TIE 418 TOOLS AND FIXTURE DESIGN

GROUP 3 TERM PAPER

TOPIC: DRILLING JIG & MILLING FIXTURES

LECTURER-IN-CHARGE: DR. BOLARINWA

2022/2023 SESSION
S/N NAME MATRIC NUMBER

1 AJIBODU CHRISTIAN 215518

2 ALABI JOSHUA 215522

3 OSENI LATIFAT 223178

4 ODENIYI ENIOLUWA 215544

5 FABIYI AKINTUNDE 215535

6 ODIATU LOUIS 215545

7 TAIWO DAMILOLA 215560

8 OLLEY SEUNDEDE 215552

9 OKECHUKWU VINCENT 215547

10 AKINOLA OLAYINKA 223145

SUBMITTED TO:

THE DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING,

FACULTY OF TECHNOLOGY,

UNIVERSITY OF IBADAN.
INTRODUCTION

Jigs and fixtures are designed to hold, support and locate the work pieces to ensure that
each part is machined within the specified limit. They provide a faster and more profitable
method of manufacturing in which components can be quickly positioned in the correct
relationship to the cutting tool. It is a device which locates and holds the component for a
specific operation. It does not guide the cutting tool. It is a work holding device that holds
supports and locates the work piece for a specific operation but does not guide the cutting tool. It
provides only a reference surface or a device. What makes a fixture unique is that each one is
built to fit a particular part or shape. The main purpose of a fixture is to locate and, in some cases,
hold a work piece during either a machining operation or some other industrial process. A jig
differs from a fixture in that as it guides the tool to its correct position in addition to locating and
supporting the work piece. It is a device which is used to hold and position the work piece. In
addition, it provides some means for guiding the cutting tool. A Jigs primary purpose is to
provide repeatability, accuracy, and inter-changeability in the manufacturing of products. A jig is
often confused with a fixture; a fixture holds the work in a fixed location. A device that does
both functions (holding the work and guiding a tool) is called a jig. The word “tooling” refers to
the hardware necessary to produce a particular product. Tooling consists of a vast array of jigs,
cutting device, dies, fixtures, gages, etc., used in production. The type of production will
determine to a large extent the type of tooling.
Drilling Jigs

A drill jig is a type of jig that, like most other jigs, is used to hold a workpiece. Drill jigs
hold the workpiece with which they are used while simultaneously guiding drills through
premade holes. They are dual-purpose work-holding tools. You can use a drill jig to hold a
workpiece in place, and you can use it to guide the drill into the workpiece.

Drilling jigs are used to machine holes in mechanical products to obtain positional
accuracy of the holes harden drill bushes or jig bushes are used to locate and guide drills and
reamers etc. In relation to the workpiece, these guide bushes are not essential but these prove to
be economical and technically desirable. The position of the jig into which the hardened bushes
are fitted is called the bush plate. Drilling jigs are either clamped to the workpiece in which holes
are to be drilled or the workpiece is housed and clamped in the jig body. If more than one hole is
to be drilled, the drill jig is made to slide on the table to the drilling machine. Such a drill jig is
moved by hand into position under the drill so that the drill radially enters the bush. During the
drilling operation, the jig is held by hand. If the drill size is large enough to produce high torque,
either stops should be provided or the drill jig should be clamped to the table of the drilling
machine. A drill jig is provided with feet which rest or slide on the table of the drilling machine.
These feet should be outside of the cutting forces, thus providing solid support. Drilling jigs
makes possible the drilling of holes at higher speed with greater accuracy and with less skilled
workers. Then is possible when the holes are laid out and drilled by hand. Also, they produce
interchangeable parts because each part drilled in a drilling jig should have the same hole pattern
as every other part.

It is clear that during the drilling operations burrs will be produced. The burr produced at
the short of the hole is smaller than that produced at the end of the hole. The first type is called
minor burs and the second type is called major burr. (when the drill makes it through the
material). When designing a drill jig these two types of burr should be taken into consideration
since they may cause difficulty in unloading the work piece from the jig after a hole has been
drilled.
Types Of Drilling Jigs

Drilling jigs may be classified as follows:

1. Template jig
2. Plate type jig
3. Open type jig
4. Channel jig
5. Leaf Jig
6. Box type jig

1. Template Jig: This is the simplest type of jig; It is simply a plate made to the shape and size
of the workpiece; with the required number of holes made it. It is placed on the workpiece
and the hole will be made by the drill; which will be guided through the holes in the
template plate should be hardened to avoid its frequent replacement This type of jig is
suitable if only a few parts are to be made.
2. Plate Type Jig: This is an improvement of the template type of jig. In place of simple holes,
drill bushes are provided in the plate to guide the drill. The workpiece can be clamped to the
plate and holes can be drilled. The plate jigs are employed to drill holes in large parts,
maintaining accurate spacing with each other.

3. Open Type Jig: In this jig the top of the jig is open; the workpiece is placed on the top.

4. Channel Jig: The channel jig is a simple type of jig having a channel-like cross-section. The
component is fitted within the channel is located and clamped by locating the knob. The tool
is guided through the drill bush.
5. Leaf Jig: It is also a sort of open type jig, in which the top plate is arranged to swing about a
fulcrum point so that it completely clears the jig for easy loading and unloading of the
workpiece. The drill bushes are fitted into the plates, which are also known as leaf, latch, or
lid.

6. Box Type Jig: When the holes are to drill more than one plane of the workpiece, the jig has
to be provided with an equal number of bush plates. For positioning the jig on the machine
table feet have to be provided opposite each drilling bush plate. One side of the jig will be
provided with a swinging leaf for loading and unloading the workpiece, such a jig would
take the form of a box. Such a jig should be as light as possible. Since it will have lifted
again and again. A typical figure of box type jig is shown:
Elements of Jigs and Fixtures

Various elements of jigs and fixtures and their details are as follows.

1. Body

2. Locating devices

3. Clamping devices

4. Tool guide(jigs bushing)

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

(A) Plane Type Jig: Plane type jig is the simplest type, it is used when plane holes are to be
drilled. It has either drilled bushes for guiding the tools or holes without bushes.

(B) Channel Type Jig: Channel type is made up from standard steel channel section.

(C) Box type Jig: Box type jig is used where a component requires drilling in more than one
plane and the jig is to be provided with an equivalent number of drill bush plates. One side
of the box is fitted with a lid which can be opened for inserting the component and for
unloading it. It should be made as light as possible.

(D) The Built Up Jig: The built up jig used dowels and screws for fabricating member
welded type. Standard steel sections are used in it for the limited numbers of details, which
are secured by means of screws and dowels, the locating pins and the blocks are positioned
so that the greatest dimensional variation of the workpiece may be accommodated.

(E) Leaf Type Jig: Leaf type jig is simply made from a block of steel fitted with two
adjustable locating screws and a spring-loaded plunger. It is used in the case of measured
large components where it may be both unnecessary and construct a jig to hold the complete
component, where madding is purely confined to a local section of the workpiece.
2. Locating Devices: The pins of various designs and made of hardened steel are the most
common locating devices used to locate a workpiece in a jig or fixture. The shank of the pin
is press-fitted or driven into the body of the jig or fixture. The locating diameter of the pin is
made larger than the shank to prevent it from being forced into the jig or fixture body due to
the weight of the workpiece or cutting forces. Depending upon the mutual relation between
the workpiece and the pin. The pin may be classified as follows:

(A) Locating Pins: When reamed or finally finished holes are available in the workpiece,
these can be used for locating purposes of the manner as shown, these are two types of
locating pins:

 Conical locating pins

 Cylindrical locating pins

(B) Support Locating Pins: With these pins (also known as rest pins) buttons or pads the
workpiece with flat surfaces supported at convenience. In the fixed support pins the locating
face is either ground flat or curved. Support pins with the flat head are usually employed and
provide location and support to the machine surface, because more contact area is available
during location. It would ensure an accurate and stable location. The spherical head or round
headrest buttons are used for supporting rough surfaces (unmachined and cast surfaces)
because they provide a point support which may be stable under these circumstances.
Adjustable type support pins are used for workpiece whose dimensions can vary. For
example sand casting, forging, or unmachined faces.
 (C) Jack Pins: Jack pins or spring pins are also used to locate the workpiece whose
dimensions are subjected to variation. The pin is allowed to come up under spring pressure
or conversely is pressed down by the workpiece. When the location of the workpiece is
secured the pin is locked in this position by means of a locking screw.

(F) C-Clamp: To unload the workpiece, the locking nut is unscrewed by giving it about one
turn and this releases the c-clamp. When the clamp is removed or swung away the
workpiece can freely pass over the nut. To reverse procedure is adopted for loading the
workpiece.

3. Tool Guide or Jig Bushing

Sometimes the stiffness of the cutting tool may be insufficient to perform certain
machining operations. Then to locate the tool relative to the work, use is made of guiding
parts such as jigs bushing and templates. These must be precise, wear-resistant, and
changeable.
 Jig bushes are used in drilling and boring, a bush fits into the hole of the jig, through
which the drill passes. The diameter of the bush depends on the diameter of the drill. Different
types of bushes are spot welded or screwed with the jig. Headless type bushes are press fit into
the hole of the job. Bushes are generally made of a good grade of tool steel to ensure hardening
at a fairly no temperature and to lessen the danger of fire cracking. Sometimes the bushes for
guiding tools may be of cast iron. Hardened steel bushes are always preferable for guiding drills,
reamers and taps, etc.

American standard bushes are classified into three categories.

1. Press-fit wearing bushes

2. Renewable wearing bushes

3. Linear wearing bushes

Types of Bushes (tool guide/jig bushes)

1. Press fit wearing bushes: These bushes are used when little importance is put on the accuracy
or finish and the tool used is a twist drill. These bushes are installed directly in the jig body and
are used mainly for short protection. There are two designs of press-fit bushing:

A. Plain or headless bush

B. Headed or flanged bush

2. Renewable bushes: When the guide bushes require periodic replacement (due to wear of the
inside diameter of the bush). Its replacement is simply by using a renewable bush. These are of
the flanged types and sliding fit into the linear bush, which is installed press fitted into the jig
plate. The linear bush provides hardened wear resistance, mating surface to the renewable bush.
The renewable bushes must be prevented from rotating or lifting with the drill. One common
method is to use a retaining screw.

3. Linear bushes: These bushes also known as master bushing, are permanently fixed to the jig
body. These act as guides for renewable-type bushing. These bushes are with or without head.

3. Clamping Device: If the work piece can not be restrained by the locating devices or elements,
it become necessary to clamp the work piece in jig or fixture body. The most common example
of clamping devices is bench vice. The purpose of the clamping is to exert a pressure to press a
work piece against the locating surfaces and hold it there in a position to the cutting forces. In
bench vice the movable jaw of the vice exert force on the work piece , their by holding it in
correct position of location in the fixed jaw of the vice. The commonly used clamping devices
are follows:

(A): Clamping Screws: Clamping screws are used for light clamping. Clamping screws are
shown in figure below
Milling Fixtures
A Milling fixture is a work-holding device which is firmly clamped to the table of the
milling machine. It holds the workpiece in the correct position as the table movement carries it
past the cutter or cutters.

Essentials of Milling Fixtures

1. Base: A heavy base is the most important element of a milling fixture. It is a plate with a flat
and smooth underface. The complete fixture is built up from this plate. Keys are provided on the
under face of the plate which are used for easy and accurate aligning of the fixture on the milling
machine table. By inserting them into one of the T slots in the table. These keys are usually set in
keyways on the under face of the plate and are held in place by a socket head cap screw for the
end key. The fixture is fastened to the machine table with the help of two T bolts engaging in the
T slots of the work table.

2. Setting Blocks: After the fixture has been securely clamped to the machine table, the
workpiece which is correctly located in the fixture, has to be set in the correct relationship to the
cutters. This is achieved by the use of setting blocks and feeler gauges. The setting blocks are
fixed to the fixture. Feeler gauges are placed between the cutter and reference planes on the
setting block so that the correct depth of the cut and the correct lateral setting are obtained. The
block is made of hardened steel and with the reference planes(feeler surfaces) grooved. In it
correct setting, the cutter should clear the feeler surfaces by at least 0.08cm to avoid any damage
to the block when the machine table is moved back to unload the fixture. The thickness of the
feeler gauge to be used should be stamped on the fixture base near the setting block.

3. Locating and Clamping Elements: The same design principles of location and clamping
applied for milling fixtures have been discussed above.
Some Design Principles for Milling Fixtures

1. The pressure of the cut should always be against the solid part of the fixture (fig a).

2. Clamps should always be from the front of the fixture (fig b).

3. The workpiece should be supported as near the tool thrust as possible (fig c).

Design Principles Common to Jigs and Fixtures

There are some principles which are useful to design jigs and fixtures.

1. Rigidity: Jigs and fixtures should be sufficiently stiff to secure the preset accuracy of
machining.

2. Fool proofing: It can be defined as “ the incorporation of a design feature in the jig or fixture
that will make it possible to lead the work into jig and fixture, in an improper position, but
will not interfere with loading and unloading the workpiece.” There are many foolproofing
devices, such as fooling pegs, blocks, or pins which clears correctly position parts but
prevent incorrectly loaded parts from entering the jig and fixture body.

3. Clearance: Clearance is provided in the jig or fixture body

(A) to allow for any variation in component sizes, especially casting and forging.
 (B) To allow for hand movements so that the workpiece can easily placed in the jig or
fixture and removed after machining.

4. Burr Grooves: A burr raised on the workpiece at the start of the cut is termed a minor burr
and at the end of a cut is called a major burr. Jigs should be designed so that the removal of
the workpiece is not obstructed by these burrs for this suitable clearance grooves or slots
should be provided.

5. Ejectors: The use of ejection devices to force the workpiece out from the jig or fixture is
important in two positions.

(A) The workpiece is heavy

(B) Machining pressure forces the workpiece to the slides or based on the jig or fixture and
the pressure and oil or coolant fill will cause the work to strick and difficult to remove on
small jigs and fixtures, a pin located under the work will remove the part radially.

6. Inserts: To avoid any damage to the fragile and soft workpiece and also to the finished
surfaces of the workpiece while clamping. Inserts of some soft material such as copper, lead,
fiber, leather, hard rubber, and plastic should be fitted to the faces of the clamps.

7. Design for Safety: Jigs and fixtures must be safe and convenient to use, following are the
some

Factors for the Safety of Workers working on Jigs and Fixtures.

(A) Sharp corners on the body of the jig and fixture should be avoided.

(B) Sighting surfaces should be cleared.

(C) Bolt and nut should be inside the body of the jig or fixture and not protrude on the
surface.

8. Sighting Surface: Machining on the workpiece must be clearly visible to the worker. He
should not be required to bend his neck to see the workpiece or work surfaces.
9. Simplicity in design: The design of the jig and fixture should be a simple one. A completed
design requires a large maintenance. They should be easy to set up, and cheap to
manufacture.

Economical: Jigs and fixtures should be simple in construction, give high accuracy, be
sufficiently rigid, and be lightly weighted. To satisfy these conditions an economical balance has
to be made.

CONCLUSION

Drill jig will be economical from the production point of view. Designed Drill jig has
good strength from a design point of view. Milling Fixture is economical and flexible from the
production and design point of view. Milling Fixtures also has less wear capacity and locking
force between the component and the jaw is very minimal and hence the damaging of the
component is reduced.

REFERENCES

Design of Drill Jig and Milling Fixture for the Component Button Lock. (2019). International
Journal of Innovative Technology and Exploring Engineering, 8(9), pp.865–870.
doi:https://doi.org/10.35940/ijitee.i7755.078919.

Jigs and Fixture by P H Joshi. TMH., 2006

Tool Design by Cyril Donaldson.TMH., 2005