gi. Production Engineering Data Memoranda Jig & Fixture Design uBisoq a4n3xi4 9 Sif Produced by The Institution of Production Engineers 146, Cromwell Road, London SW7 4EF -The Institution of Production Engineers 146, Cromwell Road, London, SW7 4EF Data Memoranda on JIG AND FIXTURE DESIGN This book illustrates and describes some typical jigs and fixtures _ to be found in current usage in British Industry. . Tiel slat te 9a acho t0 give a fair cross-section of those in use and cover non-standard and commercially available standard ‘ units. Within the book is stated the principles of good jig and fixture design which should be applied by the designer and a list of important questions is given that should be answered before the design is finalised. It is hoped that this book will provide assistance to the experienced designer as a ‘ready reference’ and to those who are embarking on a career in production engineering and seek knowledge in the fundamentals of jig and fixture design. Copies of this publication can be obtained from The Institution of Production Engineers 146, Cromwell Road, London, SW7 4EF APRIL 1973 Price £5.00ACKNOWLEDGEMENTS The Institution wishes to acknowledge the assistance rendered by its members and from British Industry. Permission to draw upon material for many of the features which appear in this book is acknowledged with thanks to those who have extended this courtesy. For permission to reprint charts from their Office Manual showing: | ‘Twist drill power and thrust calculations. Drilling load and thrust factors (inch and metric). Power for tapping threads (H.P. and kW). Recommended cutting speeds and feeds for tapping, reaming, drilling, spot-facing and counter-boring. Table of cutting speeds/r.p.m. for drilling. Milling machine tapers — spindle nose dimensions. ‘Standard morse tapers. Calculations for gear ordinates and for Figure 37. ‘Acknowledgements are given to:— Messrs Dex Gears Ltd, Bedworth Road, Longford, Coventry, Warwicks. 5, 6 and 16:— Figs.7, 8, 20, 21, 22, 23, 24, 25, 26 and 29:— Messrs Insley Industrial Ltd, Messrs Purefoy Unit Tooling Ltd, Eastern Road, Longfield Road, Bracknell, Berks. Tunbridge Wells, Kent. Fig.9:— Figs.17, 18 and 19:— Messrs Matrix Machine Tools Ltd, Messrs Spencer Franklin Ltd, P.O. Box 39, Spenklin House, Gunnersbury Avenue, Coventry, CV4 9DA. London, W4 50B. Figs.28, 34 and 36:— Fig. 15:— Middlesex Tool & Gauge Co. Ltd, Messrs W.D.S. Tooling Aids Ltd, Midleton Industrial Estate, Woodside Works, Newlay, Guildford, Sur i Oss 1003.5 , LS13 1EH. ACCESSION Ne 3 “B84ib Gri-aad 0 8DECI976 WN] CaieGoRY vFIELD INVESTIGATING, COMPILING AND EDITING by R.M.WEBB, C.Eng,, F.I.Prod.£., F.I.Q.A., A.M.LE. ILLUSTRATIONS by B.D.CHOAT, A.M.I.E.D. AND ASSOCIATES.1g and withdrawing the component from the jig should be as easy as. ‘Ample space should be left between the jig body and the component for hand move- ments. Some means of ejection should exist to release the component if it sticks in the jig. The design of the jig must be safe. Handles or levers should be large enough to clear adjacent parts so that pinched fingers are avoided. If necessary, make provision for the use of coolant. Position locations at places where there is no flash or burr on the component. If possible, eliminate spanners by the use of ball or eccentric levers. If spanners have to be used, make one spanner fit all the clamp operating bolts and nuts. Consideration should be given at the design stage to the use of standardised jig details.PRINCIPLES APPLICABLE TO DRILL JIGS It may not be possible to adhere to all the principles listed below but those applicable should be applied when designing drill jigs. Drill Jigs should be of light construction, consistent with rigidity to facilitate handling, especially when jigs have to be turned over so that holes can be drilled from more than one side. Alll unnecessary metal should be cored out of the jig body. A jig which is not bolted to the machine table should be provided with feet, preferrably four, opposite all surfaces containing guide bushings, so that it will ‘rock’ if not standing square ‘on the table and so warn the operator. Clearance holes or burr slots should be provided in the jig to allow for the burr formed when the drill breaks through the component and for swarf clearance, particularly from locat faces. Make all component clamping devices as quick acting as possible. Design the jig fool-proof by the use of foul pins and similar devices, that is arrange it so that the component, tools or bushes cannot be inserted except in the correct way. Make some locating points adjustable when the component is a rough casting and may be out of alignment. Locate clamps so that they will be in the best position to resist the pressure of the cutting tool when at work. If possible, make all clamps integral parts of the jig and avoid the use of loose parts. Avoid complicated clamping and locating arrangements which are liable to wear or need constant attention. Place all clamps as nearly as possible opposite some bearing point of the component to avoid springing the component and in accessible positions. All sharp edges should be removed from the various detail parts of the ji le the geometrical If possible, place all too! guide bushings re formed by connecting the points of location of the feet. Make, if possible, all locating points visible to the operator when plating the component in position in the jig so that the component can be seen to be correctly located. The operator should also be able to have an unobstructed view of the clamps. Before using the jig in the machine shop for commercial purposes, test all jigs as soon as they are made, The location points, which are hardened if necessary, are established with considerations to machining operations, if any, to follow and that any mating parts are located from the same datum surface. Locating and clamping arrangements are designed to reduce idle time to a minimum by using simple clamps which are easy and quick to operate and also operate without damaging the compon- ent. Springs should be used whenever possible to elevate the clamps clear of the component whilst being loaded or unloaded. Clamps should be positioned above the points supporting the component, in order to avoid distortion and should be strong enough to hold the component without bending. Generally clamps should not be relied upon for holding the work against the pressure exerted by the cutting tool. 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Sears ic = 2850" + 28464887" + 2.2701236" — 0.900" — (2 x 2.2701235 x 1.0218520) 25 2 x 28464887 emer 1 = 0.057873" + —0.0809075* — 1 = —0.ese62 0.850 — (~0.0587573 x 1.0218320) — (0.040067 x 1.4454800) . 09948652 Se n= 2850" — 1.0218328" — 14484800 mins = 0.9088692 PITCH CIRCLE DIAMETER 2r = 2.0909, x = (00587573 x 1.049661) + 1.0218529 (0.009675 x 1.089661) + 114458800 ‘Check. (em yr saat = (28464687 — 1.402476)" + (2.2701235 ~ 0.9601576)* (gS (2270860 — 0.900876)" 1402878 si3ag3 877 ety 0.9601876* + 1.402478" 2.6888 471, W = xeon dm yan’ Z = xsinotycoso omen ease Virsa — 078i" + (e869 — 0.9888) VERSE TaBEaT + (0.72A8 — 02161 19496 38, COORDINATE W = 0.2161 CO-ORDINATE 2 = 1.6959 Check. 0.782281 + JOTI + BTS ++ 1,0496610 (OR —2.5961112 not applica) = 0.9601576 = 4024780 era (0550 + 1.049661)" 2.8988 475 {019601576 x 0,8902007) — (1.402478 x 0.4863026) (0:9601576 x 0.4853926) + (1.402478 x 08902907) ‘098001 + 0.900 113406 610GEAR ORDINATES — CALCULATIONSNOTES ON THE INTRODUCTION OF ‘S.I.’ UNITS The ‘S.I.” system of uni ely to be unfamiliar to many engineers. Some general notes are considered necessary for guidance in using ‘S.l.’ notation. Conversion tables have also been added. General Notes on the Conventi to be adopted in expressing numerical data 1. Abbreviations to be given in singular form without full stops, e.g. km NOT km., kms. or kms Nm NOT N.M., Ns m or Ns.m. 2. Although it is permissible to use the solidus, e.g. N/m?, it is desirable, for consistency, to avoid its use and to write Nmv?, deg K"!, ete. 3. Multiples or sub-multiples of simple or derived units may be used but the unit itself should desirably not be altered, e.g. 1.6 MNm-? in preference to 1.6 Nmm-?. 4, Multiples or sub-multiples should differ from the basic unit in steps of 10°. The multiples 10?, 10, 10" and 10? should preferably not be used, save in obvious circumstances. A list of preferred multiples and sub-multiples with their names or prefixes is given in Table |. 5. Commas should not be used in writing numbers, which should be expressed in groups of three such as 1076 963, 1.076 963, etc. ‘Sil.’ Units for Force, Work and Energy Force N Pressure and Stress Nm? (10° Nav? = 1 bar) Work, Energy, Quantity of Heat J Power w Torque Nm Surface Tension Nm Dynamic Viscosity Nsm-? (centipoise (10-3 Nsm-2) may also be used) Kinematic Viscosity m?s (centistokes (10-® m?s"") may also be used).VALUES OF SOME UK UNITS IN TERMS OF ‘S.I.’ UNITS LENGTH 1 yd. 0.9144 m 1ft 304.8 mm Tin. 25.4 mm, 1mile 1.609344 km AREA tin? 645.16 mm? 1 ft? 0,092 903 0 m* 1yd.2 0.836 127 m? 1 mile? 2.58999 x km? VOLUME Vin? 16 387.1 mm? Tit? 0,028 316 8 m> 1. UK gal 4.546 09 dm? Note: dm? = 1 litre DENSITY Tib/in? 2.767 99 x 10* kg mr? 1ib/ft? 16.018 5 kg mr? 1 Ib/UK gal 0.099 776 3 kg dm? Note: dm? = 1 litre FORCE 1 pdl 0.138 255 N 1 bf 4.448 22 N PRESSURE 1 Ibffin.? 6.894 76 kNor? ENERGY (work, heat) 1 ft. pdl 0.042 140 1 J 1 ft. Ibf 1.355 82 J 1 cal 4.186 8 J 1Btu 1.055 06 k J VELOCITY 1 ft/s 0.304 8 m/s 1 mile/h 0.447 04 mis MASS 1 Ib 0.453 592 37 kg POWER 1 hp 746 W TEMPERATURE 1 Rankine unit 5/9 of Kelvin unit (= 1 Fahrenheit (= 5/9 of Celsius unit) unit) Note: Do not confuse temperature with increments of heat units C = 5/9 (F — 32) TABLE I Preferred Multiples and Sub-Multiples of Units in the ‘S.I.’ System Multiplication factor Prefix Symbol 102 tera oT 10° giga G 10° mega M 10° kilo k 10 milli m 10° micro # 109 nano n 10? pico PpTABLE II TABLE II Conversion of Pounds Force Per Square Conversion of Kilo Newtons Per Square Metre Inch (Ibf.in-?) to Kilo Newtons Per (kN mr?) to Pounds Force Per Square Metre (kN m-*) ‘Square Inch (Ibf.in—?) Ibf. in-? KN mr? Note: Multiples, sub-multiples of this table 1 6.895 can be derived by adjusting the 2 13,789 decimal point. Other values can be 3 20.684 obtained by addition, 4 27.679 5 34.474 KN nr? Ibf in? 6 41.369 1 0.145 7 48.263 10 1.450 8 55.158 u 1.595 9 62.053 12 1.740 10 68.948 13 1.885 " 75.842 14 2.030 13 89.632 15 2.176 7 117.211 16 2.321 19 131.000 17 2.466 23 158.579 18 2.611 29 199.948, 19 2.756 31 213.740 20 2.901 7 255.110 21 3.046 41 282.687 23 3.336 43 296.476 25 3.626 47 324.045 27 3.916 50 344.740 29 4.206 31 .! 37 41 43 a7 49LIST OF QUESTIONS TO BE ASKED BEFORE FINALISATION OF THE JIG DESIGN 1. Can component be inserted and withdrawn without difficulty? 2. Have the best points of location been chosen with regard to the accuracy of location? 3. Are hardened location points provided where necessary? 4, Can location points be adjusted where required, to make allowance for wear of forging dies or castings out of alignment? Are locations clear of flash or burr? Can jig be easily cleared of swarf, particularly the locating faces? Are all the clamps of sufficient strength? Are all the clamps and clamping screws in the most accessible and natural positions? Will any clamp operating lever or nut be in a dangerous position? i.e. near the cutter? paxnoen 10. Can spanners be eliminated by use of ball or eccentric levers? 11. Will one spanner fit all the clamp operating bolts and nuts? 12, Is the component well supported against the action or pressure of the cutter? 13, Is the pressure exerted by the cutting tool against the jig or fixture body structure and not against the clamp? 14. Is the jig fool-proof? i.e. can the component, tools or bushes, etc., be wrongly inserted or used? 15. Has the operator an unobstructed view of the component, particularly at the point of location, clamping and cut? 16. Is the jig as light as possible, consistent with strength? 17. Can coolant, if used, reach the point of cut? 18. Have loose parts been eliminated wherever possible? 19. Have standard parts been used where circumstances permit? 20, Can jig be designed to hold right and left-hand components or other similar or complementary ‘components which may be required? 21. Where will burrs be formed and is clearance for them arranged? 22. Are all corners and edges likely to cut operator shown well rac drawing? 23. Are locating or other working faces and holes protected as far as possible from swarf? 24, Will the jig as designed, produce components within the required degree of accuracy? ised or chamfered on the Drilling and Boring Jigs 25. Do drills, tools, etc. enter the component at the face which directly adjoins the face of the component to which it fits? Milling Fixtures 26. Will the machine cutter arbor clear all parts of the fixture when passing over? (And any guards.) 27. Have means of setting the cutter or cutters in the correct position been provided?Revolving Fixtures 28. 29. 30. 31. 32. Has sufficient metal been left on jig to form an integral balance weight or provision for balance weight? 5 Have arrangements been made for swarf to be shaken out or be blown out from interior of jig. Are projecting screws etc. coveret (Counter-bored or counter-sunk?) Have tool setting pieces been arranged where possible? Have pilot bushes been catered for if necessary? order to eliminate risk of injury to the operator?JIG AND FIXTURE DESIGN Definitions The difference between a Jig and Fixture is often difficult to define as sometimes a special device is designed which is a combination of both. For the purpose of this Data Memoranda, the following definitions will apply:— By the word ‘Jig’ is implied device, usually made of metal, which holds the component firmly, or is held on to the component, locates the component positively and guides the cutting tool into the component or facilitates marking off arrangements. Jigs are used particularly in drilling and boring operations. a A ‘Fixture’ is similar to a Jig but does not guide the cutting tool. It is generally of heavier construction than a Jig and it is securely clamped to the machine tool on which the operation is performed. \Fixtures are used particularly in milling, planing, shaping, broaching and grinding ‘operations. Jigs and Fixtures are used to enable components to be produced more quickly and with ‘greater accuracy and interchangeability by unskilled or semi-skilled labour.CLAMPING PRINCIPLES (Fig.1) It is of the utmost importance in the design of any jig or fixture that its structure must be sufficiently rigid and stable so as to prevent any movement, distortion or vibration of the component due to the machining loads. Whenever possible any force imparted by a cutting action should be directly opposed by a fixed location and not by a clamp or a movable loci The drawing illustrates this principle in that the upper two views conform to this require- ‘ment whereas the lower three do not. As in all cases in this volume the component and machining operations are simplified but the principles are still the same and should be applied equally when fering more sophisticated set-ups. n. CLAMPING AND LOCATION (Fig.2) staliherever possible 2 component should be located andl clamped on @ previously machined surface. For speed of operation, the clamping process should be as simple as possible consistent with providing sufficient stability. In the left hand view the component is placed on a flat surface and clamped horizontally by a single clamp screw against a nest of location The right hand view shows the same basic set-up with the addition of top clamping from a pair of threaded bushes which serve the dual purpose of initially clamping down on to the component and then providing the guide for the drilling operation performed on it.CLAMPING METHODS (Fig.3) Where more than one component is to be machined in one pass of the machine, or if a ‘component is to be clamped in more than one position, it may be advantageous to operate all the clamps by the actuation of a single clamping nut or screw. In the left hand view, three separate components are clamped horizontally against their respective locating faces by the action of a single clamping nut. As this nut is tightened, the link rods distribute the clamping effort equally to each of the three clamps. The right hand view shows a link arm system being used to apply an equally divided clamping force to a pair of clamps acting on the same component. This is particularly useful in a condition where the operator may be denied easy access to ‘one or other of the clamps. SWARF CLEARANCE (| In any machining operation it is essential to get the swarf away from the locating faces and ‘away from the handling area as soon as possible, for it provides a hazard to safety as well as to ‘accuracy of location if allowed to accumulate. Where possible, locating or contact areas should be designed to allow swarf to fall away and three examples are shown in the figure. Feet ate fitted to a simple clamping fixture to allow swarf to fall clear of the fixture without having to be cleared out as would be the case if the fixture were flat on the machine bed. The example shown in the lower view has scallops from beneath the drilling areas to allow ‘the swarf to fall clear to a position from which it may be In the right hand view, clearance holes are provided in the work surface to allow swarf to fall through into the coned interior. It can be seen that the base of the fixture is relieved to allow the swarf to be cleared without having to lift the fixture.BASIC TOGGLE CLAMP (Fig.5) The toggle clamp is a very versatile unit and may be obtained as a standard item in varying forms and sizes to suit the particular requirement. The clamping screw is in all cases adjustable so that the clamping position of the operating lever is reached when the three pivot points shown come directly into line with one another so that any re-action from the component being clamped acts along the line of pivot points which When in the straight line position effectively form a solid link. In practice it is advisable to set the clamping position so that the operating lever i fractionally past the straight line position, i.e. slightly ‘over centre’ so that the clamp will not be inadvertently released by machining vibration or reduced in efficiency by component dimensional variation. TOGGLE CLAMP (THRUST) (Fig.6) ‘Two further types of toggle clamps are shown, both working to the same principles as outlined for Figure § but with their geometric configuration modified to give different clamping characteristics. The left hand view shows a thrust type and the right hand view a hook or tension type. The latter type differs from the other by having an inward or pulling clamp action. In all cases the method of contacting the component may be adapted to suit the particular requirement and where delicate or sensitive components are being clamped a suitable soft material such as rubber or felt may be used.Pa ACTUATING LEVERHAND OPERATED CAM CLAMPS (Figs.7 & 8) The two types of cam clamps shown offer a simple and efficient method of work holding. That shown in the left hand view (Fig.7) has a clamp mounted on a swing bolt and supported by a compression spring fitted around the swing bolt. A lever is fitted to the top of the swing bolt so that it pivots freely on the swing bolt ellowing a cam profile to come into contact with 2 spherical seating and spherical washer placed between the cam profile and the clamp. As the cam lever is operated, the eccentricity of the cam profile displaces the clamp downwards on to the component. The re-action to the clamping force is taken by an adjustable heel pin positioned at the opposite end of the clamp to the component. The system shown in the right hand view (Fig.8) works in a similar manner but the position of the cam lever is moved to the end of the clamp and the cam acts on to a fixed heel block. The pivot point for the clamp remains in the centre. The clamp should be a slotted type to enable the whole clamp assembly to be withdrawn from the component. HAND OPERATED CAM CLAMP (RETRACTING) (Fig.9) retractable clamp is operated by a pair of cams pivotting on a common shaft. Initial movement of the operating lever causes the clamp to extend over the component from which point the cam profile dwells. Further lever movement causes the second cam to elevate the heel of the clamp and effect a clamping action On removal of the operating lever the clamp releases the component and is caused to retract by a spring loaded plunger acting against the clamping stud. The clamp is prevented from swivelling by the action of the heel pin engaging in a slot in the under face of the clamp.‘Clameed. UnclampedRETRACTABLE HAND CLAMPS (CAM OPERATED) (Fig.10) It is often advantageous to be able to withdraw a clamp clear of the component in order to make loading and unloading simpler. One method is shown in Figure 10 where eccentric pins are fitted in to both sides of the clamping cam so that as the component is unclamped the eccentric pins contact a pair of pins in the upper face of the clamp and causes the clamp to retract. In order to prevent the clamp from swivelling during this operation the heel pin engages in a slot in the lower face of the clamp and for ease of operation a spring loaded plunger pushes the clamp forward to the work area as the clamping lever is operated and the eccentric pins allow the clamp to move forward. (Fig.11) A second method of clamp retraction is shown in this example and it is slightly tess sophisticated than the previous one. Clamping is again by the action of a cam, but in this case the cam is operated by a clamp serew. Retraction and extension of the clamp is manuel, the operator simply pushing the clamp forward over the component before tightening the clamp screw and then pulling it clear after releasing the component. During its movement the clamp in a slot in the heel block. prevented from swivelling by the clamping cam engaging RETRACTABLE WEDGE CLAMP (Fig.12) “Vee" black locations are generally considered to be the most accurate for the positioning of cylindrical work consistant with providing a rigid support. This jig employs a ‘vee’ location and has a fixed drill bush positioned above the ‘vee' so that when the component rests in the ‘veo’ and abuts the end face of the location block a hole may be drilled into its diameter simply end accurately. The clamp used in this case is a retractable one supported by a compression spring and extended or retracted by a pivoted operating lever connected to its outer end. The clamping action is achieved by the action of @ wedge block, so profiled that as the ‘clamp is pushed over the component a follower pin on the clamp rises up the wedge and causes a clamping force to be exerted.COMBINATION TOP AND SIDE CLAMP (Fig.13) As previously stated, it is preferable to effect a clamping force in more than one direction to ensure maximum stability of the component during machining. The example illustrated is based on the toggle principle in that the horizontal clamp provides a straight line locking action from the main pivot pin through the triangular quadrant to the horizontal clamping member. Connected to the upper point of the quadrant is a further link arm connected to a further clamp arm which applies a vertical downward clamping force on to the component. The mechanism as shown is operated by a pneumatic cylinder but could obviously be used as a hand operated ‘or mechanically operated unit. COMBINATION TOP AND SIDE CLAMP (Fig.14) A simple method of achieving a combined top and side clamping action is shown in this illustration. The top clamp is a conventional one having a centre pull down stud and nut on a spherical seating and acting on a fixed heel pin. However, instead of the stud being fixed to the bese it passes through a clearance hole and is linked to a cranked side clamp pivoted in the lower part of the base so that when the top clamp has been pulled down to contact the component, further tightening of the clamping nut causes the side clamp to move towards the clamp until both clamps finally secure it. Both of the clamps are held clear of the component by separate compression springs.nm Aaa TOP CLAMP ya vertically, VoRizonra o ‘CLAMP Fi9.13 Combination top « side_clamp. Fig. 14 Combination tops side clampCLAMP (BARREL) (Fig.15) ‘Two types of standard clamp are shown, the one in the upper view (Fig.15) being operated by a cylindrical barrel cam. Actuation is by the arcuate movement of a clamping lever, the initial ‘operation of which causes the clamping sleeve to approach the component rapidly due to the profile of the cam being steep in the initial stage, At the latter part of the cam travel the lead becomes less severe and the mechanical acivantage of the clamping force over the operating force increases accordingly. It is this final movement which locks the component in position. ‘A separate view of the cam is shown and on the right hand side of the page and a typical application of this clamping device is illustrated. CLAMP (COLLET) (Fig.16) The clamp in the lower view is similar in that it affords a quick approach prior to clamping but is different from Fig.15 in the manner in which this is achieved. In this case while the actuating lever is left in the unclamped position the clamping plunger may be moved freely backwards and forwards by simply pulling or pushing the clamping lever through the appropriate linear movement. When the clamping plunger has been extended to contact the component the operating lever is then moved radially so that the worm keyed to the clamping plunger and sliding freely on it, rotates in the nut in the main housing, thus causing the clamping sleeve to be displaced along the main housing so that the tapered section at its front end imparts a wedging action on to the clamping collet via a set of ball bearings positioned around the collet. The collet is thus closed ‘on to the shaft of the clamping plunger and locks it. The final clamping movement to the component is therefore by the worm and nut immediately before the locking action is effected. It can be seen that the clamping balls are retained in position by the compression spring positioned around the collet. To unclamp the mechanism the lever is simply moved in the reverse direction thus removing the pressure exerted by the worm and nut. To ensure thet the clamping sleeve withdraws, a circlip_ positive withdrawal action is achieved to overcome the possi to the collet. ip is fitted to the worm so that a ity of the balls being jammed onHYDRAULIC RETRACTABLE CLAMP (Fig.17) Particularly where @ number of clamps are to be used on a fixture or where for reasons of expediency or environment it is undesirable to use normally operated clamps, the hydraulic clamp is a considerable asset. {In the example shown in the drawing the clamping arm may be retracted when the compon- ‘ent has been unclamped so that the component may be more easily removed from the fixture. The sequence of operation is clearly shown in the three views on the right hand side of the page. Only one signal is necessary for the complete clamping of the component and this may be by mechanically tripping a valve if the sequence is automatic or semi-automatic or by the actuation of a hand operated valve if the machine is manually controlled. The extension and clamping movements are achieved from the single input sequential. This is also the case for unclamping. Units are available as standard items in varying pneumatically operated mack hydraulic pressure, HYDRAULIC SWIVEL CLAMP (Fig.18) This type of hydraulic clamp has the same advantages as the one previously described and differs only in that instead of retracting clear of the component, the clamping arm is pivoted through 90° to provide the required clearance, It is similar in function to the previously described unit and may be operated from the same type of air/oil intensifier by a single input signal.pwvoT Fig.18__Hydroulc_ clamp fsnivel orn me Siena Clamp arm swivels through 90° ‘allow for compsnent rencralMILLING FIXTURE (HYDRAULICALLY OPERATED) (Fig.19) A simple milling fixture is shown having two ‘vee’ locations in the upper face of the main frame to position the cylindrical components. A clamping plate is positioned above the compon- ents supported by a compression spring on the piston rod of a hydraulic clamping cylinder. The clamping plate is shown as having a pair of ‘vee’ locations matching those in the main frame, and although it is not strictly necessary to have these as regards the clamping function, they serve to ensure that the clamping plate is properly positioned across the components. As shown, the clamping plate may be swivelled through 90° when unclamped for easy access to components. ‘The hydraulic cylinder is one of a standard range and is single acting. PLATE DRILL JIG (Fig.20) Perhaps the simplest of all jigs is the Plate Jig where the component is positioned between location pads, sandwiched between. the base and the bush plate and drilled in this position, A pair of alignment dowels ensure that the drill bush plate is correctly orientated relative to the base. The two parts are clamped together by thumb nuts on a pair of swing bolts positioned one at either end of the fixture,LATCH CLOSURE SWINGING PLATE DRILL JIG (Fig.21) ig is similar in construction to that in Fig.22 except that it is intended to drill holes in the opposite face of the component. As in Fig.22 the component is located on a mandrel and orientated by a dowel. What is simply a clamping plate in Fig.22 is now also the drill bush plate so as the bush plate is swung down on to the component to clamp it, the drill bushes are also lowered into position. The locking of the bush plate is achieved by a latch cam lever - Unlike the following jig, it is unnecessary to invert it prior to drilling but it does have the disadvantage that as wear or distortion takes place in the pivot pins, the accuracy of machining will deteriorate accordingly. joted at its extre SCREW CLAMP SWINGING PLATE DRILL JIG (Fig.22) Many of the parts of which a jig or fixture is made are similar one to the other and the example shown is one of many which can be constructed from standard ‘off the shelf” equipment In this case, it is only the mandrel which need be tailor made to suit the component. The component is located within its bore on the mandrel and orientated by the location dowel. When the component is in position the clamp plate is lowered and the quarter-turn ‘thumb screw turned through 90° to retain it. Clamping force is then applied to the component by the ‘tommy bar’ in the clamp plate so that the component is pressed firmly on to the mandrel and against the base plate. The jig is then inverted so that the drill bushes are uppermost and the drilling operation may take place, Whereas the operator has the added task of inverting the jig, the advantages are that the drill bushes and the mandrel will remain in their relative positions throughout the life of the jig {as they are positively located in the same surface of the jig. It would of course be necessary to employ this method if the holes to be drilled in the flange were ‘blind’ and not through holes.‘Bush plate lowered s lotch cam lever position locked in ByDRILL JIGS (Fig.23) and MILLING FIXTURES (Fig.24) These two items are similar in construction and in their location of the component but as ‘can be seen, Fig.23 is a drill jig and is fitted with the appropriate drill bushes whereas Fig.24 depicts a milling fixture and exposes the upper face of the component for machining. ‘The main view in each case shows how the component is located by its bore on a mandrel and clamped against location buttons. It can be seen that the items allow for either a right hand component or a left hand version of the same component to be machined. In the lower right hand view of each drawing is shown the item with two mandrels on which the right hand and left hand components may be machined simultaneously, a feature which is particularly useful in the case of the milling operation where two components may be machined in the same pass.removed to unload Faure for mling RH 1 LH components. simultaneous, Fig. 24 Miling_tistureDRILL JIG (ANGLED HOLES IN HUB) (Fig.25) The example illustrated was designed to drill 4 holes equispaced around the tapered hub of a hand-wheel at right angles to the hub diameter. The component is located on a mandrel and a ‘c’ washer is positioned between it and the clamping nut. As the clamping nut is tightened, the component is pulled down on to a set of 4 location. buttons which position the component for height. It can be seen that the drill bushes are positioned close to the component and normal to the surface to be drilled, and not normal to the component axis. ‘The sides of the jig are accordingly tapered so that when the jig ‘the drill bush is vertical to the bed of the drilling machine. placed on any of its 4 POT JIG (DRILLING HOLES RELATIVE TO EXTERNAL FEATURES) (Fig.26) When a component is to have a pattern of holes drilled in it which must be correctly orientated to an external feature then care must be taken to ensure that the possibility of incorrect orientation is eliminated. This jig is intended to drill a pattern of 4 holes in each end of a cylindrical component having a stepped bore and the position of the holes must be accurate relative to an external boss. The component is placed over the location in the lower half and the upper half fitted in position and clamped. Holes may then be drilled in each end in the normal manner. It can be seen that the stud carrying the clamping nut is eccentric to the location and the axis of the component. This is to ensure that the top bush plate can only be fitted in the correct orientation relative to the lower one. Whereas the radial location of the component is determined by the two dowels engaging the oss, a further fool-proofing block is fitted which loosely locates in a second external feature thus ensuring that the component is in the correct position. It would otherwise be possible for the boss to be in a radial position well clear of the dowels and still allow the jig to be clamped.POT TYPE DRILL JIG (Fig.27) The pot jig is commonly used particularly for components such as the one shown in this ‘example where holes are to be drilled around the flange of a cylinder The component is lowered into the pot, the bush plate lowered into position (located by the dowel) the ‘e’ washer swung across and the clamping nut tightened down, The machining of the holes may now take place in the normal manner and it can be seen that ‘cut-outs are provided around the flange of the pot to allow swarf to fall clear of the jig. Allowance is also made for any swarf which may fall inside the pot by the drilling of 4 large holes in the lower section, allowing swarf to fall through and not accumulate in the location ares It is clearly shown in the lower views how the holes may be drilled relative to either the bore of ‘the component or to the outside diameter of the component body.CLAMPING NUT MAIN BODY Condition _{o) Condition (b) Holes drilled relative to Sanvanent bare eo Ub ot canponert Fig 27 _Drill jig-pot typeRETRACTABLE DRILL BUSH (DRILLING ANGLED CROSS HOLES) (Fig.28) Itis a frequent requirement that drilled holes may be required to intercross in a component particularly if that component is to control the flow of fluids or gases. If the two holes are not normal one to the other then the situation may call for a retractable drill bush as shown in this example, ‘The component is located and clamped on to a central location and the slide moved forward bby the operating lever until the drill guide bush mounted on the slide enters a drilled hole in the component, at which point a shot bolt engages in the slide and locks it in position. It can be seen that the hole to be drilled in the component is approximately 45° to the normal axis of the main hole and only enters through one side. When the drilling is completed, the shot bolt is lowered by the connected lever and the slide retracted so that the drill bush is withdrawn clear of the component. PLATE DRILL JIG (Fig.29) The plate drill jig shown is a very simple design in that the component is positioned by locating a previously machined hole on to the location dowel, sliding the retractable clamp forward to rough locate between two bosses on the component and then tightening the clamp screw to lock the casting firmly against the adjustable stop screw. ‘The main clamp may then be tightened and the jig inverted on its feet so that the drill bushes in the base may guide the drills during the machining cycle. This jig can be made almost completely from standard parts.DRILL BUSH / Fig 29 __Dril jig = plate type_‘SELF-ADJUSTING CLAMP (CAM OPERATED) (Fig.30) t ‘components is the variation in ‘component size, a condition which is increased when more than one componant Is being clamped ‘The example shown provides for the simultaneous clamping of two components in two separate work stations against a common central fixed location. ‘A pneumatic cylinder is used to rotate a double sided cam which imparts linear movement via a pair of cam follower blocks to the clamping arms pivoted on the outer face of the fixture. To allow for variation in component dimensions the clamping cam is allowed to ‘float’ on the square section of the shaft thus effecting an equal clamping force to either clamping arm irrespective of component size. CLAMPING BENCH (Fig.31) The device shown in Fig.31 is used for clamping a component horizontally and drawing it down vertically on to the work surface. The clamp arms are slotted so that when the clamp sorew is rotated lowering the link arms, the clamps are guided inwards and downwards by the action of a pair of fixed pivot pins running in the slots in the clamp arms. A threaded bush is inserted into the bottom face of the work surface which may be easily replaced should excessive wear occur.CRANKSHAFT MILLING FIXTURE (Fig.32) Some components present more and the crankshaft is one of these. The fixture illustrated was designed to clamp a crankshaft while a light milling operation was carried out. In this case the cutting of a keyway in the front journal. The main journals are seated against a pair of location blocks, one at either end and the eccentric journal is allowed to rest on a location button. A pair of rocking clamps are applied to ‘the main journals through the clamp actuating bar by a large spoked clamping wheel. The profile of the clamping face forces the crankshaft journal down into the location blocks. A retractable ‘top clamp is then applied and the final clamping load applied to both the top clamp and the rocking clamps. Ity in clamping than others due to their configuration MULTLDRILLING HEAD FIXTURE (Fig.33) It is required to drill 4 holes in the face of the square flange situated at the end of a cylindrical pipe. The component is placed in the jig so that the cylindrical section is supported by the two location pads in the rear location and the flange nesting on the location pads in the front location seated firmly against the back-up bush. The horizontal clamp screw is tightened to provide lateral location and the two clamping bars are lowered on to the component, the rear ‘one directly on to the pipe and the front one through a pivoted clamp pad which allows for any irregularity in the component surface. The two clamp bars are secured by thumb nuts. It can be seen that in the ‘open’ position the clamp bars and the swing bolts are restrained from any unnecessary movement by respective stop bars.(b] Clanped postion OSS {cl Open postien. onp_bor Fig, 33 Muiti-criling_jig. eeeMILLING FIXTURE WITH SETTING BLOCKS (Fig.34) This example is a simple milling fixture on which two faces of the component may be machined simultaneously. The component rests on two seating strips and located by a pair of pins. As the cutter passes, it machines both the horizontal and the vertical faces of the component. An interesting feature is the use of a cutter setting block to which the cutter may be presented and adjusted so that when a setting piece of known thickness is a snug sliding between component and setting block, the cutter is then in the correct setting to machine the component to the required dimension. In this way, the setting up of cutters may be achieved in the minimum time. The thickness of the setting piece should be clearly marked on the setting blocks. vaFish machined foce of 6 MILLING ‘CUTTER SETTING PIECEMULTI-DRILLING HEAD FIXTURE (Fig.35) ___ Multi-drill heads are commonly used on larger components and the fixture in Fig.35 illustrates some of the techniques which may be employed when dealing with them, In this case the component is pushed along feed rails until it contacts a set of rough location pads. The section of rails supporting the component in this position are then lowered so that ‘the component drops into a set of precision location blocks at the lower level. The rails lower clear of the component, leaving it supported on precision buttons. The single diagonally positioned clamp screw is now tightened forcing the component against the location pads and then the two remaining clamp screws are tightened thus locating the com- Ponent horizontally. At this point the hydraulic clamps which have until now been retained clear of the compon- ent path are now swivelled through 90° so that they are now over the component and they then apply the downward clamping force. It should be noted that the clamps are positioned either directly above or as close as possible to the support buttons, to ensure that their downward force does not distort or damage the ‘component. As it is common practice to include the drill bush plates on the multi-head it is necessary ‘only to provide a location between the bush plate and the fixture. This feature is clearly shown.ELEVATING RAILS stamped. ‘Fig 25 Muti-drling head fiture -«Se@UENEE of comping. io S r i) ey . cemiceal avon las, ras Horzontal clamping pressure ‘in_precision locations in Idroulc clamps moy.beMULTI-HEAD DRILLING (Fig.36) When it is required to drill a number of holes in a large component on a main produ basis then @ more complicated fixture may be required, particularly if multi-drill heads are to be used. In multi-heads it is common practice to incorporate the drill bush plates in the drilling head so these need not be considered when designing the fixture, but one must consider a method of ensuring that the drill head is correctly positioned relative to the fixture, The fixture shown has facility for holding components on each of the 4 faces on the square main body. Components are located on and supported by a long central location bar and are clamped manually by a series of toggle clamps of varying types. ‘The component is located longitudinally by the action of a spring loaded plunger forcing it against an end location block. By this method 3 different component faces may be presented to the multi-head simultane- ‘ously and therefore as the fixture is indexed around each component may be machined in 3 different faces without being moved from the fixture, ‘The fixture is mounted on an axial shaft mounted between two support frames. Indexing of the fixture is by a hand-wheel and location is by hydraulically (or pneumatically) operated shot-bolt. When the fixture is correctly positioned then the hydraulic clamping cylinder is energised to pull the fixture firmly against the end location button. In order to achieve this, it can be seen that the fixture spindle must be a sliding fit in the bore of the bearings to allow for the slight axial displacement.coms coMpoNeNT EOSEton POSTIONING PLUNGER Foxture spindle to beyy Technical Editing and Reproduction Limited _ , London, WI v Sere ingland by treet, | 78Charlowe “Printed in E