Addis Ababa Institute of Technology

School of Mechanical and Industrial Engineering

Tool & Die Design in Manufacturing MIEG 6462

Chapter - 5

Design of Drilling Jig

By: Mesfin G. Aprill.2023
 Outline

 Introduction
Types of Drilling Jigs
General considerations of in the design of drilling jigs
Drilling bushings
Methods of construction
Drilling jigs & modern manufacturing

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 1. Introduction
A jig is A device that holds the work and locates the path of the tool and
also guides the cutting tool during machining
locates a work piece, guides and controls one or more cutting
tools.
provided with tool guiding elements such as drill bushes
rarely clamped on the machine table because it is necessary to
move the jig on the table to align the various bushes in the jig
with the machine spindle.
Drill Jigs
Drill jig is device to ensure a hole to be drilled, tapped or
reamed in the workpiece at proper place.
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 Cont’d…

Provide methods for

Correctly locate the workpiece with respect to the tool

Securely clamp and rigidly support the workpiece during

the Operation

Guide the tool – Position and/or fasten the jig on a machine

Advantages
Minimize tool breakage

Minimize the possibility of human error

Permit the use of less skilled labor

Reduce manufacturing time

Eliminate retooling for repeat orders

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 Cont’d…

Elements of Jig -consists of locating element, clamping

element and tool guiding or setting element. (Jig feet • Jig
bushing • Jig plate or bush)
Locating Elements- Locating elements position the
workpiece accurately with respect to tool guiding elements in
the jig.
Tool Guiding Elements -help in guiding the tools in
correct position with respect to the workpiece. Drill bushes
guide the drills accurately to the workpiece.

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 Drill jig components

Jig body
Holds the various parts of a jig assembly.
Cap screws and dowel pins
Hold fabricated parts together

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 Drill jig components

Locating devices
Pins, pads, and recesses used to locate the workpiece
on the jig.

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 Drill jig components
Clamping devices

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 Drill jig components

Locking pins

Inserted to lock or
hold the work piece
securely to the jig plate
while subsequent holes
are being drilled.

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 Types of Drilling Jigs

To position and guide the cutting tool for cutting. It may be

divided in to two
Open jig- used when the operation is to be performed only on
one side of the workpiece
Closed (Box) jig- used when the operations are to be
performed on more than one side.
Jigs are identified according to the way they are built. Most
commonly used jigs are-
Template jigs ,Plate jigs , Table jigs, Leaf jigs, Indexing jig,
Channel and tumble jigs and Miscellaneous jigs

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 Open and closed types of drill jigs

It consists of a plate with holes to guide the

drills, and may have locating pins that locate
the workpiece on the jig
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 Cont’d…
Template jigs
No clamping arrangement
Plates with or with out bushing to guide the tool
No bushes then the whole jig plate may be hardened
Directly placed on the part
Simple
Least expensive

Disadvantages
Not as foolproof as other types
Orientation of the hole pattern to w/p datums may not be as
accurate as other types
They are usually not practical when locating datums are
dimensioned
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 Nesting Template Drill Jigs

Jig body is designed to perform the

same operation by using five
dowel pins press-fitted into the jig
in lieu of the cavity to locate the
workpiece,
Template jigs –suitable for large
workpiece

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 Plate Jig

open type, slip bushing

with liner bushing-allows
more than one operation
For thin workpieces

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 Cont’d…

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 Table jig

A plate jig with

legs are called a
table jig. These
are used for
large work
piece

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 Cont’d…
turnover (or open) jig
used when the foregoing types are
unsuitable because of the
workpiece shape
seated on the four foot-nuts when
locating and clamping the
workpiece, and inverted to the
position
type is easy to load, and swarf
clearance

Disadvantage. -the lack of support given to the

AAiT
workpiece beneath the point of cutting
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 Sandwich jigs
A form of plate
jig with back
plate. This type
of jig is ideal
for thin or soft
parts which
could bend or
warp if any
other type of jig

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 Angle plate jigs
These jigs are used to hold work which are to be drilled at
right angles to their mounting locators
Pulleys and Gears use this type of jig

Modified angle plate jigs are

used for to drill at angles
other than 90˚
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 Box jig
This type of jig allow the part to be completely machined
on every surface without repositioning the part in the jig
Such a jig should be as light as possible. Why?

Such jigs are generally used

for components having
irregular shapes or that
cannot be held by common
methods.

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 Channel and tumble Jigs
They are the simplest form of box jigs. The work piece is
held between two sides and machined from the third.
component is fitted within the channel is located and
clamped by locating the knob. Limited to simple or
symmetrical shape w.p.
For drilling in more than one surface
Complicated and expensive

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 Leaf jigs
open type jig
These are small box jigs
with a hinged leaf.
the top plate is arrange to
swing about a fulcrum
point , so that it is
completely clears Easy
loading and unloading is
possible in theses jigs.
Usually equipped with
handle for easier movement
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 Equipped with a handle for easy movement
It consist of drill bush, hinge pin, set screw leaf
Chips may accumulate inside and cause trouble

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 Cont’d…

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 Tumble –box jigs

Tumble-box jigs permit drilling and similar operations from

all six sides. They are commercially available in a variety of
sizes
Box-jig with bushing on two or more sides for purpose of
drilling –tumble jig

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 Cont’d
The example illustrated was designed to drill 4 holes equi-
spaced around the tapered hub of a hand-wheel at right
angles to the hub diameter

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 Indexing jigs
Indexing jigs are used to accurately space holes on other
machined area around a part or at stated angular
positions.
The jig uses the part itself as a reference plate and plunger.
To drill holes in a pattern and uses single bushing

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 Figure 5-14. Indexing jig of welded construction.
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 PUMP or UNIVERSAL JIGS

The guide pillars attached to the jig plate have rack gear
teeth on one side.
Purpose of gear meshing by rotating the handle is to raise
or lower the rack pillar with the jig plate.
Pump jigs are suitable for drilling only a single hole on a
fixed spindle drilling machine.
One pump can be used for number of workpieces by
providing detachable jig plate and base plate for different
workpieces..
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 Pump Jig

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 General Considerations in the design of
Drilling Jigs
Rigidity:
must be strong enough to withstand all forces applied to it
must also resist deflections that may be the result of excessive
tightening of clamps that hold the w.p in place
The work must also be supported so that it does not bend under
drilling pressure
Cast iron is generally used because it absorb shocks and
compressive forces
The layout must provide adequate hand clearance for easily
loading and unloading and process for loading and unloading must be
quick
Errors arise in components due to wear, dirt, chips burns and
AAiT wear resistance surfaces should
School of beandsmall
Mechanical and
Industrial easily -replaceable.
Engineering SMiE
 Cont’d…

To increase tool life and keep the components cool, a coolant is

provided in cutting edge in sufficient quantity.
Design considerations require easy ejection of the component
from jig (particularly for heavy ones) to save the operation time and
increase the productivity, pneumatic devices are very suitable for
easy and quick ejection
Chip Control:
Space between the work and bottom of drill bushings to allow
chips to pass b/w the work and busing plate (1-0.5*dia. of drill)
Three ways of chip removal: coolant, manually with brush or
hook, compressed air

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 no corner relief
Cont’d…

Method of providing
corner relief

Button locator

Blocks locator

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 Cont’d…

Jig feet and legs:

A drill jig should stand on four feet (Or legs) rather than a
flat surface
Jig feet may be built into the jig body or purchased as
standard parts
They are usually placed on the extremities of the jig
Feet should be ground so that they are all in one plane
after they are mounted on the jig base
When jig is bolted to machine table, usually provides with
four feet instead of a flat bottom, squaring provides easily chip
removal and sustainability.
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 Types of Standard Jig Feet:

Nylon cable for fastening

jig body:

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 Cont’d…

Miscellaneous considerations:
Sharp corners should be eliminated
Provisions should be made for the coolant to get to the drill
Holes or passages for escape of the coolant
Gripping surfaces should be knurled
The jig should be large enough to hold it against the torque of the
drilling machine
It must be easy to handle

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 METHODS OF CONSTRUCTION

 Properties required Generally jigs are constructed by holding the

components together mechanically

 This is referred to as built-up construction

 Adv.: All parts can be completely machined before assembly and

worn parts can be easily replaced

 Minor adjustments can be made during assembly

 Jigs of this type are held together by socket-head, cap screws and
dowels

 Screw serve to hold the components together while the dowels

serve to hold the parts in alignment
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 Cont’d…

 Welded construction is also used in building a drill jig

 Drill jigs are sometimes constructed by a combination of

welding and mechanical assembly

 The main body may be of welded construction with the

smaller components attached by screws and dowels

 The main body of a drill jig may also be cast (Why?)

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 Materials for jig element

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 The economics approach to the provision of
special equipments

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 Assignment

1. Design a drill jig for a Φ 6.5 mm for the component

given below ( all dimensions are in mm)
 Cont’d
2. Design a drill jig for drilling Φ 6x2 mm holes for then
given component ( all dimensions are in mm)
Thank You
 Design Study – Drill Jig
1. Method of locating the part
The central hole which helps in locating as
well as indexing for the hole.
2. Clamping can be done with a nut and a C-
washer
3. Indexing will have to be done with a plunger
type retracting.