the drill bushing. This eliminates storing of chip in drill
flutes. This arrangement allows more coolant to reach the cutting edge of drill and helps
to prevent wear of drill bushings due to abrasion of chip. If the chips are continuous, they
may tangle between the workpiece and bushing and become very difficult to remove.
This is avoided by locating the bushing closer to work so that bushing will force the long
stringy chip through the bushing where any entanglement can be easily removed by the
operator.
Chips are removed from jig in three ways :
(a) Coolant helps to clean chips whenever they formed.
(b) Chips may be removed manually with the help of brush or hook.
(c) Chips may be removed by compressed air. Guards should be provided to
prevent scattering of chips throughout the working area.
SAQ 1
(a) What are various elements of jig? Explain
(b) State and explain 3-2-1 principle of location.
(c) State locating principle.
(d) Explain different types of locators.
(e) Where do you use diamond locator?
(f) State clamping principle?
(g) List various types of clamps with appropriate use.

3.3 TYPES OF JIG WITH EXAMPLES

Depending upon method of operation and construction, drill jigs can be broadly
classified as follows :
(a) Plate Jig
(b) Leaf Jig
(c) Box jig
(d) Indexing Jig
(e) Pump jig
Plate Jig
This is the simplest type of jig. Plate jig consists of single bush plate. This plate
has a provision of loading and unloading of workpiece, clamping and chip
removal. Figure 3.26 shows the construction of plate jig. The workpiece profile is
located by six location pins and clamp by two knurled screws against location pins.
In any drill jig the workpiece should be supported adequately against bending due 49
Design of Cutting to the downward thrust of drill. The disadvantage of plate jig is that only one
Tools and Holding surface can be drilled at one loading and drilling forces are generally directed
Devices
toward the clamping element. Hence, clamps should be rigid enough to withstand
drilling forces.

Align
Location Screw

Pins Jig Plate

Workpiece

Drill Knurled
Bush Screw

Figure 3.26 : Plate Jig

Box Jig
The shape of box jig is of box type. Figure 3.27 shows the construction of box jig.
The working of box jig is as follows: Hole is drilled and then reamed when the
workpiece is held by jig. The workpiece is inserted in the jig. The cam rod is taken
out of the jig and the workpiece placed in the position inside the jig. The cam rod
is then replaced and rotated to its locking position. This holds the workpiece firmly
so that drilling operation can be performed.

Drill Bushing
Cam Rod

Box Bushing

Workpiece

Cam

Figure 3.27 : Box Jig

Leaf Jig
These generally have hinged jig (bush) plate. The jig plate can be swung aside as
shown by dotted line in Figure 3.28 to load or unload the workpiece from the top.
After the workpiece has been located inside the jig, the leaf is firmly closed and
locked. The jig plate must have the resting face to ensure that the axis of bushings
is vertical during drilling. Jig plate must be clamped against the resting face by an
eye bolt. The open slot in jig plate and swinging eye bolt facilitate quick clamping
and unclamping of the jig plate. The hand knobs need to be loosened by only half a
50 turn and the eye bolt swung to the position shown by chain dotted line in order to
 permit swinging of the jig plate aside for loading and unloading of workpiece from Design of Jigs
the top. Leaf jigs are particularly suitable for workpieces having location surfaces
and holes to be drilled on opposite sides.

Hand
Knob Swinging

Jig Plate

Eye Bolt

Workpiece

Figure 3.28 : Leaf Jig

Indexing Jig
When number of holes with the same size and pitch are to be drilled in a
workpiece, then conventional drilling takes more time to drill each hole
individually and requires skilled worker for complete production run. Also one
cannot get required accuracy. This automatically increases the cost.
This arrangement is shown in Figure 3.29. Such situation is avoided by using
indexing jig. Indexing jig not only saves the time and the cost but also increases
accuracy. And unskilled worker may operate the indexing jig. Linear indexing jig
is shown in Figure 3.30.
Hole of 20 φ

Figure 3.29 : Workpiece for Linear Indexing Jig

Workpiece

Indexing
Drill Bush Pin
A B

Figure 3.30 : Linear Indexing Jig

(a) Indexing pin is first inserted into hole A. It is used as a stopper for drilling
the first hole through the drill bush. 51
Design of Cutting (b) The pin is removed from hole A after drilling. Then workpiece is moved
Tools and Holding toward right till the centerline of drilled hole coincides with the centerline of
Devices
bush B.
(c) The indexing pin is inserted into the drilled hole in the workpiece through
bush B.
(d) In this way workpiece is indexed linearly to drill the next hole at 100 mm
distance (i.e. pitch) from the hole drilled previously.
(e) By repeating step c, we can make number of holes at 100 mm pitch in the
workpiece.
Rotary Indexing Jig
Rotary indexing helps in positioning a part accurately around the axis. It can be
used conveniently for drilling equi-spaced holes in cylindrical workpieces. Rotary
Indexing is shown in Figure 3.31.

‘A’ Drill Bush Indexing Pin

Figure 3.31 : Rotary Indexing Jig

(a) Workpiece is clamped and first hole is drilled through bush A.

(b) Workpiece is unclamped and rotated clockwise to coincide the axis of
drilled hole with the axis of indexing pin.
(c) The indexing pin is inserted in the drilled hole to index the workpiece for
drilling the next hole.
(d) The workpiece is clamped again before drilling the next hole. In this way,
the rotary indexing can be used to drill number of equi-spaced holes with
only two guide bushes.
SAQ 2
(a) What are various design considerations while designing jigs?
(b) List various types of jig with examples.
(c) Explain with neat sketch the principle of indexing jig.

3.4 SUMMARY
Jigs are used to hold and locate the workpiece that positions and guides or controls the
cutting tool. Drill jig is used to ensure a hole to be drilled, tapped or reamed in the
52 workpiece at proper place. Jigs are generally used for mass production. Jig reduces
operators fatigue and increases productivity. Jig consists of locating, clamping and tool Design of Jigs
guiding elements. A workpiece can be located from plane surface, profile surface and
cylindrical surface. Location of workpiece is achieved by providing pins or diamond pin
locator or v-block or conical locator. Clamps hold the workpiece which is firmly engaged
with locators during operation. Strap clamps, screw clamps are widely used for clamping
purpose. C-washer, cam, toggle clamps are quick acting clamps. Jigs uses drill bushes for
guiding the drill, reamer and other cutting tool to the workpiece. Press fit bushes, plate
bushes and renewable bushes are commonly used for guiding the drill into hole. Jig
differs from workpiece to workpiece. Plate jig, box jig, leaf jig, indexing jig are various
types of jig.

3.5 KEY WORD

Jig : Jig is workpiece holding and locating device that
positions and guides or controls a cutting tool.
3-2-1 Principle : Workpiece will be completely controlled when
positioned against three points in one plane, two
points in another plane and one point in third
plane.

53
 Design of Fixture
UNIT 4 DESIGN OF FIXTURE
Structure
4.1 Introduction
Objectives

4.2 Design of Fixtures

4.3 Types of Fixture and its Industrial Application
4.3.1 Vise Fixture
4.3.2 Milling Fixture
4.3.3 Facing Fixture
4.3.4 Boring Fixture
4.3.5 Face Plate Fixture
4.3.6 Turning Fixture
4.3.7 Grinding Fixture

4.4 Summary
4.5 Key Words

4.1 INTRODUCTION
Fixture is a workpiece-locating and holding device used with machine tools. It is also
used in inspection welding and assembly. Fixture does not guide the cutting tool, but is
always fixed to machine or bench. By using fixture, responsibility for accuracy shifts
from the operator to the construction of machine tool.
When a few parts are to be machined, workpiece clamp to the machine table without
using fixture in many machining operations. However, when the numbers of parts are
large enough to justify its cost, a fixture is generally used for holding and locating the
work.
Objectives
After studying this unit, you should be able to understand
• the design consideration in fixtures, and
• types of fixture and its industrial application.

4.2 DESIGN OF FIXTURES

4.2.1 Design Consideration in Fixtures
(a) The main frame of fixture must be strong enough so that deflection of the
fixture is as minimum as possible. This deflection of fixture is caused
because of forces of cutting, clamping of the workpiece or clamping to the
machine table. The main frame of the fixture should have the mass to
prevent vibration and chatter.
(b) Frames may be built from simple sections so that frames may be fastened
with screws or welded whenever necessary. Those parts of the frame that
remain permanently with the fixture may be welded. Those parts that need
frequent changing may be held with the screws. In the situation, where the
body of fixture has complex shape, it may be cast from good grade of cast
iron.
(c) Clamping should be fast enough and require least amount of effort.
55
Design of Cutting (d) Clamps should be arranged so that they are readily available and may be
Tools and Holding easily removed.
Devices
(e) Clamps should be supported with springs so that clamps are held against the
bolt head wherever possible.
(f) If the clamp is to swing off the work, it should be permitted to swing as far
as it is necessary for removal of the workpiece.
(g) All locator’s clamps should be easily visible to the operator and easily
accessible for cleaning, positioning or tightening.
(h) Provision should be made for easy disposal of chip so that storage of chips
doesn’t interfere with the operation and that their removal during the
operation doesn’t interfere with the cutting process.
(i) All clamps and support points that need to be adjusted with a wrench should
be of same size. All clamps and adjustable support points should be capable
of being operated from the fronts of the fixture.
(j) Workpiece should be stable when it is placed in fixture. If the workpiece is
rough, three fixed support points should be used. If workpiece is smooth,
more than three fixed support points may be used. Support point should be
placed as farthest as possible from each other.
(k) The three support points should circumscribe the centre of gravity of the
workpiece.
(l) The surface area of contact of support should be as small as possible without
causing damage to the workpiece. This damage is due to the clamping or
work forces.
(m) Support points and other parts are designed in such a way that they may be
easily replaced if they break.

4.3 TYPES OF FIXTURE AND ITS INDUSTRIAL

APPLICATIONS
4.3.1 Vise Fixture
It is easy to clamp workpiece with regular shape and parallel sides in a vise. However,
workpieces with round or irregular shapes are very difficult to clamp properly. Hence,
special jaws are created to hold workpieces with irregular shape properly and at the same
time, it also avoid damage to the important surfaces. Various types of vise fixture are
shown in Figures 4.1(a), (b), (c), (d) and (e).

Regular
Special Jaws Workpiece Jaws

Vise

Figure 4.1(a) : Vise Jaws

56
Figure 4.1(a) shows simple pair of jaws for holding round workpiece. Figure 4.1(b) Design of Fixture
shows pair of jaws for holding a thin sheet of non magnetic material. Stop pin is used to
prevent bending of the workpiece by the application of clamping force.

Workpiece

Stop Pin

Figure 4.1(b) : Vise Jaws

Extended jaws for large workpieces are shown in Figure 4.1(c). Here guide pins are used
to secure alignment. When it is necessary to hold the workpiece firmly in all the
directions, wedge type jaws are useful. This arrangement is shown in Figure 4.1(d). If the
pressure exerted by the cutting tool is likely to tilt upward one end of the workpiece, then
the link construction as shown in Figure 4.1(e) should be used. It is suitable for rough
casting and forging because it permits considerable variation in dimensions of workpiece.

Extended Jaws

Guide Pin
Bushing

Figure 4.1(c) : Vise Jaws

Figure 4.1(d) : Vise Jaws

57
Design of Cutting Direction of Cut
Tools and Holding
Devices

Figure 4.1(e) : Vise Jaws

4.3.2 Milling Fixture

This holds the part in correct relation to the milling cutter. Fixture is attached to milling
machine table. Milling fixture consists of the base, clamps, rest blocks or nest, locating
points and gauging surfaces.
The base of milling fixture consists of a base plate. A base plate has a flat and accurate
undersurface and forms main body on which various components are mounted. This
surface aligns with the surface of the mill table and forms the reference plane with
respect to the mill feed movement. It may be constructed of steel plate or cast iron,
depending upon the size and complexity of the part. The slots are provided in the base for
clamping the fixture to the mill table. The base plate also has keyways along with length
of the base for two keys. These keys are used to align the fixture on the milling machine
table. The keys are pressed into the keyway at both ends of fixture and held there by
socket head caps screw. This arrangement is shown in Figure 4.2. It is necessary to adjust
the table by using feed movements until the correct position is attained. This can be done
by trial and error cuts in the workpiece. Milling is always first operation.

Hold-down
Slots

Key

Figure 4.2 : Underside of Milling Base

One must know the dimension of milling machine for designing the fixture. The various
dimensions include the dimension of T-slots, centre-to-centre distance of T-slot,
dimension of milling machine table and length of table travel in all three feed
58
movements. Tool designer should provide enough clearance space around hold down Design of Fixture
slots for a nut, washer and wrench. Clamps on mill fixture must be extremely rigid.
Cutting forces may change as the cutter enters or leaves the workpiece and throw an extra
load on clamps. Clamps should not be loosened by vibrations, which are caused by
interrupted cutting by the mill cutter at the beginning and at the end of the cut. Clamp
should be located opposite to bearing surfaces and locating points. These should be
designed in a way so that these can be easily operated by the operator.

Rest Plate
Rest Pad

Rest Button

Figure 4.3
Rest blocks or bearing surfaces are located with the nest and provide support for the
workpiece. These surfaces change in design according to the shape and size of
workpiece. These are usually in the form of pins, pads or plates that are accurately placed
in the base of fixture as shown in Figure 4.3. These surfaces are raised above the surface
of base to permit chips to fall away and allow easy cleaning.
4.3.3 Facing Fixture
Milling machines are extensively used for facing seating and mating flat surfaces.
Milling is often the first operation on the workpiece. Figure 4.4 shows simple face
milling fixture. The workpiece is positioned by three adjustable spherical ended pads ‘A’.
These pads are adjusted to suit the variation in the size of workpiece and lock in the
position by check nuts. Two self adjusting supports ‘A’ are pushed upward by light
spring. These springs are used to make sure that the support ‘A’ is positively in contact
with the workpiece. Clamping screw is used to lock support ‘B’. On tightening the edge
clamp, the workpiece is pushed against the fixed jaw. This jaw is keyed in the fixture
body to provide solid support to workpiece against the heavy thrust developed in the
operation. The cutter should be fed to the workpiece in such a manner that the milling
thrust should be directed towards the solid support of fixed jaws. The setting can be set in
the path of cutter to set it before starting of facing operation. Four clamping slots are
provided to take care of the heavy forces developed during the operation.
Self Adjusting Screw for Clamping ‘B’
Spring Loaded Pin

Clamping
Slots

Workpiece Setting
Pin
Fixed
Jaws Edge
Clamp

Tennon

Figure 4.4 : Face Milling Fixture 59

Design of Cutting 4.3.4 Boring Fixture
Tools and Holding
Devices According to the type of boring operation, boring fixture are used. Boring Fixture may
have characteristics of a drill jig or a mill fixture. The workpiece always has an existing
hole which is enlarged by the boring operation. It may be final or may be preliminary to
grinding and other sizing operation.
4.3.5 Face Plate Fixture
It can be used conveniently for machining of simple and small components. Addition of
locators and clamps on face plate help in quick location and clamping of workpiece as
shown in Figure 4.5. Face plate fixture is useful for facing number of workpieces
simultaneously on the lathe.
2 Clamps for Securing
Fixture on Faceplate
Workpiece

Faceplate Locating
Pins

Fixture

Clamps for
Workpiece

Figure 4.5 : Face Plate Fixture

4.3.6 Turning Fixture

These are generally special face plates. Their swing should be lesser than the swing of the
machine. These are used for quick location and clamping. Typical turning fixture is
shown in Figure 4.6. The workpiece rests on angle plate and its boss is centralized with
machine axis by sliding v-block which can be operated with knurled screw. The overhang
of turning fixtures should be minimum bare necessary for the operation. Fixture should
be balanced with workpiece in position. The clamping arrangement should be capable of
withstanding the various forces developed during operation.
(a) Cutting force tangential to cutting circle.
(b) Axial force and radial force due to feed of tool.
(c) Bending forces due to pressure of tool on workpiece.
Balanced
Knurled Screw
Weight

Adjustable ‘V’ Block

Clamps ‘C’

Facing
Tool
Machine
Back Plate T Workpiece Thickness

Figure 4.6 : Turning Fixture (Boring and Facing Fixture)

60
Back Plate for Turning Fixture Design of Fixture

It consists of workpiece locating and clamping elements. These fixtures are

generally used for facing turning and boring operation. The workpiece should be
located correctly with respect to rotating machine spindle for all these operations.
Back Plate
Fixture
Location Spigot
Clamping Holes

Machine
Spindle
Nose

Clamping
Threads

Figure 4.7 : Back Plate for Turning Fixture

Example 4.1
For boring and turning, the axis of the bore or the outside diameter to be machined
must be aligned with the machine spindle axis. Most of machines are provided
with back plate, which is permanently mounted on the machine spindle. The back
plate for turning fixture is shown in Figure 4.5. This plate is used to locate and
clamp turning fixtures. Generally, outside diameter of the back plate is super
finished. It is used for locating spigot for aligning axis of rotation of fixtures with
machine spindle. Back plate is provided with three or more equispaced holes for
clamping turning fixtures. Turning fixtures give quick loading, locating and
clamping of workpieces in mass production.
4.3.7 Grinding Fixture
The standard magnetic tables are used to rest workpiece such that resting surface will be
parallel to the surface to be ground. However, for light workpiece with lesser resting
area, the resting area tends to tilt and fly off the magnetic table due to high speed of
grinding wheel and due to high feed, also. Hence, it is necessary to provide additional
support by nesting the workpiece. This can be done by placing the solid plates around the
workpiece as shown in Figure 4.8. The nest plates are held firmly by the magnetic force
of table with more weight and more resting area. The nest plates surround the workpiece
from outside and arrest its movement in the horizontal plane. Thus, this arrangement will
help in preventing it from flying off and tilting due to high speed and feed in grinding
operation.

Nest Plate
Workpiece

Face to be
Ground Workpiece
Height
Nest Plate Height

Figure 4.8 : Nesting

The maximum possible area of magnetic table should be utilized to grind as many
workpieces as possible in a single batch. 61
Design of Cutting Example 4.2
Tools and Holding
Devices Numbers of rounded workpieces are arranged in rows with common supporting
nest plate around. Thickness of nest plate should be less than finished height of
workpiece to prevent disturbance of the grinding wheel as shown in Figure 4.9.

Workpiece Workpiece Height

Magnetic Table
Nest Plates

Figure 4.9 : Surface Grinding Layout

For odd shapes workpieces with little variation in size, an epoxy resin nest can be used as
shown in Figure 4.10. The nest prevents tilting and sliding of the workpiece during
grinding operation.

Workpiece

Magnetic Table

Figure 4.10 : Epoxy Resin Nest

SAQ 1
(a) Explain necessary design consideration in fixtures.
(b) List different types of fixtures.
(c) Discuss in brief the working of turning and grinding fixtures.
(d) Explain the working of milling fixture.

4.4 SUMMARY
Fixture is used for locating and holding the workpiece. Fixture is always fixed to
machine or bench. Fixture is generally used for mass production. Fixture reduces
operator’s fatigue. The fixture also follows the principle of locating and clamping. The
various types of fixture such as vise, milling, grinding, facing, turning, faceplate and
boring fixture are explained with examples in this unit. The design of fixture depends
upon the shape and size of workpiece. The fixture may be different for different
workpieces.
62
 Design of Fixture
4.5 KEY WORDS
Fixture : Fixture is a workpiece holding and locating
device.
Milling Fixture : It is used with milling cutter.
Turning Fixture : It is greatly used for facing turning and boring
operation.

63
Design of Cutting
Tools and Holding FURTHER READINGS
Devices
Pollack H. W., Tool Design, Reston Publishing Company, Virginia.
Donaldson C., LeCain G. H., Goold V. C., Tool Design.
Campbell P., Basic Fixture Design, Industrial Press Inc., New York.
Joshi P. H., Jigs and Fixture, Tata McGraw Hill Publishing Company, New Delhi.

64
 Design of Fixture
TOOL ENGINEERING
Tool engineering is one of the important topics in the manufacturing processes. Without
proper tool, it is difficult to manufacture a new product. You must also remember that if
you get a tool and are making a product it is not a simple task. The tool should have a
definite design and specifications with required quality. The maintenance and production
of good quality tools will be the responsibility of the design engineer or tool design
engineer.
The tool design engineer must go through the specialised training. Tool design engineer
must know about the manufacturing processes. He should be familiar with the
manufacturing machines and tools used in the production. The tool designer must
understand how tools perform their functions. So the knowledge of tool engineering
plays vital role in the production of goods.
In this course, we are discussing about the design and development of tools, fixtures, dies
etc. used in the manufacturing of products.
In Block 1, we are discussing about various types of cutting tools, like single point
cutting tools, multipoint cutting tools, jigs and fixtures etc. It also discussed about the
application of above tools in the manufacturing of products.
Block 2 gives the clear picture about the principles of die making tools, design of sheet
metal planning and piercing tools, design of forming tools and design of metal casting
tools.
In Block 3, the layout design for the tool engineering will be explained elaborately. It
also describes the tools used for basic layout and basic layout operations etc. Lastly, it
concludes with the layout work and safety issues.
Finally, Block 4 covers various aspects of tool management in advance manufacturing
systems, and design of guide ways and spindles. It also discusses about the design of
machine structures and recent developments in tool design.

65
Design of Cutting
Tools and Holding DESIGN OF CUTTING TOOLS AND HOLDING
Devices
DEVICES
This block, consistiang of 4 units deals with basics of tool engineering, design of single
point cutting tools, and design of jigs and fixtures.
In Unit 1, basic elements of tool engineering have been discussed. It also elaborates the
various types of machine tools and operational issues in tool engineering.
Unit 2 describes about the various design aspects of tool geometry and tool shank. This
unit also explains about the selection of cutting tools and required design calculations for
cutting forces.
Unit 3 deals with design of jigs and their types. In the design of jigs, comprehensive
discussion on elements of jigs, presentation of workpiece, location and various changing
methods is made.
Finally, Unit 4 explains the necessary design considerations required for design of
fixtures. It also discusses in brief about the various types of fixtures and their working
principles.

66