PRESENTATION

ON
JIGS AND FIXTURES (GROUP G)
HND MECHANICAL
ENGINEERING I
(REGULAR SCHOOL)

EGYIR MICHAEL
EMMANUEL YARTEL
DANIEL AVISEY TEGAH
EMMANUEL AGYEI
GODSON AWUYEH
ERIC AMOANI DARKO
ERIC KOTEY NEEQUAYE
ISAAC COLEMAN
ROBERT SOMETIEMAH
TAWIAH DASSAH
ASSOAH YAW EVANS
LOUIS YAWSON

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OBJECTIVE
After this lesson student should be able to
Understand the principle underlying jigs and fixtures
design.
Sketch and explain the six degrees of freedom.
Explain how clamping as a securing device prevents
or restrains body movement.
Define and explain jig and fixture.

INTRODUCTION
The application of jigs and fixtures is important aspect of
workshop engineering, and their application is worthy of some
consideration on all bit the simplest types of production, small
orders and tool room work.
Jigs and fixture are appliances used in manufacture or
assembly
and to facilitate the operation to which they are applied. The
primary object of their use might be facilitate the holding and
support of an awkward or frail article for some machining
operation. To position a component and to guide the cutters in
the operations so that every component produced will be
uniform to accommodate several component at one setting to
take advantage of multiple machining and to hold a component
which Could not be held conveniently without a fixture and so
on.

JUSTIFYING THE NEED FOR TOOLING

A clear-out direction should be issued by the
management
when a product is to be tooled, and this direction is to
be fully
or only partly tooled.
The factors which need to be considered at this stage
are as
follows:
Quantities of parts-initially and in total
Length of run, from which may be assessed the
question of wear and maintenance.
The time factor, which is governed by the urgency in
completing a programme or putting a new product on
to the market.
Nature and form of job design

THE NEED FOR JIGS AND FIXTURES

To ensure that all parts produced are identical in the
form and size.
To produce interchangeable parts at a reduced cost.
To increase accuracy and to reduce manual
operations.
To take advantage of employing semi-skilled labour.
To facilitate assembly.
To reduce overall cost.

FUNDAMENTAL OF GOOD JIGS AND FIXTURES

DESIGN
Location : The location portion of the jig or
fixtures must be definite, simple, visible and clear.
For first operation work on forgings or rough
castings, no more than three locating base points
should be used . Locations should be adjustable
when variations in size of components are likely.
Clearance : Adequate finger clearance must be
allowed to facilitate loading and unloading, and to
cater for variable dimensions of castings and
forgings. Allowance must be made also for
machining burrs.
Loading and unloading : These elemental
operations must be as simple as possible, without
being dangerous and causing the operator
fatigue.

 Clamping : The clamping of the component must be

positive and directed against a solid part of the
fixture. The most effective form of clamping should
be used, according to the type of fixture, size and
form of component and type of operation .If
hexagonal nuts are to be used, one size only should
be specified to avoid a multiplicity of spanners.
Spring placed under clamps save time, and is a boon
to the operator.
Foolproofing and safety : Jigs and fixtures must be
designed so that the component can be located only
in the required position. The addition of pegs may be
necessary in some instances to ensure safety.

 Ejecting Devices : Ejecting devices are essential

for heavy and close fitting components. Time is
saved and possibility of the tool or component being
damaged is eliminated.
Handling : Heavy jigs and fixtures should be
provided with handles, eye bolts, hand slots or other
refinements to permit easy and safe handling.

JIG
A jig is a device to which a component is fastened so that
certain machining operations may be done or carried out. The
jig is designed in such a way that one or more cutting tools are
guided to the same position on any number of similar
component that may be used in a jig.

FIXTURE
A fixture is similar to a jig, but the cutting vices are not guided.
Briefly the difference between a jig and fixture is that a jig
incorporates hardened steel bushes for guiding the tools that
are used in machining the component, whereas with a fixture,
the tools used for machining the component are worked
independently, and are in fact, guide manually by the machine
operator.

THE SIX DEGREE OF FREEDOM

The figure below illustrates a body that is suspended in
space.
The body is said to have Six degree of freedom of
movements.
(3- lateral,& 3- rotational ) Consider the possible movements
of the free body shown,ie with respect to the three mutually
perpendicular axes x - x, y - y, z - z.
3-Translations
It can Move along y y.
Move along x x.
Move along z z.
3-Rotations
Rotate about y y.
Rotate about x x.
Rotate about z z.

PRINCIPLE OF LOCATION
In order to fix, definitely, the position of a body in space, it is
necessary to account for the six degree of freedom. The body
shown may move laterally in the
directions OX, OY, OZ in addition to which it may rotate about
the axes six possibilities in all. When designing location
Facilities, we must keep this in mind so that the arrangement
will provide positive restraint as well as ensuring the surface
relationship necessitated on the job in hand. There are, in
addition , certain natural locational relationships between
surfaces, points and lines of which the reader is no doubt
aware but their significance to the matter in hand needs to be
elaborated.

Let us consider the location of triangle of points. Every reader

will be aware that a 3-legged stool always stand on its legs
but, on an uneven floor , we cannot guarantee that a 4-legged
one will do likewise. A triangular, three-point location on a
horizontal plane will restrain movements along axis OY,
and rotations about OX and OZ three of our six degree of
freedom. (Fig. 3a) if, now we modify the arrangement by
fitting ball ends to the feet and placing the two of them in a
vex groove, the natural contact conditions between a circle and
a vee will result in perfect mating in the Vee, and by resting
the third point on a flat we have put a restraint on two more of
the outstanding degrees of freedom i.e. movement along OX
and rotation about OY (Fig. 3b).
Finally by placing the third foot in a vee formed perpendicular
to the other we may restraint freedom of movement along OZ
and account for the entire six degrees (Fig. 3c) .

Now it might be argued that the effort could have been

achieved by dimples or stops on the original flat
surface. This
is quite true for one particular component, but we
should
accommodate itself to variations in size, and if a
second
component with feet slightly varying in size, or not
exactly on
the same triangle were fitted to dimples or stops it
would not
be completely located against every possible degree of
movement. This case is given merely as an example of
principles involved.

TYPES OF LOCATION
There are different types of location. Some of them are
1. Vee location
2. Button or peg location
3. Fix Block location
4. Adjustable location
5. Screw location
In order to locate an object in a definite position all the
six
degree of freedom must be accounted for. However, six
different locators are seldomly used in practice because
clamps are usually used to secure the component.

In many types of jigs and fixtures, the contacting point will be

small and for this purpose the pieces illustrated at Fig 4. The
button locators (a) and (b) are used for the side or end
location while the remainder are attached to the base of the
fixture to sit beneath the component. The button (c) is not
recommended for the following reasons. Drilling produce slight
burr around the periphery of the hole, and apart with the drill
hole, if located over (e) will not lie flat on the locating face.
This can be overcome by arranging for all drilled holes to be
countersunk, but the most satisfactory step to take is provided
such as buttons such as (c) and (d) to seat in counter bored
recesses in the fixture base. Not only do drill holes suffer from
burrs, but there is always a likely hood that the hole contains
dirt and oil which may slip out and become embedded in the
force of a jig unless a generous recesses is provided. Fig. 4
explains and shows how button or peg location is used.

At Fig. 5a. The support face

of the jig is made to the
profile to which the
component should confirm,
and when loading the jig
the job is clamp in the most
favorable condition. The
Support

show at (Fig. 5b) is spring

loaded so that it may adjust
itself to the rough face of
the
component before being
locked up.

CLAMPING
The Clamp is a device used to secure a component firmly
by friction.

1.
2.
3.

1.
2.

Requirements of a clamping device .

it must hold the work piece against the cutting force
without causing damage to it.
The clamping pressure should be directed against the
solid portion of the component.
Clamps which act against finished machined faces
should be faced with strips of copper, brass fibre or
similar soft material.
Position of the clamp
Clamping must be at the thick section of the work piece
to avoid distortion due to clamping forces.
The clamps must be positioned so that they can be
operated easily and safely by the operator.

TYPES OF CLAMPS

Strap clamp.
Universal strap clamp.
Slotted clamp.
Plate clamp.
Screw clamp.
Cam clamp.
Swinging clamp.
Bridge clamp.
Double acting clamp.
Flat clamp.
Pivoted clamp.
Wedge clamp.
Equalising clamp.

DEGREES OF FREEDOM RESTRAINED IN A VICE

A vice has a fixed jaw and a
moving jaw. The fixed jaw is
used as the positive
location
and hence it should be used
to restrain the main cutting
force. Note that the greater
the frictional resistance the
work piece can shake if not
tightened, therefore make
sure that the vice that the
vice is well tightened before
starting to cut.

DEGREE OF FREEDOM RESTRAINED IN WORK

HELD BETWEEN LATHE CENTRES
The work is first
prepared by drilling
each end with a
center drill. It is
very
important that the
center holes are
made
correctly.

DEGREE OF FREEDOM RESTRAINED IN THE

CHUCK

On axis A friction prevent the

movement of the work piece, on
B and C axis, work movement is
prevented as it bears against the
chuck jaws. On D friction prevent
the rotation of the work within
the chuck and on E and f
rotation
is prevented by the chuck jaws.
The fig.9 below shows how the
work piece is restrained form
moving when using the chuck.
With this there is only rotational
movement.

DISTINGUISHING BETWEEN RESTRAINTS FROM

FRICTION
The work piece may be restrained
from moving either by a positive
restriction or frictional resistance.
Because of the various sizes of
work which will be needed to
be accommodated in a holding
device, it is not possible to restrict
movement in all possible
directions by positive restriction.
As shown in Fig 10, the additional
restrictions
are
provided
by
friction
which occurs between the
gripping pressure of the device.

Other form of restrain is that of

solid abutment shown below. A
vice has a fixed jaw and moving
jaw, it is the fixed jaw or the
(solid abutment) that should
receive cutting force or the
impart
of the force. Working against the
moving jaw can cause the
deformation of the work piece
and also the thread of the vice,
as
they can move in the cause of
working.
Fig. 11 shows how solid
abutment
provide restrain.

CONCLUSION
As we have learnt, jigs and fixtures make a fairly simple
operation out of one which would otherwise require a lot of
skills and time. Jigs and fixtures are precision tools which
must
be taking care of. They must properly store or isolate to
prevent
accidental damage and they must be numbered for
identification for future use.
Jigs and fixture must be cleaned, undamaged and free from
swarf and grit. Components must not be forced into a jig or
fixture
So let all make it point to use jigs and fixtures correctly.

REFERENCES
1.

Greer A. and Howell W.H(1972) Mechanical

Engineering Craft Studies part 1 and 2.

2.

Dr. Chapman W.A.J (1951) Workshop Technology

Part 3.

3.

Murphy J.S and Arther D (1941) General

Engineering workshop Practice.

4.

Donald J. Walker (1980) Engineering Productivity

Volume 1.