Mfg-B10 — Tooling, Jigs and Fixture Design
Types of jigs and fixtures and their applications. Concepts of referencing, locating and planes of movement. Design characteristics for locating, clamping, assembling. machining and operational devices. Templates, vices, angle-plate, boxes and channels, Designing around the human element Modular work holding, welding fixtures and manipulators, machining and assembly fixtures. Tooling for conventional machining and numerically controlled machines, setup devices. Tooling, jigs and fixtures for high quality production. Tool materials. Considerations for design economics.
Subject outline
Mfg-B10 Tooling, Jigs and Fixture Design is a Manufacturing Engineering technical exam (PEO National Examination 08-Mfg-B10) on the design of workholding: jigs against fixtures and the vocabulary that scores; locating by the 3-2-1 principle, degrees of freedom, round and diamond pins and the sizing of a locator; clamping, clamping force and the stud-torque table the paper supplies; tolerances and the 20–50 per cent tool-tolerance rule; GD&T for tooling — MMC, virtual condition, the floating and fixed fastener formulas and functional gauges; drill bushings and their designation system; gauges and inspection; tool materials, heat treatment and coatings; jig and fixture economics; and how to take a 25-mark design question through the whole decision sequence.
The paper is 3 hours and open book — the set text, your notes and everything in this pack may be carried in — with any non-communicating calculator, for 100 marks. On the December 2020 sitting Part A is mandatory, ten short-answer questions at 2 marks each (20 marks); Part B is both questions, B1 identifying six workholding devices at 2.5 marks each (15 marks) and B2 five calculations on one drill jig (15 marks); and Part C is three design questions at 25 marks of which two are answered (50 marks) — half the paper, each wanting a sketch, balloons, a bill of materials, a named locating scheme, calculations and a materials specification. Read the front page and the Part C header before you write: the cover says "any two questions, of your choice" while the header printed above the questions says C1 or C2 and C3, so the pair that is legal under both — C3 and one of C1/C2 — is the one to answer, with a line saying which instruction you followed. Note 1 invites you to state your assumptions, and Note 5 lists the deliverables every design answer is marked on: production plan and tolerance block assumed, type of jig or fixture and why, main dimensions and tolerances, balloons and a bill of materials, surface finish, heat treatment and coatings. December 2011 is shaped differently but examines the same ground: Q1 is ten short sub-questions (a)–(j) of equal value; Part A is Q2 (a locating layout), Q3 (seven devices to identify) and Q4 (engineering economics), of which two are answered; and Part B is the three design questions Q5, Q6 and Q7 — a drilling-and-reaming jig, a milling fixture and an inspection fixture — each producing an assembly sketch and a bill of materials.
What this course gives you
Worked solutions — December 2020 and December 2011 in full: twenty short answers, thirteen devices named and explained with their characteristics and applications, every B2 calculation worked, and all six design questions taken through the whole sequence — type of tooling and why, locating, clamping, the sketch and its balloons, the bill of materials, materials and treatments. Every published number has been recomputed from the drawings and the paper's own supplied tables, and the errors the pack finds in the published solutions are flagged and corrected. Where a published figure stands it is used; where it does not, the original is shown and a flagged correction of its own — headed, and set into the working at the exact step that goes wrong — explains what went wrong and gives the corrected value. Nothing has been silently overwritten. One of the errors is a physical impossibility rather than a rounding slip: the December 2020 A10 locating pin is sized 10.1525 mm for a hole whose minimum is 10.15 mm, so it cannot enter (the sign-corrected pin is 10.1475 mm). Among the rest: December 2011 Q6 chooses a .500 end mill for a slot held .500/.498, which leaves no controlled margin (the pack offsets a 7/16, .4375, cutter instead); the B2.5a true position of ±.0019 in against a floating-fastener geometry that gives ±.0110 in; the December 2011 Q7 "11 mm" gage pin, which sits at the hole's own MMC — right only for zero positional tolerance — where the ∅0.2 mm position tolerance the pack adds calls for a ∅10.80 mm virtual-condition gauge; a Q2 locating pin of ∅9.5 ±0.05 mm for a ∅9.5 mm hole, which cannot work; a B2.4 plate thickness reasoned from the bushing diameter instead of the tool diameter; a reaming clearance quoted as an unsourced absolute 1/16 to 1/8 in and justified by chip clearance rather than as the accuracy exception to the 1 to 1½ times tool-diameter rule; and page citations that point at the PDF pages of one ebook file rather than the printed pages an examiner can check. Where a published answer is right — December 2011 Q4's break-even at n = 375 is right the whole way through — the pack says so plainly. Three sittings, two of them solved — December 2020 and December 2011 are solved in full; December 2010 exists only as a question paper, which is why it ships unmarked below as the one genuinely unseen sitting. Five of December 2020's ten Part A questions are December 2011's Q1(a)–(e) almost word for word, so the notes map the two papers question by question and the shared block is learned once. Study notes — eleven condensed topics: how this paper works; jigs versus fixtures, and the vocabulary; locating — 3-2-1, degrees of freedom and pins; clamping, clamping force and the torque table; tolerances and the 20–50 per cent rule; GD&T for tooling; drill bushings — the heart of this paper; gauges and inspection; tool materials, heat treatment and coatings; jig and fixture economics; and how to answer a 25-mark design question — each ending with where it is examined on the two papers. Practice & case studies — ten multiple-choice questions and five longer problems — a drill jig sized end to end (bushings, liner, press fit, plate and chip gap), a locating scheme with a round and a diamond pin, clamping from cutting force to thread size and dowel-pin shear, gauging under both conventions with a functional gauge, and the economics of choosing a better jig together with an inspection plan — with worked answers for every one. Formula sheet — two pages: the 20–50 per cent rule, the floating and fixed fastener formulas, the diametral-to-coordinate conversion, virtual condition, go/no-go gauge sizing and the 10 per cent convention, the three numeric bushing rules and the designation decoder, clamping force from the supplied table, dowel pins by shear, locator-pin clearance, and cost per part and break-even. This exam is open book, so it goes in with you. Printable resources — ten cards, including the paper's own press-fit and clamping-force tables with the interference and the stud-to-clamp relation worked out, the bushing decoder, a tap and clearance drill chart, a tool-materials table and the design-question checklist, plus four blank exam stationery templates. All of it may be carried into the exam. Practice papers — two question papers on their own, unmarked, for a timed run: December 2020, the sitting solved above, to sit cold and mark yourself against the worked answers, and December 2010, which this pack does not solve, so it is genuinely unseen.
Throughout, 103 figures were drawn for this pack — 49 in the solutions and 54 in the notes — alongside 27 crops taken from the question papers, the tables supplied with them and the published solutions being corrected, so the bushing stacks, locating schemes, tolerance zones, gauge limits and cost lines are drawn rather than described.