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Project Report

for

BFF3632_DESIGN OF JIGS & FIXTURES

Department of Manufacturing Engineering, FKP University Malaysia Pahang,

Lebuhraya Tun Abdul Razak, 26300 Kuantan, Pahang.

Lecturer

MUHAMMED NAFIS BIN OSMAN ZAHID

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

2.0 Machining Process Planning ........................................................................................ 5


2.1 Gantt Chart of Activities Planning ............................................................................. 5
2.2 Machining Process Flow Chart ................................................................................... 6
2.3 Product Planning ......................................................................................................... 7
2.4 Processing Time ......................................................................................................... 10
2.4.1 Jig and Fixture Body and its Components ......................................................... 10
2.4.2 Taglines (product) ............................................................................................... 10

3.0 Development of Jigs and Fixtures ................................................................................ 11


3.1 Design of Taglines (product) ..................................................................................... 11
3.2 Design of Jigs and Fixtures ....................................................................................... 12
3.3 Drawing of Fabricated Components......................................................................... 12
3.3.1 Body ..................................................................................................................... 12
3.3.2 Clamp Bar ........................................................................................................... 13
3.4 Fabrication and Assembly Processes ........................................................................ 13
3.4.1 Processing Clamp Bar (Three Pieces) ................................................................ 13
3.4.2 Processing Body .................................................................................................. 14
3.4.3 Assembly Process ................................................................................................ 15

4.0 Jigs and Fixtures Validation ....................................................................................... 17


4.1 Machining Parameters .............................................................................................. 17
4.2 Simulation Stage ........................................................................................................ 19
4.3 Processing Taglines ................................................................................................... 21

5.0 Economic Analysis ...................................................................................................... 22


5.1 Jig and Fixture Design .............................................................................................. 22

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5.2 Material Selection ...................................................................................................... 23
5.3 Process Parameters ................................................................................................... 23
5.4 Manufacturing Processes .......................................................................................... 24

6.0 Conclusion and Recommendations .............................................................................. 25


6.1 Recommendations ................................................................................................... 25
6.2 Conclusion ................................................................................................................. 25

7.0 References ..................................................................................................................... 25


Appendices .......................................................................................................................... 26

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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.

Figure 1.1: Assembly of jig and fixture, and product.

1.1 Problem Statement


The thickness of the product is limited and the material used is quite soft resulting
crack or break on the surface of product when machining. The process parameters like
cutting force, cutting speed should be encountered into the design of whole assembly
product so that the product can be successfully fabricated.

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.

2.0 Machining Process Planning


2.1 Gantt Chart of Activities Planning

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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

1. Project briefing and grouping

2. Select leader

3. Generate ideas of jigs & fixture

4. Design the product

5. Select one design

6. Draw component

7. Design analysis

8. Machine process planning

9. Fabrication

10. Finishing work

11. Project presentation

12. Submit final report & product

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Flow Chart 2.2: Details of process planning
2.3 Product Planning

Table 2.3: Details of process planning

Product / Process Characteristics


Process Machine,
Process Name / Device, Jig, Remarks
Number Operation Tools for Specification
Characteristic
Description Manufacturing &
Description
Tolerance

• 1*150mm*340mm*25
mm body

ruler, band saw • 3*35mm*40mm*15m ,


10 Cutting ±0.1mm
machine m clamp bar

• 100mm*240mm*4mm
product

Measuring pencil, ruler,


hole position for drilling
20 and center punch,
on 2 clamp bar
Marking hammer

D6.8 drill bit,


1* 15mm thru hole, ±0.1mm,ø±
30 Drilling drilling
6.8mm diameter hole 0.1mm
machine

D6 end mill , 1*6mm depth slot on


40 Slotting milling the surface of clamp ±0.1mm
machine bar

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 „F‟, „K‟, „P‟ thru pockets,


mill, CNC „┌‟ ,‟┘‟,
110 Roughing ±0.1mm
milling „T‟H‟E‟,‟O‟,‟N‟,‟E‟ primary
machine shape on the product.

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

Cutting process of raw materials 2hours and 30minutes

Measuring and Marking process 45minutes

Drilling process(3 Locator Bars) 1hour

Slotting process(3 Locator Bars) 3×25minutes

Chamfering(3 Locator Bars) 3×5minutes

Roughing process(Body Jig) 15minutes

Drilling process(Body Jig) 15minutes

Tapping(Body Jig) 10minutes

Total Processing Time 6hours and 25minutes

2.4.2 Taglines (product)


Squaring(3 taglines) 3×20minutes

Grinding(3 taglines) 3×15minutes

Roughing(3 taglines) 3×55minutes

Sweeping(3 taglines) 3×4hours and 15minutes

Total Processing Time 17hours and 15minutes

3.0 Development of Jigs and Fixtures


3.1 Design the Taglines (product)

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Figure 3.1.1: Top view Figure 3.1.2: Isometric view

Figure 3.1.3: Front view Figure 3.1.4: Right view


3.2 Design of Jig & Fixtures

Figure 3.2.1: Top view Figure 3.2.2: Isometric view

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Figure 3.2.3: Front view Figure 3.2.4: Right view

3.3 Drawing of Fabricated Components


3.3.1 Body

Figure 3.3.1.1: Top view Figure 3.3.1.2: Isometric view

Figure 3.3.1.3: Front view Figure 3.3.1.4: Right view

3.3.2 Clamp Bar

Figure 3.3.2.1: Top view Figure 3.3.2.3: Isometric view

Figure 3.3.2.2: Front view Figure 3.3.2.4: 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.

3.4.1 Processing Clamp Bar (Three Pieces)


Firstly, the clamp bar is undergoing facing to form the exact size by using milling machine as
shown as the Figure 3.4.1.1.

Figure 3.4.1.1: Cutting process


Then, the hole for screw for passing is formed by using drilling machine. After the
hole formed, the slotting and chamfering processes are carried out to shape the clamp bar
into desired shape which had shown in Figure 3.4.1.2.

Figure 3.4.1.2: Slotting process

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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.

Figure 3.4.2.1: Roughing process

Figure 3.4.2.2: Drilling process

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.

Figure 3.4.3.1: Body with locators and pins

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.

Figure 3.4.3.3: Full assembly


The assembly product is then placed and clamped using T-slot nuts and screws on the machine
table of milling machine for further operation.

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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

Machine Steel 20 - 30 100 - 125


Tool 18 - 20 40 - 60
Steel Cast 15 - 25 40 - 60
Iron 20 - 35 60 - 120
Bronze 150 - 300 150 - 300
Aluminium
Note: The data are adapted from “BFF1811_Machining 2_Milling and Grinding Operation”.

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.

Table 4.1.2: Type of tool and its Feed

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)

where, F: Cutting force (N)

𝑘𝑐: Specific cutting force (N/mm2)

𝑎𝑝: Depth of cut (mm)

𝑓: Feed (mm/rev)

Table 4.1.3: Value of specific cutting force, 𝑘𝑐

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

0.04mm/min is 1050 N/mm2.

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:

𝐹 = 1050 × 0.3 × 0.04


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= 12.6N

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.

4.2 Simulation Stage

Front view

Top view

Figure 4.2.1: Force is being applied to the workpiece (Deformation)

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Figure 4.2.2: Force is being applied to the body (Von Mises Stress)

Table 4.2.1: Result of design analysis from CATIA software

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.

Figure 4.3.2: Sweeping process

Figure 4.3.3: Finished product

5.0 Economic Analysis


5.1 Jig and Fixture Design
Firstly, the jig and fixture body is designed as 150 340mm in order to fit in the whole
workpiece and the t-slot screws. The thickness of the body is remained unchangeable from
the raw material in order to minimize the material lost and the processing time as well as
the cost.
When designing the jig and fixture, two bars used as the components supporting the
workpiece are first generated instead of using the standard locators. After suggested by Dr

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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

Figure 5.1: Before improvement

Figure 5.2: After improvement

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)

Ball Indentation Hardness 425

Flexural Modulus 25

Flexural Strength 85

Compressive Strength 135


Note: The data are adapted from “Technical Specification”. Retrieved
from http://www.gentechpu.com/gt2/EPSB.PDF

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.

5.3 Process Parameters


 The type and size of tool selection is very important for the manufacturing process.
The depth of cut of product depends on the size and diameter of tool.
This is because the small diameter tool has the shorter length of cutting flute, so
it may cause the tool breakage during the process. The tool breakage may lead to
the damage of product and
 The approach and retract tool position must be checked and be aware of the
positions. The macro ramping is commonly used for the tool position to avoid
direct hit on the workpiece which causes tool wear or breakage.
 As shown in section 4.1, the feed rate and spindle speed should align correctly
with the type of material used in the workpiece. If used incorrectly, the process
might slow down and uneconomical efficient.
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5.4 Manufacturing Processes
 The setting of the manufacturing process which is created with the 3D drawing
software (catia) is very important in the determination of the time for whole
process. The distance between the tool path and the maximum depth of cut must
be concerned according to the material of product. The unnecessarily process
should be avoided to reduce the cost in terms of machine equipment, labor cost,
manpower and so on.
 The dimension and the size of those drilling holes must be accurate as the incorrect
location may cause failure during assembly process and in resulting the cost
inefficiency. The cost of overhead and man power is important in economical
aspect.
 The less-skill operator must be careful when carry out the manufacturing process
in order to reduce the accident occurred.

6.0 Conclusions and Recommendations


6.1 Recommendations
 Eliminate the sharp edges no matter in producing the taglines or the jig and fixture to
ensure safety.
 Investigate the suitable clearance fit that used for different purpose of locators and pins.
 Drill more holes with different sizing to enable different size of product can be produced
through the same jig and fixture.
 Make the adjustable clamp bar to allow different thickness of workpiece can be processed.

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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