Jigs

JIGS: Meaning, Configurations, Elements, Materials used & Applications

Hello Readers, welcome to your own website to understand each and every topic related to the manufacturing process where we transform complex content into simpler ones. In this article, we are focused to cover the meaning of jigs, types of jigs, bushings for jigs, production devices, elements of jigs, materials used in jigs, advantages, disadvantages, and applications.

MEANING

Jigs are workholding gadgets utilized for controlling hole making instruments into precisely found workpieces.

Although used for variety of hole making processes, like boring, reaming, tapping, and so forth, most of jigs are used for drilling.

A regular jigs utilized in penetrating would incorporate a baseplate, or then again a crate, with various finders and braces for holding the workpiece further more, (solidified steel) bushings comparing to the quantity of openings to be drilled.

JIGS CONFIGURATIONS

Jigs setups differ from basic format:

TYPE OF JIGS:

Type jigs that would permit drilling in various angles.

PLATE JIGS

Plate jigs are varieties of templete type jigs that also incorporate clamping devices for precisely and safely holding the workpiece.

Leaf jigs constitute the most common configuration.

Leaf jigs
Fig. 1 Leaf jigs

A workpiece is mounted onto the base portion of the jig, found precisely, and therefore braced set up by the bringing down of the upper portion of the jigs.

Cam-activity type latches allow for loading/unloading cycles.

BOX JIGS

Channel and box jigs are regularly intended for complex part calculations and additionally for assembling measures that would require drilling from a number of unmistakable points, so one necessities the part to be held precisely while repositioning the jigs.

Box jigs
Fig. 2 Box jigs

As in plate jigs, various finders set on various dividers of the case find the workpiece safely while drilling is done.

As in leaf jigs, the box is closed by the pivoting wall.

Normal arrangement of bushings on moving wall sections of the box jigs should be avoided for better accuracy.

BUSHINGS

Drill bushings are ordinarily fabricated from wear-safe, solidified steel.

The most widely recognised sorts are press-fit, sustainable, and liner bushings.

Press fit bushings
Fig. 3 Press fit bushings

Press-fit bushings are fabricated with or without heads and squeezed straight forwardly into the jigs plate for short creation runs that would not need continuous changes of the bushings.

Renewable bushings
Fig. 4 Renewable bushings

Inexhaustible bushings slide into their particular areas in the jigs plate with great fit and the set up is held by a locking component.

Liner bushings
Fig. 5 Liner bushings

These are normally utilized when different opening creation activities are performed on a similar opening, which require distinctive diameter bushings (e.g., exact hole extension, tapping, and so on).

PRODUCTION DEVICES

Production devices are large work holders with or without apparatus.

Jigs are provided with instrument guiding components, for example, drill bushes.

These direct the device to the correct situation on the workpiece.

Jigs are rarely clipped on the machine table because it is neces­sary to move the jigs on the table to adjust the different bushings in the jigs with the machine spindle.

Jigs hold the workpiece safely in the correct situation concerning the machine/cutter during activity.

There is some­ times an arrangement of the apparatus for ‘setting’ the instrument as for the workpiece/installation, however the device isn’t guided as in a jig.

Fix­tures are frequently clamped to the machine table.

ELEMENTS

Finding Elements: These position the workpiece accu­rately concerning the apparatus directing or setting components in the installation.

Clamping Elements: These hold the workpiece safely in the found situation during activity.

Tool Guiding and Setting Elements: These guide managing or setting of the devices in right situation regarding the workpiece.

Drill bushings manage the drills precisely to the workpiece.

Milling fixtures use setting pieces for correct po­sitioning of processing cutters as for the workpiece.

MATERIAL USED IN THE JIGS

Jigs is made from an variety of materials, some of which can be solidified to oppose wear.

It is in some cases important to utilize nonferrous metals like phospher bronze to reduce wear of the mating parts, or nylons or fiber to forestall harm to the workpiece.

Given beneath are the materials regularly utilized in jigs, press instruments, collets, and so on.

HIGH SPEED STEELS (HSS)

These contain 18% (or 22% ) tungsten for durability and cutting strength , 4.3% chromi­um for better hardenability and wear opposition and 1% vandadium for maintenance of hardness at high temperature (red hardness) and impact resistance.

HSS can be air or oil solidified to RC 64-65 and are appropriate for cutting instruments like drills, reamers and cutters.

DIE STEELS

These are likewise called high carbon ( 1.5-2.3% ) high chromium (12%) (HCHC) cold working prepares and are utilized for cutting press tools and thread framing rolls.

Hot die steels with lesser carbon (0.35%) and chromium (5%) however alloyed with molybdenum (1%) and vanadium (0.3-1%) for maintenance of hardness at high temperature are utilized for high temperature work like forging, casting and ex­trusion.

CARBON STEELS

These contain 0.85-1.18% carbon and can be oil hardened to RC62-63.

These can be utilized for instruments for cutting softer materials like woodwork, farming, and so on

And further more for hand instruments like documents, chisels and razors.

The parts of jigs and fixtures like bushings and locators, which are exposed to weighty wear can likewise be produced using carbon prepares and hardened.

COLLECT STEELS (SPRINGS STEELS)

These contain about 1% carbon and 0.5% Manganese. Spring prepares are typically tem­pered to RC 47 hardness.

OIL HARDENING NON-SHRINKING TOOL STEELS (OHNS)

These contain 0.9-1.1% carbon, 0.5-2% tungsten and 0.45-1% carbon.

These are utilized for fine parts like taps, hand reamers, milling cutters, engraving tools, and intri­cate press devices which can’t be ground in the wake of hardening.

CASE HARDENING STEELS

These can be carburised and hardened to give 0.6-1.5 thick, hard (RC 59-63) exte­rior. 17 Mn1Cr95 steel with 1% manganese and 0.95% chromium is broadly utilized.

Ni2Cr1Mo15 steel with addi­tional nickel (2%) diminishes warm extension up to 100°C.

Case hardening steels are suitable for parts which require just nearby hardness on little wearing surfaces where cost­lier, hard to machine full hardening device prepares are not wanted.

HIGH TENSILE STEELS

These can be arranged into medium carbon prepares with 0.45%-0.65% carbon (En8-9) and alloy steel like 40 Ni2Cr1M028 (En24).

The tensile strength can be expanded up to 125 kg/mm2 (RC 40) by tempering.

Medium carbon steel are utilized broadly for fasteners and structural work while alloy steels are utilized for high stress applications like press rams.

MILD STEEL

It is the least expensive and most generally utilized mate­rial in jigs.

It contains under 0.3% carbon. It is conservative to make parts which are not exposed to much wear and are not highly focused from mild steel.

CAST IRON

Self­ greasing up properties make cast iron reasonable for machine slides and guide-ways.

The brilliant forming of a projecting and the example can save a great deal of machining time.

In spite of the fact that the strength of cast iron is just a large portion of the strength of mild steel, a wide variety of grades have been created.

Nodular cast iron is just about as strong as mild steel.

ADVANTAGES

It eliminates the setting time required before machining.

It increases the machining accuracy and also increases production capacity.

Requires less skilled operation.

They reduce the production cost.

Increases machine and labor utilization.

They simplify the work handling.

Increases the quality of production in the industry.

DISADVANTAGES

Can wear away over time.

Another one is the high initial set up costs (and time).

And can use a lot of material and be bulky.

APPLICATIONS

Mass production of automobile parts.

Inspection of parts in continuous production in manufacturing industries.

Cutting the ingots in the steel plant.

In the refrigeration industry.

Pump assembling process for drilling the flanges and drilling holes to any required angles.

For multi-spindle machining.

CONCLUSION

We have covered all the important concepts related to jigs. Hope you all are crystal clear with understanding all the concepts mentioned here. If you have any questions please use the comments section to get in touch with us. Till then have fun and always keep reading!

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