What is a jig? An Overview

In the intricate world of mechanical components, the term “jig” holds a pivotal role that might not be as familiar to those outside the manufacturing sphere. In this article, we will be exploring their significance, applications, and the fundamental question: What is a jig?

Example of a jig used in precision manufacturing of custom components.
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What is a jig? How does it function?

A jig is a device with an auxiliary role in machining, used to fix the workpiece being processed and guide the machining process. It is also referred to as an auxiliary tool. For example, when trying to screw a workpiece with a contoured shape on a flat workbench, it becomes challenging to firmly hold the workpiece. In such cases, using a jig stabilizes the workpiece, making the task easier.

 

Jigs not only stabilize the workpiece but also serve various roles, such as ensuring consistent quality and expediting the work process.

 

 

There are broadly two types of jigs: variously shaped jigs used in processing lines, and jigs used to fix workpieces during machining. Since jigs are custom-made to suit the item being processed and the nature of the processing, they are not mass-produced. Typically, technicians from the production engineering department or specialized jig manufacturers create them one by one to match their specific applications.

Jigs Used in Manual Operations

Jigs used in processing lines include mainly the following:

 

 

  • Stabilizers for holding the workpiece in place during processing and measurement by operators or machines.
  • Devices for positioning parts during tasks like adhesion.
  • Guides for inserting other components or tools, functioning like a mold during insertion.
  • Masking devices to prevent contamination of other areas during processes such as painting or sealing.
 

These jigs come in various materials and shapes depending on the usage and purpose. For lighter tasks like manual operations, jigs made of lightweight and flexible materials like nylon resin, sometimes combined with small clamps, are commonly used. On the other hand, for demanding conditions such as high temperatures or heavy loads, jigs like quenching fixtures are made from robust metals. There are cases where the jig itself is automated, acting as a device or machine, automatically activating clamps to secure the workpiece once placed.

Jigs Used in Mechanical Processing

Example of a jig used in mechanical processes.

While jigs used in processing lines exhibit various shapes and materials, those employed in CNC and other machining equipment are predominantly crafted from robust metals like stainless steel. Their size varies depending on the type of processing, with larger fixtures sometimes requiring the use of cranes for movement. 

 

Unlike temporary fixtures like clamps, the fixation of the workpiece involves sturdy mechanisms such as screws.

 

In the above image, the portion carrying the machined metal is the “fixture.”

Especially in the case of fixtures used with CNC and similar machines, they may feature numerous screw holes to accommodate multiple workpieces with a single fixture.

Conclusion

Jigs are relatively unknown to those outside the manufacturing industry. However, in reality, much like machine tools, jigs play a crucial role in supporting manufacturing. When designing machinery, considering fixtures needed for processing can yield various benefits such as cost reduction and improved quality.

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