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DRILLING FIXTURE ”
A PROJECT REPORT
Submitted by
BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
BONAFIDE CERTIFICATE
SIGNATURE SIGNATURE
Prof. G.MAIKANDAN Mr. K.BALASUNDARAM
HEAD OF THE DEPARTMEN PROJECT GUIDE
Professor, Lecturer,
Dept. of Mechanical Engineering Dept. of Mechanical Engineering
K.C.G. College of Technology K.C.G. College of Technology
Karapakkam, Chennai-600097. Karapakkam, Chennai-600097.
________________________________________________________________
We would like to express our sincere and heartfelt gratitude to our guide
Mr.A.Venkatesan , Lecturer, Department of Mechanical Engineering , KCG
college of technology, for being patience and valuable guidance.
With deep feeling of indebtedness we owe many special and heartful thanks
to all staff members for their complete co-operation, help and suggestion.
DESIGN AND FABRICATION OF MULTI-POINT DRILLING
FIXTURE
ABSTRACT
Our project is based on the need for the work holding devices. This design and fabrication
which will enable the operation of drilling easier. Our project is mainly composed of design
and fabrication of the “SPRING INDEXING MECHANISM” which cover the absolute
design to the specified dimensions of the work piece. This drilling fixture is economical
means to produce
4. These are light weight these can be used either by fastening them with the table
6. With these features, we sincerely hope that our project serve as a valuable
LIST OF TABLES 8
LIST OF FIGURES 9
1 INTRODUCTION
1.1 General 1
1.2 Definitions 2
1.3 Difference between jigs
And fixtures 3
1.4 Advantages 4
1.5 Essential features 5
1.6 General rules for designing of
Jigs 7
1.7 Factors to be considered for
Design of jigs 9
1.8 Tolerance and fits 14
1.9 Material for bushes 15
1.10 Types of bushes 15
1.11 Elements of jigs 16
1.12 Types of jigs 17
2 DESIGN CALCULATIONS
4 COST ESTIMATION
5 ADVANTAGES 28
6 LIMITATIONS 42
7 DRAWINGS
8 CONCLUSION 37
9 PHOTOGRAPHY 38
10 REFERENCES 38
LIST OF TABLES
NO . DESCRIPTION PAGE NO
LIST OF FIGURES
1.1.GENERAL
1.2 DEFINITIONS
1.2.1 FIXTURES:
A fixture is a work holding device, which only holds
and positioned the work, but does not itself guide, locate or
positioning the cutting tool. The setting of the tool is done by
machine adjustment and a setting block or by using slip gauges.
A fixture is bolted or clamped to the machine table. It is usually
heavy in construction.
1.2.2 JIGS:
A jig may be defined as a device which hold and
positions the work, locate or and guides the cutting tool relative
to the work piece and usually is not fixed to the machine table.
It is usually lighter in construction.
Jigs are designed to hold, support and locate the work
piece to ensure that each part is machine within the specified
tolerance. Jigs are usually fitted with hardened steel bushes for
other cutting tools.
1.3. THE DIFFERENCE BETWEEN FIXTURES & JIGS
Table 1
FIXTURES JIGS
It is a work holding device It is a work holding device
that holds supports and that holds, supports , locates
locates the work piece and the work piece and guides
does not guides the tool cutting tool for a specific
for specific operation operation.
PRODUCTIVITY
A fixture increases the productivity by eliminating the
individual marking, positioning and frequent checking. The
operation time is also reduced due to increase in speed, feed and
depth of cut because of high clamping rigidity.
INTERCHANGEABILITY AND QUALITY
A fixture facilitates the production of articles in large
quantities with high degree of accuracy, uniform quality and
interchangeability at a competitive cost.
SKILL REDUCTION
There is no need for skillful setting of work on tool. Fixture
makes possible to employ unskilled or semi skilled machine
operator to make saving in labors cost.
COST REDUCTION
Higher production, reduction in scrap, easy assembly and
saving in labor cost results in ultimate reduction in unit cost.
It increases the versatility of machine tool.
It becomes possible to accommodate several components at
setting and thus taking advantages of multiple machining.
Fixture reduce the expenditures on quality control of machine
Parts.
1.5 ESSENTIAL FEATURES OF FIXTURES
Inserts or pads:
It is a very necessary provision in all fixtures.
Inserts or pads of the soft materials like brass, leathers or fibers
should be riveted to those faces of the clamps which will come
in contact with the finished surface of the work piece, so that
these surfaces are not spoiled as a result of the metallic contact.
Fool-proofing:
Since the use of fixtures allows for the
employment of unskilled worker, the design of such equipment
should be such that it would not to permit the work piece or the
tool be inserted in any position other than the correct one.
Economic soundness:
The equipment to be used should be
economically sound that is the cost of its designing and the
manufacturing should be proportion to the quantity and price of
the producer.
Easy manipulation:
The fixtures should be as light in weight as
possible and should be easy to handle and manipulate so that the
workman is not subjected to under fatigue.
Position of clamps:
The clamps should be so positioned that clamping
occurs directly above the points supporting the work piece so as
to avoid distortion and springing of the work, which otherwise
will result is an inaccurate work. Moreover the clamps should
be strong enough to resist bending under clamping pressure.
Clearance:
Sufficient amount of clearance should be provided
around the work in around the operator’s hands could easily
enter the body for placing the work piece and any variation in
the work piece can be accommodated.
Rigidity & Stability:
The fixtures should be so designed that it remains
perfectly rigid and stable during the operation. If needed,
provision should be made for proper positioning and rigidly
holding the fixtures on the machine table or spindle by means of
bolts and nuts and similar others means.
Safety:
The design of jig should be such that it should not
constitute any anger to the operator.
Welded construction
a. Weld construction is used in drill jig.
b. Welded jig must be stress relieved.
c. Faster to weld the components together
Safety device:
Jigs designed to assure full safety to the operation. Protruding
sharp edges should be avoided.
Cost:
All components should be simple as possible. The initial
investment required to design and built the jig should be
optimum.
2. Push fit:
This fit requires light hand pressure on tapping for
assembly of mating parts. It is used mainly for precise assembly
of replaceable locaters in jigs.
3. Press fit:
The mating parts must be assembled by hammering or by a
press. There is a positive inference b\w the hole and shaft. This
prevent rotary as well as axial movement b\w the assembled
parts. Hence press fit is used widely for assembly of drill bushes
(outside diameter) and locaters, which are rarely replaced.
4. Force fit:
It is used for permanent assemblies wheels and hubs of
shafts, force fit parts require heavy pressure for assembly.
2. Renewable bushes
a. Fixed bushes
b. Slip bushes
3. Liner bushes
4. Threaded bushes
5. Screw or clamping bush
1.11Elements of jigs
i.Jig body:
The jig body supports the work piece and has locating and
clamping elements in it. It is provide with four jig feet and rests on
the machine table.
ii.Jig feet:
A jig feet which is not bolted to machine tool is provide with
four jig feet, instead of the entire bottom surface lying flat on the
machine table. Jig feet are either cast with the jig body or
detachable or welded to the base.
They are usually hardened and ground to have flat bottom.
iii.Jig bushing:
For guiding drills, reamer and boring bars, hardened steel
bushes are employed which are fixed in the jig plates. The bushes
can replaced when worn-out with less cost than replacing entire jig
plates.
iv.Jig plate or bush plate:
Usually the jig plate carries jig bush for guiding the tool. The
jig plate may be rigidly construed as a single unit of a jig or it may
be of leaf.
In this type, the plate must be clamped with the jig frame.
v.Locaters:
Locaters help a work piece to resist in proper position in a
jig. Depending on the type of work piece. Various types of locators
are used for locating components. In the jig with reference to the
tool. The locators are usually detachable type, fixed to the jig
frame. So whenever wear occurs, the locators are replaced new
ones.
vi.Clamps:
Clamps are used for holding the work piece rigidly against all
disturbing forces. They also keep the work piece firmly in locating
pins of surfaces.
Sufficient thickness of section should be provided to with standing
clamping forces.
vii.Fool proof element:
These elements prevent the work from being loaded wrongly
loaded into the jig. The elements may be simple tousling pegs,
cross pins or pins.
2. SELECTION OF BUSH
Press fit is preferred, therefore select fixed bush with
hole range diameter 8mm.
Generally the out side diameter of the bush will be push fit or press fit
and inner hole will be running fit.
Select bush of fixed type DDB; 5.100
The dia meter to be drill the work piece is=10mm
For 10mm diameter,
As per design norms bush(Short)dimensions
L1=12mm
L2= 8mm
D3=20mm
But in our project bush dimension is
L1=25mm
L2= 20mm
D3=25mm
3. SLECTION OF LOCATERS:
DESIGN ASPECTS
Physical property:
Density - 7860 Kg/m3
Melting point - 1427˚c
Thermal conductivity – 63
Carbon content:
Low Carbon (or) Mild steel – 0.15% to 0.45% carbon
Mechanical property:
Elasticity
Ductility
Toughness
Weld ability
In our design, pin locator have a main part hence the calculations are
concentrated on it.
2.3.Types of fixtures:
a. Template jig
b. Plate jig
c. Channel jig
d. Leaf jig
e. Pot jig
f. Turnover jig or table jig
g. Box jig or tumble jig
h. Trunion jig
i. Indexing jig
j. Post jig
k. Sandwich jig
l. Nut cracker jig
m. Pump or universal jig
n. Latch jig
FURTHER OPERATION
Cleaning
Assembling
3.1.1. Shaping
Shaping operation is used to reduce the dimensions of the
plates. In this project the plates are in need of shaping process.
It is done by shaping machine.
3.1.2. Drilling
Drilling is used to produce holes in objects. In this project
the jig plates requires the holes for making bolted assembly.
Also to fitting the bushes holes are required. These holes are
done by conventional vertical type drilling machine.
3.1.3. Tapping
Internal threading operation is used to produce threads inside
the hole. It is also called as tapping process. In this project the
holes except the holes for bushes are required tapping process.
This is done for the purpose of holding the supporting block and
making the jig box by bolt assembly.
3.1.5. Boring
Boring is the process which is used to make material
removal internally. In this project it is used to boring on the two
cover plates to hold the l-bow with flange. Through bores are
also produced on the two cover plates. This is done by using
lathe.
3.1.6. Grooving
It is used in this project to make the groove on the both
sides of top cover plate. This is done by conventional lathe.
Assembling
It is the operation, which deals with the assembling of various
parts produced by above operations.
BILL OF MATERIALS:
Table 2
SL. NO. PART NAME MATERIAL QUANTITY
1 Bush EN8 2
2 Bush holder Mild steel 1
Work-piece
3 Mild steel 1
clamping holder
4 Pad Mild steel 1
Adjustable
5 Mild steel 1
Mandrel
6 Spring plunger Mild steel 1
4. COST ESTIMATION
4.1 MATRIAL COST:
Table 4
S.NO COMPONENTS QUANTITY COST
1 Bush 2 200
2 Bush holder 1 400
Work-piece clamping
3 1 300
holder
4 Pad 1 200
5 Adjustable Mandrel 1 200
6 Spring plunger 1 100
Total 1400
5. ADVANTAGES:
It eliminates the individual marking, positioning and
frequent checking.
The operation time is reduced due to increase in speed, feed
and depth of cut because of high clamping rigidity.
It is very much useful in mass production.
It makes possible to employ unskilled or semi skilled
operator to make savings in labour cost.
It reduces the expenditures on quality control of machine
parts.
6. LIMITATIONS:
It is restricted to objects of certain diameter only.
Forces causing deflection may come from handling.
CONCLUSION & SUGGESTION:
This report deals with the design and fabrication of multi-point drilling fixture and
the detailed drawing of the components and assembly. The project carried out by us
made an impressing task in drilling works. It is very useful in industries for mass
REFERENCES
Tool design by Donaldson, Lecain, Goold published by Tata
McGraw Hill company
Machine tools by Elanchezhian, M.Vijayan published by
Anurada agencies
Machine tools and tool design by P.C. Charma published by
S.Chand and company
Design of jigs, fixtures and press tools by C.Elanchezhian,
T.Sunder selwyn, B.vijaya Ramnath Published by Eswar press.
Design of jigs, fixtures and press tools by Venkataraman
published by Tata McGraw hill
Jigs and fixtures by PH Joshi published by Tata McGraw hill
Production technology by P.C Sharma published by S.Chand
and company
Manufacturing technology by RAO published by Tata McGraw
hill
Machine drawing by N.D Bhatt, V.M. Panchal published by
Charotar publishing house
Machine drawing by K.R. Gopalakrishna published by Subhas
publication
Design data book by P.S.G college of technology