Drill Jig and Fixture

Group-MAE-7

Team(Advent Boys) Members-

Vitthal Vashishth(046) Deepak Gahlan(002) Yatin Bhasin(053) Rohit Sharma(019) Amit Saraswat(035)

Index-

Introduction Material 2D Design of Drill Jig and Fixture

Design of Drill Jig and Fixture (PRO-E) Development Process Developed Model of Drill Jig and Fixture

INTRODUCTION

The successful running of any mass production depends upon the

interchangeability to facilitate easy assembly and reduction of unit cost.

Mass production methods demand a fast and easy method of positioning

work for accurate operations on it. jigs and fixtures are production tools

used to accurately manufacture duplicate and interchangeable parts. Jigs

and fixtures are specially designed so that large numbers of components

can be machined or assembled identically, and to ensure

interchangeability of components.

JIGS

It is a work holding device that holds, supports and locates the work

piece and guides the cutting tool for a specific operation. Jigs are usually

fitted with hardened steel bushings for guiding or other cutting tools. A

jig is a type of tool used to control the location and/or motion of another

tool. A jig's primary purpose is to provide repeatability, accuracy, and

interchangeability in the manufacturing of products. A device that does

both functions (holding the work and guiding a tool) is called a jig.

FIXTURES

It is a work holding device that holds, supports and locates the work

piece for a specific operation but does not guide the cutting tool. It

provides only a reference surface or a device. What makes a fixture

unique is that each one is built to fit a particular part or shape. The main

purpose of a fixture is to locate and in some cases hold a workpiece

during either a machining operation or some other industrial process. A

jig differs from a fixture in a way that it guides the tool to its correct

position in addition to locating and supporting the workpiece.

Examples: Vises, chucks

MATERIAL

Mild steel- It is the most common form of steel. It is not brittle. It is

cheap. It is often used when large amount of steel is needed.

Mild steel is a carbon steel typically with a maximum of 0.25%

carbon and 0.4-0.7% manganese, 0.1-0.5% silicon and some traces of

other element such as phosphorous, it may also contain lead (Free

cutting mild steel) and sulphur (again free cutting steel) called

resulpherised mild steel.

Many every day object are made from mild steel, even some of your

pots and pans.  'Mild steel' is typically carbon steel, with a comparatively

mild amount of carbon (0.16% to 0.19%). It has ferromagnetic

properties, which make it ideal for manufacture of electrical devices and

motors.

2D DESIGN OF DRILL JIG AND FIXTURE

DESIGN OF DRILL JIG AND FIXTURE (PRO-E)(STEP-BY-STEP APPROACH)

1. Step 1 (base of fixture):

Pro e software is opened and file>new> part.

Then go to extrude feature and select placement plane as front

plane as shown on figure and then

Make the sketch and extrude to given depth.

Then click on scroll button.

Extruding it.

2. Step 2 (creation of vertical plate):

Select the back face of base plate as placement for extrude and create

the sketch as shown below and then extrude it to given length.

Then click on scroll button.

Extruding vertical plate.

3. Step 3(top plate):

Now select top face of the vertical plate as placement for extrude and

then create the sketch as shown below and then extrude it.

And then click on scroll button.

Extruding it.

4. Step 4(creation of pins for holding work piece):

Select the back face of the vertical plate as extrude placement then

create a sketch as shown below and then extrude it to given length.

Extruding it.

5. Final view of the drill jig and fixture developed in pro-e:

Completed Design

DEVELOPMENT PROCESS

The development process of the drill jig and fixture consists of the

following operations:

a. Shaping process

b. Grinding process

c. Drilling process

d. Welding process

e. Finishing process

Shaping process

In this process we have taken a long bar of mild steel of thickness 13mm and cut it into 2 parts one for base (dimension 73.3mmX51.3mm) and other for vertical plate (dimension 73.3mmX36.3mm) then we have taken another bar of thickness 4mm and cut it in dimension 73.3mmX47mm and in this process we have to continuously pour water on the metal because its temperature rises sharply.

Surface grinding process

After the cutting process we done some grinding process

In this process we put metal on the machine and with the help of

electromagnetic base it holds the metal without any vibrations and then

grinding wheel is rotated and dimension is putted into tolerance limit.

Surface Grinding machine

Drilling process

In this process drilling of holes is done

Plates are held in the fixture and then holes are drilled.

Welding process

Welding is done on the plates and the joint is T joint both outer and

inner edge is weld for strength purpose.

Finishing process

The extra weld (slag) is chipped off and then again grinding is done.

DEVELOPED MODEL OF DRILL JIG AND FIXTURE

Front view Side view

Top view Front Back view

ISOMETRIC VIEW