CHAPTER 1

INTRODUCTION

1.1 JIG

A Jig is a work-holding and tool guide used in the manufacturing

industry. Jig are used to securely locate (position in a specific location or
orientation) and support the work, ensuring that all parts produced using the
fixture will maintain conformity and interchangeability. Using a jig improves
the economy of production by allowing smooth operation and quick transition
from part to part, reducing the requirement for skilled labour by simplifying
how work pieces are mounted, and guide the tool in constant path. A jig differs
from a fixture in that when a fixture is used, the tool must move relative to the
work piece, the jig is a tool that guides the cutting (or machining) tool.

A Jig’s primary purpose is to provide repeatability, accuracy and

interchangeability in the manufacturing of products. A jig is often confused with
a fixture; a fixture holds the work in a fixed location. A device that does both
functions (holding the work and guiding a tool) is called a jig.

An example of a jig is when a key is duplicated; the original is used as a

jig so the new key can have same path as the old one since the advent of
“automation” and “computer numerical control (CNC)” machines, jigs are often
not required because the tool path is digitally programmed and stored in
memory.

Jigs may be made for reforming plastics. Jigs or templates have been
known long before the industrial age. There are many types of Jigs, and each
one is custom-tailored to do a specific job.

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 Jig also allow for a higher degree of operator safety by reducing the
concentration and effort required to hold a piece steady. Economically speaking
the most valuable function of a jig is to reduce labour costs.

Many jigs are created because there is a necessity to do shown by the

tradesmen. Some are made to increase productivity thought consistency, to do
repetitive activities or to do job more accuracy. Jig may be well made for
frequent use or may be improvised from scrap for a single project, defending on
the task.

A drill jig is a type of jig that expedites repetitive hole centre location on
multiple interchangeable parts by acting as a template to guide the twist drill or
other boring device into the precise location of each intended hole centre. In
metalworking practice, typically a hardened drill bushing lines each hole on the
jig plate to keep the tool from damaging the jig.

Drill jig started falling into disuse with the invention of the jig borer.
Since the widespread penetration of the manufacturing industry by CNC
machine tool, in which servo controls are capable of moving the tool to the
current location automatically, the need for drill jigs is much less than it used to
be.

Most jigs have a solid component, affixed to the floor or to the body of
the machine and considered immovable relative to the motion of the machining
bit, and one or more movable components known as clamps. These clamps
(which may be operated by many different mechanical means) allow work
pieces to be easily placed in the machine or removed, and yet stay secure during
operation. Many are also adjustable, allowing for work pieces of different sizes
to be used for different operations

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 Jigs are in many different types, in a drilling process majorly ten types.
They are briefly explained below. Our industrial project is designing a indexing
type of Jig.

1.2 TYPES OF JIG

 Closed Jig
 Plate Jig
 Sandwich Jig
 Angle Plate Jig
 Box Jig
 Channel Jig
 Turnnion Jig
 Pump Jig
 Indexing Jig
 Template Jig

1.2.1 INDEXING JIG

Indexing jig is used to drill holes which are spaced equally along a circle.
in this example four equally spaced holes are to be drilled on the periphery of
the work piece. The work piece has a machined bore. The work piece is located
by a C-washer and a nut. A drill bush is fitted in the bush plate. The drill is fed
through the bush to drill the first hole. After this, by rotating the hand wheel, the
work piece is indexed for drilling the next hole. The indexing is done with the
help of an index plate and an indexing device(Shown in figure 1.2.1)

Fig 1.2.1 Indexing Jig

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1.2.2 PLATE JIG

This is the simplest type of jig. Plate jig consists of single bush plate.
This plate has a provision of loading and unloading of work piece, clamping and
chip removal. Figure 1.2.2 shows the construction of plate jig. The work piece
profile is located by six location pins and clamp by two knurled screws against
location pins. In any drill jig the work piece should be supported adequately
against bending due 50 to the downward thrust of drill. The disadvantage of
plate jig is that only one surface can be drilled at one loading and drilling forces
are generally directed toward the clamping element. Hence, clamps should be
rigid enough to withstand drilling forces.

Fig 1.2.2 Plate Jig

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1.2.3 BOX JIG

The shape of box jig is of box type. Figure 1.2.3 shows the construction
of box jig. The working of box jig is as follows: Hole is drilled and then reamed
when the work piece is held by jig. The work piece is inserted in the jig. The
cam rod is taken out of the jig and the work piece placed in the position inside
the jig. The cam rod is then replaced and rotated to its locking position. This
holds the work piece firmly so that drilling operation can be performed

Fig 1.2.3 Box Jig

1.2.4 LEAF JIG

These generally have hinged jig (bush) plate. The jig plate can be swung
aside as shown by dotted line in Figure 1.2.4 to load or unload the work piece
from the top. After the work piece has been located inside the jig, the leaf is
firmly closed and locked. The jig plate must have the resting face to ensure that
the axis of bushings is vertical during drilling. Jig plate must be clamped against
the resting face by an eye bolt. The open slot in jig plate and swinging eye bolt
facilitate quick clamping and unclamping of the jig plate.

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 The hand knobs need to be loosened by only half a turn and the eye bolt
swung to the position shown by chain dotted line in order to 51 permit swinging
of the jig plate aside for loading and unloading of work piece from Design of
Jigs the top. Leaf jigs are particularly suitable for work pieces having location
surfaces and holes to be drilled on opposite sides.

Hand
Knob Swinging

Jig Plate

Eye Bolt

Workpiece

Fig 1.2.4 Leaf Jig

1.2.5 ANGLE PLATE JIG

These are used to hold parts which are to be drilled at right angles or
some other angles to their mounting locators.

Fig 1.2.5 Angle Plate Jig

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1.3 POKA-YOKE METHOD

A Poka-Yoke is any mechanism in a lean manufacturing process that

helps an equipment operator avoid mistakes. Its purpose to eliminate the
product defects by preventing, correcting, or drawing attention to human errors
as they occur. It is originally description as Poka-Yoke, but as this means “fool
proofing” or “Idiot proofing” then the name was changed to the Poka-Yoke.

1.4 EXISTING METHODOLOGY

Mass production targets on increasing productivity and increasing

accuracy by reducing the setup cost and manual fatigue. One of the common
practices to achieve the goals of mass production is to use jigs.

Let us consider an example that one gets an order of 1000 product in such
a way that three holes are to be drilled in a work piece. In such situations,
designer will lay out the position of each hole with the help of square,
straightness, scribers, centre punch etc. Generally, trial and error method is
practiced until the axis of hole is properly aligned with the axis of drill. Thus, a
lot of time will be consumed to maintain the accuracy. Ultimately it increases
operator’s fatigue.

1.5 PROPOSED METHODOLOGY

Instead of laying out the position of each hole on each workpiece with the
aid of square, straightness, scribers, centre punch etc., the operator uses a jig to
position and guide the drill into proper place. Drill jig increases productivity by
eliminating individual marking, positioning and frequent checking.
Interchangeability is one of the advantages of jigs. There is no need for selective
assembly.

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 Automated Drill Jig

Base plate

Vertical
Plate

Bush Plate
Ball Bearing & C-Washer
Component locator

Work piece
Drill Bush Locator pin

Fig 1.5 Block Diagram on Automated drill jig

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 CHAPTER 2

LITERATURE REVIEW

SUPPORTING JOURNEL 1
Muzaffar Momin and Sanket Lokhande “DESIGN AND
MANUFACTURING OF ACRYLIC JIG” Jig is a special device that holds,
supports, or is placed on a part to be machined. It is a production tool made so
that it is not only locates and holds the work piece but also guides the cutting
tool as the operation is performed. Jigs are usually fitted with hardened steel
bushings for guiding drills or other cutting tools.

A jig is designed and built to hold, support and locate every component
(part) to ensure that each part that is drilled or machined within the specified
limits. The correct relationship and alignment between the tool and the work
piece is maintained. We studied the problems which were occurring during
drilling operations in “Kirloskar Ebara Pumps Limited KirloskarWadi”.

We find that we will make design and manufacture of acyclic jig so as to

overcome the problem occurring when manual marking is performed. Also due
to Acrylic jig the cost of jig manufacturing is reduced.

Jig is designed as per job requirements. In this study we use acrylic

material for jig manufacturing. Also, for reducing production cycle time we
implemented combination of two PCD (Pitch Circle Diameter) on single jig.

The journal give the general information about the jig and the industries
which are used jig is explained in this process. The method of manufacturing
the jig is can be understand using this journal.

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SUPPORTING JOURNEL 2
Russell Heins, and Robin Spargo”SUCCESSFUL APPLICATIONS
OF THE INLINE PRESSURE JIG WITH PARTICULAR REFERENCE
TO THE RECOVERY OF GOLD AND DIAMONDS” The Gekko Systems
Inline Pressure Jig is a unique and efficient gravity separation device, which has
found a wide variety of applications within the mining industry.
The unit was originally developed in Australia for recovery of placer
gold. The IPJ very quickly moved into the recovery of gold in grinding circuits
given the unit’s low water consumption and capital cost benefits. In the late
1990’s research into the use of the IPJ in diamonds was commenced envisaging
a number of potential benefits including security, low cost performance and
simplicity of operation.
Some of the advantages and applications of the IPJ in the recovery of
diamonds including actual operating plant experience are covered in this paper.
Other potential applications and the use of the IPJ for environmental
rehabilitation are also discussed.
The journal summary is give details about the movement of drilling jigs.
The environmental of the industries is discussed in the journal. It is useful to
designing the jig.
SUPPORTING JOURNEL 3
Charles Chikwendu Okpala and Ezeanyim Okechukwu C.
“THE DESIGN AND NEED FOR JIGS AND FIXTURES IN
MANUFACTURING” The paper gave a detailed definition of jigs and
fixtures, and also identified the numerous advantages that are associated with
the use of jigs and fixtures in manufacturing to include: production increase,
cost reduction, interchangeability and high accuracy of parts, reduction of the
need for inspection and quality control expenses, reduction of accident as safety
is improved, automation of machine tool to an appreciable.

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 The work also explained that since the design is dependent on numerous
factors which are analyzed to achieve an optimum output, that jigs and fixtures
should be made of rigid light materials to facilitate easy handling. For adequate
strength and rigidity, a mild steel with 16 millimeters diameter was chosen for
the design of a sample jig and fixture. Mild steel which contain about 0.29% of
carbon are very cheap, and because of their easy availability are often the
choicest material for the making of jigs of fixtures.
With 1.5 as the material factor ‘k’ for mild steel, a feed rate of 0.17
millimeter per revolution, and a drill diameter of 16 millimeters, the
Thrust/Drilling force was calculated as 3094.2 N. The Force acting on each of
the lips was calculated as 1700 N, the Torque (M) was gotten as 1360N-mm,
while the value of the Clamping Force was also calculated as 4080N.The
calculated values confirmed that a 16-millimeter diameter mild will lead to the
construction of a rigid and strong jigs and fixtures that will guarantee high
machining accuracy, consistent quality of products, and interchangeability.
Finally, the paper advocated that jigs and fixtures must be provided with
adequate clearance which should allow for variations in size of components
especially during forging, milling, and casting operations.The need of jig in the
manufacturing and the automobile industry and the process are detailed in the
journal. The detail of machines used to design the can be understood using this
journal.

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 CHAPTER 3
DESIGN AND DEVELOPMENT

3.1 PROJECT METHODOLOGY

The steps involved in the automated drill JIG is shown in the following
flow chart in figure 3.1.

Problem Identification in Drilling

Design of JIG

Selection of Material

Selection of Components

Testing of Jig

Conclusion

Fig 3.1. Methodology

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3.2 DESIGN OF JIG

The layout of the Jig is design according the below represented figure 3.2,
figure 3.3, figure 3.4 and figure 3.5 with the dimensions.

(ALL DIMENSIONS ARE IN MM)

Fig 3.2 Base Plate

(ALLDIMENSIONS ARE IN MM)

Fig 3.3 Bush Plate

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 (ALL DIMENSIONS ARE IN MM)

Fig 3.4 Component Locator

(ALL DIMENSIONS ARE IN MM)

Fig 3.5 Vertical Plate

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 CHAPTER 4
COMPONENTS DESCRIPTION
There are several categories of components which are employed here and
they are mechanical components. The brief descriptions on those are as follows:

4.1BASE PLATE

It is a metal plate which can withstand the total weight of the Jig
construction which is mounted in the bottom of this drill Jig. This base plate is
shown in the following figure 4.1.

Fig 4.1 Base plate

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4.2 BUSH PLATE

Here the bush plate can be employed as it is a fixed or removable

cylindrical metal lining used to constrain, guide, or reduce friction. The
following Figure 4.2 shows the basic bush plate and its dimensions as given
below.

Fig 4.2 Bush plate

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4.3 C-WASHER

C-Washers are designed to be slide in and out of position on a bolt or

shaft in a partially completed assembly or can be used as a retention device on a
grooved shaft to keep components in place. The following figure 4.3 shows the
C-washer which have been given below.

Fig 4.3 C-washer

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4.4 DRILL BUSH

A Drill bushing is a tool used in metalworking jigs to guide cutting tools,

most commonly drill bits. Other tools that are commonly used in a drill bushing
include Counter bores, countersinks and Reamers. They are designed to guide,
position and support the cutting tool.

The Figure 4.4 shows the Drill bush used in this Jig construction given
below as follows.

Fig 4.4 Drill bush

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4.5 LOCATOR PIN

Locator pins are great way to make sure the parts putting together fit the
way as to want them fit. Drill two holes opposite each other in each part, install
a cylindrical locating pin, and drilling task gets started.

The Figure 4.5 shows the diagram of the Locator pin.

Fig 4.5 Locator pin

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4.6 VERTICAL PLATE

It is a metal plate which is used for supporting the construction of the

drilling Jig. This construction can be explained by the following component
diagram on the Figure 4.6.

Fig 4.6 Vertical plate

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4.7 BALL BEARING

It is the Deep groove ball bearing are versatile, self-retaining bearing with
solid outer rings, Inner rings and ball and Cage assemblies. These products are
of simple design, durable in operation and easy to maintain.

The SKF6207 Deep groove Ball bearing can be shown in the Figure 4.7
given below.

Fig 4.7 Ball bearing

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4.8 COMPONENT LOCATOR

In Figure 4.8Component Locator ensure work pieces are precisely

positioned and rigidly supported. These Component locators must be selected to
ensure that the work piece can be easily loaded and unloaded.

Fig 4.8 Component locator

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4.9 COMPONENT DETAILS

Table 4.9 Details of the components used here.

NAME OF THE WEIGHT(Kg) MATERIAL

COMPONENT
Base Plate 3.940 MS
Vertical Plate 2.870 MS
Bush Plate 0.435 MS
Drill Bush 0.033 EN31
Component Locator 0.695 EN31
Locator Pin 0.104 EN8
C-Washer 0.074 EN8
Ball Bearing 0.470 SKF6207

MS - Mild Steel

EN8 - Medium Carbon Steel

EN31- Hard Carbon Steel

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 CHAPTER 5
PROJECT DESCRIPTION
5.1 OVERVIEW OF THE PROJECT
The essential features of jigs include:
 Clamps position
 Neatness of work-piece
 Standardization
 Idle time reduction
 Set up time reduction
 Hardened surfaces
The application of jigs and fixtures in manufacturing operations lead to the
production of faster, more accurate, and reliable products at a reduced cost.
5.2 CONSTRUTIONAL DETAILS
5.2.1 MATERIAL SELECTION

Material selection is one of the foremost functions of effective

engineering design as it determines the reliability of the design in the terms of
industrial and economical aspects. A great design may be fail to be a profitable
product if unable to find the most appropriate materials combinations. So, it is
vital to know what the best material for a design? In this aspect engineers use
several facts of material to come to the most reasonable decision. They are
mainly concentrated on the properties of the materials which are identified as
the potential materials for that specific design.

Mechanical properties

When a certain design is going to be actually produced it must be

subjected to a number of manufacturing practices depending on the material and
the design process. At the completion of production, it must be totally fit for the
service phase, too.

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 In order to predict the reliability of both of these requirements, the
material must be withstand a certain load .therefore, the material is must
possess a certain strength and stiffness .Selected materials are examined for
strength and stiffness values, and the potential materials are further inspected
for other desires properties.

Material selection is one of the prime concerns in mechanical engineering

design as mechanical engineers possess good deals with various loads and
temperature variations. Materials selection in engineering designs such as civil
engineering structure also very crucial

Wear of materials

Wear is a problem when the materials are contacting each other are
contacting each other in a product. So, it must be ensured that the selected
materials have sufficient wear resistance .one of the best examples for this
designing gear to cope with wear.

There are many production techniques available to improve the wear

resistance and make the materials is more suitable for the application. This is
also very important factor to consider when selecting a material for a particular
design. In the engineering design process this has to be considered with great
care.

Corrosion

The importance of material selection in engineering is clearly visible in

corrosive environments. Also, it is an important engineering design criterion for
designs open to the environment for a longer period of time. Some materials are
very likely to be corroded in the service depending on the service environment.
Metals like iron are heavily prone to corrosion if it not prepared to resist
corrosion.

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 Therefore, it must be assured that the material is capable of being
employed for the particular design before selecting it. Painting or any other
surface coating method, cathode protection, etc. are possible ways to minimize
the effect and increase the service life.

Ability to manufacture

Although the material is well capable of using for the design, it may be
difficult to manufacture. This is particularly applicable in mechanical
engineering design. If these selection criteria are neglected the manufacture
process might be very costly making it unprofitable as a commercial product.
So before selecting the material this fact also must be considered. These facts
are widely varied with the type of manufacturing method. For an example, when
producing a gear its dimensions must be very accurate it has to be machined in
the production. So, the selected material must able to be machined with a
minimum cost. Otherwise there is no point of selecting that material for that
particular gear.

Cost

Cost is a critical fact to consider when selecting materials for a certain

design for most products because they are facing a severe competition in the
market. So, you may see that most of the metal or other valuable materials are
replaced by plastics in most of the designs which they are applicable such as
mechanical engineering design. The cost factor can be neglected when
performance is given the top priority. When estimating costs, all the associated
cost factors must be considered to get a more reasonable value. It may involve
the transportation, processing, etc.

The end material selection is not the end of the design process. The best
material may be yet to come in future. Also, it has to perform design function
satisfactorily, not for just one or two days, but for a long period of time.

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 In this tough test, the design may fail comprehensively. Therefore, the
designer has to consider the ways to improve the performance in all possible
aspects.

Material used in jig

 MS (mild steel)
 EN8(medium carbon steel)
 EN31(hard carbon steel)

MS

The steel which contains only a small percentage of carbon and is strong
and easily worked but not readily tempered or hardened. Mild steel is the most
commonly used steel. It is used in the industries as well in the different
everyday objects we use. Even the pans and spoons of the kitchen are
sometimes made of mild steel. The mild steel is very important in the
manufacturing of metal items. Almost 90% steel products of the world are made
up of mild steel because is the cheapest form of steel.

Mild steel composition:

Carbon -0.16 to 18% (maximum 0.25% is allowable)

Manganese-0.70 to 0.90%

Silicon maximum-0.40%

Sulphur maximum- 0.04%

Phosphorous maximum 0.04%

Mildest grade of carbon steel or mild steel contains a very low amount of
carbon -0.05 to 0.26%

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EN8

EN8 is a medium carbon steel usually supplied untreated.EN8 has good

tensile strength and is often used in applications such as shafts, gears, stressed
pins,studs,bolts,keys,etc.EN8 is a very popular grade and is readily machinable
in any condition. It can be further surface-hardened to components with
enhanced wear resistance, typically in the range 50-55HRC through induction
processes.

EN8 composition:

Carbon -0.36 to 0.44%

Manganese-0.10 to 0.40%

Silicon -0.10 to 0.40%

Sulphur -0.050 max

Phosphorus -0.050 max

EN31

EN31 is an excellent high carbon alloy steel which offers a high measure
of hardness with compressive strength and abrasion resistance. EN31 material is
harder than the EN8 material, EN31 composition:

Carbon -0.90 to 1.20%

Manganese -0.30 to 0.75%

Silicon -0.10 to 0.35%

Chromium - 1.00 to 1.60%

Sulphur -0.050 max

Phosphorus - 0.050 max

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5.2.2 DESIGN OF JIGS

Elements of Jig

Jig generally consists of locating element, clamping element and tool guiding or
setting element.

 Locating Elements

Locating elements position the work piece accurately with respect to tool
guiding elements in the jig.

 Clamping Elements

Clamping elements hold the work piece securely in the located position
during operation.

 Tool Guiding Elements

Tool guiding elements help in guiding the tools in correct position with
respect to the work piece. Drill bushes guide the drills accurately to the.
Work piece

5.2.3 DESIGN CONSIDERATION IN JIGS

The main frame of jig must be strong enough so that the deflection of jig
is as minimum as possible. This deflection of jig is caused due to the forces of
cutting, clamping of the workpiece or clamping to the machine table. The
mainframe of the jig should have the mass to prevent vibration and chatter.

Frames should be built from simple sections so that frames can be

fastened with screws or welded, whenever necessary. Those parts of the frame
that remain intact with the jig may be welded. The parts needing frequent
changing may be held with the screws. Where the body of jig or fixture has
complex shape, it may be cast from good grade of cast iron.

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 Clamping should be fast enough and require least amount of effort.
Clamps should be arranged so that they are readily available and may be easily
removed. Clamps should be supported with springs so that clamps are held
against the bolt head wherever possible.

If the clamp is to swing off the work, it should be permitted to swing as

far as it is necessary for removal of the workpiece. All locators, clamps should
be easily visible to the operator and easily accessible for cleaning, positioning
or tightening.

Provision should be made for easy disposal of chip so that storage of

chips doesn’t interfere with the operation and that their removal during the
operation doesn’t interfere with the cutting process. All clamps and support
points that need to be adjusted with a wrench should be of same size. All clamps
and adjustable support points should be capable of being operated from the
fronts of the jig.

Work piece should be stable when it is placed in jig. If the work piece is
rough, three fixed support points should be used. If work piece is smooth, more
than three fixed support points may be used. Support point should be placed as
farthest as possible from each other.

The three support points should circumscribe the centre of gravity of the
work piece. The surface area of contact of support should be as small as
possible without causing damage to the work piece. This damage is due to the
clamping or work forces. Support points and other parts are designed in such a
way that they can be easily replaced on failure.

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 The Figure 5.1 shows the flowchart for the construction of automated
drill jig.

Component study machine details

machining operation required

Jig layout planning

Design of jig elements, clamping system,

locator and jig body and tool guiding
system

Assembly and evaluation of jig,

completion of design

Fig 5.1 Flow chart on the Automated drill jig construction

5.2.4 ASSEMBLY

The assembly can be done in this automated drill jig as the sequential
order of arrangement and can be explained as follows.

Step 1: At first, the Drill bush can be mounted on the bush plate and then the
bush plate can be tightened in the Vertical plate at the top portion of it.

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Step 2: At the centre of the Vertical plate, a ball bearing can be attached in
which the component locator have been mounted and the locator pin has been
used to hold the component locator and can disable the movement.

Step 3: The threaded screw can be used here to adjust the C-Washer, which can
hold the work piece tightly and firmly.

Step 4: Then, the completed Vertical plate assembly can be fixed on the Base
plate by the means of Bolts.

Step 5: Atlast, this automated drill jig unit has been mounted strongly at the
Table of the Drilling machine.

Fig 5.2Assembly of Automated Drill Jig

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5.3 WORKING

5.3.1 PRINCIPLE

Work piece will be completely controlled when positioned against three

points in one plane, two points in another plane and one point in third plane.

5.3.2 WORKING PROCEDURE

The working of the Automated drill jig can be very simple and can be
explained easily as follows.

 The Workpiece can be fixed in the component locator and then the C-
washer can be used to hold tightly the workpiece. The tightness can be
adjusted by the Threaded screw.
 Before the drilling process gets start, the locator pin in the bush plate can
be used to fix the Component locator and can disable its movement
further after the workpiece gets fixed.
 After the Drilling operation initiated, the drill pit can be guided by the
drill bush provided in the bush plate to workout a proper drilling process
in a given workpiece.
 For drilling different points on the same workpiece, the screw can be
adjusted and the workpiece can be turned and fixed again for the desired
position.
 Finally, the most accurate Drilling process in the workpiece can be
successfully executed.

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5.4PRODUCTION (TIME TAKING)

Table 5.4 Time Table for Production

WORK PIECE / 1 HOUR 8HOUR 24HOUR

TIME
Before Jig Used 6 to 8 50 to 65 175 to 190
After Jig Used 15 to 18 125 to 146 380 to 430

Before Jig Used = One Piece Take Time 7 to 10 minutes

After Jig Used =One Piece Take Time 3.5 to 4 minutes

5.5 ADVANTAGES

The advantages of jigs can be given in the following:

 Production increase.
 Low variability in dimension, thereby leading to consistent quality of
manufactured products.
 Cost reduction.
 Ensures interchangeability and high accuracy of parts.
 Reduces the need for inspection and quality control Expenses.
 Reduces accident, as safety is improved.
 Semi-skilled machine operators can easily use them thereby saving the
cost of manpower.
 The machine tool can be automated to an appreciable extent.
 Complex and heavy components can be easily machined.
 Easy assembly operations saves labour, and also lead to reduction of
defective products.

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 They eliminate the need for measuring, marking out, punching,
positioning, alignments, and setting up for each work-piece thereby
reducing the cycle and set up time.
 Increases technological capacities of machine tools.
 The application of more than one tool simultaneously on a work-piece
can be achieved.
 Setting of higher values of some operating conditions like depth of cut,
speed, and rate of feed can be attained because of the increased clamping
capability of jigs.

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 CHAPTER 6
COST ESTIMATION
Table 6.1 Cost Estimation

S.NO COMPONENT SHIPPING MACHINING TOTAL

COST COST COST

1. Base plate 500 1300 1800

2. Vertical plate 500 2100 2600

3. Bush plate 50 1350 1400

4. Drill plate 30 400 430

5. Component locator 330 970 1300

6. Locator pin 65 170 235

7. C-Washer 120 320 440

8. Ball bearing 330 - 330

9. Worker cost 2500 - 2500

TOTAL 4425 6610 11035

(RUPEES ELEVEN THOUSAND THIRTY FIVE ONLY)

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 CHAPTER 7

CONCLUSION AND FUTURE SCOPE

7.1 CONCLUSION
These automated drill Jigs are manufacturing tools that are employed to
produce interchangeable and identical components. They are unique tool-
guiding and work holding devices designed specifically for machining and
assembling large number of parts. They eliminate the need for a special set-up
for every work-piece thereby facilitating production and also ensuring that
every work piece is manufactured within a predetermined tolerance.
The design of jigs is dependent on the operation type as well as the
machine tool to be used for the operation. They are fabricated with heat-treated
steel that are corrosion and wear resistant.
7.2 FUTURE SCOPE
 The design can be made more modular i.e. more PCD combination can be
done.
 Other than steel material, Plastics also used in fabricating the jigs.
 Instead of Acrylic Plastic and other material can be used.
 We can fix bush size and interchange the liner size according to the drill
size.

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 REFERENCES

1. Joshi, P. “Jigs and Fixtures” Tata McGraw Hill Education, New

Delhi, India.
2. Nanthakumar, K. and Prabakaran, V. “Design and Fabrication Testing
of Combined Multipurpose Jig and Fixture” IOSR Journal of
Mechanical and Civil Engineering(www.iosrjournals.org)
3. Lin, Q., Burdick, J., and Rimon, E “Constructing Minimum
Deflection Arrangements Using Invariant Norms” IEEE Transactions
on Automation Science and Engineering, Vol. 3, No. 3. Science
Research.
4. Blogspot “Introduction to Jigs and Fixtures” [Online]
engineeringhut.blogspot.com/jigs-andfixtures.html
5. Spogel “Mini project on Jigs and Fixtures” [Online]
http://files.spogel.com/miniprojectsin-mech/p-0027--Jigs-and-
Fixtures.pdf
6. Kaija, T. and Heino, P. “The Optimization of OnwaferShield-Based
Test Fixture Layout” IEEE Transactions on Microwave Theory and
Techniques, Vol. 54, No. 5.
7. Meduettaxila. “Jigs and Fixtures Module” [Online]
https://2k9meduettaxila.files.wordpress.com/2012/04/scanjigs-and-
fixtures.pdf
8. Mechnol. “Applications of Jigs and Fixtures” [Online]
http://www.mechnol.com/applications-of-jigs-andfixtures.html

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9. Pachbhai, S. and Raut, L. “A Review on Design of Fixtures”
International Journal of Engineering Research and General Science,
Vol. 2, Issue 2.
10.Chennu, V “Jigs and Fixtures and their Purposes”[Online]
http://www.memechanicalengineering.com/2015/02/jigs-and-
fixtures.html

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 PROJECT IMAGE

WITH WORK PIECE

WITH OUT WORK PIECE

40
 SIDE VIEW

TOP VIEW

41