DESIGN OF DRILL JIG

Prepared By : Sanket P. Shinde T. Y. B. Tech (Production) Roll No : L081040007

Finished Component

Sequence of Operations
1. Milling of reference surface A, B & C.

2. Milling of slots A, B & C.

3. Drilling dia 10 mm hole. 4. Tapping of M10

Design

PRINCIPLES OF DESIGN
Location Clamping Loading & Unloading

Location
Location is done using 3-2-1 locating principle Surfaces A, B, & C are used for locating purpose Locating pads are used as locators; these pads are spaced as far as possible to reduce inaccuracies due to variation in workpiece.

Clamping
Clamping is done using Hand Knob and Clamp

Loading
Loading 1.Pull the hand knob with clamp backside. 2.Place job properly under on the base plate resting on 3 sides. 3.Align the clamp through slot and push it through the slot . 4.Turn the clamp 90 5.Tighten the hand knob 6.The gap between the job and jig plate is 3 mm so that chip can be removed easily

Unloading
Unloading 1.Loosening the hand knob 2.Turning the clamp by 90 3.Pulling the clamp and knob backside 4.Removing the component

Parts
QTY.

1. Base plate 2. Vertical plate 3. Side plate 4. Jig plate 5. Linear bush 6. Slip bush 7. Resting pads (locators) 8. Tap bush 9. Dowels 10. Soc. Headed cap screw 11. Hand knob 12. Clamp

1 1 1 1 1 2 6 1 6 6 1 1

Base
1. Base plate is made out of cast iron 2. Recess are made for vertical and side plate on it 3. Also recess is provided at bottom to reduce contact area 4. Ribbing is done from bottom of plate to increase strength.

Vertical plate
1. Vertical plate is made of mild steel plate 2. Hole is provided for clamp to pass through it 3. Dowel holes are provided 4. M8 tapping is done to fix it on base plate 5. Also holes are provided for resting pads 6. All sharp corners are chamfered

Side plate
1. Side plate is made of mild steel 2. Recess is provided for jig plate 3. Dowel holes are provided 4. Hole is provided for resting pad 5. M6 tapping is done for clamping jig plate

Jig plate
1. Jig plate is made of mild steel 2. It has hole for linear bush which is chamfered for easy entry 3. Dowel holes are provided 4. Counter boring is done to accommodate the head of screw

Linear Bush
1. Linear bush is made up of HCHCr 2. Its entry edge is chamfered 3. Linear bushes are press fitted in the jig plate 4. Linear bush is hardedned upto 58 60 HRC

Slip Bush
1. Slip bush is made of EN24 (58-60 HRC) 2. It fits into the linear bush 3. It has a slot, which is provided for restricting it from coming out while drilling is going on 4. Slip bush is slide fitted in linear bush 5. The external diameter of bush is ground to maximum accuracy

Resting Pads

1. Resting pads locate the component and supports the component 2. It also helps in swarf removal

Dowels

1. Dowels are used for locating purpose 2. They are placed as far as possible

Soc. headed cap screw

This are meant for fastening purpose

Hand knob

1. Hand knob is used for clamping purpose 2. It is fast and easy way of clamping compared to nut and bolt

Clamp

1. Clamp is designed such a way that it passes through the milled slot

Assembly
1. Assembly of resting pads in base plate, vertical plate and side plate 2. Assembly of linear bush in jig plate 3. Doweling of base plate and vertical plate 4. Screwing of base plate and vertical plate 5. Doweling of jig plate and side plate 6. Screwing of jig plate side plate 7. Doweling of base plate and side plate 8. Screwing of base plate and side plate 9. Assembly of hand knob washer and clamp

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