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UNIVERSITI MALAYSIA PAHANG
DECLARATION OF THESIS AND COPYRIGHT
Author’s Full Name : ALI ZULFAKAR BIN KHAIRUDIN
Identification Card No : 930118075763
Title : DESIGN AND DEVELOPMENT OF DRILL BIT
SHARPENING JIG FOR BENCH GRINDER
Academic Session : 2015/2016
I declare that this thesis is classified as:
CONFIDENTIAL
(Contains confidential information under the
Official Secret Act 1972)
RESTRICTED
(Contains restricted information as specified by
the organization where research was done)*
OPEN ACCESS
I agree that my thesis to be published as online
open access (Full text)
I acknowledge that Universiti Malaysia Pahang reserve the right as follows:
1. The Thesis is the Property of University Malaysia Pahang.
2. The Library of University Malaysia Pahang has the right to make copies for the purpose of
research only.
3. The Library has the right to make copies of the thesis for academic exchange.
Certified by:
_____________________________ _____________________________
(Author’s Signature) (Supervisor’s Signature)
ALI ZULFAKAR BIN KHAIRUDIN DR. MUHAMMED NAFIS BIN OTHMAN ZAHID
Date: 10 JUNE 2016 Date: 13 JUNE 2016
DESIGN AND DEVELOPMENT OF
DRILL BIT SHARPENING JIG FOR
BENCH GRINDER
ALI ZULFAKAR BIN KHAIRUDIN
Report submitted in partial fulfillment of the requirements
for the award of the degree of
Bachelor of Engineering in Manufacturing Engineering
Faculty of Manufacturing Engineering
UNIVERSITI MALAYSIA PAHANG
June 2016
i
SUPERVISOR’S DECLARATION
I hereby declare that I have checked this thesis/project and in my opinion, this thesis/project is
adequate in terms of scope and quality for the award of the degree of Bachelor of Engineering
In Manufacturing.
Signature :
Name of supervisor : DR. MUHAMMED NAFIS BIN OSMAN ZAHID
Position : SUPERVISOR
Date :29 May 2016
ii
STUDENT’S DECLARATION
I hereby declare that the work in this thesis/project is my own except for quotation and
summaries which have been duly acknowledged. The thesis/project has not been accepted for
any degree and is not concurrently submitted for award of other degree.
Signature :
Name : ALI ZULFAKAR BIN KHAIRUDIN
ID Number : FA12032
Date : 29 May 2016
vi
TABLE OF CONTENTS
Page
SUPERVISOR’S DECLARATION iii
STUDENT’S DECLARATION iv
ACKNOWLEDGEMENTS v
ABSTRACT vi
ABSTRAK vii
TABLE OF CONTENTS viii
LIST OF TABLES ix
LIST OF FIGURES x
LIST OF SYMBOLS xi
LIST OF ABBREVIATIONS xii
CHAPTER 1 INTRODUCTION
1.1 Introduction 1
1.2 Project Background 2
1.3 Problem Statement 2
1.4 Project Objectives 3
1.5 Project Scopes 3
CHAPTER 2 LITERATURE REVIEW
2.1 Introduction 4
2.2 Introduction of Jigs And Elements of Jigs 4
2.2.1 Jig Body 4
2.2.2 Locating Devices 5
2.2.3 Clamping Devices 5
2.3 Design Consideration In Fabrication of Jigs 5
2.4 Importance of Jigs 6
2.5 Introduction of Drill Bit Sharpening Jigs 7
2.6 Material Selection
vii
2.6.1 Phosphor Bronze 7
2.6.2 Die Steels 8
2.6.3 High Speed Steels 8
2.6.4 Carbon Steel 9
2.6.4 Mild Steel 10
2.7 Previous Research Of Jig Design 11
2.8 Previous Research Of Material 17
2.9 Conclusion `20
CHAPTER 3 METHODOLOGY
3.1 Introduction 21
3.2 Methodology Overview 21
3.3 Product Drawing Using CATIA softwaree 23
3.4 Analysis using CATIA-Generative Part Structural Analysis 23
3.5 Processes
3.5.1 Milling Process 24
3.5.2 Lathe Process 25
3.5.3 EDM Wirecut 26
3.5 Conclusions 26
CHAPTER 4 RESULT AND DISCUSSION
4.1 Introduction 32
4.2 Design Phase 33
4.2.1 Concept Screening 33
4.2.2 Concept Scoring 34
4.2.3 Finite Element Analysis 35
4.3 Fabrication Phase 36-37
4.4 Analysis Phase 38-39
CHAPTER 5 CONCLUSION AND RECOMMENDATION
5.1 Introduction 40
5.2 Recommendation 41
viii
REFERENCES 44
APPENDICES 45
ix
LIST OF TABLES
Table No. Title Page
2.1 Requirements for high-speed tool steels per ASTM 10
4.2.1 Concept Screening of Drill Bit Sharpening Jig 33
4.2.2 Concept Scoring of Drill Bit Sharpening Jig 34
4.4.1 Data from the surface roughness analysis 38
4.4.2 Average Minimum Surface roughness (µm) for both holes on the workpiece39
4.4.3 The difference of surface roughness(µm) 39
x
LIST OF FIGURES
Figure No. Title Page
2.1 Requirements for high-speed tool steels per ASTM 9
2.2 Drill bits sharpening jigs 11
2.3 Universal Device for Sharpening Drill Bits 12
2.4 Device for grinding the spiral drill 14
2.5 Drill grinding fixture 15
2.6 The Drill Bits Sharpening Device 16
2.7 Figures of lip angle, clearance angle and web angle 17
2.8 Influencing factors on the die life of die casting tools 19
3.1 Flow chart for final year project progress 22
3.2 The Von Mises stress distribution in ISO value 24
3.3 Milling machine Makino KE55 25
3.4 Lathe machine Romi C420 25
3.5 Example of wirecut process 25
xi
4.1 Design generated in CATIA software 32
4.2.3 The Finite Element Analysis (FEA) in CATIA Generative Stress Analysis 34
4.3.1 Milling process using Makino KE55 milling machine 35
4.3.2 Manual tapping for the adjust bolt fitting thread 36
4.3.3 The jig setup on bench grinder 37
4.3.4 Drill bit surface (Before resharpening) 37
4.3.5 Drill bit surface (After resharpening) 38
4.3.6 The continuous chips formed 38
4.3.7 Drilling holes on the aluminium block 39
4.3.8 Surface Roughness Analysis 39
4.4.1 Graph of the differences of the hole surface roughness 41
\
xii
LIST OF SYMBOLS
ω Natural frequency
ε Total strain, Bandwidth parameter
Raw rating of concept j for the ith criterion
Weighting for ith criterion
Total score for concept j
RM Ringgit Malaysia
xv
LIST OF ABBREVIATIONS
AA Aluminum alloy
Al Aluminum
ASTM American Society for Testing and Materials
CAD Computer-aided drafting
CAE Computer-aided engineering
DOF Degree-of-freedom
DTP Discretized turning point FE Finite element
FEA Finite Element Analysis
FFT Fast Fourier transform
FRF Frequency response function
MBD Multibody dynamics
PDF Probability density function