TOOL DESIGN

JIGS AND
FIXTURES

GAUGES

PRESS
TOOLS

CUTTING
TOOLS

Introduction to semi-automatic and single spindle automatic

screw lathes, Design of cams for automats

PRODUCT
O C
DESIGN

PROCESS
PLANNING

TOOL
OO
DESIGN

PRODUCT
O C
PRODUCTION

Books:
Jigs and Fixtures by P H Joshi
Tool Design by Donaldson, LeCain, Goold

PURPOSE OF TOOL DESIGN

Tool design is the process of
designing and
d
developing
l i
th tools,
the
t l
methods
th d and
d techniques
t h i
necessary to improve manufacturing efficiency and
productivity.
productivity
It gives the industry the machine and special tooling
needed
d d for
f
t d
todays
hi h speed,
high
d high
hi h volume
l
production.
Ensures level of quality and cost.
Since no single tool or process can serve all forms
of manufacturing, tool design is an ever changing,
growing process of creative problem solving.
2

TOOL DESIGN OBJECTIVES

Provide simple, easy to operate tools for maximum
efficiency.
y
Reduce manufacturing expenses by producing parts
possible cost.
at the lowest p
Design tools which consistently produce parts of
high
g q
quality.
y
Increase the rate of production with existing machine
tools.
Design the tool to make it foolproof and prevent
improper
p p use.
Select materials which will give adequate tool life.
Provide protection in the design of the tools for
maximum safety of the operator.
3

PLANNING THE DESIGN

All of the information and specifications pertaining
to the proposed product are evaluated,
evaluated so that the
most efficient and cost effective tool design can be
selected.
selected
The tool designer must understand the part and the
manufacturing
f
i processes.

PART DRAWINGS
When analyzing the part drawing, the tool designer
must consider several general factors which directly
influence the design choices. These factors are:
Overall size and shape of the part.
Type
ype a
and
d co
condition
dto o
of tthe
e material
ate a used for
o tthe
e pa
part.
t
Type of machining operation to be performed.
Degree
D
off accuracy required.
i d
Number of pieces to be made.
Locating and clamping surfaces.

JIG AND FIXTURE DESIGN

INTRODUCTION
The accuracy achieved during machining process
depends
p
upon
p
the p
precision with which the tool and
the work-piece are mounted.
Chucks, vises etc. are suitable for g
general p
purpose
p
but for mass production set up and clamping time
becomes unacceptable.
Hence separate jigs and fixtures are to be designed
for specific applications.

IMPORTANT CONSIDERATIONS WHILE

DESIGNING
Study of work-piece and finished component size and
geometry.
Extent of automation of machine.
Provision of locating devices in the machine.
Available clamping arrangements in the machine.
g devices,, their accuracy.
y
Available indexing
Rigidity and of the machine tool under consideration.
Study of ejecting devices,
devices safety devices,
devices etc.
etc
Required level of the accuracy in the work and quality to
be produced.
produced
8

 Production Devices which are g

generally
y work
holders with / without tool guiding / setting
arrangement.
g
These are called jjigs
g and fixtures.

JIG

FIXTURE
9

JIGS
Jigs are production devices which are used to hold,
support and locate the work
work-piece
piece moreover it also
guides the cutting tool.
The most common application of jigs are for all hole
making operations.
yp of jjigs:
g
Types
drilling, boring, reaming etc.
Open jig, closed or box jig
Template jig, plate jig, table jig, sandwich jig, angle
plate jig, modified angle plate jig, tumble jig, channel jig,
l f jig,
leaf
ji indexing
i d i
ji trunnion
jig,
t
i
ji pump jig,
jig,
ji multi-station
lti t ti
jig
10

FIXTURES
Fixtures are the production devices which are used
f locating,
for
l
ti
h ldi
holding
and
d supporting
ti
th work-piece
the
k i
however unlike jigs they are not used for guiding the
cutting tool.
tool
Used for much wider applications than jigs involving
all other machining processes.
processes
Due to the increased tool forces, fixtures are built
stronger
t
and
d heavier
h
i
th
than
a jig
ji would
ld be
b for
f
th
the
same part.
Fi
Fixtures
t
are normally
ll classified
l
ifi d by
b the
th type
t
off
machine on which they are used.
11

FIXTURES
The following is a partial
operations that use fixtures.
fixtures

list

Assembling
Boring
Broaching
Drilling
Forming
Gauging
Grinding
g
Heat treating
Honing

Lapping
Milling
Planing
Sawing
Shaping
Stamping
Tapping
pp g
Testing
Turning

Inspecting

Welding

of

production

12

ADVANTAGES OF JIGS AND FIXTURES

Productivity
Interchangeability
I t h
bilit
Skill reduction
Cost reduction
Low variability and consistent quality

ELEMENTS OF JIGS AND FIXTURES

Locating elements
Clamping elements
Tool
oo guiding
gu d g and
a d setting
sett g elements
e e e ts
13

PRESENTATION OF WORKPIECE
A jig or fixture drawing shows the workpiece in
position with the jig/fixture.
The workpiece should be discernible from the
jig/fixture.
The workpiece is drawn in a chain
chain-dotted
dotted line,
preferably in colour (red, green or blue).
The workpiece
p
is considered transparent.
p
As the workpiece is transparent, it would not
obstruct or block the view of any part of the
jig/fixture.

14

LIMITS AND FITS

Running fit / clearance fit
Push fit: transition fit
Press fit
Interference fit
Force fit

In tool making,
making accuracy grades 7-11 have been found to be the
most convenient. H7 holes are the most preferred which are
obtained by careful reaming.

15

MATERIALS USED IN JIGS AND FIXTURES

This is a partial list of materials often used for making
jigs, fixtures, press tools, collets, etc.
High speed steels (HSS)
Die steels
Carbon steels
Collet steels (spring steels)
Oil hardened non-shrinking
tool steels

Case hardened steels

High tensile steels
Mild steel
Cast iron
Nylon and fibre
Phospher bronze

Materials are chosen to resist wear of the tools, reduce

wear of the mating parts and prevent damage to the
workpiece.
16

LOCATING PRINCIPLES
Workpiece requisites: The location has to meet
dimensional requirements
q
of the workpiece
p
stated
on the component drawing.
80
40

110

Accuracy: Location should be done on the most

accurate surface of the workpiece. A machined
surface is preferable to an un-machined one.
17

LOCATING PRINCIPLES
Constraints: Location should prevent linear and
rotary motion of the workpiece along and around the
three major axes X, Y and Z.

Motion economy:
y Location system
y
should facilitate
easy and quick loading of the workpiece in the
fixture.
18

LOCATING PRINCIPLES
Redundant locators: redundant locators should be
avoided.
id d

Fool proofing: The location system should positively

prevent wrong loading of the workpiece in a fixture
by fool proofing.

19

LOCATING METHODS
A plane surface
p
A profile
A cylindrical surface
Examples
p
Cylindrical locators
2-Cylindrical
y
locators ((for connecting
g rod))
Conical locator
Adjustable V
V locators

20

STANDARD LOCATING ELEMENTS

(TYPES OF LOCATORS)
Pin and button locators
Cylindrical locator
Conical locator
Jack pin locator
Drill bush locator
Fixed V locator
Sliding V locator

21

LOCATING FROM A PLANE SURFACE

Locating pins/pads
Adjustable supports
Adjustable locators/spring loaded pads
Wedge pin used
sed for height adjustment
adj stment
Equalizing rocker location for square or rectangular
workpiece

22

SIX-POINT LOCATION
(3-2-1 LOCATION PRINCIPLE)
Provide a rest to workpiece on
three points on the bottom x-y
surface.
Movement along z-axis, rotation
with respect to x-axis and y-axis
restricted.
Rest the workpiece on two points
of side surface (x-z), to fix the
movement of workpiece along yy
axis and rotation with respect to zaxis.
Six-point location in a jig

Provide a support at one point of

the adjacent surface (y-z) that will
fix
other
remaining
g
free
movements.
23

LOCATING FROM A PROFILE

For simple components, a sighting plate can be used.
The workpiece
p
can be p
positioned on the sighting
g
gp
plate
in such a way that there is equal margin on all the
sides.
The profile of the workpiece can be located by
confining the profile with cylindrical locating pins.
pins
When there is considerable variation in workpiece
di
dimensions
i
f
from
b t h to
batch
t batch,
b t h an eccentric
t i locator
l
t
can be used.
Workpieces with little variation can be located
precisely with nesting plates with suitable provision for
loading and unloading.
24

LOCATING FROM CYLINDER

Spigots used for locating bores should have ample
lead for easy entry and their length should be short
to prevent jamming of the workpiece.
Long locators for fragile workpiece should be
relieved at the centre.
Location p
posts,, which are also used for clamping
p g
must be retained by a nut or a grub screw.
When two location pins are used, the less important
one should be made diamond-shaped.
Rough cored holes and bosses are located by
conical locators, which often
f
have integral clamping
arrangement and drill bush.
25

LOCATING FROM CYLINDER

Fixed V blocks are used to locate approximately the
outside surface of a cylinder
cylinder.
For precise location, an adjustable guided V block is
necessary. The V block can be adjusted by a screw
or a cam.
The V block should be p
positioned in such a way
y that
the variation in the workpiece would not affect the
location for the operation. For drilling central holes,
th centre
the
t line
li off V should
h ld be
b vertical.
ti l
Clearance grooves should be provided at flash line
of cast,
cast forged and moulded workpieces.
workpieces

26

LOCATOR FOR PLANE SURFACE

Fig.1

Fig.2

Fig.3

27

LOCATOR FOR PLANE SURFACE

In fig 1 undercut is provided at the bottom where two
perpendicular surfaces intersect each other.
other This is
made for swarf clearance.
Th
The figure
fi
2 shows
h
fl t headed
flat
h d d button
b tt
t
type
l
locator.
t
There is no need to made undercut for swarf
clearance.
l
Th button
The
b
can be
b adjusted
dj
d to decide
d id very
fine location of the workpiece.
There can be a vertical button support shown in
figure 3, which is a better arrangement due to its
capacity to bear end load and there is a provision for
swarf clearance automatically.
28

CYLINDRICAL LOCATORS
For locating components
having drilled holes.
The cylindrical component
to be located is gripped by a
cylindrical locator fitted to
the jig
jigs
s body and inserted
in the drilled hole of the
component.
p
The face of the jigs body
around
the
locator
is
undercut to provide space
for swarf clearance.
29

CONICAL LOCATORS
For locating the workpiece
having cylindrical hole
The workpiece
p
is located by
y
supporting it over the conical
locator inserted into the
drilled hole of the workpiece.
Degree of freedom along zaxis can also be restrained
by putting a template with the
help of screws
30

JACK PIN AND V LOCATORS

This is
Thi
i used
d for
f locating
l
ti
th
the
circular and semi-circular
type of workpieces.
workpieces
31

V LOCATORS
This is quick and effective method of locating the
workpiece with desired level of accuracy. This is
used for locating the circular and semi-circular type
of workpieces.
workpieces
The main part of locating device is Vee shaped
block which is normally fixed to the jig.
jig
The fixed type locator is normally fixed on the jig and
adjustable locator can be moved axially to provide
proper grip of Vee band to the workpiece.
This locator can be of two types fixed Vee locator
and adjustable Vee locator.
32

Screw adjusted V-locator

Female locator

33

Cam operated
p
V-locator

Quick action V-locator

Q
34

C
Correct
t position
iti off V

W
Wrong
position
iti off V

35