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Introduction
Fixtures : being used in machine shop, are strong
and rigid mechanical devices which enable easy, quick and consistently accurate locating, supporting and clamping of blanks against cutting tools and result in faster and accurate functional machining ability with and consistent quality,
interchangeability.
alignments etc.
Easy, quick and consistently accurate locating, supporting and clamping the blank in alignment of the cutting tool. Guidance to the cutting tool like drill, reamer etc. Increase in productivity and maintain product quality consistently.
Easy and quick loading and unloading the job to and from the jig or fixture. Use of minimum number of parts for making the jig or fixture. Use of standard parts as much as possible. reasonable amount of flexibility or adjustability, if
feasible, to accommodate slight variation in the job dimensions. Easy, quick and accurate indexing system if required.
- Buttons should be as far apart as possible because Greater the spread, lesser alignment error.
12 degrees of freedom
basic principles or rules need to be followed while planning for locating blanks in fixtures.
One or more surfaces (preferably machined) and / or drilled / bored hole(s) are to be taken for reference. The reference surfaces should be significant and important feature(s) based on which most of the dimensions are laid down. Locating should be easy, quick and accurate. In case of locating by pin, the pins and their mounting and contact points should be strong, rigid and hard.
A minimum of three point must be used to locate a horizontal flat surface. The locating pins should be as far apart as feasible. Vee block and cones should be used for self-locating solid and hollow cylindrical jobs. For locating large jobs by rough bottom surface one of the three pins may be replaced by a pivoted arm. The pivoted arm provides wo contact points.
fixture.
5. 6.
9.
easily replaceable.
10. Clamping force should act on heavy part(s) and against supporting and locating surfaces. 11. Clamping force should be away from the machining thrust forces. 12. Clamping method should be fool proof and safe. 13. lamping must be reliable but also inexpensive
Methods of Clamping
Clamping method and system are basically of two categories :
1. General type without much consideration on speed of clamping operations. 2. Quick acting types.
The clamping end of the strap is pressed against a spring which enables quick unclamping.
Clamping from side for unobstructed through machining (like milling, planing and broaching) of the top surface.
Such clamping are simple and relatively quick in operation but is suitable for jobs of relatively smaller size, simpler shape and requiring lesser clamping forces.
Cam Clamping
Press fitted thin sleeve type bushes are generally used for shorter runs and are not renewable. Renewable type slip bushes are used with liner. screw bushes, though renewable may be used without or with liner. Bushes may be
Without head
With head With a flange being screwed on the bracket
Some special jig bushings are often designed and used as and when required.
Types of Jigs
Open jig (Plate jig or drill template)
It is the simplest type of drill jig.
It consists of a plate with holes to guide the drills, and may have locating pins that locate the workpiece on the jig.
Locating devices
Pins, pads, and recesses are used to locate the workpiece on the jig.
Clamping devices
Locking pins
Template Jig
Template jigs are normally used for accuracy rather than speed. This type of jig fits over, on, or into the work and is not usually clamped. Templates are the least expensive and simplest type of jig to use.
Plate Jig
Plate jigs are similar to templates. The only difference is that plate jigs have built-in clamps to hold the work. These jigs can also be made with or without bushings, depending on the number of parts to be made. Plate jigs are sometimes made with legs to raise the jig off the table for large work. This style is called a
table jig.
Plate jig
Table jig
Sandwich Jig
Sandwich 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 warp in another style of jig. The use of bushings is determined by the number of parts to be made.
Sandwich jig
Angle-Plate Jig
Angle-plate jigs are used to hold parts that are machined at right angles to their mounting locators. Pulleys, collars, and gears are some of the parts that use this type of jig. A variation is the modified angle-plate jig, which is used for machining angles other than 90 degrees.
Angle-plate jig
As the drill exits the product being drilled, it has little or no room for the drill point to clear the product completely, produce a round hole all the way through the part wall, and avoid drilling the part locator.
This is most noticeable, where an angled hole requires additional clearance to the relieved portion of the part locator. Additional clearance here would allow the drill to complete the hole and avoid drilling the relieved portion of the locator.
Channel Jig
Channel jigs are the simplest form of box jig. The work is held between two sides and machined from the third side. In some cases, where jig feet are used, the work can be machined on three sides.
Leaf Jig
Leaf jigs are small box jigs with a hinged leaf to allow for easier loading and unloading. The main differences between leaf jigs and box jigs are size and part location. Leaf jigs are normally smaller than box jigs and are sometimes made so that they do not completely
Indexing Jig
Indexing jigs are used to accurately space holes or other machined areas around a part. To do this, the jig uses either the part itself or a reference plate and a plunger. Larger indexing jigs are called rotary jigs.
Types of Fixtures
Jigs and fixtures are made basically the same way as far as locators and positioners are concerned. The main construction difference is mass. Because of the increased tool forces, fixtures are built stronger and heavier than a jig would be for the same part.
Classification of Fixtures
Fixtures are normally classified by the type of machine
Plate Fixture
Plate fixtures are the simplest form of fixture. The basic fixture is made from a flat plate that has a variety of clamps and locators to hold and locate the part. The simplicity of this fixture makes it useful for most machining operations.
Angle-plate Fixture
The angle-plate fixture is a variation of the plate fixture. With this tool, the part is normally machined at a right angle to its locator. While most angle-plate fixtures are made at 90 degrees, there are times when other angles are needed.
Angle-plate fixture
Vice-jaw Fixture
Vise-jaw fixtures are used for machining small parts. With this type of tool, the standard vise jaws are replaced with jaws that are formed to fit the part. Vise-jaw fixtures are the least expensive type of fixture to make. Their use is limited only by the sizes of the vises
available.
Indexing Fixture
Indexing fixtures are very similar to indexing jigs. These fixtures are used for machining parts that must have machined details evenly spaced.
Multistation Fixtures
Multistation fixtures are used primarily for high speed, high-volume production runs, where the machining cycle must be continuous. Duplex fixtures are the simplest form of multistation fixture, using only two stations. This form allows the loading and unloading operations
For example, once the machining operation is complete at station 1, the tool is revolved and the cycle is repeated at station 2. At the same time, the part is unloaded at station 1 and a fresh part is loaded.
Duplex Fixture
Profiling Fixtures
Profiling fixtures are used to guide tools for
This bearing is an important part of the tool and must always be used.