Jigs and Fixtures
INTRODUCTION
• Fixtures are workholding devices designed to hold,
locate and support workpieces during
manufacturing operations.
• Fixtures provide a means to reference and align the
cutting tool to the workpiece but they do not guide
the tool.
• Fixtures that have the added function of guiding
the tool during manufacturing are called jigs.
INTRODUCTION
Fixtures….
• being used in machine shop, are strong and rigid mechanical devices
• which enable easy, quick and consistently accurate locating,
• supporting and clamping, blanks against cutting tool(s)
• and result faster and accurate machining with consistent quality, functional ability
and interchangeability.
• Jig is a fixture with an additional feature of tool guidance.
Both jigs and fixtures — but especially fixtures — can be
considered work holding devices used to keep a workpiece (the in-
progress part being made) stable and secure during manufacturing.
INTRODUCTION
Fixturing devices include:
• Various standard clamps, chucks, and vises
• Metal plates containing dowel and/or tapped locating holes or key
slots
• Dedicated fixtures with specific design and build requirements
Jig
• In short, a jig is a tool used to control or guide the movement of a cutting
tool such as a drill (and sometimes to simultaneously hold the workpiece).
• By introducing a tool that precisely guides the movement of a cutting tool,
a manufacturer can, for example, guarantee repeatability: ensuring the
same cut is made in exactly the same place on several duplicates of a part.
• The same jig can be used over and over, resulting in the same outcome
with each use.
Jig
• Since their purpose is primarily to guide and direct cutting tools,
jigs are most commonly used for manual work, i.e. manual
machining and drilling.
• CNC machines are less dependent on jigs, since they are designed
to provide micron-level precision without assistance; their cutting
tools are “guided” by computer instructions.
Types of Jig
• Template jig: A simple jig that can be fitted onto the workpiece, it has holes through which
a cutting tool (e.g. drill) can be guided.
• Plate jig: Similar to a template jig but with drill bushes instead of just holes.
• Angle-plate jig: Used to prop up the workpiece at an angle to facilitate the drilling of e.g.
diagonal holes.
• Leaf jig: A jig with a hinged leaf that can be swung open and closed for faster loading or
unloading.
• Diameter jig: Used to enable the drilling of rounded workpieces that cannot easily be
secured in other types of jig.
Fixtures
• Fixtures have a few features in common with jigs, but their purpose is
essentially different.
• The sole function of a fixture is to keep a workpiece stable and secure
during manufacturing; a fixture is therefore a work holding device in the
truest sense.
• Fixtures can perform several functions such as
i. By keeping a workpiece fully secure, they ensure accuracy and
repeatability.
ii. They can also be adjusted to hold a workpiece at a specific angle,
allowing for cutting operations in a range of directions.
Fixtures
• Fixtures also minimize errors and guarantee the safety of workers by
preventing the workpiece from being accidentally flung from the work
table.
• Like jigs, fixtures are often used in machining operations.
• While jigs are typically held in place with fasteners or even held
manually by the machine operator, fixtures have a variety of clamping
options, including hydraulic, pneumatic, and vacuum systems for
applying the requisite force
Types of Fixtures
• Turning fixture: Typically mounted on the machine spindle or a face
plate, turning fixtures are useful for more complex lathe-made parts.
• Milling fixture: Typically secured to the work table with fasteners,
these fixtures enable a variety of milling operations.
• Drilling fixture: Comprising hole and bushing, drilling fixtures are
sometimes used in place of (or in addition to) jigs.
• Grinding fixture: Used to support a workpiece during grinding
operations.
Basic purposes of Jig and Fixtures
• To eliminate marking, punching, positioning, alignments etc.
• Easy, quick and consistently accurate locating, supporting and
clamping the blank in alignment of the cutting tool
• Guidance to the cutting tool like drill, reamer etc.
• Increase in productivity and maintain product quality consistently
• To reduce operator’s labour and skill – requirement
• To reduce measurement and its cost
• Enhancing technological capacity of the machine tools
• Reduction of overall machining cost and also increase in
interchangeability
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Advantages of Jig and Fixtures
• The use of jigs and fixtures during manufacturing can lead to
significant benefits in terms of production and part quality.
• Increased production rate
• Eliminates need for manual measurement and alignment
• Consistency and accuracy across multiple parts
• Reduced dependence on manual skill of machinist
• Reduced dependence on post-manufacturing quality control
measures
• Improved safety for workers
• Allows machinist to adjust feeds and speeds for faster production
Elements of Jigs and Fixtures
The body: The body is the most
outstanding element of jigs and
fixtures.
It is constructed by welding of
different slabs and metals. After the
fabrication, it is often heat-treated
for stress reduction as its main
objective is to accommodate and
support the job.
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and-fixtures/designing-jigs-and-fixtures.html
Elements of Jigs and Fixtures
• Clamping devices: The clamping devices must be
straightforward and easy to operate, without sacrificing
efficiency and effectiveness.
• Apart from holding the work-piece firmly in place, the
clamping devices are capable of withholding the strain of the
cutting tool during operations.
• The need for clamping the work-piece on the jig or fixture is
to apply pressure and press it against the locating
components, thereby fastening it in the right position for the
cutting tools
Elements of Jigs and Fixtures
Locating devices:
• The pin is the most popular device applied for the
location of work-piece in jigs and fixtures.
• The pin’s shank is press-fitted or driven into a jig or
fixture.
• The locating width of the pin is made bigger than the
shank to stop it from being pressed into the jig or fixture
body because of the weight of the cutting tools or work-
piece.
• It is made with hardened steel.
Elements of Jigs and Fixtures
Jig bushing or tool guide:
• Guiding parts like jig bushings and templates are used to
locate the cutting tool relative to the component being
machined.
• Jig bushes are applied in drilling and boring, which must
be wear resistant, interchangeable, and precise.
• Bushes are mainly made of a reliable grade of tool steel
to ensure hardening at a low temperature and also
reduce the risk of fire crackling
