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In this project it is based on the need for the work holding devices. This design
and fabrication which will enable the operation like drilling, reaming, tapping process
easier. This project is mainly composed of DESIGN AND FABRICATION OF THE
ANGLE PLATE JIG which cover the absolute design to the specified dimensions of
the work piece. This angle plate jig is economical means to produce
1. INTRODUCTION
1.1 INTRODUCTION
Mass production aims at high productivity to reduce unit cost and interchange ability
to facilitate easy assembly. This necessitates production devices to increase the rate
of manufacture and inspection device to speed-up inspection Procedure.
Jigs are special purpose tools which are used to facilitate production like machining,
assembling and inspection operations. The mass production of work-piece is base
on the concept of interchange ability according to which every part produced within
an established tolerance. Jigs provide a means of manufacturing interchangeable
parts since they establish a relation with predetermined tolerances, between the
work and the cutting tool. Once the jig is properly set up, any number of duplicate
parts may be readily produced without additional set up.
Jigs are used on drilling, reaming, tapping, milling and tapping. There are many
Advantages for using jigs in production. Jigs eliminate individual making, positioning
and frequent checking. This reduces operation time and increase productivity. There
is no need for selective assembly.
1.2 OBJECTIVES
i.
This jig has built in accuracy, the precision positional relationship b/w jig
ii.
iii.
iv.
v.
2. LITERATURE REVIEW
2.1 INTRODUCTION
This chapter discussed about literature review of jigs designing for the angular
cylindrical part. It begins with introduction to the jigs, type of jigs and components in
the jigs. Furthermore, the advantages and disadvantages of the jigs were discussed
and the important of the jig design were discussed briefly.
2.2 INTRODUCTION TO JIGS
Mass
production
aims
at
high
productivity
to
reduce
unit
cost,
and
ii.
Easy loading and unloading of the work piece and prevention of wrong
iii.
iv.
v.
loading.
Prevention of bending or movement of the work piece during drilling.
Ample chip clearance which facilitates for swarf removal and cleaning.
Light weight to minimize operator fatigue due to repeated handling.
Jig body
Jig feet
Jig bushing
Jig plate or bush plate
Locators
Clamps
Fool proof element
Jig body
The jig body supports the work piece and has locating and clamping elements in
it. It is provided with four jig feets and rests on the machine table.
ii.
Jig feet
a jig feet which is not bolted to machine table is provided 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, reamers and boring bars, hardened steel jig bushes are
employed which are fixed in the jig plates. The bushes can be replaced when wornout with less cost than replacing the entire jig plate.
5
iv.
be rigidly constructed as a single unit of jig or it may be of leaf or latch type. In this
type, the jig plate must be clamped with the jig frame.
v. Locators
Locators help a work piece to ret in proper position in a jig. Depending on the
type of work piece, various types of locators are used for the locating the
components, in the jig with reference to the tools, the locators are usually detachable
type, fixed to the jig frame. So whenever wear occurs, the locators can be easily
replaced with 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 contact with locating pins of surfaces.
Sufficient thickness of section should be provided to withstand clamping forces.
vii.
Fool proof element
This element prevents the work from being loaded wrongly into the jig. The
elements may be simple fouling pegs, cross pieces or pins.
Productivity
Jigs eliminate individual marking, positioning and frequent checking. This
reduces operation time and increases productivity.
6
ii.
Interchange ability
Jigs facilitate uniform quality in manufacture. There is no need for selective
assembly. Any part of the machine would fit properly in assembly, and all
similar components are interchangeable.
iii.
Skill reduction
Jigs simplify locating and clamping of the work-pieces. Tool guiding elements
ensure correct positioning of the tools with respect to the work pieces. There
is no need for skilful setting of the work-piece or tool. Any average person can
be trained to use jigs. The replacement of a skilled workman with unskilled
labour can effect substantial saving in labour cost.
iv.
Cost reduction
Higher production, reduction in scrap, easy assembly and savings in labour
costs result in substantial reduction in the cost of work-pieces produced with
jigs.
2.3.2 Disadvantages
In industry, using jigs is very important in operation. Nowadays, tool is more
important than workman skill. This will make the industrial lacking skilful man in
workplace. When the tool is breakdown, the production rate will be decrease. Cost
for maintenance will be higher.
2. Drill Jig
2. Plate Jig
9
3. Sandwich Jig
4. Latch or Leaf Jig
5. Channel Jig
6. Box Jig
7. Post jigs
8. Angle plate Jig
9. Angular post Jig
10. Turnover jig or Table type Jig
11. Pot Jig
10
19.
I.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
Template Jig
42.
43.
45.
of holes to be made in the work piece. Size of template jig should be same as that
of the work piece. It is overlapped with the work piece and drilling is done quickly.
Use of this jig avoids the marking operation completely.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
II.
Plate Jig
64.
65.
Figure 2.6: Plate Jig
67.
68.
Plate jigs are similar to templates jigs. The only difference is that plate
jigs have built-in clamps to hold the work. These jigs can also be made with or
without bushings, depending on the number of parts to be made.
69.
70.
71.
72.
73.
74.
66.
3. Sandwich Jig
75.
76.
77.
79.
backup plate found on the sandwich jig. This back up plate allows the jig to hold very
thin parts that could bend or distort under tool pressure. The sandwich jig can also
be used as a combination jig in which one side of the tool is used to locate the part
for drilling. The opposite side is used for reaming or tapping the part.
80.
81.
83.
hinged cover, a leaf which can swing open to load or unload the work piece. After the
work piece has been located inside the jig, the leaf is firmly closed and locked inside
the jig. The leaf is held on to the jig body with the help of an eyebolt where the eye is
hinged to the body with a pin and a nut on the threaded portion of the bolt tightens
the leaf. The drill bushes are fitted in the leaf.
84.
Leaf jigs can be loaded and unloaded quickly and are suitable for
complicate work pieces with irregular contours. The disadvantage of leaf jigs is that
chips may accumulate inside and cause trouble unless provisions are made for
disposing them. Also, if the drill bushings are fitted in the leaf, play in the hinges may
affect drilling accuracy.
85.
86.
87.
88.
89.
90.
91.
92.
93.
5. Channel Jig
94.
95.
97.
96.
Channel jigs are the simplest form of box jig. The work is held between
two sides and machined from the third side. In some cases, where jig feet are used,
the work can be machined on three sides.
98.
99.
100.
101.
102.
103.
104.
105.
6. Box Jig
106.
107.
109.
jig allows the part to be completely machined on every surface without the need to
reposition the work in the jig. Channel jigs are the simplest form of box jig. The work
is held between two sides and machined from the third side. In some cases, where
jig feet are used, the work can be machined on three sides.
110.
111.
112.
113.
114.
115.
116.
7. Post Jig
117. Vertical
118.
119.
120. Horizontal
121.
122.
124.
the drill plate to be removed without removing the hand nut. The post jig is also used
for drilling and reaming, a C washer is used to obviate the need to remove the hand
nut.
8. Angle Plate Jig
125.
126.
128.
angles to their mounting locators. Pulleys, collars, and gears are some of the parts
that use this type of jig.
129.
130.
131.
132.
133.
134.
135.
136.
137.
138.
9. Angular Post Jig
139.
140.
142.
141.
Angle-plate jig, which is used for machining angles other than 90
degrees. Figure shows an angular post jig of welded construction. The drill bush is
extended and shaped to prevent drill run, and yet allow removal of work piece. The
clamping nut is of the quick-action type because the smallness of the work piece
bore demands that the nut be removed when the work piece is removed.
143.
144.
145.
146.
10. Turnover Jig or Table Type Jig
147.
148.
149.
Plate jigs are sometimes made with legs to raise the jig off the table for
153.
154.
155.
157.
and clamped. Circular work pieces which have both an external diameter and an
internal diameter suitable for location purposes are drilled in pot type jigs. The jig
essentially consists of two parts. The body which is in the form of a pot carries the
work piece and also the bush plate.
158.
Figure illustrate a pot jig in which the work piece is located from its
outside in the bush, and the drill bush is located on a post; the drill plate is located to
line up with swarf clearance grooves.
12. Solid Jig
159.
160.
161.
Figure 2.18: Solid Jig
163.
The figure shows a solid jig that is made from a block of steel. The
162.
164.
work piece is clamped by a button clamp, and burr groves are provided so that the
work piece can be easily recovered. Two grooves are required because one burr will
be produced at the point of drill entry, and a second burr is produced at the point of
drill break through.
165.
166.
167.
168.
169.
170.
171.
172.
173.
174.
175.
176.
177.
178.
13. Trunnion Jig
179.
180.
182.
be drilled in several faces, it is mounted in a trunnion jig so that the faces requiring
drilling operations can be turned easily and positioned. Every time, the jig is rotated
and it is locked so that the face in which the hole is to be drilled is absolutely
horizontal. The pin and the locating hole for locking the jig should be wear resistant.
183.
184.
185.
14. Indexing Jig
186.
187.
Figure 2.20
189.
188.
Indexing jigs are used to accurately space holes or other machined
areas around a part. To do this, the jig uses either the part itself or a reference plate
and a plunger. Larger indexing jigs are called rotary jigs.
190.
191.
192.
193.
194.
195.
15. Universal Jig or Pump Jig
199.
196.
197.
Figure 2.21: Universal Jig or Pump Jig
198.
Pump jigs are commercially made jigs that must be adapted by the
user. The lever-activated plate makes this tool very fast to load and unload. Since
the tool is already made and only needs to be modified, a great deal of time is saved
by using this jig.
200.
201.
202.
16. Multi Station Jig
203.
204.
206.
Multi station jigs feature is how it locates the work. While one part is
drilled, another can be reamed and a third counter bored. The final station is used for
unloading the finished parts and loading fresh parts. This jig is commonly used on
multiple-spindle machines. It could also work on single-spindle models. There are
several other jigs that are combinations of the types described. These complex jigs
are often so specialized that they cannot be classified. Regardless of the jig
selected, it must suit the part, perform the operation accurately, and be simple and
safe to operate.
207. 2.5 Materials
208.
iii.
iv.
v.
ix.
221.
Cast Iron
222.
fabrication
223.
CI usage requires a pattern for casting
224.
Contains more than 2% carbon
225.
226.
227.
x.
xi.
261.
284.
285.
286.
The angular post jig construction is vertical plate is welded in the base
plate. Top plate is welded in the vertical plate. The one end of the angular plate is
welded in the base plate then other end is welded in the top plate. Angular plate
used for supported the work piece. Index plate is fitted upper surface of the angular
plate with the help of plunger pin. Quick-action nut is used for locking and also
supporting the work piece. Drill bushes are fitted in top plate according to the work
piece.
287.
288.
289.
290.
291.
292.
293.
294.
295.
296.
297. 3.3 Part drawing
298.
299.
300.
301.
302.
303.
304.
FRONT VIEW
SIDE VIEW
TOP VIEW
ISOMETRIC VIEW
316.
3.5 Advantages
Produce high accuracy of parts
Save labour cost
Quick and accurate location of work piece
Easy loading and unloading
Mass production
Reduce the cost of production
317.
318. 3.6 Applications
Mass production industries
Angular component manufacturing
319. 3.7 Bill of Material
320. S. No
321. Part
322. Mater
323. Quan
324. 1
Name
325. Base
ial
326. M.S.
tity
327. 1
328. 2
plate
329. Vertic
330. M.S.
331. 1
332. 3
al plate
333. Top
334. M.S.
335. 1
336. 4
plate
337. Angul
338. M.S.
339. 1
340. 5
344. 6
ar plate
341. Bush
345. Index
342. M.S.
346. M.S.
343. 1
347. 1
plate
348.
349. Table 3.1: Bill of Material
350.
351.
352.
353. 3.8 Essential Features of Jigs
i. Reduction of idle time
354.
Should enable easy clamping and unloading such that idle time is
ii.
iii.
minimum.
Cleanliness of machining process
355. Design must be such that not much time is wasted in cleaning of
scarfs, burrs, chips etc.
Replaceable part or standardization
is possible.
Provision for coolant
357. Provision should be there so that the tool is cooled and the swarfs and
v.
vi.
vii.
in contact with finished surfaces of the work piece so that they are not spoilt.
Fool-proofing
360. Pins and other devices of simple nature incorporated in such a
position that they will always spoil the placement of the component or hinder
viii.
the fitting of the cutting tool until the latter are in correct pos.
Economic soundness
361.
Equipment should be economically sound; cost of design and
ix.
x.
xi.
xii.
aids.
Initial location
363.
Should be ensured that work piece is not located on more than 3
points in anyone plane test to avoid rocking, spring loading should be done.
364.
Position of clamps
365.
Clamping should occur directly above the points supporting the
work piece to avoid distortion and springing.
Clearance
366.
Sufficient amount of clearance should be provided around the
work so that operators hands can easily enter the body for placing the work
xiii.
xiv.
368.
Provision should be made for proper positioning and rigidly holding the jigs and
xv.
fixtures.
Safety
369.
370.
371.
372.
373.
374.
375.
376.
377.
378.
379.
380.
381.
382.
383.
384.
385.
386.
387.
388.
389. CONCLUSION
390.
399.
400.
401.
402.
403.
404.
405.
406.
407.
408.
409.
410.
411.
412. REFERENCE
413.
Jigs and fixtures, press tools C. Elanchezhilan and B. Vijaya Ramnath
www.jigsand fixtures.com
414.