0% found this document useful (0 votes)
3 views46 pages

MT MODULE- IV

The document discusses jigs and fixtures, which are tools designed to hold and support workpieces during machining operations to ensure accuracy and efficiency. It outlines the advantages of using these tools, principles of design, and various methods of clamping and locating workpieces. Additionally, it covers specific types of clamps, including strap, side, swinging, hinged, vacuum, and magnetic clamps, detailing their functionalities and applications.

Uploaded by

Sarath Babu
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
0% found this document useful (0 votes)
3 views46 pages

MT MODULE- IV

The document discusses jigs and fixtures, which are tools designed to hold and support workpieces during machining operations to ensure accuracy and efficiency. It outlines the advantages of using these tools, principles of design, and various methods of clamping and locating workpieces. Additionally, it covers specific types of clamps, including strap, side, swinging, hinged, vacuum, and magnetic clamps, detailing their functionalities and applications.

Uploaded by

Sarath Babu
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 46

MODULE- IV

JIGS AND FIXTURES

Jigs and fixtures are designed to hold, support and locate the work
pieces to ensure that each part is machined within the specified limit
Use of jigs and fixtures provides a faster and profitable method of
manufacturing in which components can be quickly positioned with
respect to the cutting tool
ADVANTAGES OF USING JIGS
AND FIXTURES

It helps in the production of articles in large quantities with a high


degree of accuracy and inter-changeability at a competitive cost
To reduce machining time by eliminating time for handling and
setting up of the component parts
Use of jigs and fixtures ensures the uniformity of finished products
It facilitates the holding and supporting of the components , to
position the components properly and guide the cutters
It is possible to accommodate several components in one setting and
taking advantage of multiple machining
It makes possible to employ unskilled or semi-skilled machine
operators
JIG
JIG


A device in which a component is held and located for a specific
operation in such a way that it will guide one or more cutting tools to
the same zone of machining
The figure shows a simple drilling jig, in which the work piece to be
drilled is held and positioned in the drilling jig and the bush(es) guide
the drill(s) at desired location(s) in the work piece
Machining operations in which jigs commonly used are drilling and
reaming
FIXTURE
FIXTURE

 A production tool that locates, hold and supports the work in a fixed
orientation with respect to the tool so that the required machining
operation can be performed
Fixtures vary in design from relatively simple tool to expensive
complicated devices
They are always attached to machine tool or table
Machine tool operations in which fixtures used are milling,
broaching, etc.
PRINCIPLES OF JIG AND
FIXTURE DESIGN

1. Reduction in idle time


2. Rigidity
3. Clearance between jig and component
4. Locating points and support
5. Easy loading and unloading of jig
6. Clamping
7. Fool-proofing
8. Design for safety
9. Accuracy
LOCATION

•The work piece must be accurately located to establish a definite


relationship between the cutting tool and some points of surfaces of
the work piece
•The locating device should be designed that each successive work
piece when loaded and clamped will occupy the same position in the
work holding device
•The locating device selected for a given work holding device will
depend on the nature of work piece and requirements of the metal
removing operation
•In the design of jigs and fixtures the location of the components is
very important aspect as the correct location influences the accuracy
of the finished part
BASIC RULES FOR LOCATION

The basic rules for locating the components are as follows:


1. Locators should be spaced as far apart as possible, using fewer
locators and assuring sufficient contact over the locating surface
2. Locators should be positioned to contact the work on a machined
surface
3. Locators provided should be fool proof i.e., the component can
only be loaded into the fixture in the correct position
4. Locating devices should reduce the degrees of freedom to zero
with no redundant location feature
DEGREES OF FREEDOM
DEGREES OF FREEDOM

A body in space have twelve degrees of freedom .i.e., it is capable of


moving into space in the twelve different direction
The body can move in either of two opposed directions along three
mutually perpendicular axis and may rotate in either of two opposed
direction around each axes clockwise and counter-clockwise
Each direction of movement is considered as one degree of freedom
Thus there are twelve degrees of freedom for any work piece in space
3-2-1 PRINCIPLE OF LOCATION
3-2-1 PRINCIPLE OF LOCATION

3-2-1 principle is also known as six point location principle


It is used to constrain or prevent the body from moving in any direction
along the three axes XX,YY and ZZ
By providing six locating pins- three in a base plane, two in a vertical
plane and one in a plane perpendicular to the first two the nine degrees
of freedom are controlled
The different locating pins provided arrest the degrees of freedom as
follows
1. Pins A,B,C will restrict the body from rotating about X and Y axes
and the body cannot move downward along Z axis
Thus 1,2,3,4 and 5 degrees of freedom will get restricted
The faces of the pins A, B, C supporting the body form a plane
parallel to the plane that contains X and Y axes
3-2-1 PRINCIPLE OF LOCATION
(CONT…)
2. Pins D and E whose face are in a plane parallel to the plane containing
the X and Z axes will prevent the body from rotating the body about Z
axis and also the body cannot move along Y axis in the direction of
8.Thus degrees of freedom number 6,7,8 will get restricted
3. Pin F which is inserted in the vertical face of the body will be able to
restrict the degree of freedom 9
4. The remaining three degrees of freedom 10,11 and 12 will remain
unrestricted
To restrict these three more pins are needed. But this will completely
enclose the work piece making its loading and unloading into jigs
and fixture impossible.
The rest three degrees of freedom are arrested by three external forces
usually provided directly by clamping
LOCATING FROM PLANE
SURFACES
LOCATING FROM PLANE
SURFACES

The basic reference for locating a flat plane, generally a machine table
The machine table is usually at right angles or parallel with the machine
feed movement
All locating devices are made with regard to the basic reference
plane(machine table)
If the work piece has flat side to mate with machine table becomes the
locating surface
If the 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 locating
surface
A minimum of three points (or locator) must be used to locate the work
piece although four or more may used to provide adequate support
LOCATING FROM CIRCULAR
SURFACES
LOCATING FROM CIRCULAR
SURFACES

The basic reference for locating from circular surfaces is the flat
plane of the machine tool surface
Instead of locating the flat plane of the work piece parallel to the
reference plane, it is necessary to locate the axis of the circular work
piece
LOCATING FROM CIRCULAR
SURFACES (CONT...)

One of the common methods of locating from a circular surface is by


using cones, a method commonly referred to as conical location and
usually employed when locating is done from a hole
Conical locators are used mainly to locate rough un-machined
cylinders in castings and forgings
V method used primarily to locate round work pieces or work pieces
with convex circular surface
It has been found that the best general V angle is 90̊
Smaller included angle hold a round work piece more securely but
are more susceptible to location errors
CONCENTRIC LOCATING

Concentric locators locate a


work piece from its axis
This axis may or may not be in
the center of the work piece
The most common type of
concentric location is a locating
pin placed in a hole
CLAMPING

Clamping element hold the work piece firmly engaged with the
locating element during operation
The clamping system should be strong enough to withstand forces
developed during operation
The clamping force should not dent or damage the work piece
Speed of operation, operator fatigue and strategic positioning are
other important considerations for contriving a clamping system
PRINCIPLES OF CLAMPING

1. Position
2. Strength
3. Productivity
4. Operator fatigue
5. Workpiece Variation
POSITION
POSITION
Clamping force shall be directed Clamp shall be directly inline with the
towards support / locators. support
POSITION
Clamping force shall be directed Clamps shall apply force against
towards support/locators. supported area of work piece
POSITION & STRENGTH

1.Position
Clamping should be positioned to direct the clamping force on a strong,
supported part of the work piece
Clamping on unsupported part bends slender work pieces ,this affects the
accuracy of the operation
Clamping system should not obstruct the path of loading and unloading
of the work piece
2.Strength
The clamping system should be capable of holding the work piece rigidly
against the forces developed during operation
The clamping force should not damage the work piece with excessive
pressure
PRODUCTIVITY & OPERATOR
FATIGUE

3.Productivity
Clamping time should be minimised by using hand knobs, tommy
bars, knurled screws, hand wheels and handles
So that the clamps can be tightened or loosened manually without
using spanners, as a spanner further adds motions of picking,
aligning, laying it down
4. Operator Fatigue
Operator fatigue should be taken into account
If a considerable number of clamps are to be tightened and loosened
repeatedly, it is better to use pneumatic or hydraulic clamping which
,in addition to reducing operator fatigue, also saves clamping time
HAND OPERATED CLAMPING
DEVICES
PRINCIPLES OF CLAMPING
(CONT..)
PRINCIPLES OF CLAMPING
(CONT..)

5. Workpiece Variation
The clamping points should be provided with ample radius to make
the clamp operable even if there is variation in the workpiece
Heel pin pressure surface should also be made spherical to permit
some tilting of the clamp
Misalignment between the clamp surface and the clamping nut due to
tilting of the clamp can be countered by use of spherical washer
between the clamp ant the nut
STRAP OR PLATE CLAMPS
STRAP OR PLATE CLAMPS
These are made of rectangular plates and acts like levers
In its simplest form the clamp is tightened by rotating a hexagonal nut on a
clamping screw
One end of the clamp presses against the workpiece and the other on the
heel pin, loading the clamp like a simply supported beam
The clamping face of the clamp is curved and the pressure face of the heel
pin is made spherical to take care of any variation in the workpiece
The provision for spherical washers between the clamp and the hexagonal
nut provides a spherical joint which permits the clamp to tilt with respect to
the screw and the nut
The clamp operates satisfactorily, even if there is considerable variation in
the workpiece height
STRAP OR PLATE CLAMPS
(CONT..)

Strap clamps are provided with a washer and a spring below the
clamp
The spring lift the clamp as the nut is loosened
The workpiece becomes free of even the gravitational load due to
clamp weight
The spring holds the clamp in a raised position during loading and
unloading of the workpiece
SIDE CLAMP
SIDE CLAMP

In a side clamp, the bar clamps the workpiece from one side while the
other side rest against the body of the jig
An arm having a pin joint at the middle and a bolt on other end
clamps the workpiece when the bolt is tightened
In cam operated slide clamp the clamping force is produced by
rotating an eccentric cam with the help of a lever
It clamps the workpiece quickly
It pushes the V-block and the workpiece is clamped between the jig
and block
SWINGING CLAMPS
SWINGING CLAMPS

Swinging clamps are swung to the position.


In swinging clamps, the axis of rotation is square to the clamping
plate face
The swing clamps rotate in the planes of their plates
The above figure shows swinging clamp which is pivoted about the
shoulder screw
The work piece is clamped by the knurled head screw
For loading and unloading the workpieces, the clamp is swung aside
as shown by chain dotted line
HINGED CLAMPS
HINGED CLAMPS

Hinged clamps provide rapid clearance of the loading and unloading


passage
It is generally clamped with a swinging eyebolt
The clamp has an open slot through which the eyebolt can be swung
into position
The tightening of the hexagonal nut clamps the workpiece
For loading and unloading the work piece the hexagonal nut is
loosened half-a-turn and the eyebolt is swung out of the open slot to
free the hinged plate
The hinged plate is swung aside loading and unloading
VACUUM CLAMPING
VACUUM CLAMPING

Vacuum clamping is convenient for securing thin flat sheets which


are vulnerable to distortion under heavy clamping force
Vacuum clamping provides light clamping
The holding face is provided with 0.025mm deep grooves which
serve as vacuum ducts
The clamping face is circumscribed by a rubber seal groove all
around
The seal in the groove segregates the clamping vacuum area from the
space outside the seal
The vacuum pressure is usually limited to 1kg/cm2
MAGNETIC CLAMPING
MAGNETIC CLAMPING

Magnetic clamping force can be developed by permanent magnets and


electromagnets
(a) Permanent magnets
They are mounted on a sliding members which can be moved under non
magnetic material on a table to block magnetic flux
This releases the workpiece
For clamping the workpiece, permanent magnets are moved under the
magnetic part of the table
This allows the magnetic flux to pass through the workpiece and hold
magnetically
The permanent magnets are slid in the clamping and unclamping position
by a lever
MAGNETIC CLAMPING (CONT..)

The magnetic table area is divided into alternate strips of magnetic


and non magnetic material
The non magnetic strips block the path of magnetic flux and force the
flux to pass through the workpiece to clamp it magnetically
The non magnetic strips acts as flux dams or barriers
In permanent magnet tables, the magnets are slid below the non
magnetic strips to completely block the magnetic flux during
unclamping
MAGNETIC CLAMPING (CONT..)

(b) Electromagnetic clamping


Electromagnetic tables use solenoid coils as temporary magnets
When DC current is passed through the solenoid coil, it acts like a
magnet
The coils and the table is demagnetised on switching off the current
and the workpiece is released
The magnetic clamping force can be varied by varying the current
passing through the solenoid coil
Magnetic clamping leaves some residual magnetism in the workpiece
This can be removed by demagnetising the workpiece

You might also like