QB - ME5635-Design of Jigs, Fixtures and Press Tools-Jan-May.2014

Question Bank April/May 2014 ME5635-Design of J igs, Fixtures And Press Tools
Saveetha School of Engineering

Saveetha University
Chennai 602 105
Department of Mechanical Engineering
Academic Year 2012- 2013 / 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 J igs and
Fixtures Types of J igs 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: J ig 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
Dept. of Mech. Engg. Page 1 of 27 SSE, Saveetha University
4. Case Hardening Steel
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?
mpletely restrained by providing three
0. Define locating devices.
ts of a jigs or fixture which help a workpiece to seat in proper
1. Name any four locators that are generally used.
rs and nest or cavity locators.
Ans: According to this principle, a workpiece can be co
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.

1
Ans: Locators are those par
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.

1
Ans: Pin and button locators, V-locators, bush locato


12. Define jack pin locator.
itions itself automatically by means of spring force according to the
3. Define clamping devices.
d to hold the workpiece in the correct relative position in the jig or
Ans: The locator which pos
need is known as jack pin locator.

1
Ans: clamping devices are use
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?
tionship between mating parts with respect to the amount of clearance
6. Define and show the diagrammatic representation of clearance fit.
hole size for all possible
7. Show the diagrammatic representation of interference fit.
ize being larger than the maximum
Ans: Fit expresses the rela
or interference which exists when they are assembled together.

1
Ans: This fit results when the shaft size is always less than the
combinations within their tolerance ranges. Relative motion between shaft and hole is always
possible.

1
Ans: This is a fit which always results in the minimum shaft s
hole size for all possible combinations within their tolerance ranges. Relative motion between the
shaft and hole is impossible.


18. Define and show the diagrammatic representation of transition fit.
the same size. This fit is
9. What is meant by tolerance?
of an error of manufacturing. It is the acceptance of the fact
0. Distinguish between unilateral and bilateral tolerance.
irection from the nominal size, the
Ans: A pure transition fit occurs when the shaft and hole are exactly
theoretically the boundary between clearance and interference and is practically impossible to
achieve, but by selective assembly or careful machining methods, it can be approached within
very fine limits.

1
Ans: Tolerance is the acceptance
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.

2
Ans: Unilateral tolerance is one that applies in one d
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.

21. 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 principles employed in jigs and fixtures design. [8]
(b) List out the advantages of jigs and fixtures. [8]
2. (a) Explain briefly the main elements of jig and fixture. [6]
(b) Compute the fundamental deviations for a circular hole of 35 mm diameter finished to
H7 tolerance. [10]
3. Discuss in detail the 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 device 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 J igs
components Design and development of J igs for given components.

PART A (2 Marks)
1. What are the elements of jigs?
Ans: J ig 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 J ig
b. Plate jig
c. Channel jig
d. Leaf jig
e. Pot jig
f. Turnover jig or table jig
g. Box jig or tumble jig
h. Trunnion jig
i. Indexing jig
j. Post jig
k. Sandwich jig
l. Nut cracker jig
m. Pumping or universal
n. Latch jig
o. Vise jig
p. Solid jig
q. Angle plate 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 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 and what are they used for?
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 static fixtures?
Ans: The static fixtures are set-up clamping or fit-up fixtures used for accurate positioning of
workpieces and companion parts of the product assembly.
13. What are the steps involved in operating pressing fixtures?
Ans: i) Location arrangement of housing
ii) Locator for the part to be pressed
iii) System for alignment of the parts to be pressed with the housing
iv) Arrangement for application of press force to drive the part into the housing
14. 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

15. What are the important elements of inspection fixtures?
Ans: a) Locating element
b) Clamping element
c) Gauging element
d) Auxiliary element
16. 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.
17. 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.
18. 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.
19. What are the sub-classification of special purpose fixtures?
Ans: a) Static fixtures
b) Mobile or dynamic fixtures
20. How are mobile fixtures classified?
Ans: a) Unitary fixtures
b) Multiple fixtures


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.
2. With proper sketch explain the operation of a modular fixture with example used in practice.
3. Illustrate the working of a lathe fixture.
4. Illustrate the working of a Gang milling fixture.
5. Design a milling fixture to make a slot of 30 x 10 x 10 mm as shown in the following Fig.
3.1.

Fig. 3.1

6. Design a milling fixture to make a slot of 70 x 10 x 10 mm as shown in the Fig. 3.2.

Fig. 3.2

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
b. Punching
c. Shearing
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
b. High productivity
c. Uniformity of parts
d. Use of less labour.
6. What are the applications of press working operations?
a. Electronic appliances
b. Steel furniture
c. Coach building
d. Automobile industry
7. Name some types of forming operations.
a. Bending
b. Drawing
c. Squeezing
d. Embossing
8. List out the press working terminology.
a. Base
b. Bolster plate
c. Die holder
d. Die
e. Stripper
f. Punch
g. Pitman
h. Stroke
i. Guide pin
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
b. Compressive strength
c. Bending 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
b. Die space
c. Size and type of die
d. Stroke length
e. Shut eight
f. Type of operation
g. peed of operation
12. List down the material used for press working operations.
a. Mild steel
b. Stainless steel
c. Brass
d. Copper
e. Aluminium
f. Hard rubber
g. Fiber
13. What is a progressive die? When should a progressive die be used?
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
b. Centre-post design
c. Diagonal-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)
2. What are the factors to be considered while selecting a press? (16)
3. Explain briefly the functions of following parts in press tool. (16)
(i) Stripper
(ii) Pilots
(iii) Shedder.
4. a) (i) explain briefly the function of the following parts applied to press working.
i) Stock stop
ii) Knockout rod (6)
(b) Sketch a suitable press tool to manufacture square component 40 mm side having a central
square hole 20 mm side, the material thickness being 1.5 mm. (10)
5. Explain step by step procedure for the computation of press capacities and tonnage
requirements for cutting and drawing operations. (10+6)
6. Design and sketch the views of compound die that produces steel washers. Dimensions of the
washer may be assumed suitably. (16)


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
angle is known as spring back. The spring back varies from 0.5
o
to 5
o
for steel.
8. List the factors affecting spring back.
Ans:
a. Material type
b. Thickness
c. Hardness
d. Bend radius
9. List four factors affecting drawing
Ans:
a. Type of material
b. Ductility
c. Yield strength
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
b. Urethane
c. Heavy grease
d. Oil
e. Water
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. Design and sketch any two views of a progressive die to manufacture the outer plate of a
cycle-chain links.
2. A steel cup of height 30 mm and internal diameter 40mm 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 any two views
of a draw die.
3. A rectangular steel component of size 20 mm x 60 mm is to be made from 4 mm thick sheet.
Sketch the scrap strip by layout and determine the percentage of stock used.
4. Design and draw any two views of a progressive die to make a steel washer of 30 mm outside
diameter with 15 mm hole from1.6 mm thick steel sheet. The ultimate shear stress of the material
is 320 N/mm
2

5. Sketch and design a drawing die as shown in the Fig. 5.1 from medium carbon steel F
t
=3600
kg/cm
2

All dimensions in cm.

Fig. 5.1

6. Calculate the developed length of part as shown in theFig. 5.2.
All dimensions in cm.

Fig. 5.2


REFERENCES

1. Edward G Hoffman- J igs & Fixture Design, Thomson Delmar Learning, Singapore 2004
2. Donaldson. C, Tool Design, Tata McGrawHill, 1986
3. Kempster, J igs & Fixtures Design, The English Language Book Society, 1978
4. J oshi, P.H., J igs & Fixtures, Second Edition, Tata McGrawHill Publishing Company
Limited, New Delhi 2004
5. Hiram E Grant, J igs 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 April/May 2014 ME5635-Design of J igs, Fixtures And Press Tools

Saveetha School of Engineering

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