Jigs and Fixtures:

Enhancing Manufacturing
and Construction Efficiency

Nandan Mittal (20BME033)

Aabhas Tejasvi (20BCS002)
 Agenda
Design
Introduction to Types of Jigs Applications of
Principles for
Jigs and Fixtures and Fixtures Jigs and Fixtures
Jigs and Fixtures

Challenges and Innovations in Safety

Limitations Jigs and Fixtures Consideration
Introduction
to Jigs and
Fixtures
Definition: Jigs and fixtures are specialized tools used in
manufacturing and construction processes to enhance
efficiency, precision, and consistency. Jigs guide tools,
while fixtures hold workpieces in position.
Importance in Manufacturing and Construction
Processes:
Efficiency: Jigs and fixtures streamline operations, reducing
production time by eliminating manual setup and adjustments.

Precision: They ensure accuracy and consistency, minimizing errors

and defects.

Consistency: By maintaining the same setup, they contribute to

product quality and uniformity.
Types of Jigs

• Template Jig
• Plate Jig
• Channel Jig
• Diameter Jig
• Leaf Jig
• Ring Jig
• Box Jig
Template Jig
The template jig is the simplest of all the
models. The plate, having two holes, acts
as a template fixed on the component to
be machined. The drill is guided through
these template holes, and the required
holes are drilled on the workpiece at the
same relative positions as on the
template.
Plate Jig
A plate jig improves the template jig
by incorporating drill bushes on the
template. The plate jig is employed to
drill holes on large parts, maintaining
accurate spacing with each other.
Channel Jig
Channel jig is a simple type of jig having
a channel-like cross-section. The
component is fitted within the channel
and is located and clamped by rotating
the knurled knob. The tool is guided
through the drill bush.
Diameter Jig
Leaf Jig
The leaf jig has a leaf that may be swung
open or closed on the work for loading or
loading purposes.
Ring Jig
Ring jig is employed to drill holes on
circular flanged parts. The work is securely
clamped on the drill body, and the holes are
drilled by guiding the tool through drill
bushes.
Box Jig
Box jig is of box-like construction within
which the work is rigidly held so that it
can be drilled or machined from different
angles at a single setting depending on
which face of the jig is turned toward the
tool.
Types of Fixtures
Turning Fixtures
These fixtures are generally mounted on the
nose of the machine spindle or a faceplate, and
the workpieces hold them. The fixture may
have to be provided with a counterweight or
balance the unbalance fixture whenever
necessary.
Milling Fixtures
Milling fixtures are typically mounted on the
nose of the machine spindle or a faceplate,
and the workpieces hold them. The table is
shifted and set in the proper position about the
cutter. The workpieces are located in the base
of the fixture and clamped before starting the
operation.
Broaching Fixtures
Broaching fixtures are used on different
broaching machines to locate, hold and
support the workpieces during the operations,
such as keyway broaching operations, such as
keyway broaching, hole broaching, etc.
Indexing Fixtures
Several components need machining on
different surfaces such that their machined
surface surfaces or forms are evenly spaced.
Such elements must be indexed equally as
many as the number of surfaces to be
machined. The holding devices (jigs or
fixtures) used are made to carry a suitable
indexing mechanism. A fixture having such
a device is known as an indexing fixture.
Grinding Fixtures
These fixtures may be the standard work-holding
devices, such as chucks, mandrels, chuck with
shaped jaws, magnetic chucks, etc. For external
surface grinding, cylindrical grinding utilizes plain
or tapered mandrels. The workpiece is located and
held on the mandrel with the help of the bore so that
the external surface may be machined truly
concentric to the bore. For internal grinding, the
chuck is the most standard fixture. For holding
irregularly shaped components, the fixture is
designed the same as turning or boring fixtures.
Boring Fixtures
This fixture incorporates almost all the
prevailing principles of jig and fixture design;
their construction need not be as sturdy as that
of the milling fixtures because they never have
to bear as heavy cutting loads as involved in
milling fixtures because they never have to
endure as heavy cutting loads as involved in
milling operations.
Tapping Fixtures
Tapping fixtures are specially designed to position and firmly secure identical
workpieces to cut internal threads in drilled holes. Odd-shaped and unbalanced
components will always need such fixtures, especially when the tapping operation is
to be carried out repeatedly on a mass scale on such parts.

Assembly Fixtures
The function of these fixtures is to hold different components together in their
proper relative position when assembling them.
Duplex Fixtures
It is the name given to the fixture which holds two
similar components simultaneously and facilitates
simultaneously machining of these components at
two separate stations.
Welding Fixtures
Welding fixtures are carefully designed to hold
and support the various components welded in
proper locations and prevent distortions in
welded structures. For this, the locating
element needs to be careful; clamping has to
be light but firm, and the placement of
clamping elements has to be clear of the
welding area. The fixture must be pretty stable
and rigid to withstand the welding stresses.
Difference Between Jig and Fixture
 Design Principles for Jigs and Fixtures

• LOCATING POINTS: Locating the work is a prime necessity and requires suitable facilities. The
correct setup ensures smooth insertion of a workpiece in the proper position and removing a workpiece
from a jig without operational hassles or time consumption. The workpiece position needs to be precise
with the guiding tool in the jig or setup pieces in the fixture.
• FOOLPROOF: A foolproof design of jigs and fixtures does not permit a tool or workpiece to be
placed in any other way other than the intended one.
• REDUCTION OF IDLE TIME: Jigs and Fixtures must be designed in such a way that ensures
smooth loading, clamping, machining, and unloading of material.
Design Principles for Jigs and Fixtures
• WEIGHT OF JIGS AND FIXTURES: A jig and fixture must be compact, easy to
handle, and low cost regarding the number of materials used without giving up stiffness
and rigidity.
• JIGS PROVIDED WITH FEET: Some jigs require feet so that they can be placed on
the table firmly.
• MATERIALS FOR JIGS AND FIXTURES: Jigs and Fixtures are usually created with
hardened materials to resist wear & tear and avoid frequent damage—for example, Mild
steel, Cast iron, Die steel, High-speed steel, Cesium.
• CLAMPING DEVICE: A suitable clamp is rated for its strength. It should be able to
hold a workpiece firmly in its position while bearing the strain of the cutting tool
simultaneously, without springing.
Applications of Jigs
and Fixtures
• Automotive Industry: Welding fixtures ensure
precise alignment of car parts during assembly.
• Aerospace Industry: Drilling jigs maintain strict
tolerances for aircraft components, ensuring
safety.
• Electronics Manufacturing: PCB assembly
fixtures aid in the soldering of miniature
components, guaranteeing functionality.
Advantages and Benefits
• Productivity
Jigs and fixtures increase productivity by eliminating frequent repositioning and checking. Operation
time is reduced due to an increase in speed, feed and depth of cut because of high clamping rigidity.
• Interchangeability and Quality
Jigs and fixtures enable the production of many workpieces repeatably, accurately and with uniform
quality and interchangeability at a competitive cost.
• Skill Reduction
There is no need for the skillful setup of workpieces on a machine. Jigs and fixtures allow unskilled
or semi-skilled machine operators to set up the workpieces reducing labor cost.
• Cost Reduction
Higher production, reduced scrap, easy assembly and savings in labor cost result in an ultimate
reduction in unit cost.
Challenges and Limitations
• Maintenance: Regular maintenance is crucial to ensure fixtures
remain in optimal condition.
• Adaptability to New Products: Design challenges arise when
adapting existing fixtures to new workpieces.
• Initial Costs: Investment in design, fabrication, and setup can be
substantial.

Overcoming Challenges: Implement preventive maintenance

programs, consider modular designs for adaptability, and perform cost-
benefit analyses for initial investments.
Innovations in Jigs and Fixtures
3D Printing for Custom Fixtures: Rapid prototyping allows for cost-
effective and custom fixture creation.

Smart Fixtures with Sensors: Integration of sensors provides real-time

data on workpiece positioning, improving quality control.

Lightweight Materials: The use of lightweight and durable materials

like carbon fiber enhances portability and efficiency.
Safety Consideration

Proper Training: Train employees on safe usage, maintenance, and

emergency procedures.

Regular Inspections: Conduct routine inspections to identify wear

and damage.

Compliance with Regulations: Ensure adherence to industry safety

standards and regulations.
Thank You