Course Design of Manufacturing Technology

Instruction booklet for the Final work

Design of a jig structure

for milling surface

Student number: 91815850E104

Student name: 成萨
Date: 10.01.2022
 Jigs and Fixtures

What is a jig and fixture? Jigs and fixtures are the common elements to be used in large
volume manufacture. They are manufacturing tools that are used to produce identical and
interchangeable components. These work-holding and tool guiding devices are designed for
use in the machining and assembly of parts.

To get the greatest benefit from jigs and fixtures, a basic understanding of their construction
is necessary. Jigs and fixtures are identified one of two ways: either by the machine with
which they are identified or by their basic construction. A jig, for instance, may be referred
to as a “drill jig.” But if it is made from a flat plate, it may also be called a “plate jig.”
Likewise, a mill fixture made from an angle plate may also be called an “angle-plate fixture.”
The best place to begin a discussion of jig and fixture construction is with the base element
of all work-holders, the tool body.

The accuracy achieved during a machining process depends upon the precision with which
the tool and the work piece are mounted in the machine tool along with their accurate
movement. Normal work holding devices such as chucks and vices are suitable for general
purpose work, but when required to be used repeatedly for a large number of identical
parts, the setup and clamping time become unacceptable. Hence for production work
involving large number of parts, it is necessary to have separate jigs and fixtures to be
designed for specific application such that the setup time is reduced to the absolute
minimum that is possible.

Jigs and fixtures are the production devices that are used for the accurate production of
repeated parts essentially for mass production. The required accuracy is achieved by
maintaining the precise relationship between the various surfaces of the fixture and the part
to be manufactured. A jig or fixture needs to provide the following functionality to be an
effective production device: Location; Clamping; Support; Resistance to Cutting forces;
Safety.

Both jigs and fixtures hold, support, and locate the work piece. However, a jig, also guides
the cutting tool. In a similar fashion a fixture has a reference point for setting the cutting
tool with reference to the work piece. Jigs are commonly used for making parts that contain
holes. The tools used for making holes are generally slender and need to be supported
because of the long overhang ratios. The jig bush is employed for this purpose. The most
common application of jigs is for drilling and boring. Though both of them are similar in
nature the sizes are generally distinct with the boring jigs being larger in size. In addition to
these applications, jigs can be used for all the hole making operations such as tapping,
reaming, chamfering, counter boring, and countersinking.

Jig:
A Jig is defined as a device that holds and locates a workpiece, guides and controls one or
more cutting tools. The holding of the work and guiding of the tool are such that they are in
true positions relative to each other. In construction, a jig comprises of a plate, a structure, a
box made of metal or in some cases non-metal having provisions for holding the
components in identical positions one after the other, and then guiding the tool in correct
position on the work in accordance with the drawing, specification or operation lay out. Jigs
are also identified by its construction as open and closed. Open jigs carry out operations
generally on only one side of a work piece while closed jigs operate on two or more sides.
The most-common open jigs are template jigs, plate jigs, table jigs, sandwich jigs, and angle
plate jigs. Typical examples of closed jigs include box jigs, channel jigs, and leaf jigs. Other
forms of jigs rely more on the application of the tool than on their construction for their
identity. These include indexing jigs, trunion jigs, and multi-station jigs. Details of these
types of jigs are given later.

Fixture:
A fixture may be defined as a device which hold and locates the workpiece during an
inspection or for manufacturing operations. The fixture does not help in guiding the tool. In
construction, a fixture comprises of a different standard or specially designed work holding
devices, which are clamped on the machine table to hold the work in position. The major
advantages of using jigs and fixtures are listed below

 Eliminates the marking out, measuring, and other setting methods before
machining.
  Increases the machining accuracy, because the workpiece is automatically located
and the tool is guided without making any manual adjustment.
 Enables production of identical parts which are interchangeable. This facilitates the
assembly operation.
 Increases the production capacity by enabling number of workpieces also greatly
reduced to quick setting and locating of work. The speed, depth of cut and feed for
machining can be increased due to high clamping rigidity of jigs and fixtures.
 Reduces the operators labor and consequent fatigue as the handling operations are
minimized.
 Enables semi-skilled operator to perform the operations as the setting operations of
the tool and the work are mechanized. This saves labor cost.
 Reduces the expenditure on quality control of the finished products.
 Reduces the overall cost of machining by fully or partly automatizing the process.

Fixtures are used for a much wider applications compared to jigs. These can be used for all
other machining applications, depending upon the type of the cutting tool used and the
geometry of the work piece. The motion of the cutting tool is more complex, involving the
movement in two different axes and hence cannot be guided like a drill. These will be
provided with setting blocks for the tool setting. The fixtures are generally identified by the
machine tool in which they will be used along with the type of machining to be performed.
For example, milling fixture or string milling fixture can be used to completely classify the
operation performed.

Advantages of Jigs and Fixtures:

In manufacturing operations, it's important to meet the higher demands of customers. This
means producing quality products as fast and efficiently as possible. Jigs and fixtures help
make manufacturing processes more efficient and precise. By utilizing jigs and fixtures in
machining processes, manufacturers benefit from:

 increased production
 decreased manufacturing costs
 improved product consistency
  improved assembly line safety
 a reduction in non-productive hours
 reasonable automation capabilities interchangeability and accuracy

The jigs and fixtures are classified into different types based on quality and complexity of
the work or machining operation. Below mentioned are a few types of jig and fixtures.

1) Template Jig: It consists of a plate with two holes at required positions serves as template
which is fixed on the component that is to be machined as shown in the Figure 1. The tool is
guided through these templates and to carry out the machining process.

Figure 1

2) Plate Jig: Figure 2 depicts a plate jig setup. Plate jigs are improvised versions of the
template jig by incorporating drill bushes. The plate jigs are used to obtain higher accuracy
and precision while machining.
 Figure 2

3) Channel Jig: A channel jig setup is presented in the Figure 3. A Channel jig consists of
channel like cross section, where-in the workpiece is fixed by means of knurled knob.

Figure 3

4) Diameter jig: The Diameter jig is used in the cases where radial machining is involved. The
work-piece is mounted on the V-Block and is clamped under clamping plate by means of
clamping bolt as shown in Figure 4.

Figure 4
5) Leaf Jig: The Leaf Jig consists of hinge pin to open or close the jig, set screws and leaf
clamping screws to constrain the motion of workpiece in horizontal and vertical direction as
shown in the Figure 5. Due to complex mechanism, the work-piece might experience more
clamping force compared to that of other Jigs.

Figure 5

7) Box Jig: A Box jig is used when there is a need for machining a workpiece at different
angles and at different places. The main component is located by buttons within a box like
construction. The cam clamps the work-piece and locates it as shown in Figure 6.
 Figure 6

Merchant Circle Diagram

 A Merchant Circle Construction for Side face milling is proposed to study the cutting
forces on the workpiece.
 A typical Merchant Circle Diagram is presented in the Figure 7.
 A reference line is constructed perpendicular to the cutting velocity.
 A suitable Scale is considered to convert Cutting velocity, Cu into centimeters.
 Cutting force which is into the component, pz is obtained by placing dynamometers
on the component, pz is scaled and marked on Cu. Also the perpendicular forces pxy
obtained from the dynamometer is scaled and extended perpendicular to Cu from
the end pz .
 The resultant of pz and pxy as diameter a circle is drawn which is Merchant circle, and
the diagram is MCD.
 Rake surface is the surface of the work-piece with which the tool makes an angle.
 The Frictional force can be obtained by extending the Rake Surface to meet the
Circle
Figure 7
 Milling operation review

1. Milling Machines and Cutters

Milling can be carried out in multiple methods. A milling machine is an equipment or a tool
that helps chipping off the extra material from the workpiece that is fed in the opposite
direction of the rotating cutter (single/multi flute cutter). The milling operators produce a
better surface finish than the other conventional cutting procedures. Different types of
millings are listed as follows:

2. Column and Knee type

A column and knee type milling is presented in the figure below. A Column and Knee type
milling is used for both horizontal and vertical milling operations. The table holds the work
piece against the spindle or the cutter rotation. The spindle/cutter rotates in a fixed position
whereas the work piece is given a linear feed by adjusting or moving the table that is holding
it. Different types of millings that fall under column and knee type are Hand milling, Plain
milling, Universal milling, Vertical milling.
 3. Manufacturing or Fixed bed type
Figure below shows a typical fixed bed type milling machine. In this milling type both the
positions of work-piece and cutter can be altered simultaneously. The work piece is held by
the table on the fixed bed which can only move in the longitudinal direction. The spindle or
the cutter can only move in vertical direction. Fixed bed milling is categorized as Simplex
milling, Duplex milling, Triplex milling.
 4. Planer Type
Planer type is generally used to mill heavy work-pieces. The workpiece is clamped on the
table which can only move in the Z- direction i.e., into the paper direction which is located
on fixed bed. It consists of four cutters as shown in the figure below that can move
horizontally and vertically to perform milling operation.
Milling Machinery is mainly comprised of:

1) Base: It is the casting of grey cast iron which serves as the support or holding component
for the entire milling machine.

2) Column: The column is mounted vertically on base that acts as supporting frame
assembled with nuts and bolts, that constraints unnecessary movements of the spindle and
the table feed.

3) Knee: A Knee slides vertically of the column face. Screws mounted helps the component
adjust the height. It also serves as house for feed mechanism of the table.

4) Saddle: The Saddle moves horizontally and its position can be altered by means of screw-
nut arrangement to provide guideways for the table. It is located on top of the Knee and
moves perpendicular to the column face. Various processes performed by different milling
cutters are grouped under three separate headings they are peripheral milling, face milling
and end milling.

1) Peripheral Milling: This milling operation is carried out to produce the machine surface
parallel to the axis of rotation of the cutter. For Peripheral milling, the cutting force is not
constant throughout length of cut by each tooth due to which shock is developed in the
driving mechanism that leads to vibration. Depending on the relative movement between
the tool and the work, peripheral milling is furthered classified as.

a) Up Milling: Up milling is also known as conventional milling, wherein the cutter is rotated
against to the work-piece travel. Figure below shows the working of Up milling. The chip
thickness will be maximum when the cut terminates. The cutting force is directed upwards
and this tends to lift the work-piece from the fixture. In this kind of a milling due to the
typical nature of the cut, difficulty is experienced in pouring coolant just on the cutting edge
from where the chips begin. As the cutter progresses, the chips accumulate at the cutting
zone and may be carried over with the cutter spoiling the work surface. The surface
generated by up milling appears to be wavy as the cutter teeth do not begin their cut as
soon as they touch the surface. This process is the most widely used milling procedure even
though it has so many disadvantages.
b) Down Milling: Down Milling also called Climb Milling. In this process, the metal is
removed by a cutter which is rotated in the same direction of travel of the workpiece. The
working of down milling is shown in the figure below. Initially the chip thickness is maximum
and reduces to minimum as the cut terminates. Unlike Up Milling, in Down Milling the cutter
starts the cutting operation as soon as it touches the surface without slipping or sliding. In
down milling, the position of the fixture becomes easy as the direction of the cut enables
the fixture to sit and not get up in like up milling. The chips are also disposed easily, do not
interfere with the cutting operation and the coolant can be poured directly over the cutting
surface. The results obtained in down milling are much better than up milling the surface
finish diminishes the heat generated. Even though down milling has so many advantages
due to the backlash error in the old milling machines these are not used extensively.
2) Face Milling: Face milling operations are performed to produce a flat machined surface
perpendicular to the axis of rotation of the cutter. The peripheral edges of the cutter do the
actual cutting, whereas the face cutting edges finish up the work by removal of very small
amount of material. Both up and down milling may be performed, simultaneously on the
work surface. The thickness of the chip is maximum at the end of the cut and minimum
initially.

3) End Milling: End milling is a combination of both peripheral and face milling operation.
The cutter has teeth on both the face and the periphery. The direction of helix of the cutter
and the direction of rotation must be the same in end milling and vice-versa when
peripheral cutting edges are being used.
 Design model

This section is related with design work of every element of the jig structure as well as the
workpiece given to us for the work. The design procedure of Jig-Fixture is according to the
design guidelines and is as follows. The workpiece structure is designed initially followed by
the base plate, vertically and horizontally supporting structures with the shaft at the end.
The entire assembly and modeling of the parts are designed in SolidWorks.

1. Workpiece
First of all, the model of the workpiece needed, since that’s the main part in the whole
assembly, because the jig-fixture structure is designed around it. All the dimensions were
given to us, so it was quite clear what exactly we need to model. The part is a long and
completely unsymmetric figure with inclined parts. The model has quite a lot details with
some holes, outstanding parts and cuts. The whole length of the structure is 166,4 mm, the
widest part is about 60 mm with the largest thickness of 42 mm.
 2. Base plate
The design of the base plate is shown below. It is basically just a rectangular box
113mmx50mmx65mm with three holes on the top for the shaft and two bolts. The diameter
of the hole for the shaft is 16mm, which is the same as the workpiece’s hole. It does not go
through, because the shaft has to stop as long as it is fully inside the workpiece. This base
plate is the support structure that rests on the ground and bares all the weight. The base
plate plays a very vital role in providing strength to the structure. The workpiece structure
along with the top plate rests on the base plate. The base connects with the workpiece with
the help of a shaft to fix the workpiece which doesn’t let it to move except in rotation.
Additionally fillet feature is used for all sharp edges of the plate to make it look good.
 3. Side fixing block
The design of the structure is shown below. There are two of them exactly the same size. It
is basically a rectangular box without a block in one corner. It rests on the base box and fixes
the workpiece structure on both sides that doesn’t let to move the workpiece sideways.
Additionally, there are two holes for the bolts. One of them is threaded.
 4. Top plate
The screenshot below shows the design of the top plate. Top plate and the peripherals play
a vital role in this jig and fixture arrangement as they hold the workpiece firmly. The top
plate rests on top of the workpiece. It finally fixes the workpiece to the base plate, where
the workpiece is not able to move anywhere. The overall shape of the figure is a rectangular
box with an arc looking extruded cut in center, which lets the plate to be in contact with the
workpiece. There are also two holes on each side for the bolts to be screwed.
 5. Shaft
The shaft plays a very important role in the assembly, since it is one of the parts that fixes
the workpiece and does not let it to move sideways and incline. The shafts length is 62 mm,
diameter 16 mm. It also has a fillet on two ends of it, so its easier to take away.
 6. Assembly
The workpiece structure, base plate, top plate, side blocks and shaft are assembled as per
the design specifications. The model is firmly fixed to the jig structure.