Professional Documents
Culture Documents
for
Lecturer
Section
01
Group
02
Name ID
TAN ZHI QING FA13021
MOHAMMAD FAIZ BIN CHE MAT FA13053
NURUL AIN BT ZAKARIA FA14047
TEH MUY SHIN FA14051
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Table of Contents
1.0 Introduction .................................................................................................................. 4
1.1 Problem Statement .................................................................................................... 4
1.2 Objectives .................................................................................................................. 4
2
5.2 Material Selection ...................................................................................................... 23
5.3 Process Parameters ................................................................................................... 23
5.4 Manufacturing Processes .......................................................................................... 24
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1.0 Introduction
Design Jigs and Fixtures Project is conducted as a medium of application for student
to apply the knowledge about this course. In general, a “jig” works as a device to hold the
workpiece meanwhile guide the tool way. While, a “fixture” works as a holding and positioning
device. As compared to jig, a fixture is usually less lightly in construction.
In order to fulfil the requirements of this project, students have to design and develop
a jig and fixture that can clamp the plate product which made by 5 mm Aluminium sheet metal
and guide the tool way. Figure 1.1 shows the jig and fixture that designed by our group.
1.2 Objectives
To design and develop a jig and fixture for machining Aluminium sheet metal.
To develop a tagline design combined of cutting and slotting processes.
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The project is started in week 3 until week 14. The project gantt chart is listed as shown
in Table 2.1.
Table 2.1: Project gantt chart
Activities W3 W4 W5 W6 W7 W8 W9 W10 W11 W12 W13 W14
2. Select leader
6. Draw component
7. Design analysis
9. Fabrication
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Flow Chart 2.2: Details of process planning
2.3 Product Planning
• 1*150mm*340mm*25
mm body
• 100mm*240mm*4mm
product
D6 end mill ,
1*20mm*15mm*6mm
50 Slotting milling ±0.1mm
depth slot
machine
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D4 ball end
2*1.5mm*45degree of
60 Chamfering mill, milling ±0.1mm
chamfers
machine
• 4*D10 edges
D8 end mill, • 2*4mm*20mm*5mm
ø±0.1mm
70 Roughing CNC milling depth slot
±0.1mm
machine • 2*D12*25mm
T-slot hole
depth
depth
D8 end mill,
4*ØR4*5mm pin hole ø±0.1mm
80 Drilling milling
±0.1mm
machine
hole
D8 end mill,
5*ØR4*10mm on the
90 Drilling milling ø±0.1mm
body
machine
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D5 drill bit,
2* ØR2.5*15mm screw hole
100 Drilling Drilling ø±0.1mm
on the body
machine
D6 flute tap
2*ØD6*15mm depth thread
110 Tapping Hand-tapping ø±0.1mm
holes
tool,
D4 ball end
„┌‟ ,‟┘‟,
mill, CNC
110 Sweeping „T‟H‟E‟,‟O‟,‟N‟,‟E‟ on the ±0.1mm
milling
product .
machine
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2.4 Processing Time
2.4.1 Jig and Fixture Body and its Components
Type of Process Processing Time
10
Figure 3.1.1: Top view Figure 3.1.2: Isometric view
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Figure 3.2.3: Front view Figure 3.2.4: Right view
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3.4 Fabrication and Assembly Processes
The raw materials are first selected in which the body is Bakelite, and both of the clamp
bar and product are also Aluminium. The raw materials of body, clamp bar and product are
cut through electrical hand saw, band saw and shearing machine respectively.
Then, the machining processes shown in Table 2.3 are discussed in following section.
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3.4.2 Processing Body
The body is first facing to obtain a flat surface by using milling machine. Then the
roughing and drilling processes are carried out by input the G programming code into
milling machine to form the desired shape of the body. Both processes had shown in Figure
3.4.2.1 and Figure 3.4.2.2.
Then the tapping process is carried out to form the thread for clamp bar to screw in.
3.4.3 Assembly Process
Firstly, the locator and support pins are assembled on the body as figure below.
Then the workpiece is placed guided and supported by the locators and pins.
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Figure 3.4.3.2: Body with workpiece
The clamp bars used to clamp the workpiece are tighten up by using Allen key All the
components are assembled to be used as the jig and fixture for machining the tagline of the
product as shown in figure below.
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4.0 Jigs and Fixtures Validation
4.1 Machining Parameters
Table 4.1.1: Milling Machine Cutting Speeds
Cutter Material
Carbide
High Speed Steel
Cutter
Cutter m/min
Raw Material m/min
Based on Table 4.1.1, the cutter material is carbide cutter while the raw material is aluminium, the
mean cutting speed is selected and applied to the calculation.
Note: The data are adapted from “BFF1811_Machining 2_Milling and Grinding Operation”.
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Based on Table 4.1.2, the tool will be used for processing material is cylindrical cutter, and
the mean value of feed is chosen to be calculated as follow.
𝐹 = 𝑘𝑐 × 𝑎𝑝 × 𝑓 (1)
𝑓: Feed (mm/rev)
Note: The data are adapted from “Technical Reference”. Retrieved from
https://www.tungaloy.com/common/products/catalog/ee/15_technical_ee.pdf
Based on the Table 4.1.3, for Aluminium work material, the specific cutting force at
Moreover, the depth of cut in is set to be 0.3mm to minimize the force exerted. Thus, the
cutting force can be calculated by using equation (1) as follow:
The result of the theoretical cutting force exerted in three directions on the Aluminium
workpiece is 12.6N. Thus, a higher force of 20N is being set up to run the design analysis
by using CATIA software as shown in section 4.2.
Front view
Top view
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Figure 4.2.2: Force is being applied to the body (Von Mises Stress)
The material used for making the body is mild steel and the product is Aluminium
sheet metal. The forces in three directions which are Fx, Fy, and Fz as well as the moment
generated are set-up as shown in Table 4.2.1.
As the result shown in Figure 4.2.2, the product can afford a stress at 20N without
changing the shape of the taglines. Since the stress applied to the assembly in theoretical
calculation is much lower than that in the stress analysis, the design can be regarded as
successful through the testing.
4.3 Processing Taglines
After assembly all the components as Figure 3.4.3.1, the whole thing is clamped at the
working table of milling machine. At first, “dial indicator” is used to check the parallelism
between the jig and fixture body and the working table to ensure that the tagline will be
formed parallel to the Aluminium plate. After checking the parallelism, the roughing G-
code is imported to the milling machine, and the cycle start to make the tagline on the plate.
Figure 4.3.1 shows the roughing process.
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Figure 4.3.1: Roughing process
Lastly, the sweeping process is carried after roughing is done as figure below.
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Muhammed Nafis, the bars are replaced by using five locators to minimize the cycle time
and also the cost for fabrication
Furthermore, although the force simulation showing the result is successful, but the
number of clamp bar is increased from two to three after discuss among group members.
This is because there are many environmental variables that do not be encountered during
the simulation, therefore enough force must be ensured to clamp the workpiece preventing
it from vibrate during the machining operations. The clamp bar is designed to be screwed
by using allen key to advance the operator in setting all things.
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5.2 Material Selection
Bakelite also known as Phenolic is used as the material of the jig and fixture body. It
belongs to one of the members under thermosetting polymers which would not be deformed
again once it set.
Table 5.2.1: Mechanical properties of Bakelite
Mechanical Properties Value (MPa)
Flexural Modulus 25
Flexural Strength 85
Based on the table above, the Bakelite is strong enough to withstand the cutting force
since the cutting force is only 12.6N which is around 248 Pa. Through this, it can effectively
work as a jig and fixture to hold the workpiece and guide the tool way during the machining
processes. Moreover, this kind of material has excellent thermal stability up to 150 which
can withstand the high temperature during operations. Other characteristics of Bakelite
included insulator, and resistant to chemical action.
6.2 Conclusions
In conclusion, the jig and fixture is proved to be used to machine the part by duplicating
the same taglines on the Aluminium plate. By using the jig and fixture, the products
produced are low variability in dimension, in other words, this could ensure the quality,
and reduce the time, cost and else in the production line. In short, the objectives are
achieved and this project is successfully done.
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7.0 References
1. Operation, G. (n.d.). Machining _2.
2. Settings, E. (2004). Technical Reference. Retrieved from
https://www.tungaloy.com/common/products/catalog/ee/15_technical_ee.pdf
3. Specifications, T. (1900). G e n t e c h E n g in e e r in g P l a s t ic s G e n t e c h
E n g in e e r in g P l a s t ic s, 1–2. Retrieved from http://www.gentechpu.com/gt2/EPSB.PDF
Appendices
I. Drafting of Tagline II. Drafting of Body III. Drafting of Clamp Bar
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