A

PROJECT REPORT ON
“Designing of Jig for Vertical Broaching Machine”
Submitted to

Shri Guru Gobind Singhji Institute of Engineering and Technology,

Vishnupuri, Nanded.

In partial fulfilment for the award of the Degree of

BACHELOR OF TECHNOLOGY
IN
PRODUCTION ENGINEERING

Submitted by

Chaitanya Bante (2015BPR025)

Rajan Wani (2015BPR027)
Omkar Daiwalkar (2015BPR021)

Under the guidance of

Dr. M. K. Rodge
Head of Department
Department of Mechanical Engineering

DEPARTMENT OF PRODUCTION ENGINEERING

SGGS INSTITUTE OF ENGINEERING AND
TECHNOLOGY, NANDED, INDIA 431606
Academic year 2018-19

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 ACKNOWLEDGEMENT

We take this opportunity to remember and acknowledge

the co-operation, goodwill and support both moral and
technical extended by several individuals out of which this
technical project has evolved. We shall always cherish our
association with them. We are greatly thankful to Mr.
Vishram Jamdar, CEO, Kinetic Gears LTD.for extending his
help and encouragement.

We are greatly thankful to Mr. Vilas Mohurle, Head of

Quality Department, Kinetic Gears LTD. We have immense
pleasure in expressing our thanks and deep sense of gratitude
for their guidance and assistance.

We would like to express our gratitude towards our

project guide Dr. M. K. Rodge and Dr. L. N. Wankhede,
Head of the Department, Production Engineering, SGGSIE&T,
Nanded for their valuable guidance, suggestions and co-
operation.We are very much thankful to Prof. Dr. Y. V. Joshi,
Director for providing all the facilities necessary to carry out
the project. Last but not the least; we are thankful to all our
friends who have been contributed through advice and timely
support in the improvement of this dissertation work.

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 DECLARATION

We hereby declare that this submission is our own work and that,
to the best of our knowledge and belief, it contains no material previously
published or written by another person nor material which has been
accepted for the award of any other degree or diploma of the university or
other institute of higher learning, except where due acknowledgement has
been made in the text.

The information and data given in the report is authentic to the best
of our knowledge.

Chaitanya Bante (2015BPR025)

Rajan Wani (2015BPR027)
Omkar Daiwalkar (2015BPR021)

Date: / /2019

Place : Nanded

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 CERTIFICATE

This is to certify that the Project Report entitled:

Designing of Jig for Vertical Broaching Machine

Submitted by
Chaitanya Bante (2015BPR025)
Rajan Wani (2015BPR027)
Omkar Daiwalkar (2015BPR021)

to the SGGS Institute of Engineering & Technology towards partial

fulfilment of the requirements for the award of the degree of Bachelor of
Technology in Production Engineering is a bonafide record of the work
carried out by them under our supervision and guidance.

Date: / /2019

Place : Nanded

Dr. M.K.Rodge Dr.B.M.Dahade Dr. L. N. Wankhade

(Project Guide) (Project Coordinator) ( Head of the Department)

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 ABSTRACT

This report is about designing of a jig for a vertical broaching machine on which slotting operation is
carried out on spline bush in Kinetic gears, Nagpur. 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. Currently in the industry the jig used on the machine has a reference pin on
it. The spline bush is first marked by an operator according to the desired angle needed and this marked
spline bush is made coincident with the reference pin which is there on the machine.
Our project is to eliminate the marking process by designing a suitable jig. The suitable jig has a female
counter part on it which coincides with the missing tooth of spline bush and thus eliminating the marking
process. By introducing the new jig ,the marking process has been eliminated and also accurate angles are
obtained. This will increase productivity, reduce cycle time and decrease the labor cost.. Focusing upon
reliable and durable manufacturing process we have discussed several models and their features.

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 INDEX

Chapter 1 Introduction
1.1 About Kinetic Gears
1.2 Employee pyramid
1.3 Mission & Vision
1.4 Quality Policy
1.5 Products
Chapter 2 Literature Review
2.1 Current status of problem in company
Chapter 3 Objectives
Chapter 4 Data collection
3.1 Need for time study
3.2 Time study
Chapter 5 Methodology
5.1 Effective parameters of jig
5.2 Present scenario
5.3 Proposed design 1
5.4 Proposed design 2
5.5 Proposed design 3
5.6 Proposed design 4
Chapter 6 Results
Chapter 7 Conclusions and suggestions for further work
Chapter 8 References

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 CHAPTER 1
INTRODUCTION

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 1.1 About Kinetic Gears

Established in 1980 as SSI Unit, Kinetic Gears is a ISO 9001:2000

certified organisation since 1999 & at present it’s a family owned
business. The unit is an approved supplier in Automobile, Textiles, Coal,
Steel, Power, Defence and Aviation Sector.
With inception in Nagpur at Maharashtra, India in 1980, they have been
successful in establishing themselves as the leading manufacturers and
suppliers in the industry. Company specializes in manufacturing all kinds
of Heavy Duty Industrial Gears, Gear Boxes and Gear Cutting Tools.
The robust manufacturing unit is spread in a sprawling area which has a
large production capacity. Moreover, they have been successful in meeting
the bulk and urgent requirements of their customers. The research and
development unit with their continuous research help to offer innovative
range of products to customers. Also, the innovation and quality offered in
products have helped to remain ahead of competitors in the industry.
Company employs a stringent quality control policy at each and every step
of manufacturing process. Ensuring the products are quality tested on
various parameters like corrosion resistance, durability, high performance,
raw material employed and dimensional accuracy. Under the well
experienced guidance of mentor, Mr. Vishram Jamdar, they have been
successful in attaining heights of success in the industry. As a client
centric organization, they offer user friendly payment options, employ
transparency and ethical business policies at every step of business.

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1.2 Employee pyramid

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1.3 Mission & Vision

Mission

”To adequately empower individual workers, supervisors and staff to

significantly increase his/her performance capabilities in order to achieve
the desired goal through mutual understanding and cantered leadership“

Vision

”To produce and supply defect free Gears, Gearboxes and Machined
Components at the most competitive prices as and when required by our
values customers.“

1.4 Quality Policy

“To fully satisfy the customer by supplying him the required components
and services related to machining of the components in general & Auto
Gear Transmission in particular, by conforming to agreed specifications of
the respective customer at all times, so as to suit the mutual interest of
supplier, organisation and the customer.”

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 Products:

1. Helical Gear

Features
 Great quality
 Rust proof
 Very robust
 Long lasting

2. Worm Gear

Features
 Excellent strength
 Supreme functionality and efficiency
 Economical

3. Bevel Gear

Features
 Best quality
 Very reliable
 Excellent functionality
 Long lasting

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Products Image

G S Finger

Speedo Worm

Selector Arm

Leaver

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Trigger Wheel

Shift Finger

CAM

Slow Group sub

Assly

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Clutch Plate

O D Selector

Selector Plate

Detend Plunger

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Pluse Disk

Screwed Bush

Tehno Pinion

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Big Bearing Plate

C M Gear

Fan Shaft

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Big Washer

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 CHAPTER 2

LITERATURE REVIEW

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Broaching Machine

The broaching process may be used to generate irregular internal and

external part features, and therefore has many potential industrial
applications. Slotting, spline cutting, and production of internal helical
gears are the major applications in which the broaching process has been
used. One of the advantages of broaching over other competitive processes
is its higher productivity. However, since the material removal rates are
relatively high for broaching, the cutting forces are also high. As a result
there will be large deflection which gives rise to high surface errors.
Therefore, careful attention must be directed towards the design of the
broach geometry and the selection of process conditions

Broach teeth usually are divided into three separate sections along the
length of the tool. These include roughing teeth, semi finishing teeth, and
finishing teeth. The first roughing tooth is proportionately the smallest
tooth on the tool. The subsequent teeth progressively increase in size up to
and including the first finishing tooth. The difference in height between
each tooth, or tooth rise, usually is greater along the roughing section, less
along the semi finishing section. All finishing teeth of a broach are almost
the same size with microns difference.

Historically, broaches have been designed based on experience or through

trial and error. As more emphasis is placed on part accuracy and precision,
it becomes less likely that satisfactory broach geometry can be designed
based on experience. Additionally, as manufacturers struggle to reduce
costs and non-productive time, it becomes clear that trial and error
approaches to tooling design will not be satisfactory. To design a broach
early in the life cycle of a product, a model for how a broach will perform
during the operation would be extremely advantageous, for a given raw
part and broach geometries. The mechanistic modelling of cutting forces
in broaching process is important for the design of broach tool.

Maximum force on an internal pull broach is a function of minimum cross

section of the tool and yield point of tool material. The allowable pulling
force used to be determined empirically in earlier days. Russian scientists
have given empirical relation to determine the maximum allowable
broaching force in broach tool which can withstand without damage. They
specified a broaching constant whose value is a function of work piece
material. The cutting force is dependent on width of cut, depth, or rise per
tooth, and so forth. Many mechanistic models for systems in machining
are described in the literature; these models are however used in turning
and boring operation. Models have been developed for multipoint tool
process such as end milling and face milling .

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Types of broaching machines:

● Horizontal Broaching Machine ● Vertical Broaching Machine

Horizontal Broaching Machine:- Mostly all the horizontal broaching

machines are pull type, surface broaching, continuous broaching, and
rotary broaching. Both internal and external broaching can be done.
Consists of a box type
bed having length is
twice the length of
stroke. All modern
machines are provided
with hydraulic drive
housed in the bed. Job
located in the adapter
which is fitted on front
vertical face. Small end
is connected to hole of
the job, and then
connected to pulling end
which is mounted on
front end of ram. Ram is
connected to hydraulic
drive. Rear end is
supported by guide. Pull
style machines are basically vertical machines laid on the side with a
longer stroke. Surface style machines hold the broach stationary while the
work pieces are clamped into fixtures that are mounted on a conveyor
system. Continuous style machines are similar to the surface style
machines except adapted for internal broaching. Horizontal machines used
to be much more common than vertical machines; however, today they
represent just 10% of all broaching machines purchased. Vertical
machines are more popular because they take up less space. Broaching is
often impossible without the specific broaching or keyway machines
unless you have a system that can be used in conjunction with a modern
machining centre or driven tooling lathe; these extra bits of equipment
open up the possibility of producing keyways, splines and torx through
one-hit machining.

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Jigs & Fixtures.

The traditional jigs and fixtures proved helpful in increasing the

production units per unit time, saving the time consumed in the process.
The thorough study of the entire process, it was found that all the above
mentioned parameters can further be improved with the help of improved
jigs and fixtures. Both the jigs and the fixtures are used to reduce the non-
productive time of any mass production process. The jig is used for
guiding the cutting tool (like a drill bit), and for doing so, jigs have
components like a bush, which comes in contact with the cutting tool. On
the other hand, a fixture never comes in direct contact with the cutting
tool. Fixtures assure the position and alignment of the work pieces for
getting the required machining operation done

Spline bush

Splines are ridges or teeth on a drive shaft that mesh with grooves in a
mating piece and transfer torque to it, maintaining the angular
correspondence between them. Kinetic Gears LTD is a leading
manufacturer of spline bush for various customers in that region. Due to
high demand of these components in industry attaining very economical
and effective production rate is a real challenge. Spline bush have teeth
profiles on outer diameter and a groove (keyway) on inner diameter. On
outer diameter there is a missing tooth. The angle between missing tooth
on outer diameter and groove on inner diameter is very crucial. It must be
accurate to ±15 minutes of tolerances which require precise machining.
Kinetic Gears use vertical broaching machine to make the groove. To get
exact angle, current system use marking and reference pin in jig which is
time consuming.

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2.1 Current status of problem in the company
 Slot in the spline bush is done on vertical broaching machine.
There are various types of spline bush with various angles between
missing tooth and slot to get that angle reference pin is used.
 Before loading the job on machine marking process is carried out
in which the marking is done at different number of tooth so to get
perfect angle (to get 56⁰13’ the marking is done between 13th and
14th teeth.)
 Operator mounts the job such that marking and reference pin
coincides.
 After that the broaching operation is carried out and we get desired
slot.
 Marking need to be done in lot of 100 jobs and hence the operator
remains ideal for same time.
 Also this creates a bottle neck in process.
 Marking is done manually with marker and scale so there are
chances of mistake.
 These human errors can cost significant revenue to the company.

Our focus is on eliminating the marking process. This will eliminate

human factor and the time required for marking will be saved.

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 CHAPTER 3

OBJECTIVES

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 The purpose of this step is to clearly articulate the business
problem, goal, potential resources, project scope and high-level project
timeline. Daily production of spline bushes may hit upto 600 numbers
depending upon the customer demand. Usually it varies in between 500 to
600 numbers. In order to fulfil current requirement two operators are
working together in a shift of 8 hours. One operator bring tray of 100
bushes from shaping section on equal intervals of time, checks them for
dimensional tolerances and the second one does the broaching. Main
functions of overall operation includes following:
 Take tray of 100 jobs from shaping section
 Inspection of every job and marking
 Broaching operation
 Cleaning and deburring of spline bush

When the operator mounts the job on broach, he makes sure that the mark
is coincident with reference pin. Reference pin is different for different
types of spline bushes. The perfection of job mounting solely depends on
operator concentration and there are chances that reference pin and mark
are not coincident. In such case the broach do not have any counter
mechanism to check whether the job is fixed properly or not. This may
result in wastage of job as it will create keyway at wrong angle.
Studying various possibilities and need of improvement we decided
following objectives:

1. To minimize the possibility of human error, this may take place while
mounting the job on jig due to operator mistake.

2. To eliminate the marking step which consume about 24.70% of time as

compared to actual broaching operation.

3. To eliminate the bottleneck in cycle. This is caused by storing 100 jobs

for marking in a tray waiting to be machined.

4. To improve production rate.

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5. To improve manpower utilization as current system requires two
operators, we are trying to bring it on one operator.

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 CHAPTER 4

DATA COLLECTION

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 3.1 Need for time study

To reduce the cycle time for the production of spline bushes on Vertical
Broaching Machine, we need to study the process from its beginning.
Steps involved and time required for particular operations is discussed
below:

1. After machining outer and inner diameters spline bushes

are sent to shaping section where teeth profiles are
generated. After shaping 100 bushes are carried in a tray to
broaching shop.
2. As soon as the tray of 100 bushes arrives one operator take
scale marker and a go-nogo gauge to check dimensional
tolerances and mark at particular teeth location.
3. As discussed earlier company produces 6 types of spline
bushes and they are different from each other with respect
to the angle between the missing teeth on outer diameter
and slot (keyway) on inner diameter.
4. In below illustration angle between the missing tooth and
keyway is 15⁰.

Work table

Mark

Fixed Indicator pin

Spline bush body

Broach

Missing teeth on
external body

15⁰

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 5. We are concerned with the time spent in completing
marking and inspection of 100 bushes. So we carried out
time study.

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 3.2 Time study

Operation Marking

Sr Sample Size Total Time required Time for one Average time for one
No. (sec) job (sec) job(sec)

1 50 312 6.24
2 50 315 6.3 6.24
3 50 310 6.2

Operation Broaching

Sr Sample Size Total Time required Time for one Average time for one
No. (sec) job (sec) job(sec)

1 25 630 25.2
2 25 650 26 25.26
3 25 615 24.6

As it is very clear from above observation that marking of jobs takes much
time and it is about 24.70% if compared to time taken by actual broaching.

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 CHAPTER 5

METHODOLOGY

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 The purpose of this step is to objectively establish current baselines as the
basis for improvement. This is a data collection step, the purpose of which is to
establish process performance baselines.

In Methodology, we are going to discuss the various methods adapted to

achieve our objectives which we have discussed earlier.

The main objective is to eliminate the marking process.

We have overcome this by using a suitable jig which is directly mounted

on the broaching machine.

5.1 Effective Parameter of jig

1. Must hold the job tightly
2. Also guide the tool to get the slot on desired position
3. Also provide repeatability
4. Must give accurate slots
5. Restrict degree of freedom of jobs
6. Must be easy to mount on machine
7. Easy to use for operator
8. Easy to adapt, no need for special training
9. Must be fool proof
10. Reduction of idle time
11. Less weight
12. Must be safe to use

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 5.2 Present scenario:

Spline Bush FIP Broaching (Different types of jobs differing in angles)

Sr. No. Part NO Model Angle ‘X’ Mark (No of teeth

±15’ from missing teeth)
1 X1600315 HA6DT2D 16⁰39’ 4th clockwise

2 X1600415 HA6DTI2N 12⁰6’ 12th anticlockwise

HA6DTI2U
3 X1600515 HA4CTI2U 54⁰54’ 12th anticlockwise

4 X1600815 HA4CTI3N 65⁰24’ 6th clockwise

5 FS200119 H4E3N95 19⁰ 17th anticlockwise
6 FS200711 AL4CTIDG1 68⁰38’ 4th clockwise
AL4CTIDG2
AL4CTIDG3

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5.3 Proposed design 1:

This is the 1st proposed jig which we designed for the broaching machine

This jig consists of two major parts:

1.Main body – Main body is the part on which the spline bush will be mounted
.main body holds the job for broaching process to be carried out.

2.Female counter part – Female counter part consists of the reference pin and has
got a slot in which the missing tooth of the spline bush will be made to coincident.
This mechanism helps to inspect and also helps to hold the job.

The female counter part can slide over the arc so that for different angles we have
can adjust the female part.

Limitations:
1. The horizontal jig pin can give error in our desired angle which has to be
produced.

2. There are chances of slippage of job.

3. It will initially hold the job firmly but as soon as the broach slides downward,
forces in job will not be balanced by single pin feature.

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5.4 Proposed design 2:

This is the 2nd proposed design of jig.

In this design, we have fixed a ring around the main body on which the female
counter part will revolve.

The female counter part is attached with the ring using two rods and springs
arrangement. Springs are necessary because some tolerance has to be maintained
between our job and counter part so that it doesn’t get stuck between main body
and counter part.

According to the desired angle of job, the position of the female counter part will
vary. For this purpose a screw has been provided to fix the counter part at that
position.

Limitations:
1.This design acquires more space on the broaching machine and it obstructs the
coolant pipes.

2.Since, springs aren’t durable for industrial purpose.

3.The friction between the ring and female counter part attachment could be
affected by the chips which are formed during broaching operation. This may
dislocate the attachment from the ring.

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5.5 Proposed design: 3

This is the 3rd proposed design of jig.

In this design we have directly mounted the female counter part to our main body.

The counter part is attached to main body by using two pins (diamond pin,
cylindrical pin). According to the 6 different angles there are 12 holes on the base
plate.

The jig is fixed to the main body according to the angle which we have to produce
on our job. The jig has to be removed and then attached to the main body
according to the angle which we have to get on our job.

This jig also acts as a go-no go gauge which is a part of inspection process.

Therefore, this jig is eliminating marking process and also doing the inspection.

Limitations
1. There is an area on the front side of main body on which this jig
cannot be mounted and there certain angles (12.1⁰, 16.65⁰, 19⁰)
where the jig has to be fixed on the front side which is difficult..
2. There are chances that the job might get struck between the main
body and female counter part.

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5.6 Proposed design 4

Main assembly of jig

Main assembly from different angle

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 Main body

Support for female counter part

Female counter part

This is the 4th proposed design of jig.

In this design, we have used quarter section of the female counter
part.
Because of this a lot of space is saved and there is no obstruction
between the coolant pipes and our jig.
This design gives accurate angles compared to the first three
design.
Also, the female counter part slides on the quarter section and all
the desired angles can be generated by keeping the female counter
part over this quarter section.

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 Therefore, the quarter section is the fixed part of the jig and the
female counter part is the movable part of our jig.
Horizontal tapered pins are used to fix the female counter part in
the counter section.

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 CHAPTER 6

RESULTS

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After thorough discussion with industry officials we have concluded that proposed
design no. 4 is more rigid, durable and mistake proof. Moreover it has added
advantage of easy dismantling and assembly for different types of spline bushes
which are manufactured in the company.

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 CHAPTER 7

CONCLUSIONS AND SUGGESTIONS FOR

FURTHER WORK

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7.1 Conlusions:

 The proposed jig design avoid misfit of job and thus human error are
eliminated. As in new jig design job needs to be fitted with reference to
missing teeth on outer diameter.
 There is no need to mark on spline bush and hence time required for
marking is saved.
 Since the marking is eliminated there won’t be any need of the second
operator (who marked the job) and hence saving man power.
 Also, there wouldn’t be any bottleneck in the system as the machined
spline bushes will be directly loaded on the broaching machine.
 Because of these things the productivity of the industry will increase
which in turn will increase the profit of the industry.
 By eliminating marking, we are saving 6.24 sec behind each job.
 Therefore, we are saving 4056secs behind 600 jobs which is approx.
1.12hrs

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 7.2 Suggestions

Besides working present system which is used in manufacturing of

spline bushes and particularly on broaching shop, we tried to
improve the jig and add value to the product. It is seen that saving
of time and manpower will ultimately increase the revenue of
company as it may produce more jobs in the same amount of time
and number of operators.

Above work was focused upon eliminating marking step and

saving time and manpower required for the same. While studying
the manufacturing process we came to know that cleaning of
broach tool is necessary after each single operation. This
consumes significant amount of time. Further work could be done
on mechanising the cleaning process of broach tool. Also coolant
is now continuously flowing over jig to lubricate the job. Coolant
continues to flow even if there is not any job on jig. Operator
sometime turns of the coolant manually. This causes loss of
coolant oil as well as energy. There is scope to automate coolant
mechanism.

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 REFERENCES

 www.kineticgears.com
 https://en.wikipedia.org/wiki/Broaching_(metalworking)
 Introduction to Jig and Tool Design: Kempster M. H. A. English language book
society.
 Jigs and Fixtures by Joshi P. H., Tata McGraw Hill, New Delhi
 Production Technology by HMT, TMH publications
 Production Science: Pandya and Singh, Standard Publications
 Metal cutting theory and cutting tool design: V. Arshinov, G. Alekseev:
Mir Publishers,Moscow.
 Properties and Selection of Tool materials, V. A. Kortesoja, ASM
publications, Ohio (1975)

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