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CHAPTER 1
INTRODUCTION

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1.0

INTRODUCTION

Some machining operation are so simple which are done quite easily, such as turning, the
job is held in position in the chuck and turning operation is done easily. No other device is
required to hold the job or to guide the tool on the machine in such an operation. But some
operations are such type in which the tool is required to be guided by means of another
device and also some jobs are of such forms which are required to be held in position on the
machine by means of another device. The device which guides the tool is called jig and the
device which holds the job in position is called fixture.
Jigs and fixtures are special purpose tool which are used to facilitate production (machining,
asslembling and inspection operations), when work piece is based on the concept of
interchangeability according to which every part will be produced within an established
tolerance. Jigs and fixtures provide on means of manufacturing interchangeable parts since
they establish a relation with predetermined to tolerance between the work and cutting tool.
So A jig is may be de-fined as a device which hold and position the work; locate or guides
the outing tool relative to the work piece and usually not fixed to the m/c table. It is usually
lightly in construction.
A fixture is a work holding device and position the work; but doesnt guide locate or position
the cutting tool the setting of the tool is done by machine adjustment and a setting blocker
using slip gauges. A fixture is hold or clamp-ed to the machine table. It is usually heavy in
construction.
Jigs are used on drilling , reaming , tapping and couter boring operations , while fixtures are
used in connection with turning , milling , grinding , shaping , planning and boring operations.
In this kind of mini project, the jig and fixtures that will be produce is related to mechanical
application by using bench drill machine. The bearing part that need to fit is quite difficult so
that this project will be created to design the suitable jigs and fixture for drilling the parts.

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1.1

JIGS

The most-common jigs are drill and boring jigs. These tools are fundamentally the same.
The difference lies in the size, type, and placement of the drill bushings. Boring jigs usually
have larger bushings. These bushings may also have internal oil grooves to keep the boring
bar lubricated. Often, boring jigs use more than one bushing to support the boring bar
throughout the machining cycle.

In the shop, drill jigs are the most-widely used form of jig. Drill jigs are used for drilling,
tapping, reaming, chamfering, counter boring, countersinking, and similar operations.
Occasionally, drill jigs are used to perform assembly work also. In these situations, the
bushings guide pins, dowels, or other assembly elements.
Jigs are further identified by their basic construction. The two common forms of jigs are open
and closed. Open jigs carry out operations on only one, or sometimes two, sides of a work
piece. Closed jigs, on the other hand, operate on two or more sides. The most-common
open jigs are template jigs, plate jigs, table jigs, sandwich jigs, and angle plate jigs. Typical
examples of closed jigs include box jigs, channel jigs, and leaf jigs. Other forms of jigs rely
more on the application of the tool than on their construction for their identity. These include
indexing jigs, trunnion jigs, and multi-station jigs.
Specialized industry applications have led to the development of specialized drill jigs. For
example, the need to drill precisely located rivet holes in aircraft fuselages and wings led to
the design of large jigs, with bushings and liners installed, contoured to the surface of the
aircraft. A portable air-feed drill with a bushing attached to its nose is inserted through the
liner in the jig and drilling is accomplished in each location.

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1.2

FIXTURES

A fixture is a device for locating, holding and supporting a workpiece during amanufacturing
operation. It is a production tool that locates, holds, and supports the work securely so the
required machining operations can be performed.
Fixtures have a much-wider scope of application than jigs. These workholders are designed
for applications where the cutting tools cannot be guided as easily as a drill. With fixtures, an
edge finder, center finder, or gage blocks position the cutter. Examples of the more-common
fixtures include milling fixtures, lathe fixtures, sawing fixtures, and grinding fixtures.
Moreover, a fixture can be used in almost any operation that requires a precise relationship
in the position of a tool to a workpiece.

Fixtures are most often identified by the machine tool where they are used. Examples
include mill fixtures or lathe fixtures. But the function of the fixture can also identify a fixture
type. So can the basic construction of the tool. Thus, although a tool can be called simply a
mill fixture, it could also be further defined as a straddle-milling, plate-type mill fixture.
Moreover, a lathe fixture could also be defined as a radius-turning, angle-plate lathe fixture.
The tool designer usually decides the specific identification of these tools.

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The following is a part list of production operations that use fixtures :

1.3

Assembling

Milling

Boring

Planning

Drilling

Welding

Forming

Turning

HOW DO JIGS AND FIXTURES DIFFERENT

JIGS

FIXTURE

1. It is a work holding device that holds, supports

1. It is a work holding device that holds,

and locates the workpiece and guides the cutting

supports and locates the workpiece for a

tool for a specific operation

specific operation but does not guide the

cutting too

2. Jigs are not clamped to the drill press table

2. Fixtures should be securely clamped

unless large diameters to be drilled and there is

to the table of the machine upon which

a necessity to move the jig to bring one each

the work is done.

bush directly under the drill

3. The jigs are special tools particularly in drilling,

3. Fixtures are specific tools used

reaming, tapping and boring operation.

particularly in milling machine, shapers

and slotting machine

4. Gauge blocks are not necessary.

4. Gauge blocks may be provided for

effective handling.

5. Lighter in construction.

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5. Heavier in construction.

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1.4

IMPORTANCE OF JIGS AND FIXTURES

The productivity is increased by the usage of jigs and fixtures in the production
process

High degree of accuracy is offered along with uniform quality in the interchangeability
at a modest cost.

There is no need for any skill in the work tool setting in an operation.

As the production rate is increased with a reduction in scrap that finally reduces the
unit cost.

The dimensional variability can be achieved easily with low manufacturing processes
that support consistent quality in the usage of jigs and fixtures.

The production life cycle is reduced.+

Quality examination is not required as the usage of jigs and fixtures are employed
with ensured quality of employment.

1.5

IMPORTANCE OF JIGS AND FIXTURES (bearing)

Reduce cost
Higher production, savings in labour cost results in ultimate reduction in unit cost.

Save Time
This product can reduce the production and manufacturing time because it can
complete four part in cycle production

Easy to use
Easy use and safe during machining operation

Safety
This kind of jig can improve work safety

1.6

OBJECTIVE OF PROJECT

To produce and design a drill jigs

To securely locate, position in a specific location or orientation and support the work

To create a simple but effective jig and fixtures that have capacity to perform the
function

To make all the product achieve the required dimension for all manufacturing

To create a productive jig that can be used to do a production.

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CHAPTER 2
METHODOLOGY

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2.1 FLOWCHART
A flowchart is a formalized graphic representation of a logic sequence, work or
manufacturing process, organization chart, or similar formalized structure. The purpose of a
flow chart is to provide people with a common language or reference point when dealing with
a project or process.Flowcharts use simple geometric symbols and arrows to define
relationships.

START
Mini project brief
Find group
member's

Planning

Sketching

Data Analysis

Design
Outcome

Final design

Technical report

Presentation

End

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Mini project brief
The starting of the mini project is started with a brief introduction about the importance of
Mini Project and presentation by lecturer.

Find group members

Find a group of member for mini project.

Planning
Planning stage is to focus more brief the idea of the project. Plan the concept idea of the
design for jigs and fixtures for mechanical application before started to sketch.

Sketching
Sketching part is the part after know the problem to be solved. The sketching of the project
must have criteria or elements that always a jigs and fixtures need such as clamping,
locator, tool guiding and setting element. Then, develop the concept idea to the purpose
concept.

Data Analysis
Data analysis is to analysis what kind of product that want to use. The process of evaluating
data using analytical and logical reasoning to examine each component of the data
provided. Data from various sources is gathered, reviewed, and then analyzed to form some
sort of finding or conclusion. There are a variety of specific data analysis method, some of
which include data mining, text analytics, business intelligence, and data visualizations.

Design Outcome
Design that had been choose.

Final Design
Final design which is from design outcome that had been choose

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Technical Report
A report that records the procedure adopted and results obtained from a scientific or
technical activity or investigation.A report that include drawing details, objective of the
product and many more.
Presentation
Present our complete product.

2.2

GANT CHART

A Gantt chart, commonly used in project management, is one of the most popular and useful
ways of showing activities (tasks or events) displayed against time. On the left of the chart is
a list of the activities and along the top is a suitable time scale. Each activity is represented
by a bar; the position and length of the bar reflects the start date, duration and end date of
the activity.

Task/Time
27th April28th April29th April30th April1th May 2th May 3th May 4th May 5th May 6th May 7th May 8th May 9th May 10th May11th May
Mini project brief
Find group member's
Planning
Skecthing
Data Analysis
Design Outcome in solidworks
Final Design
Technical Report
Presentation

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2.3

DESIGN CONCEPT AND COSIDERATION

CONCEPT
Safety

CONSIDERATION

This kind of jigs can improve work

safety

Ensure the tool body rigid enough to

resist all cutting forces.

Strong

This jigs strong enough to withstand

all forces applied to it.

Tool guiding

Bushes are provide on jigs for guide

the cutting tools.

Easily loading and unloading

The layout of the jig must provide

adequate hand clearance for easily
loading and unloading and process
for loading and unloading must be
quick

Provide coolant

To increase tool life and keep the

components

cool,

coolant

is

provided in cutting edge in sufficient

quantity.
Resist deflections

It must also resist deflections that

may be the result of excessive
tightening of clamps that hold the
workpiece in place.

Bushes

Bushes are provided on a jig for

guding drills, reamers and borings,
for the desired positioning.

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CHAPTER 3
DRAWING

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3.1

INTRO DESIGN

Drill Bushing
Drill bushing is a tool guiding. Its isto guide cutting tools. Drill Bushes, or Jig Bushes are
primarily for positioning and stabilizing a drill in a jig to ensure repeated precision positioning
in a work piece.
Clamping
A clamp is to hold objects tightly together to prevent movement or separation through the
application of inward pressure.
Handle
Handle is use to hold the clamping part. It is to make sure that the clamping part is easy to
use.
Base
Base is a part of the product where it is to put the material and supporting surface.
Locator
To perform properly, workholders must accurately and consistently position the workpiece
relative to the cutting tool, part after part. To accomplish this, the locators must ensure that
the workpiece is properly referenced and the process is repeatable.
Holder
Holder is use to hold the product so that the product are easy to use and easy to handle.

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3.2

DESIGN DETAIL

3.2.1 Sketching

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3.2.2

Detail Drawing

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3.2.3 Bill of Material

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CHAPTER 4
DISCUSSION
AND
CONCLUSION

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4.1

DISCUSSION

4.1.1

Important elements of Jig or Fixtures Design

1. The successful running of any mass production depends upon the interchangeability
to facilitate easy assembly and reduction of unit cost. Mass production methods
demand a fast and easy method of positioning work for accurate operations on it.
Jigs and fixtures are production tools used to accurately manufacture duplicate and
interchangeable parts. To fulfill their basic purpose, jigs and fixtures are comprised of
several elements.

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Clamping

Tool guide

Locator

Base

Body

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4.1.2

Economic
Jigs and fixtures are special purpose tool which are used to facilitate production.
Before this, drilling process by using bench drill machine will take 2 minutes per part
to be done. But now, the implement of jigs and fixtures would be able to produce 4
parts in 1 cycle of production that takes just 1 minutes.
1. Have a machining who earns RM10 per hour, drill the bearing base at a rate of
60 part per hour.
2. Use drill jigs that costs RM200 in the production deparment.

COMPARATION WORK SHEET

Economic &
Productivity factor

Alternative
1

1000

1000

Tool cost

200

Parts per hour

30

240

Labor/hour

Labor/lot

266.7

33.3

Cost per part

0.27

0.23

Lot size

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Alternative 1

L=

XW

1000

30

x8

= 266.7

CP =

0+266.7
1000

= 0.27

Alternative 2

L =

xW

1000
240

x8

= 33.3

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CP =

200+33.3
1000

= 0.23

Total Savings

TS = LS x (Cp1 Cp2)
= 1000 x (RM 0.27 RM 0.23)
= RM 40

From this calculation, it prove that by using Drill jig is more economic.

4.1.3

User (friendly and safe)

Easy to use and improve work safety

4.1.4

The specialty of the design

1. The jigs was created to the process of mechanical.

2. We create a product that can complete four part in cycle production.
3. A product that has a hole at the clamping, so it would be easy to remove chip.
4. Using xyz movement on bench drill machine because of the drilling part is heavy.
5. Provide with a holder to move easily.
6. Locating on the jigs can be exchange.
7. Easily to unload and load

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4.1.5

The principle (how it works)

Attach Drill Jig on the Bench Drill machine. Use existed holder from the Drill Jig for easier
lifting and move the Drill jig.

Place the workpiece that you want to drill on locating device. Drill jig is designed to complete
the process for 4 part in one cycle. Then, use the clamp to secure the workpiece.

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Start the drilling process. Use screw handle to easily move the Drill Jigs on the x-axis and zaxis for the drilling process.

Unclamp the workpiece when all the drilling process complete. Move the workpiece from the
locating device.

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Before start the new process, clean the Drill jig from chips using air gun. The chip will fall
through the holes specifically designed to ease the process of cleaning.

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4.1.6

Materials generally used

1. Mild steel (Locating)

Mild steel is the most common form of steel as its price is relatively low while it
provides material properties that are acceptable for many applications. Low carbon
steel contains approximately 0.050.15% carbon and mild steel contains 0.160.29%
carbon therefore it is neither brittle nor ductile.
2. Stainless steel (Bushing)
Stainless steels are iron alloys with a minimum of 10.5% chromium. Other alloying
elements are added to enhance their structure and properties such as formability,
strength and cryogenic toughness

3. Steel (Tool body,base)

Steel is an alloy of iron and other elements, primarily carbon, widely used in
construction and other applications because of its high tensile strength and low cost.

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4.2

CONCLUSION

Jigs and fixtures 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.
There are numerous advantages that are associated with the use of jigs and fixtures, they
include: production increase, low variability in dimension thereby leading to consistent quality
of manufactured products, manufacturing cost reduction, 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.
Other benefits are: the machine tool can be automated to an appreciable extent, complex
and heavy components can be easily machined, easy assembly operations save labour,
reduction of defective products, elimination of the need for measuring, marking out,
punching, positioning, alignments, and setting up for each work-piece thereby reducing the
cycle and set up time, increase technological capacities of machine tools, 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 and fixtures.
As the conclusion, this project must achieve all the objectives above. From this project, the
design of the jig and fixtures of this mechanical application can rigid and stable for support
product during machining operation. This kind of jig and fixtures, can make all product
achieve the required dimension for all manufacturing process because of the accuracy and
economical of the jigs for this welding application. Also can achieve less reject project and
low cost of manufacturing because no rejection during mass production

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