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عدد المساهمات : 26 التقييم : 68 تاريخ التسجيل : 26/03/2011 العمر : 37 الدولة : egypt العمل : engineer
| موضوع: كتاب Jigs and Fixtures - Design Manual السبت 14 يونيو 2014 - 8:39 | |
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أخواني في الله أحضرت لكم كتاب Jigs and Fixtures - Design Manual P. H. Joshi Consultant Production Engineering Services Pune Foreword and Edited by: Robert 0. Parmley, P.E.
و المحتوى كما يلي :
Contents Foreword to the Reprint of the Second Edition Preface to the Second Edition Preface to the First Edition ix XI Xlil 1. Introduction — Production Devices 1 Inspection Devices 3 Materials Used in Jigs and Fixtures 7 Presentation of Workpieces 9 1 2. Location — Principles 11 Locating Methods 16 Summary 39 11 3. Clamping 42 Principles of Clamping 42 Types of Clamps 46 Compensating Differential Clamps 76 Summary 77 4. Indexing Devices Linear Indexing 79 79 5. Drilling Jigs 87 Drill Bushings 87 Press Fit Bushings 88 Various types of Jigs 94 Summary 110 6. Milling Fixtures Types of Milling Machines 112 Types of Cutter 113 Direction of Feed 113 112Essentials of Milling Fixtures 113 Special Vice Jaws 116 Facing Fixtures 117 Slotting Fixtures 122 Summary 125 7. Turning Fixtures 127 Standard Chucks 129 Face Plate 133 Spring Collets 133 Cylindrical Liners 138 Mandrels 138 Turning Fixtures 142 Summary 144 8. Grinding Fixtures Grinding 145 Cylindrical Grinding 147 9. Broaching Fixtures — Key-way Broaching 150 External Surface Broaching 151 10. Welding and Assembly Fixtures Pressing Fixtures 157 145 149 153 11. inspection Devices Gauges 161 Special Gauges 163 Receiver Gauges 165 Workpiece Marking and Setting Gauges 168 Materials and Wear Allowance 170 161 12. Shop Setups 172 13. Estimating 179 Material Costs 179 Machining costs 181 Pleat treatment Expenses 182 Assembling and Try-out Costs 182 14. Reference Tables 184 15. Exercises 203 Process Planning 203 Workpieces for Practices 205 Bibliography Index 230 231 viii0 0 Index A renewable 89, 194 slip 90-91, 194 special 93-94 spring clamped 92 threaded 91-92 Accuracy of location 12 Adhesive clamping 75 Adjustable locators 18, 175, 177, 178 Adjustable support 15-17-19 Adjustable vee locator 37-38 Advantages of jigs & fixtures 2 Allowances for fits 4 Angle plate jig 97 Assembly fixtures 157 Axially clamped mandrels 139-140 c C‘’ Washers 60-61 Cams 61-63, 156, 186 Carbon steels 7, 195 Case hardening steels 8, 195 Castings ferrous 8, 195-196 non-ferrous 197 Channel jig 95-96 Chucks, lathe 129-133 Clamping 42-78 adhesive 75 distortion 42 double 46, 67 electrostatic 75 fusion 75 magnetic 73-74 milling fixtures on m/c 114-115 multiple 46, 67-68 operator fatigue, elimination 43 power 68-74 B Back plate for turning fixtures 127-128 Balancing turning fixtures 142 Ball, indexing 84 Bayonet clamp 63-65 Bibliography 230 Box jig 100-101 Broaching fixtures 149-152 keyway 150-151 surface 151-152 Burr clearance in location 21 Bushings collared 88, 193 collarless 89232 JigsandFixturesDesign Manual productivity 43 spherical washer 45, 49, 188 stacking workpieces 68 summary of the chapter 77 turning fixtures to m/c 127-144 vacuum 73 workpiece variation compensation 44, 46, 49 Clamps, ‘C’ washers 60-61 cams 61-63, 156, 186 chucks (for lathes) 129-133 collets (see also Collets) 133-137 differential 76 dogs, locking 200 double ( 2 in 1) 67 Clamps edge 51-53, 55, 63, 117 equalizer clamps 46, 67 support (rectangular workpiece) 20 eyebolts 38, 46, 187 floating pads 48, 197-199 hand-operated 44 heel pins 45, 49-51, 191 hinged 55-56 hook bolts, swinging 58, 173, 189 latches 59, 60 pivoted 54-55 plate 49 position 42 quarter turn screw 65-67, 187 screw 47-48 slotted 49, 190 special 51-52, 54 spherical floating pad 48 spherical washers 45, 49, 188 strap (plate) 49, 50, 190, 192 strength 43 swinging 50-51, 192 toggle 66 two-way 56-57 types 46 ‘U’ 50 welding 154 Collets, 133-137 dead length 137 liners 138 pull-in 136 push-out 135 Concentricity checking fixture 168 Conical locators 34-35 Cost reduction through jigs & fixtures 2 Cylinder mounting styles 71 D Diamond pins 29-34 Differential clamp 76 Distortion of workpiece due to redundant locator 15 Distortion of workpiece due to clamping 42 Dividing fixture (std) 86 Double clamping 46, 67 Dowels usage 29 Down milling 113 Drill bushings 87-94, 193-194 collared 88, 193 collarless 89 renewable 88, 194 slip 90-91, 194 special 93-94 spring clamped 92 threaded 91-92 Drill jigs 87-112 adjustable 106-109 angle plate 97 box 100Index 233 channel 96-97 indexing 80, 82, 83 leaf (latch ) 99 multispindle m/cs 105-106 plate 95 pot 95-96 pump 104 requirements 87 sandwich 103 summary of chapter 110 trunnion 101-102 turnover (table) 97-98 types 94 broaching 149-152 definition 1 face plate, lathe 134 facing on lathe 142, 143 grinding (also see Grinding Fixtures) 145-148 inspection 168 milling (also see Milling Fixtures) 112-126 pressing, hush 157-160 turning (also see Turning Fixtures) 127-144 welding (also see Welding Fixtures) 153-159 Floating pads 48, 197-199 Flush pin gauges 163-164 Foolproofing against wrong loading 15-16 Force fit 4 Fusion clamping 75 E Eccentric locator 23 Electro-static clamping 75 Elements of jigs & fixtures 1-2 Epoxy usage for nesting 147 Equalizer support for rectangular workpieces 20 Equalizer clamps 46, 67 Expanding mandrel 140-141 Eye bolts 38, 46, 187 Estimating of jig/fixture cost 179 assembling costs 182 constituents of cost 179 example 183 heat treatment 182 machining cost 181 thumb rules 182 Exercises, workpieces 207-229 G Gang milling 119 Gauges 161-171 caliper 162 center distance 165 concentricity 168-169 flush surface 163-164 keyway 163 length 162 marking 168 materials, heat treatment 170 plug 161 receiver 165-166 setting 168-170 snap 162 special 167-168 standard 161 tapered holes 163-164 F Face plates for lathes 133-134 Feed direction in milling 113 Fibre usage 9 Fits 3-4 Fixtures, assembly 157234 Jigs andFixtures Design Manual wear allowance 170-171 Grinding fixtures 145 surface 145-147 cylindrical 147 K Keyway broaching fixtures 150-151 gauges 163 milling fixtures 124 H L Lead on locators 26-28 Leaf, latch jigs 99 Limits and fits 3-6, 184-185 Linear indexing 79-80 Liners for collets 138 Location 11-41 accuracy 12 burr clearance 21 constraints 12 cylinders 25-39 dowels usage 29 fool-proofing 15 large fixtures 21 methods 16 motion economy 13 nesting 24-25, 147 pins 23 plane surface 16 pot 28, 95-96 principles 11 profiles 22, 23 six degrees of freedom 13 six point location 21-22 summary of chapter 39 two holes 30 of turning fixtures on m/c 127-128 vee 34-39 workpiece variation effect 23, 29-34, 36-39 Locators, adjustable 18, 175, 177, 178 axial pull due to clamping 26-27 conical 34-35 diamond pin 30 Hand operated clamps 44 Heel pins 45, 49-51 adjustable (std.) 191 High speed steels 7, 195 High tensile steels 8, 195 Hook bolts, swinging 58, 173, 189 Hydraulic clamping 68-71 Independent 4-jaw chuck 129-130 Indexing Devices 79-86 ball 84 linear 79-80 plate 81-83 plungers 84 rotary 81-83 tables 83-86 Index milling 120-121 Inspection devices 2, 161, 168 fixtures 168 Interchangeability of workpieces 2 J Jamming of locators 26-27 Jaws, soft (lathes) 131 special (lathes) 131-133 special (vices) 116 Jigs, drilling ( see Drill jigs) 87-112Index 235 eccentric 29-34 fixed height 16-17 jamming 26-27 redundant 14 vee (also see Vee blocks) 34-39 Locking dogs std. 200 essentials 113 indexing 81, 120 keyway 124 motion economy 115 pendulum ( reciprocal) 121 setting 114, 119 slotting 122 strength 113 string 122, 124 summary of chapter 125-126 swarf disposal 115 tenons 114-115 thrust direction 11 3 summary of chapter 125 M Magnetic clamping 73-74 Mandrels 138-142 axially clamped 139-140 expanding 140-141 tapered 139 threaded 141 Marking gauge 168-170 Materials 7-9, 195-197 carbon steels 7, 195 case hardening steels 8, 195 cast-ferrous 195-196 cast-non-ferrous 197 collets, spring 7, 195 die steels 7, 195 fibre 9 gauges 170 high speed steels 7, 195 mild steel 8, 195 nylon 9 oil hardening, non-shrinking steels 8, 195 phospher bronze 9, 197 Milling 112-126 cutters 113 feed direction 113 gang 119 machines 112 rotary 121 straddle 118-119 Milling fixtures 112-126 clamping to m/c 114-115 N Nesting 24-25, 147 Non-conventional clamping 75-76 P Pendulum milling 121 Phospher Bronze 9, 197 Plate clamps 49 Plate jig 95 Plug gauges 161 Pneumatic clamping 71-72 Pot jig 95-96 Power clamping 68-75 Presentation of workpiece in jigs/fixtures 9-10 Press fit 3 Press fit bushings 88-89, 193 Pressing fixture, bushing 157-159 Process planning 203-204 Principle of clamping 42 Principle of location 11236 Jigs andFixtures Design Manual Profile location 22-23 Pump jig 104 Push fit 3 Shoulder screws 59, 191 Sighting plate location 22-23 Six degrees of freedom (workpiece) 13 Six point location of cube 21-22 Skill reduction through jigs & fixtures 2 Slip bushings 90, 91, 194 Slotting fixtures (milling) 122 Snap gauges 162 Softjaws (lathe) 131 Special bushings 93-94 jaws (lathes) 131-133 (vices) 116 Spherical floating pad 48 Spherical washers 45, 49, 189 Spring clamping of bushings 92 Stacking for multiple clamping 68 Steels for jigs, fixtures, tools 7, 8, 195 Straddle milling 118-119 Strap clamps 49 String milling 122-124 Standardized parts for jigs &. fixtures 186-202 Summary: clamping 77 drill jigs 110 location 39 milling fixtures 125-126 turning fixtures 144 Q Quarter turn screw 65-67, 187 Quick action clamps 38, 46, 61, 65, 68 R Receiver gauge 165-166 Reciprocal milling 121 Reference tables 184-202 Renewable bushes 89, 194 Running fit 3 s Sandwich jig 103 Self-centering chuck (lathe) 129 Second operation fixtures (turning) 143 Setting milling cutler 114, 119 Setting gauge (cast workpieces) 168-170 Shop set-ups 172-178 Shop set-up elements Adjustable locators 177 for lathe 175 milling 178 Slotted plates 176 ‘T’ nuts 172-173 ‘T’ slot mounted edge clamps 174 hook bolts 173 vee blocks 176, 202 T Tapered holes gauges 163-164 mandrel 139 Tenons for milling fixtures 114-115 Threaded bushings 91-92 mandrel 141 Thrust, feed (milling) 113 Toggle clamps 66 Tolerances for shafts and holes 184-185Index 237 Turning fixtures 127-144 alignment with m/c 127-128 back plate 127-128 balancing 142 location & clamping 127-128 summary of chapter 144 Turning (m/c ) chucks 129-133 combination 130 independent, 4 jaw 129-130 power operated 130-131 Jaws, soft 131 special 131-133 standard 132 Turning (m/c) collets 133-137 dead length 137 liners (split) 138 pull-in 136 push-out 135 Faceplates 133-134 Turnover (Table) jig 97-98 V (Vee ) blocks adjustable 37—38 fixed 35 inclined 36 location 34 positioning correctly 36, 38, 39 quick action (long withdrawal) 38 standard for long cylinder 201 short 202 w Washer, spherical 45, 49, 188 Welding clamps 154 Welding fixtures 153-159 considerations 153 for fly nut 155 angles 156, 159 pipes 157 spatter grooves 155, 156 Workpieces for exercises 207-229 Workpiece presentation in jigs/fixtures 9-10 Workpiece variation, accommodation in location 23, 29-34, 36-39 accommodation in clamping 44, 49 u Up milling 113 V Vacuum clamping 73 Variation in workpiece: accommodation in location and clamping
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