By Pawan

Failure of jigs and fixture 1

 Proper designing and making of
clamps is very much important, as faulty
clamps may cause spoilage in the work as
well as injure the operator. Thus clamping
devices are an essential part of both jigs&
fixtures and may either clamp jig to the
work piece or vice versa, but very
frequently clamps hold a work piece in
place in a jig or fixture.

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 Point more than necessary should not be
used to secure location in any one plane.
However if more are used such as for
finished surfaces, the extra ones should only
be inserted because they serve a useful
purpose and care must taken that they do
not impair the location. Extra supports if
needed should be made adjustable also.

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 Locating points should be chosen as far
apart as possible on any work piece surface.
Thus, for a given displacement of any
locating point from another the resulting
deviation decreases as the distance between
the points increases.

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 When accuracy require, do not attempt to
locate from a hole or position previously
machined, on which a wide tolerance is
permissible, but consider the advisability of
having the tolerance tightened so that the
required result on subsequent operations
may be obtained.

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 The benefits gained from small locating
surfaces such as on rest buttons,
supporting pins or cylindrical locators are
Less time for cleaning.
Reduced chance for lodgement of
disturbing particles.
A more realistic approach to the mean
plane of a rough surface.
Some saving in material & labour

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 The only thing against this benefit is
greater rate of wear causing early
replacement. Therefore, these surfaces
should not be too small, which also create
high specific pressure on the work piece at
such points.

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 All locating points, Which require
replacement due to wear & tear, should be
easily replaceable or repairable. Pins should
driven into through holes for easily driving
them out to replace. Rest buttons and
cylindrical locaters should similarly be also
pressed into through holes.

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 All corners that collect small chips &
swarf must be avoided by relieving them.
Undercut should be provided to all locators
where they create a corner with the surface
to which they are fixed. Numerous kinds of
design in these locators are available to
avoid blind corners at some of these points.

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 One of the most important considerations
affecting the design of tools is the safety of the
operator. Any features, which might cause injury,
must be eliminated. Adequate operating
accessories, such as suitable and efficient levers
and locks, are essential for safety in operation. The
design of drill jigs should provide means of clamping
to the machine table if large drills are used or when
the jig needed not be shifted. Convenient holding
devices should be provided as a safety factor
whenever necessary.

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 Simple angle plate milling fixtures:
Objectives:
To describe simple angle plate milling
fixtures and indicate their purposes.
To discuss features of design common
to this type of tool.
To explain the purpose and use of
setting blocks.
To point out some advantages and
disadvantages of angle plate fixtures

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 The work, which can be performed on
milling machines, is varied and extensive,
but for every milling operation some
method must be devised for supporting
and holding the work piece securely while
it is being milled. The work piece may be
bolted directly to the machine table, or if
practicable, it may be held in a milling
machine vice, or it may require a special
holding fixture.

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 For production milling, each work piece
should accurately located and clamped in a
fixed position so that the relation between
the work and the cutter is maintained.
Milling fixtures generally should be designed
for quick loading & clamping to reduce to a
minimum the time in which the machine is
idle.

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 An angle plate milling fixtures consist mainly
of an angle plate having surfaces which are
perpendicular or at some other required angle to
each other. One surface is bolted or clamped to
the milling machine table; the other surface is
used for locating, supporting, and clamping the
work piece. The angle plate fixture is designed
to hold a circular work piece upon, which a flat
surface is to be milled. The fixture is for milling
a shoulder lengthwise on a rectangular work
piece.

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 Angle plate milling fixtures are generally
used when milling surfaces, grooves, slots
etc. On flat and comparatively thin pieces at
an angle to some other finished surfaces.

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 Angle plate fixtures may be made from cast
iron angle plates, or structural steel angles.
Other angle plates for fixtures may be built up
by welding flat plates of hot-rolled, cold-drawn
or other steel plate. Major factors determining
the choice of the cast or welded types are cost
and time. The time required to make a pattern
(especially when but one casting is to be made)
and the time required to mould and cast and to
machine the working surface is an important
consideration.

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 This total time and the possible delays in
making the cast type should be compared to
the time needed to cut off the steel, weld
the pieces, relieve the strain by heat
treatment, and to true up the working
surfaces by machining.

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 The welded cold drawn steel body has
desirable features. Its un finished
surfaces are smoother than those of
castings; It can be made lighter because
steel is stronger than cast iron; and it can
be case hardened to resist wear. Further
more, less material needed be to
removed from welded bodies to make
surface smooth, flat, square or parallel.

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 However, one disadvantage is that the
welded steel bodies require a normalizing or
an annealing heat treatment to relieve all
stresses caused by the welding heat. After
normalizing and before any machining is
done, it is desirable to sand blast the
surfaces to remove all scale and to improve
the appearance of the tool.

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 For accurate performance, milling
fixtures are aligned with the table of the
machine. One or more keys or tenons are
inserted and fastened in a slot milled in
the bottom of the fixture. The tenons fit
in to the T-slots in the table, and the
fixture is secured with strap clamps and
T-bolts. The strap clamps and bolts are
milling machine equipments and are not a
part of the fixture.

Failure of jigs and fixture 20

 The shape and the condition of the
work piece for which a fixture is to
designed govern the method of locating it
in the fixture. A previously finished
surface, shoulder, groove, or hole may be
utilized for locating if it has a definite
relation to the surface to be milled. When
holes in the part are used for locating,
they may be fitted over hardened locating
pins or plugs in the fixture.

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 Various methods have been devised
for the quick clamping of parts in C
fixture. A single strap clamp with a
support under one end may be
satisfactory for an inexpensive fixture for
low production. The clamp can be
tightened by means of Nut on a stud.
Some means are usually provided to set
the milling cutter in the proper position
to remove the correct amount of stroke.

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 This can be done by the use of one or
more hardened and ground set blocks, which
are dowelled and fastened accurately and
securely to the body of a fixture. These
blocks are placed in a definite relation to
work locators in the fixture. The setting
faces of the blocks are usually ground to the
required dimension after assy.

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 To set cutter in position for depth, one of
the cutting edges is positioned directly over the
ground face of the set block. The Knee of the
machine is then raised until a feeler gauge of a
given thickness will pass or fit between the
cutter edge and the setting block. The Knee is
then clamped retain this setting. To set a cutter
in a correct lateral position, the saddle of the
milling machine is adjusted, so that the same or
another feeler gauge will just fit between the
side of the milling cutter and another face of the
same block or on a second set block.

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 The saddle is then clamped to retain the
cutter setting. Thus the cutter properly located
with relation to depth and to lateral position;
duplicate milling operation may then be
performed. Setting cutters with set blocks
eliminates the cut and try method by which the
first few pieces may be spoiled. it also possible
to frequently and easily check the set up for
accuracy. The fixture should be designed to have
the thrust of the cutter against the solid portion
of the fixture or against stops attached to the
fixture, and not against the clamps.

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 The advantages of an angle plate milling fixtures are
It can be designed to positively locate each work
piece in the same position
The cutter can be set so that all work pieces will be
uniform, there by reducing gauging and inspection time.
Rapid locating and clamping methods, and fool
proofing features can be incorporated in the design.
The thrust of the cutter is usually against the solid
vertical member of angle plate.

The disadvantage of an angle plate fixture is that it

is limited in the height at which it can be used and still
retain rigidity.

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