JIGS QB 2016revised As On 11.2.2016

Question Bank (May 2016) revised as on 11-02-2016 ME5635-Design of Jigs, Fixtures And Press Tools
Saveetha School of Engineering

Saveetha University
Chennai 602 105
Department of Mechanical Engineering
Academic Year 2015- 2016 / Even Semester
QUESTION BANK
Sub. Code/Name: ME5635-Design of Jigs, Fixtures and Press Tools
Year/Sem: III/VI
(Use of approved design data book is permitted)

UNIT I PURPOSE, TYPES AND FUNCTIONS OF JIGS AND FIXTURES
Tool design objectives Production devices Inspection devices Materials used in Jigs and
Fixtures Types of Jigs Types of FixturesMechanical actuation Pneumatic and Hydraulic
Actuation Analysis of clamping force Tolerance and Error analysis.
Part A (2 Marks)
1. Define the term tool design.
Ans: Tool design is the process of designing and developing the tools, methods and techniques
necessary to improve manufacturing efficiency and productivity.
2. What are the types of tooling?
Ans: (i) Cutting tools (single and multiple point cutting tools), (ii) press tools, (iii) dies, (iv) jigs
and fixtures, and (v) gauges.
3. Define the term jig.
Ans: Jig is a work holding device that holds, supports and locates the workpiece and guides cutting
tool for a specific operation.
4. Define the term fixture.
Ans: Fixture is a work holding device that holds, supports and locates the workpiece for a specific
operation but does not guide the cutting tool.
5. Name any two materials commonly used in jigs and fixtures.
Ans: 1. HSS (High Speed Steel),
2. High Tensile Steel,
3. Oil Hardening Non-shrinking tool steel, and
4. Case Hardening Steel
Dept. of Mech. Engg. Page 1 of 25 SSE, Saveetha University

6. What is fool proofing?

Ans: The locating system should positively prevent wrong loading of the workpiece in a fixture by
fool proofing.
Make the jig fool proof; That is, to arrange it so that work cannot be inserted except in correct
way.
7. What is meant by referencing?

Ans: Referencing is the process of properly positioning the part with respect to the cutter or other
tool.
8. Define degree of freedom?
Ans: An unrestricted object is free to move in any of the twelve possible directions. An object is
free to revolve around one move parallel to any axis in either direction.

9. What is meant by 3-2-1 location or 6 point location?

Ans: According to this principle, a workpiece can be completely restrained by providing three
location points in one plane, two location points in second plane and one location point in the third
plane. Therefore, it is called 3-2-1 principle of location.
10. Define locating devices.

Ans: Locators are those parts of a jigs or fixture which help a workpiece to seat in proper position
in it. Depending on the type of work, locators are designed. There is a large variety of locating
devices or locators and methods of locating available to a jig and fixture designed. The majority of
workpieces can be located with these methods.
11. Name any four locators that are generally used.

Ans: Pin and button locators, V-locators, bush locators and nest or cavity locators.

12. Define jack pin locator.

Ans: The locator which positions itself automatically by means of spring force according to the
need is known as jack pin locator.
13. Define clamping devices.

Ans: clamping devices are used to hold the workpiece in the correct relative position in the jig or
fixture. It should ensure that the workpiece is not displaced under the action of cutting forces. For
efficient operation, firm clamping of the workpiece is must.
14. Sketch a Bayonet clamp.
Ans:

15. What is meant by fit?

Ans: Fit expresses the relationship between mating parts with respect to the amount of clearance
or interference which exists when they are assembled together.
16. What is meant by tolerance?

Ans: Tolerance is the acceptance of an error of manufacturing. It is the acceptance of the fact that a
dimension cannot be economically made to the exact size specified by the designer. Tolerance is
the difference between the maximum limit of size and the minimum limit of size.
17. Distinguish between unilateral and bilateral tolerance.

Ans: Unilateral tolerance is one that applies in one direction from the nominal size, the permissible
variation in the other direction is zero. The bilateral tolerance, the tolerance is split into two parts
(equal or unequal) and applied on either side of the nominal size. The deviations on either side are
expressed as plus and minus values to the nominal size.

18. What are the different types of errors considered in design of jig?
Ans: 1. Locating errors, 2. Clamping error, and 3. Fixture error
Part B (16 Marks)

1. (a) Discuss in detail the design principles employed in jigs and fixtures. [8]
(b) List out the advantages of using jigs and fixtures. [8]
2. (a) Define tolerance and fit. Explain the various fits with its diagram. [6]
(b) Compute the fundamental deviations for a circular hole of 35 mm diameter finished to H7
tolerance. [10]
3. Discuss in detail about various locating principles. [16]
4. With a neat sketch explain air to hydraulic pressure booster for clamping application.
[16]
5. (a) Describe any two types of locating elements (locators) with neat sketches. [8]
(b) Compute the fundamental deviations for a circular shaft of 60 mm diameter finished to g6
tolerance. [8]
6. Sketch and explain any two of the mechanically actuated clamps. [16]

UNIT II JIGS
Drill bushes Different types of jigs Plate latch Channel, box- post- angle plate- angular post-
turnover- pot jigs Automatic drill jigs Rack and pinion operated Air operated Jigs
components Design and development of Jigs for given components.
PART A (2 Marks)
1. What are the elements of jigs?
Ans: Jig body, jig feet, jig bushing, jig plate or bush plate, locators, clamps, fool proof element.
2. List the construction methods of jigs?
Ans: Built up construction, Welded construction, cast construction.
3. List the types of jigs.
Ans:
a. Template Jig j. Post jig
b. Plate jig k. Sandwich jig
c. Channel jig l. Nut cracker jig
d. Leaf jig m. Pumping or universal
e. Pot jig n. Latch jig
f. Turnover jig or table jig o. Vise jig
g. Box jig or tumble jig p. Solid jig
h. Trunnion jig q. Angle plate jig
i. Indexing jig r. Angular post jig.
4. What is the function of jig bushes?
Ans: Drill bushes are used to guide drills, reamers and other cutting tools to the workpiece. 5.
What is an open press fit bush?
Ans: Press fit bushes are the most common type of bushes and are pressed by interference fit in the
bush plates also referred to as jig plates.
6. What is meant by renewable bush?
Ans: These bushes are generally used for continuous or for large batch production. These bushes
are used in liner bushings which are installed in the jig plate.

7. How the rotation and movement of bush can be prevented? Show with sketch.
Ans: By providing set screws, the bushes are retained with the jig plate.

8. Sketch the headed drill bush.

Ans:
9. Sketch a shaped drill bush.

Ans:
10. Sketch a channel jig.

Ans:

11. State the use of angular post jig.

Ans: These jigs are used to drill holes in the workpiece at some angles.
12. State the use of post jigs.

Ans: The post jig is used for drilling and reaming operations. It is named so because it has a solid
post to locate the workpiece from its bore. These jigs are mainly useful for hollow workpiece.

13. Define sandwich jig.

Ans: These jigs are a form of plate jig with a back plate. This type of jig is ideal for thin or soft
parts that could bend or wrap in another style of jig. Here again, the use of bushings is determined
by the number of parts to be made.
14. State the provision made on latch or leaf jigs.

Ans: Leaf plate is capable of swinging about a fulcrum point so that it can open or close the load
or unload the workpiece.

15. What are the advantages of trunnion jig?

Ans: (i) the workpiece is located and clamped to the carrier which also carries the drill plates.
(ii) the carrier is mounted on trunnion so that it can be rotated from face to face.
(iii) it can be positioned and locked using an indexing device.
16. Define indexing device.

Ans: Device used for dividing the rotation of the circular workpiece into equal number of portions
is known as indexing device.
17. What are the various possibilities to operate automatic drill jigs?
Ans: (i) Mechanical
(ii) Pneumatic or air operated
(iii) Hydraulic operated
(iv) pneumo-hydraulic

Part B (16 Marks)

1. (a) Explain the important elements of any jig. [8]
(b) Explain any two types of drill bush with neat sketch. [8]
2.With neat sketches explain the uses of plate and channel jigs. [16]
3.Explain the use of turnover jig with a neat diagram. [16]
4. Design a drill jig for the use when drilling the 12 mm diameter hole in the shank of the adapter
show in Fig. 2.1. 16]
Fig. 2.1
5. Explain the box jig and angular post jig with neat sketch. [16]

6. Design and develop a jig which can be used for drilling holes on the web of a flange coupling
as shown in Fig. 2.3. [16]
Fig. 2.3

UNIT III FIXTURES

General principles of boring- lathe- milling and broaching Fixtures Grinding- planning and
shaping fixtures- assembly- Inspection and welding fixtures Modular fixtures Design and
development of fixtures for given component.
PART A (2 Marks)
1. What are fixtures?
Ans: Fixtures are used to hold work pieces during machining when they are to be produced in
large numbers. Fixtures are a form of tooling that are used to position parts relative to each other
for fabricating purposes.
2. What are the standard work holding devices used in lathes?
Ans: i) Chucks
ii) Collets
iii) Face plate
iv) Mandrels
3. State any four design points to be considered while designing a lathe fixture.
Ans: i) The fixture should be accurately balanced in order to avoid vibrations while revolving.
ii) Clamps and other holding devices should be designed in such a way that they will not be
loosened by centrifugal force.
iii) There should be no projections of the fixture which may cause injury to the operator.
iv) The fixture should be light in weight as far as possible, since it is rotating.
4. What is the function of mandrels in turning fixture?
Ans: It is used to hold the hollow workpiece and mandrels.
5. Mention the application of turning fixture.
Ans: The fixture body is designed to drill a hole in the face of a cubical shaped workpiece.
6. Mention any four essential features made on milling fixtures.
Ans: i) Base
ii) Tenon strips
iii) Setting block
iv) Locating elements

7. What are the factors to be considered while selecting string milling fixture?
Ans: i) The length depends on the size of the workpiece.
ii) Length of milling machine table
iii) Length of stroke of the table.
iv) The workpiece should be clamped properly to ensure accurate machining.
8. When are indexing fixtures used?
Ans: When a number of surfaces are to be milled on a periphery of a workpiece are gear teeth,
slots, splines in shafts, etc.
9. State the classification of boring bars.
Ans: i) Stub bar
ii) Single-piloted bar
iii) Double-piloted bar
10. What are the different types of broaching operations?
Ans: i) Keyway broaching
ii) Hole broaching
iii) Gear broaching
11. Define key way broaching fixture.
Ans: The fixture which is used for cutting internal key-ways in pulleys, gears, sprockets, etc are
known as key way broaching fixtures.
12. What are inspection fixtures? State its types.

Ans: Inspection fixtures are used to check the quality of the workpieces as well as the components
or parts of the machines. Types:
a) In-process inspection fixtures
b) Off-line inspection fixtures
13. What are the important elements of inspection fixtures?

Ans: a) Locating element
b) Clamping element
c) Gauging element
d) Auxiliary element
14. Mention any two design principles applicable to welding fixture.

Ans: Welding spatter should not be allowed to fall on the threaded parts of the clamping elements.
Welding fixture should not be so designed that it does not get overheated due to continuous
work.
15. What is the use of tack welding fixture?
Ans: Tack welding fixtures are used to locate the components of a weldment in their correct
relationship with proper clamps while a welder tacks them prior to their final welding.
16. State the main function of assembly fixtures
Ans: The main function is to hold different components together in their proper relative position at
the time of assembling them.
Part B (16 Marks)

1. Design a suitable milling fixture to cut a keyway of size 3 x 3 mm on a solid shaft of 30 mm
diameter and 100 mm length.
Keys: Milling fixture diagram with components marking: 8 Marks and Description: 8 Marks
2. Describe the construction and working of planing and shaping fixtures with near sketches.
Keys: Planer fixture diagram with components marking: 4 Marks and Description: 4 Marks
Shaper fixture diagram with components marking: 4 Marks and Description: 4 Marks
3. What are the standard work holding devices used in lathes? Illustrate the working of faceplate
fixtures.
Keys: standard work holding device: 2 Marks, Faceplate fixtures Diagram: 8 Marks and
Description: 6 Marks
4. What is meant by Gang Milling? Illustrate the working of a Gang milling fixture.
Keys: Gang Milling Definition: 2 Marks, gang milling fixture diagram: 8 Marks and Description:
6 Marks
5. Define broaching and explain the types of broaching milling fixtures with neat sketches.
Keys: Broaching Definition: 2 Marks, broaching milling fixture diagram: 8 Marks and
Description: 6 Marks

UNIT IV PRESS WORKING TERMINOLOGIES

Press working terminology Presses and press accessories Computation of capacities and
tonnage requirements Elements of progressive combination and compound dies Die block die
shoe Bolster plate Punch plate Punch holder Guide pins and bushes Strippers
Knockouts Stops Pilots Selection of standard die sets strip lay out Strip lay out calculations.
Part A (2 Marks)
1. How is cutting operation carried out?
The work piece is stressed beyond its ultimate strength and cut-off into two pieces.
2. List out the various cutting operations.
a. Blanking c. Shearing
b. Punching d. Parting off
3. Mention the three different ways of working sheet metal in presses.
a. Shearing
b. Bending
c. Drawing
4. Classify sheet metal operations
a. Cutting operations
b. Forming operations
5. State the advantages of press working operations.
a. Material economy c. Uniformity of parts
b. High productivity d. Use of less labour.
6.What are the applications of press working operations?
a. Electronic appliances c. Coach building
b. Steel furniture d. Automobile industry
7.Name some types of forming operations.
a. Bending c. Squeezing
b. Drawing d. Embossing
8.List out the press working terminology.
a. Base c. Die holder
b. Bolster plate d. Die

e. Stripper h. Stroke
f. Punch i. Guide pin
g. Pitman j. Back up plate
9. When will be hydraulically driven presses used?
Whenever large force and slow speed are required in forming, pressing and drawing operation,
hydraulically driven presses are used.
10. How will you select the proper material for press tools?
a .Hardness c. Bending strength
b. Compressive strength d. Toughness
11. What factors are considered for selecting an appropriate press for a given job?
a. Force required to be cut the metal e. Shut height
b. Die space f. Type of operation
c. Size and type of die g. speed of operation
d. Stroke length
12. List down the material used for press working operations.
a. Mild steel e. Aluminium
b. Stainless steel f. Hard rubber
c. Brass g. Fiber
d. Copper
13. What is a progressive die?
A die which is used to perform two or more operations at different stages every time when the
ram descends is called progressive die. It is mainly used where the accuracy of the products is
maintained.
14. Explain the function of bolster plate in press tool.
The bolster plate is the thick plate mounted on the base. It is used for locating and supporting the
die assembly. It is usually 5 to 12.5 mm thick plate.
15. What are the methods of holding pilots?
a. Direct pilots
b. Indirect pilots
16. What are the types of stock stop?
a. Lever or latch type b. Automatic stop
c. Shoulder stop d. Starting stop

17. List down the various methods of arranging guide pins in the die set.
a. Back-post design c. Diagonal-post design
b. Centre-post design d. four-guide post design
18. What are the types of die set?
a. Precision die set
b. Commercial die set.
PART-B (16 Marks)
1. Describe briefly the various press working operations. (16)

Key: i) cutting operations blanking, punching or piercing, shearing, parting, notching, trimming,
shaving, perforating, slitting, and lancing 10 Marks ii) Forming operations bending, drawing,
sequeezing, and embossing 6 Marks
2. Describe briefly the press working terminologies. (16)
Keys: Diagram: 8 Marks, Description of each components: 8 Marks
3. Explain briefly the functions of following parts in press tool. (16)
(i) Stripper
(ii) Pilots
(iii) Shedder.
Keys: Stripper Diagram: 3 Marks, Stripper Description: 3 Marks, Pilot Diagram: 3 Marks, Pilot
Description: 3 Marks, Shedder Diagram: 2 Marks, Shedder Description: 2 Marks
4. (a) Explain briefly the function of the following parts applied to press working.
i) Stock stop and (ii) Knockout rod (6)
(b) Briefly explain the compound die with neat sketch. List out the merits and demerits of this
compound die. (10)
Keys: (a) (i) Stock stop diagram and description: 3 Marks, (ii) Knockout rod diagram and
description: 3 Marks
(b) Diagram of compound die: 4 Marks: Description of diagram: 3 Marks, Merits and demerits: 3
Marks.
5. Explain the procedure for the computation of press capacities and tonnage requirements for
cutting and drawing operations. (16)

Keys: Press capacities for cutting operations: 6 Marks, Press capacities for drawing operations:
10 Marks

UNIT V DESIGN AND DEVELOPMENT OF DIES

Design and development of progressive and compound dies for Blanking and piercing operations
Bending dies Development of Bending Dies forming and Drawing Dies Development of
Drawing Dies Design considerations in Forging Extrusion Casting and Plastic Dies.
PART A (2 Marks)
1. Write down the formula for calculating cutting forces required in a cutting operation.
Ans: Cutting force, for round holes
for other contours
D = Diameter of the hole to be cut

t = Thickness of material
= Ultimate shear strength of the material
= Shearing length
2. Write down the formula for calculating drawing force required in drawing operations.
Ans: Drawing force,

where
d = Outside diameter of the shell
t = Thickness of material
Yield strength of metal
Diameter of the blank to be cut
0.6 0.7 for ductile materials
3. What is the purpose of stock-stop?
Ans: It is used to stop the die at a required distance. It avoids over penetration of die in materials.
4. What is meant by bending allowance?
Ans: It is also called spring back allowance. Spring back allowance is defined as the tendency of
sheet metal to change the shape from final shape.
5. What is meant by flash and gutter?
Ans: The portion of extra metal near the parting line is known as flash. In addition to this, again
some extra metal is added with flash as extension is known as gutter.

6. What are the various types of bending?

Ans: The various types of bending are:
a. Edge bending
b. V bending
c. U bending
7. What is spring back?
Ans: The tendency of the metal to resume its original position causing a decrease in bend
o o
angle is known as spring back. The spring back varies from 0.5 to 5 for steel.
8. List the factors affecting spring back.
Ans:
a. Material type c. Hardness
b. Thickness d. Bend radius
9. List four factors affecting drawing
Ans:
a. Type of material c. Yield strength
b. Ductility d. Drawing speed
10. What are the types of drawing dies?
Ans: a. Single action dies
b. Double action dies
11. What are the methods used for bulging dies?
Ans:
a. Rubber d. Oil
b. Urethane e. Water
c. Heavy grease
12. What are the advantages of coining?
Ans: a. Excellent surface finish
b. Closer tolerances
13. What are the factors affecting bending?
Ans: a. Properties of material
b. Length of bend
c. Condition of cut edge at the ends of bend line

d. Direction of orientation of the axis of the bend to the direction in which material was
rolled
PART B (16 Marks)

1. A steel cup of height 30 mm and internal diameter 40 mm with a flange width of 10 mm is to be
deep drawn from a sheet 1 mm thick, determine the diameter of the blank and the drawing force.
What is the draw ratio? Can the cup be drawn in a single operation? Sketch the view of a draw die.
Keys: step by step procedure: 8 Marks and drawing die diagram: 8 Marks
2. Design and sketch a blanking die to make 20 mm square part from 2 mm thick carbon steel
metal.
Keys: step by step procedure: 12 Marks with appropriate diagram: 4 Marks
3. Sketch and design a progressive cutting die to make a steel washer 30 mm outside diameter with
15 mm hole from 1.6 mm thick steel sheet. The ultimate shear strength of the material is 320
2
N/mm .
Keys: step by step procedure: 10 Marks with appropriate diagram: 6 Marks
4. Write a short note on
(i) Bending Die and its classification
(ii) Bending Force
(iii) Bend Allowance
(iv) Spring Back Effect
Keys: Each subdivision carries 4 Marks for description with appropriate diagram.
5. Calculate the bending force and press capacity required, if the ultimate tensile strength of
2
material is 3500 kg/cm for the given Fig. 5.1. The die radius is 5 mm. Thickness is 3 mm. All
dimensions are in mm.
50
3R
3R
60

Fig. 5.1
Keys: Total Blank Length: 144.57 mm (Formula and answer: 8 Marks), Width of die: 1.3 cm
(formula and answer: 2 Marks), Bending force: 9.32 tonnes (Formula and Answer: 4 Marks), and
Press capacity: 10. 252 tonnes (2 Marks)
REFERENCES
1. Edward G Hoffman- Jigs & Fixture Design, Thomson Delmar Learning, Singapore 2004
2. Donaldson. C, Tool Design, Tata McGrawHill, 1986
3. Kempster, Jigs & Fixtures Design, The English Language Book Society, 1978
4. Joshi, P.H., Jigs & Fixtures, Second Edition, Tata McGrawHill Publishing Company
Limited, New Delhi 2004
5. Hiram E Grant, Jigs and Fixture Tata McGrawHill, New Delhi, 2003
6. Fundamentals of Tool Design, CEEE Edition, ASTME, 1983
7. Design Data Handbook PSG College of Technology, Coimbatore.

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Question Bank (May 2016) revised as on 11-02-2016 ME5635-Design of Jigs, Fixtures And Press Tools

Saveetha School of Engineering

(Use of approved design data book is permitted)

Dept. of Mech. Engg. Page 1 of 25 SSE, Saveetha University

6. What is fool proofing?

7. What is meant by referencing?

Dept. of Mech. Engg. Page 2 of 25 SSE, Saveetha University

9. What is meant by 3-2-1 location or 6 point location?

10. Define locating devices.

11. Name any four locators that are generally used.

Dept. of Mech. Engg. Page 3 of 25 SSE, Saveetha University

12. Define jack pin locator.

13. Define clamping devices.

Dept. of Mech. Engg. Page 4 of 25 SSE, Saveetha University

15. What is meant by fit?

16. What is meant by tolerance?

17. Distinguish between unilateral and bilateral tolerance.

Dept. of Mech. Engg. Page 5 of 25 SSE, Saveetha University

Part B (16 Marks)

Dept. of Mech. Engg. Page 6 of 25 SSE, Saveetha University

Dept. of Mech. Engg. Page 7 of 25 SSE, Saveetha University

Dept. of Mech. Engg. Page 8 of 25 SSE, Saveetha University

8. Sketch the headed drill bush.

9. Sketch a shaped drill bush.

10. Sketch a channel jig.

Dept. of Mech. Engg. Page 9 of 25 SSE, Saveetha University

11. State the use of angular post jig.

12. State the use of post jigs.

Dept. of Mech. Engg. Page 10 of 25 SSE, Saveetha University

13. Define sandwich jig.

14. State the provision made on latch or leaf jigs.

Dept. of Mech. Engg. Page 11 of 25 SSE, Saveetha University

15. What are the advantages of trunnion jig?

16. Define indexing device.

Dept. of Mech. Engg. Page 12 of 25 SSE, Saveetha University

Part B (16 Marks)

3.Explain the use of turnover jig with a neat diagram. [16]

Dept. of Mech. Engg. Page 13 of 25 SSE, Saveetha University

Dept. of Mech. Engg. Page 14 of 25 SSE, Saveetha University

UNIT III FIXTURES

Dept. of Mech. Engg. Page 15 of 25 SSE, Saveetha University

12. What are inspection fixtures? State its types.

13. What are the important elements of inspection fixtures?

14. Mention any two design principles applicable to welding fixture.

Part B (16 Marks)

Dept. of Mech. Engg. Page 17 of 25 SSE, Saveetha University

UNIT IV PRESS WORKING TERMINOLOGIES

Dept. of Mech. Engg. Page 18 of 25 SSE, Saveetha University

c. Shoulder stop d. Starting stop

1. Describe briefly the various press working operations. (16)

Dept. of Mech. Engg. Page 20 of 25 SSE, Saveetha University

Dept. of Mech. Engg. Page 21 of 25 SSE, Saveetha University

UNIT V DESIGN AND DEVELOPMENT OF DIES

D = Diameter of the hole to be cut

Ans: Drawing force,

Dept. of Mech. Engg. Page 22 of 25 SSE, Saveetha University

6. What are the various types of bending?

Dept. of Mech. Engg. Page 23 of 25 SSE, Saveetha University

PART B (16 Marks)

Dept. of Mech. Engg. Page 24 of 25 SSE, Saveetha University

Dept. of Mech. Engg. Page 25 of 25 SSE, Saveetha University

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