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Jigs and fixtures play a crucial role in manufacturing by ensuring accuracy and efficiency. This document discusses different types of jigs and fixtures and their uses. It also summarizes various manufacturing processes like turning, milling, drilling, forming, and heat treatment. Forming processes include bulk deformation techniques like rolling, forging, extrusion and wire drawing. Common heat treatment processes outlined are annealing, normalizing, tempering and hardening.

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047 Karunakaran M
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45 views35 pages

Dryijftjv

Jigs and fixtures play a crucial role in manufacturing by ensuring accuracy and efficiency. This document discusses different types of jigs and fixtures and their uses. It also summarizes various manufacturing processes like turning, milling, drilling, forming, and heat treatment. Forming processes include bulk deformation techniques like rolling, forging, extrusion and wire drawing. Common heat treatment processes outlined are annealing, normalizing, tempering and hardening.

Uploaded by

047 Karunakaran M
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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LEARNINGS ON

JIGS & FIXTURES


AND
MANUFACTURING PROCESSES
PRESENTER TEAM
SANKARA NARAYANAN D
KARUNAKARAN M
EYAS AAMIR P A
HARI PRADEEP N
DEVA S

OBJECTIVE
1. Jigs and Fixtures
2. Manufacturing processes
3. Forming processes
4. Heat treatment processes
1. Introduction:
Jigs & Fixtures
In the vast landscape of manufacturing, the
significance of jigs and fixtures is paramount.
These versatile tools, often overlooked, play a
crucial role in ensuring accuracy, efficiency,
and cost-effectiveness in various industrial
processes. From assembly lines to machining
operations, their multifaceted applications
streamline production and enhance quality
control. Let us embark on a journey to
uncover the untold importance of jigs and
fixtures in the world of manufacturing.

333
1.1 JIGS and it’s Types

A jig may be defined as a device which holds


and located a workpiece and guides and
controls one or more cutting tools. The
holding of the work and guiding of the tool is
such that they are located in true positions
relative to each other.

Key components:
1. Jig bush.
2. Locating pin
3. Supporting pin
4. Adjustable locating pin
5. clamp
1.2 Types of Jigs
1.Template jig

2.Plate jig

3.channel jig

4.Diameter jig

5.Leaf jig

6.Box jig
1.3 Fixtures
A fixture is a device which holds and locates a
workpiece during an inspection or for a
manufacturing operation. The fixture does not
guide the tool.
1.4 Types of fixtures
1.Turning fixtures.

2.Milling fixtures.

3.Broaching fixtures.

4.Grinding fixtures.

5.Boring fixtures.

6.Indexing fixtures.

7.Tapping fixtures.

8.Duplex fixtures.

9.Welding fixtures.

10.Assembly fixtures.
1.5 Factors to
Consider when
Designing Jigs
and Fixtures
When designing jigs and fixtures, there are
several factors to consider. These include the
special requirements of the project, the materials
being used, the production volume, the cost-e
ectiveness of the design, and the ergonomics of the
workspace. By carefully considering these factors,
engineers can create optimized jigs and
xtures that enhance productivity and
ensure consistent and accurate
manufacturing processes.
1.6 Innovations
and Trends in
Jigs and
Fixtures
In the rapidly evolving manufacturing
industry, there are several innovative trends
in jigs and fixtures. From the use of 3D
printing to create custom fixtures to the
integration of sensors for real-time monitoring
and optimization, engineers are constantly
finding new ways to improve productivity and
accuracy in manufacturing processes.
Staying updated on these trends ensures
that companies can stay competitive and
maximize their e iciency.
TURNING OPERATION

Turning is a machining process in which a cutting tool


move against rotating work piece to removal of
material.
TYPES OF TURNING
OPERATIONS
Straight Turning
The straight turning produces a cylindrical surface by
removing excess metal from the workpiece

Taper Turning
Taper turning means to produce a conical shape
by a gradual reduction in diameter from a
cylindrical workpiece.
Knurling
This is done to provide a better gripping surface
when operated by hands.

Thread Cutting

It is the important operation in the lathe to


obtain the continuous ”helical grooves” or ”
threads’‘.
Facing
Operation of reducing a flat surface on the
end of the workpiece

Chamfering

Operation of getting a bevelled surface at


the edge of a cylindrical workpiece
CNC Turning
MILLING PROCESS
CNC MILLING MACHINE
MILLING CUTTER

(a) Face mill cutter

(c) Shell end mill cutter

(b) Slab mill cutter


(d)Thread mill cutter
(e) End mill cutter
DRILLING PROCESS
- Cutting process

- Circular crossection

- Drill press

- Rotating rate
Application of
drilling machine
The process is suitable for drilling into
automobile, aerospace, and construction parts –
for example, the dashboard, engine, etc. It is
accompanied by other CNC machining process
Flat drill bit
• It is used for drilling larger diameter
holes into wood
• It is applicable in angled surface
Twist drill bit
* It is particularly good for drilling
through hard materials such as titanium,
cast iron and stainless steel
Counter sink drill bit
It is used to ensure that flat head
screws or fasteners sit flush against the
workpiece.
FORMING PROCESS
• Forming is the process of obtaining the
required shape and size on the raw material
by subjecting the material to plastic
deformation through the application of tensile
force, compressive force, bending or shear
forces.

• The applications are widely used in


automotive and defence industries.
BULK DEFORMATION
Rolling Process:
• Rolling is a metal forming process in which
metal stock is passed through one or more
pairs of rolls to reduce the thickness, to make
the thickness uniform, and/or to impart a
desired mechanical property.
• This has a major applications in rods and tubes.
Forging Process:
• Forging is a manufacturing process involving
the shaping of a metal through hammering,
pressing, or rolling. These compressive forces
are delivered with a hammer or die.
• This has a major applications in cars and
trucks.
Extrusion process:

• Extrusion, process in which metal or other


material is forced through a series of dies to
create desired shapes. Many ceramics are
manufactured by extrusion, because the
process allows efficient, continuous
production.
• This has a major applications in pipes and
tubes.

Wire drawing:

Wire drawing is a metalworking process used


to reduce the cross-section of a wire by pulling
the wire through a single, or series of, drawing
dies.
Sheet Metalworking:
Bending operation:

This is one of the most common sheet metal


fabrication operations., This method is used
to deform a material to an angular shape.
This is done through the application of force
on a work piece.
This has a major applications in household
appliances.

Deep drawing:

Deep drawing is a sheet metal forming


process in which a sheet metal blank is
radically drawn into a forming die by the
mechanical action of a punch. The process is
considered "deep" drawing when the depth of
the drawn part exceeds its diameter.
Shearing process:
• Shearing is the process of cutting sheet
metal to size out of a larger roll or flat
stock.
• As the material moves through the
shear machine, cutting blades come
together in order to fracture the material
into separate, smaller pieces.
• This process creates quality clean cuts
that can be repeated quickly.
• It is used for cutting of metal into small
size.
• Shearing-type operations
include blanking, piercing, roll slitting,
and trimming.
HEAT TREATMENT
Heat treatment Is the process of giving the
controlled heating and cooling to derive different
properties in the materials.

STAGES OF HEAT TREATMENT PROCESS

Stage 1: Heating a metal or alloy beyond the


critical temperature.
Stage 2: Holding at that temperature for a
sufficient period of time to allow necessary
changes to occur.
Stage 3: Cooling the metal or alloy at a required
rate to obtain the desired properties.
IRON CARBON
DIAGRAM
 Iron – carbon equilibrium diagram is the
graphical representation of the phase changes
undergone by iron with respect to the carbon
content and temperature on cooling or heating.
 This diagram is very much used to identify the
suitable metal alloys for different heat
treatment processes, carbon content and
required temperature for the process.
 This diagram is drawn by taking the carbon
content in X-axis temperature inY-axis.
ANNEALING
 The Process of Slow Cooling Is Knows As
Annealing.
 The Materials Are Heated Above Critical
Temperature.
 Then The Temperature maintain For a Period
Of Time.
 Then allow it to cool slowly to room
temperature In Side the Furnace It Self..
 Cooling is usually done in the furnace itself by
decreasing the temperature 10°C to 30°C per
hour.
NORMALIZING
Normalizing is similar to annealing but cooling is
done by still air rather then furnace.
 Material Is Heated Above 40°C - 50°C Above Its
Upper Critical Temperature.
 Then The Temperature maintains For a Period
of Time.
 Then allow it to cool slowly to room temperature.
 But cooling is done in still air.
 The Normalizing process consisting of ferrite
and pearlite for hypoeucetoid steels. and pearlite
and cementite for hyper eutectoid steel.
TEMPERING
The tempering is done to reduce hardness of
steel and improve ductility and toughness. In
this process the heating is done for the
metals which are already hardened steel.

 The hardened metal is heated to a


temperature between 250°C To 650°C.
 Then The Temperature maintains For a
Period of Time (1-2 hours )
 This followed by slow cooling to room
temperature in air
HARDENING
Hardening heat treatments invariably involve
heating to a sufficiently high temperature to
dissolve solute-rich precipitates. The metal is
then rapidly cooled to avoid reprecipitation;
often this is done by quenching in water or
oil.
 The biggest difference between each
process is that case hardening creates a
thin layer on the surface.
 Surface hardening hardens the outer
surface and keeps the core soft
throughout the entire process.
ADVANTAGES &
DISADVANTAGES
 The advantages include increased strength
and wear resistance while reducing stress
levels.

 However, there are potential problems,


such as oxidation or thermal shock, that
could occur if not done correctly or with the
right equipment

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