DESIGNING JIG

ASSIGNMENT 1

GROUP NO : 6

NIKHIL SUNIL – 8969869

DENIL LINSON –
MAHESH PANTHALATH - 8983971
 INTRODUCTION
 A customer wants 100 Guide Blocks which have already been pre-machined for overall
shape and profile but is missing the 2 holes.
 100 Guide Blocks to be machined
 Guide Block is made of 1018 steel, Carburized – Hardened with black oxide finish
 Base plate, Drill bushings, Jig plate, Jig Rest buttons, Clamp are used for machining

PART NO FIT STUD SIZE A B C D E F G H J

CL-8-GB 5/8-11 .515 .25 5/8 1-1/2 1/4 1-5/8 1/4-20 1 1-1/8
 HEAD PRESS FIT BUSHINGS (H)
 Head Press Fit bushings are used for machining .
APPLICATION
• Similar to a P bushing, but with a head to resist heavy axial loads. H
bushings are permanently pressed into the jig plate.
• They are generally used for single-step drilling or reaming operations
when you do not expect to replace bushings during the tooling’s
lifetime.
• The head can be left exposed or recessed by counterboring the
installation hole.

CALCULATIONS
 JIG PLATE
 A custom-made jig plate is used which consists of two drill bushings
 A through-hole has been provided for drill bushings

CALCULATIONS
• Jig-Plate Thickness = 2 x drill bit diameter
= 2 x .282
= .564 (non-standard)
Instead of using a non-standard size used the bush size is .625 same as the Jig Plate
Jig Plate Thickness = .625”
 CLAMP
CLAMP – PUSH / PULL – CL-100-SPC (300lbs)

• It is used to hold the workpiece to arrest the movement.

• Tiny, yet extremely powerful plunger clamp with a forged
steel base.
• Requires very little mounting space due to its
narrow base and compact low profile.
• Locks in extended or retracted position. 5/8" plunger travel.
Plunger is tapped to accept any 1/4-20 spindle
 JIG REST BUTTONS
 Jig rest buttons used as a locator
APPLICATION
 Precision rest button with a press-fit shank. Excellent as either a workpiece support or
a jig foot.
 CHIP CLEARANCE
 Our drill size is 0.282 in, we need to allocate one times the drill size
CHIP CLEARANCE = 0.282 in
DIAGRAM
 BILL OF MATERIALS
 Jig rest buttons used as a locator
MACHINING PROCESS

INSERT PART

TIGHTEN THE CLAMP

ARRANGE THE PART IN THE SLOT

OPEN THE CLAMP AND REMOVE PART

PROCESS WITH DRILLING

REPEAT THE CYCLE

 CONCLUSION
 Purpose of the Jig is to provide repeatability and precision.
 Reduced costs by using preformed and standardized parts.
 Simple Built-up tool body.
BRAINSTORMING
CALCULATIONS
THANK YOU