JIGS AND FIXTURE

1. What is drill jig and how was the term fixture derived?
DRILL JIG
Drill jig is a device which is ensuring that a hole to be reamed, tapped or drilled in a work
piece will be machine in the proper phase.

FIXTURE
A fixture is a work holding device and position the work but doesnt guide locate or position
the cutting tool, the setting of the tool is done by machine adjustment and a setting blocker
using slip gauges. A fixture is hold or clamped to the machine table. It is usually heavy in
construction.

2. What is the advantages of tumble jigs or box jigs?

It contains bushing on two or more sides for the purpose of the drilling on different
sides of the part.
After one face is drilled, the next side may be drilled by simply flopping the jig to
expose this side to the drill spindle.
Greater accuracy can be obtained and less part handling is necessary.
Allow drilling more than one surface in part without relocating it in jig.
Because of less part handling so less time needed to handle the part.

3. Why should a drill jig stand on four legs rather than three?
A drill jig should stand on four legs instead of flat surface. If the jig stands on flat surface,
chips will get under flat surface and imbalance the jig. To avoid imbalance, jigs stand on four
legs. Jig legs may be built into the jig body or purchased as a standard part. They should be
placed on these legs so that all bushings are within the area covered by legs, which are
placed on extremes of the jig. Legs should be ground so that they all lie in one plane after
they are mounted on jig base.
Stability
Normal jigs should always be provided with feet or legs on all sides which are opposite to the
holes of bushings, so that the jig can be placed level on the table of the machine.
On the sides of the jig, where no legs are required if the body made from casting, it is
advantage to have small projecting lugs for bearing surfaces when laying out and planning.
Safety
While jigs are most commonly provided with four legs on each side, in some case it is
sufficient to provide the tool with three legs but care should be taken in either that all
bushings and places where pressure will be applied to the tool are placed inside the
geometrical figure obtained by connecting, using lines, the points of location of the legs.

Providing three legs jigs means that the jig will obtain a bearing on all the legs if the machine
not plane. Quite not safe use smaller number of support such as three legs because a chip or
any objects is liable to come under one leg then throw the jig and the piece out of the line,
without being noticed by the operator. If the same thing happened to four legs jigs it can be
predicted.
4. Explain in detail the economic aspects of the use of a jig or fixture.
PRODUCTIVITY:
Jigs and fixtures increases the productivity by reduces the production cycle time so increases
production capacity. Simultaneously working by more than one tool on the same workpiece
is possible.
INTERCHANGEABILITY AND QUALITY:
Jigs and fixtures facilitate the production of articles in large quantities with high degree of
accuracy, uniform quality and interchangeability at a competitive cost .
SKILL REDUCTION:
There is no need for skillful setting of work on tool. Jigs and fixtures makes possible to
employ unskilled or semi-skilled machine operator to make savings in labor cost.
COST REDUCTION:
Higher production, reduction in scrap, easy assembly and savings in labor cost results in
ultimate reduction in unit cost.
SAVE TIME:
It reduces or sometimes eliminates the efforts of marking, measuring and setting of
workpiece on a machine.

5. Explain in details the factors need to be considered when designing jigs and fixtures.
1. Component Design to be studied carefully
Ensure work is performed in a proper sequence
Maximum operations should be performed on a machine in
single setting
2. Capacity of the machine Careful consideration to be performed on type and capacity
of machine.
3. Production requirements Design to be made on basis of actual production
requirements. Then comes decision on manual and automatic
tooling arrangements.
4. Location Location should ensure equal distribution of forces throughout all sequence of
operation.
Location should be hard resistant, wear resistant and high degree of accuracy.
Movement of workpiece should be restricted.
Should be fool proofed to avoid improper locations of the workpiece.
Should facilitate easy and quick loading of workpiece.
Redundant locators should be avoided.
Sharp corners must be avoided.
At least one datum surface should be establised.
5.Loading and Unloading arrangements There should be adequate clearance for loading and
unloading. Hence process becomes quick and easy.
Size variation must be accepted.
It should be hardened material and non sticky.
6. Clamping arrangements Quick acting clamps must be used as far as possible.
The clamping should not cause any deformation to the workpiece.
It should always be arranged directly above points supporting the work.
Power driven clamps are favoured as they are quick acting, controllable, reliable and
operated without causing any fatigue to the operators.
7. Clearance between Jig and Component To accommodate various sizes if work
Chips to pass out of the opening between them
8. Ejectors To remove work from close fitting locators.
Speeds up unloading of the part from the tool and hence
production rate.
9. Base and Body construction Methods used: Machining, Forging and machining, Casting,
Fabricating, Welding.

10. Tool guiding and cutter setting By adjusting the machine or using cutter setting block, thecutter is set
relative to the work in a fixture. The drill bushes fitted on jig plates guides
the tools.
11. Rigidity and vibration Must possess enough rigidity and robustness.
Should not vibrate as it may lead to unwanted movement of
workpiece and tools.
12. Safety Operation should be assured full safety.
13. Cost Should be simple as possible.
Cost incurred should be optimum.