Jigs and Fixtures

INDIAN INSTITUTE OF TECHNOLOGY ROORKEE
Theory of Production Processes - I

MIN-216
Unit 5
Jigs and Fixtures
By
Prof. Navneet Arora
Department of Mechanical and Industrial Engineering
Indian Institute of Technology Roorkee
Roorkee - 247667
BOOKS
1. Hoffman E.G. ‘Jigs and Fixtures Design’

Thompson Delmar Learning, 2003
2. Colvin and Haas ‘Jigs and Fixtures’ McGraw-Hill
3. Franklin & D. Jones ‘Jigs & Fixtures Design’ Allied Publishers
4. Hiram E. Grant Jigs & Fixtures Non Standard Clamping
Devices’ Tata McGraw Hills
2
Jigs and Fixtures
Introduction : The world’s demand for manufactured goods is
constantly growing.
A lot of advancement is seen in
Cutting Tools Machine Tools Production Methods
but basic requirement of the holding the workpiece has
remained constant.
• Every part produced must be held while it is being
Machined / Joined / Inspected or any no. of operations have to be
performed on it.
• Whether the operation requires a simple drill press or the
multiple - axes computer or Numerically controlled machining
center, the work piece must be accurately located and
securely held throughout the operation.
3
Jigs and Fixtures
• Just as no single machine tool will perform every required

operation, no individual Jig or Fixture can possibly hold every
part.
• Jigs & Fixtures (J & F) were developed
• To increase productivity
• To have consistent quality
• To achieve interchangeability.
• J & F are special purpose tools which are used to facilitate
production when w/ps are to be produced on a mass scale.
By using J or F, the set up time is drastically reduced .
• With J & F, we can achieve easy loading, unloading, holding
and operational facilities and ensured interchangeability of
machined workpieces for quick assembly.
4
Jigs and Fixtures
Fig.1 Shows the difference between a Fixture and a Jig
5
Jigs and Fixtures
Definition: A Jig is a device which holds and positions the

work, locates or guides the cutting tool relative to the w/p.
• It is usually not fixed to the machine table.
• It is usually lighter in construction.
• Used in drilling, reaming, tapping etc.
• Reaming (follows drilling) - To give accurate size and good surface finish and
Tapping - To produce internal and external threads with standard taps.
Fixture is a work holding device which only holds and positions
the work, but doesn’t in itself guide, locate or position the
cutting tool.
• A fixture is bolted or clamped to the machine table.
• A fixture is usually heavy in construction
• Used in turning, milling, grinding, shaping, planing, boring operations
6
Distinction between a Jig and a Fixture
Jig Fixture
Purpose Hold & locate the Hold and locate the

workpiece and guide the workpiece only
tool
Construction Smaller in size, lighter Massive and heavier
Clamping Clamping on machine Clamping rigidly on the

unnecessary table is essential
Operations Useful in drilling, reaming, Turning, milling, boring,
and tapping grinding, planning etc.
Skill Less skill More skill is necessary
Fabrication time and cost Less More
7
Advantages of Using Jigs and Fixtures
The advantages of using Jigs and Fixtures in mass production
work are as follows:
• It eliminates the laborious work of measuring, marking and
setting of workpiece before machining and this reduces cost
of production.
• It increases machining accuracy and ensure
interchangeability as
• Workpiece is automatically located without aligning the machine tool
and cutting tool is guided (J)
• It increases productivity as
• Workpieces can be simultaneously machined
• Number of cutting tools can be simultaneously operated
• Handling time (setting up and aligning the workpiece) is reduced
8
Advantages of Using Jigs and Fixtures (contd.)
• It minimizes machining time as

• We can operate on higher depth of cut, feed and speed due to better
clamping rigidity of the workpiece and guiding tool (J)
• It saves labour.
• It facilitates use of semi-skilled labour.
• It decreases cost on quality control.
• It minimizes operator’s fatigue due to less material handling.
• It minimizes overall cost of the product by partly or fully
automizing the process.
9
Jigs and Fixtures Basic Elements
Basic elements of Jigs And Fixtures:

• Sufficiently rigid body into which workpieces are loaded
(called body/ base/ frame)
• Locating devices or elements
• Clamping devices or elements
• Tool guiding elements (J)
• Elements for Positioning the J/F on the machine on which it
is used.
• Indexing or Rotary elements (optional)
• Power device for operating clamping devices (optional)
10
Jigs and Fixtures….Design Principles
Underlying design principles of Jigs and Fixtures:

1. Idle time reduction
As the Total machine time includes work handling time
Thus Methods of location/clamping should be such that idle time is
minimum or in other words locating and clamping should be quick-acting
2. Simplicity
• J/F design should allow easy loading and unloading of workpiece.
3. Rigidity
• Ensure that jig and fixture are rigid enough
• Cast iron absorbs shocks more readily, hence recommended for
fixture bodies.
4. Jig and fixture should be as open as possible to minimize
chip accumulation and easy removal.
11
5. Fool Proofing
Fool Proofing is such a Design feature which makes improper loading of
work piece impossible
• Fouling pegs/blocks/pin may be used which clear correctly position
parts but prevent incorrectly loaded parts from entering jig and fixture
body
Fig. Fool Proofing
12
13
6. Clearance
• To allow for variation in component size (casting/ forging)
• To allow for hand movements so that the work piece can easily be
placed/removed from J/F.
7. Eye Bolts or rings may be provided to handle heavy J/F.
Fig. Lifting angle when using eyebolts

14
8. Burr Grooves
• A burr raised on the work at the start of a cut is termed as
‘minor burr’ and that at the end of a cut a ‘major burr’
(called secondary and primary burr) respectively.
• Suitable clearance grooves or slots should be provided to
accommodate these burrs.
Fig. Primary and Secondary Burrs
15
9. Ejectors
• To force work piece out from the J/F, use ejectors
specially in two cases :
▪ Work piece is heavy
▪ Machining pressure forces work piece onto the sides of
J/F, and pressure and oil coolant film will cause the
work to stick and be difficult to remove
Fig. Ejectors
16
10. Cost Estimation - Ensure that the cost of J/F should not
exceed the expected gain.
11. Adjustability
• For rough castings, make some of the locating points
adjustable
Fig. Methods
of relieving
locators
17
12. Locate clamps so that they will be in the best position to

resist the pressure of the cutting tool when at work.
13. Core out all unnecessary metal, making the J/F as light as
possible, consistent with rigidity and stiffness.
14. Tolerance
• When designing J/F, the designer must keep the part tolerance
in the mind, as a general rule, the tool tolerance should be
between 20 and 50 percent of the part tolerance
Eg. If a hole in the part must be located within ± 0.01 inch, then
the tolerance of hole in the jig must be between ± 0.002 inch
and ± 0.005 inch. This is necessary to maintain the required
precision.
18
Fig. Tolerance relationship
19
15. Duplicate Locators

• The use of duplicate locators should always be avoided
because
✓ With Duplication - cost increase
- inaccuracies increase
Example: Flange is located on both the underside of the flange
and bottom of the hub
Fig. Duplicate Locators
20
✓ Since these are parallel surfaces only one is needed and other
should be eliminated.
✓ If the reference surface is the flange (Fig B), the hub locator is
not necessary.
✓ If the hub locator is the reference surface (Fig C), the flange
locator is unnecessary.
✓ Thus, first determine that which surface is to be referenced.
The designer must specify whether the part is to be located
from its holes or its edges, never both.
16. Design for Safety
Also sharp edges should be removed from parts forming J/F
unit.
21
J/F Locating and Clamping Methods
Introduction
• A large portion of tool designers time is spent in the solution
of locating and clamping problems.
• Locating refers to dimensional and positional relationship
between the work piece and the cutting tool used on the
machine.
• The various forces acting upon the work piece during
machining operation require a means of clamping it in
position after it has been correctly located
• Selection of L and C methods depend upon the original
machining operation and configuration of the part
22
J/F….. Basic Principles of Location
Basic Principles of Location:

• Configuration is the major factor in determining how a
workpiece will be located.
• Configuration is determined by a combination of flat, circular
and irregular surfaces. These surfaces may be Rough
(Before machining such as casting, forging, weldment etc.) or
Finished (Machined one).
I. Locating from plane surface:
All locating devices are made with regard to the basic
reference plane ( machine table).
23
Jigs and Fixtures….. Basic Principles of Location
Fig.1 Most machines have

three standard
movements and move the
workpiece
i. Vertical
ii. Longitudinal and
iii. Cross.
24
• Fig.2 If the workpiece

with a plane surface is
placed upon the basic
reference plane, it will
remain in position
because of the forces of
gravity acting up on it.
• The machine table acts
as a stop and becomes
a locating surface.
25
• Fig.3 If work piece does not have a flat side to mate with
the machine table, the flat plane of the machine table
cannot be used as a locating surface. Contact area is
reduced by sharp points, with enough body to prevent
breaking and rapid wear.
26
• Three points or locators must be used,

• Although 4 or more may provide better support but 3 would
establish same location of work piece,
• eg. On an uneven floor it is stable with three legs but with
four legs it gives table tops in two different planes.
• Fig.4 and 5, Longitudinal and cross feed movements can
shift the work piece, So To locate part in same position each
time (compare 4 & 5). Two stops or locators must be
provided on one side of the part and on third side one stop or
locator will be sufficient.
• Now complete location has been accomplished by 3 points in
the reference plane, 2 in second plane and 1 in 3rd plane.
• This is called 3-2-1 principle of location from flat surface.
27
28
Fig. Planes of movement
29
Fig. Three pin base restrict five direction of movement
30
Fig. Five pin base restrict eight direction of movement

31
Fig. Six pin base restrict Nine direction of movement

32
Fig.6 Locating points should be placed as far apart as possible to

minimize the effect of inaccuracies in the workpiece and locator. This
separation also provides greater support because the locators are
nearer the outer extremities of the workpiece.
33
II. Locating from circular surfaces
• Fig.7 here basic reference location is Flat plane of machine
tool-table surface. But instead of locating the flat plane of the
workpiece parallel to the reference plane, it is necessary to
locate the axis of circular workpiece.
34
Fig.8 Locating from circular surface is by using cone/cups

35
Fig.9 Another way is V-Method. Here smaller included angles hold a round
workpiece more securely but are more susceptible to location error caused
by burrs, chips, dirt and workpiece inaccuracies.
36
Fig.10 Any variation in

work size will cause the
axis of the round work
piece to shift
37
• Fig.11 use of standard

chucks as locating method,
called concentric location,
as work is usually
positioned to a common
center. Chucks may be
used where chuck and
workpiece revolve, chuck
and workpiece stationary.
• The location of workpiece
is not affected by variation
in diameter, location and
clamping can be quickly
and readily.
38
III. Locating from irregular surfaces: V locating methods

may be used to locate certain parabolic surfaces (finished
one).
39
40
Locating methods and devices

• Earlier discussed were general locating methods, now we will cover
specific locating methods
• Locators are universally used and are commercially available and tool
designer is to select according to one's need
A. Pin and Button Locator
• Used to firmly support or hold the workpiece in position
• Difference between pin and button is in length
– Buttons are generally shorter than pins and are used for vertical
location
– Pins are used usually for horizontal location and larger pins are
referred to as plugs
41
• Fig.15
• (a)vertical location
button
• (b,c) horizontal
location button,
pin respectively
• (d) location from a
hole(pin)
42
Fig.16 standard pins and buttons

(a) button - workpiece surface is flat
(b)button - workpiece surface is rough or irregular
(c) button - screw rest button( easy removal of button possible)
43
(d) pin
(e) pin –gives workpiece support and act as locating pin too
(f) button - contains a dirt groove when installed in a J/F
baseplate
Fig.17 - Lock screw pin: Used where pin is subjected to
excessive wear and must be replaced frequently.
A hardened liner is pressed into the base of the J/F to receive
the lock screw locating pin which in turn is held in to the liner by
lock screw.
44
45
• Fig.18- Workpiece
may use previously
located and drilled
holes for locating
and reference points
• Diamond pins are
relieved on two
sides to allow for
variations in the
centre to centre
distance of the
holes.
46
Fig. 19 standard diamond pins.

Fig. 20 Spherical locating plugs - prevent sticking because of
misalignment, as a sphere has only one dimension and therefore will not
bind in a hole no matter which way it is turned.
47
B. Rest Pads and Plates:

– Used to support and locate work vertically (with larger and heavier
workpiece)
– Rest pads are similar to rest buttons but do not have a Shank
Fig.21 They are held to the J/F base plate by socket-head cap screws.
Fig.22
Rest plates are essentially rest pads with larger bearing surfaces. Used to
support Larger parts on previously machined surfaces
– Rest plates are Grooved to reduce bearing area - less sticking and
easy ejection, to provide space for small chips that would affect
accuracy of locating the workpiece and edges of groove act as a chip
cleaner to scrap the chips from locating surface when workpiece is
slid over them.
48
49
50
C. Nest or Cavity Location
Fig. 23 Nest of a J/F should

be a pocket or cavity into
which the workpiece is
located and placed.
51
• For blanked parts a nest

may be pierced directly
into a piece of sheet stock
and be bolted directly into
the base plate
• Easy removal should be
insured,
• Provide area relief under
the path to allow for chips
that would prevent the
work piece from seating
properly
52
Disadvantages Of Nest Location

• Often difficult to lift out of the cavity because it is completely
surrounded.
Solution:
– Provide ejecting device - but additional expense
– Partial nest (as shown in Fig. 25) permits easier removal
53
54
D. Locating methods and chip control:
• Large chips can be removed quickly from the work location
but small chips tend to collect in corners and cause error in
location.
Fig.26 - Provide relief or opening at areas where chips
would tend to accumulate and prevent the work piece from
properly contacting the locator
(a) Area relief - to reduce the contact area between the
supporting surface and work piece
(b,c) - chip and burr groove
(d, e & f) - relief in corners.
In ‘e’ - see open construction of the locator to allow chips to
pass under the locator without becoming packed in corners.
55
56
Jigs and Fixtures….. CLAMPING
IV. CLAMPING:
Once a workpiece is located, it is necessary to press it
against the locating surfaces and hold it there against the
forces acting upon it. This action is clamping and the
mechanisms used for this action are known as clamps
Essential Requirement of a Clamp:
• Work piece must be held rigidly while the cutting tools are in
operation
• Time required for loading or unloading the work piece must
be as short as possible which means the clamping device
must be quick-acting
• When subjected to vibration, chatter or heavy pressure, the
clamping must be positive
• The clamp must not damage the work piece
57
Jigs and Fixtures….. CLAMPING
Principles for Clamping Devices:
• Clamping pressure should be directed parallel towards the
cutting operation. The cutting force should be arranged against
a fixed stop or substantial part of the fixture body. Clamps
should never be relied upon for holding the workpiece against
the cutting force.
• The clamping and cutting forces should be directed towards the
locating pins, otherwise the work piece may get bent or forced
away from the locating pins during machining.
• Clamping should be simple, quick and fool proof. Complicated
clamps lose their effectiveness as they wear.
• Whenever possible, lifting of clamp by hand should be avoided,
if it can be done by means of a spring fitted to it.
• Fibre pads should be riveted to the clamp faces, otherwise soft
and fragile workpiece can be damaged.
58
Jigs and Fixtures….. CLAMPING DEVICES
CLAMPING DEVICES:
1. Strap Clamp: Fig. 27
– Simplest and most commonly used clamp
– Employ principles of levers
– Clamping bar (strap) can be slid into and off of the workpiece
for easy workpiece removal
– Compression spring holds the bar in position when knob is
loosened
– Pillar rests in a groove of the bar to prevent it from turning
when the clamping knob is loosened
– Hardened washer is used to prevent it (knob) from rubbing the
bar
59
60
2. Cam Clamps (Fig 28, 29)

Effective and rapid means of clamping
– but not a positive clamping method and may loosen under
vibrating forces
– should not be used where heavy clamping forces are required
Eccentric Cam: easy to make
Spiral Cam: locking better
61
Ecentric (Fig 28) - Direct acting cam

Circle radius – r, Centre at – C, Lever is pivoted by pin – P and
Ecentricity - E
• Handle if rotated clockwise the center C will travel in a circle
A until the circumference contacts the workpiece at B.
• Any force applied at handle will be exerted at B but there will
be a counteracting force resulting from the force F acting
with the lever arm.
• If there is a sufficient friction and the force is not too large,
the clamping may hold.
62
• Spiral Cam: (Fig - 29) Shown how to outline cam
63
Other cam clamps:
Cam handle is at the center of the strap

When other type is not convenient
64
Under an overhanging part or workpiece Spiral cam edge clamp -

advantage of compactness
Space limited - go for modified cam and
screw clamp
65
3. Screw Clamps - Incorporated screw thread to clamp a

workpiece
Advantage:
• Exert adequate force
• Resist loosening tendencies setup by vibration
• However, relatively slow and not suitable for high production
66
• Standard items uses for construction of screw clamps
67
Screw clamp assembly: Here locking screw is loosened and

the clamp assembly is revolved by 90° to allow workpiece
removal.
68
69
4. Latch clamps – used for relatively light work

Advantages: Ease and speed
Fig 37 shows a simple form of latch
70
• In operation the jig is loaded and unloaded upside down. The

leaf is unlatched and then swung open and the workpiece is
replaced by a new one. Locating pins ensure that the
workpiece is placed right. After loading, the leaf is swung to
a closed position and surface S strikes the surface L, the
latch swing back to allow the leaf to pass. Once the leaf is in
a horizontal position, the latch is forced back by the spring,
where it catches and locks the leaf.
71
5. Wedge clamps:
It consist of a movable incline Improved - adding levers and links

plane which forces the workpiece Taper angle of wedge may range 6°
against a fixed stop and have a to 18°, depending upon the
tendency to loosen under vibration coefficient of friction of the metal.
72
A pinch clamp employing the A pair of clamp to ensure balanced

wedge principal in conjunction pressure
with a strap clamp
73
6. Toggle clamp
• Depend upon the movement of rigid link for their movement
• Used to hold sheet metal parts in position while they are being welded
• Provide heavy clamping pressure
– Quick acting
– Ample clearance for loading and unloading
74
75
7. Hydraullic and Pneumatic Clamping

• Many of previously mentioned clamps may be actuated by
hydraulic or pneumatic methods when large production
quantities justify them
Advantages
– Faster clamping
– Uniform and equalized pressures
– Less operator fatigue
Fig. 46 Air to hydraulic power booster

It is used to convert low pressure air into higher hydraulic
pressure for operating a hydraulic work cylinder.
76
77
Jigs and Fixtures….. JIGS
V. DRILL JIGS:
A drill jig is a device for ensuring that a hole to be
drilled, tapped or reamed in a workpiece will be machined in
the proper place. Hardened drill bushes are used to guide drills,
reamers etc. and bushes are fitted in bush plate.
BUSH LENGTH = 2 * DIAMETER HOLE
Types of Drill Jigs
1. Leaf Jig: (Fig.2)
• Hinged cover or leaf is swung open to load or unload J.
• Loading/Unloading is quick. Multi holes possible on
complicated work pieces.
• Drilling bushings located in leaf.
78
Disadvantages: - Chip accumulation may cause trouble

- Play in hindge may affect drilling accuracy
79
2. Box Jig: (Fig.3)

• Loading - cam rod is taken out of jig and workpiece placed in
position inside the jig. The cam rod is then replaced and
rotated to its locking position
80
3. Tumble Jig: (Fig.4)

• When a box jig contains bushing on two or more sides for
the purpose of drilling holes on different sides of the part, it is
referred to as a tumble jig
Advantage - Greater accuracy, less part handling
81
82
4. Template Jig: (Fig.5)
• Used for locating hole patterns on large workpiece
• It may contain locating devices or it may be necessary for
the operator to locate by means of measurement. Some
have provisions for clamping.
83
5. Plate Jig: (Fig.6)

• It is having a plate containing bushing and it forms the main
structural member.
• It is of open construction which facilitates part loading and
removal, chip removal and clamping. Also called open jig.
• Thin parts maybe stacked for drilling several parts at one
time.
Disadvantages - only one surface can be drilled at one loading
84
85
6. Indexing Jig: (Fig.7)

It is horizontal and vertical mount type
• To drill circular hole pattern
• Workpiece is located and clamped under a single bushing.
The position of bushing is adjustable for height and location
over the workpiece.
86
87
Jigs and Fixtures….. FIXTURES
FIXTURES:
• Fixture is a device used for holding a workpiece during
machining operations.
• Name is derived from the fact that a fixture is always
fastened to a machine or bench in a fixed position.
• Many machining operations can be performed by clamping
the workpiece to the machine table without using a fixture
especially when few parts are to be machined.
Types:
Vise, milling, boring, broaching, lathe, grinding fixtures + other
types of tooling used for positioning parts relative to each other
example assembly and welding fixtures.
88
1. Vise Fixture: (Fig.8)
(a) - A pair of jaws for holding a round work piece

(b) – A pair of jaws for holding a thin sheet of non magnetic
material
The use of stop pin - prevents bending the work piece by
clamping action.
(c) - Extended jaws
89
Fig. 8 SPECIAL VICE JAWS

(d) - Tongue and groove - assure accurate alignment
(e) - Wedge type jaw to hold work piece firm against pressure
in all directions
(f) Link Construction - where the pressure exerted by the
cutting tool is likely to cause one end of work piece to tilt
upward. Advantage : Permit variation in work piece dimensions
suitable for handling rough casting.
90
2. Milling Fixture: (Fig.9,10) A mill fixture holds the part in the
correct relation to the milling cutter as the table movement
carries the part through the cutter.
Main parts - Base, clamps, rest blocks, locating points and
gaging surfaces.
Fig. 9 Temporary indexing

fixture utilizing a circular
milling table (Cincinnati
Milacron Inc.)
91
Fig10 Face-milling fixture showing manual clamping methods(Cincinnati Milacron Inc.)

92
3. Lathe Fixture
(Fig.11)
• Special fixture
designed to be
mounted on a
late spindle
• Lathe fixture
should not be
confused with
the commercially
available chucks.
93
4. Boring Fixture
• Boring basically is the cutting of an internal diameter with a
single point tool. Either the work piece or the tool may be
rotating.
• Lathe fixtures or chucks are used when work piece is rotated
On the other hand boring fixture is used when the boring tool is
rotated.
Fig. 12 Horizontal production boring fixture are typically
designed for high production use with precision boring
machines.
94
95
Fig. Primary and
Secondary Locater
96
97

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INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

Theory of Production Processes - I

1. Hoffman E.G. ‘Jigs and Fixtures Design’

• Just as no single machine tool will perform every required

Fig.1 Shows the difference between a Fixture and a Jig

Definition: A Jig is a device which holds and positions the

Purpose Hold & locate the Hold and locate the

Clamping Clamping on machine Clamping rigidly on the

Fabrication time and cost Less More

• It minimizes machining time as

Basic elements of Jigs And Fixtures:

Underlying design principles of Jigs and Fixtures:

Fig. Fool Proofing

Fig. Lifting angle when using eyebolts

Fig. Primary and Secondary Burrs

12. Locate clamps so that they will be in the best position to

Fig. Tolerance relationship

15. Duplicate Locators

Fig. Duplicate Locators

Basic Principles of Location:

Fig.1 Most machines have

• Fig.2 If the workpiece

• Three points or locators must be used,

Fig. Planes of movement

Fig. Three pin base restrict five direction of movement

Fig. Five pin base restrict eight direction of movement

Fig. Six pin base restrict Nine direction of movement

Fig.6 Locating points should be placed as far apart as possible to

Fig.8 Locating from circular surface is by using cone/cups

Fig.10 Any variation in

• Fig.11 use of standard

III. Locating from irregular surfaces: V locating methods

Locating methods and devices

Fig.16 standard pins and buttons

Fig. 19 standard diamond pins.

B. Rest Pads and Plates:

C. Nest or Cavity Location

Fig. 23 Nest of a J/F should

• For blanked parts a nest

Disadvantages Of Nest Location

2. Cam Clamps (Fig 28, 29)

Ecentric (Fig 28) - Direct acting cam

• Spiral Cam: (Fig - 29) Shown how to outline cam

Other cam clamps:

Cam handle is at the center of the strap

Under an overhanging part or workpiece Spiral cam edge clamp -

3. Screw Clamps - Incorporated screw thread to clamp a

Screw clamp assembly: Here locking screw is loosened and

4. Latch clamps – used for relatively light work

• In operation the jig is loaded and unloaded upside down. The

It consist of a movable incline Improved - adding levers and links

A pinch clamp employing the A pair of clamp to ensure balanced

7. Hydraullic and Pneumatic Clamping

Fig. 46 Air to hydraulic power booster

Disadvantages: - Chip accumulation may cause trouble

2. Box Jig: (Fig.3)

3. Tumble Jig: (Fig.4)

5. Plate Jig: (Fig.6)