Tool Design

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CH # 3
Drill Jig:

Dasign of Drilling jigs

A drill jig is device for a ensuring that a hole to be drilled, tapped, or reamed in a work piece will be machined in the proper place. Thus instead of laying out the position of each hole on each work piece with the aid of a square, straight-edge, scriber, and canter punch, the operator uses a jig to guide the drill into the proper place. The drill is guided by the bushings. If the work piece is of simple construction, the jif may be clamped on the work piece. In most cases, the work piece is held by the jig and the jig is arranged so that the work piece can be quickly inserted and quickly removed after the machining operation is performed. Jigs make it possible to drill, ream and tap holes much greater speeds and with greater accuracy then when the holes are produced by conventional hand methods. The term jig should be used only for devices employed while drilling, reaming, or tapping holes.

Types of Drill jigs:
There are so many types of drill jigs. Various companies and industries may refer to the same type of jig by different names. But some common type of jig are as follows. Leaf jigs Box and tumble jigs Template jigs Plate jigs Indexing jigs Universal or pump jigs Vise jigs J

Leaf jigs:
This type is distinguished by its hinged cover, or leaf. Leaf jig is easy to load or unload. Leaf jigs can be loaded and unloaded quickly and are suitable for complicated work piece irregular contours_______. Drill bushings are fitted in the leaf, play in the hinges may affect drilling accuracy. The bushings must be located in the leaf or hinge plate.

Box and tumble jigs:
This type receives its name from its shape which, in general, resembles a box. In jig the hole is drilled and then reamed while in the jig. The loading is as follows: the cam rod is taken out of the jig and the work pieced in position inside the jig. The cam rod is then replaced and rotated to its locking position. When a box jig contains bushings on two or more sides for the purpose of drilling holes on different sides of the part.

Tool Design

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Template jigs:
This is simple type used for locating hole patterns on large work pieces. It may contain locating device, or it may be necessary for the operator to locate by means of measurement. Some have provisions for clamping. In template jig the hole pattern itself is quite accurate.

Plate jigs:
The plate jig is so named because a plate containing bushing forms the main structural member. It is open construction, which facilitates for loading and unloading chip removal, and clamping. For this reason it is sometimes referred to as an open jig. The jig may or may not have legs. Thin parts may be stacked for drilling several parts at one time. The disadvantages of plate jig are that only one surface can be drilled at one loading.

Indexing jigs:
Indexing jigs are used for circular hole patterns in which the part is indexed successively to the different positions under a single bushing. The location of the holes may be taken from the first hole drilled, or from other holes in the part. This jig was developed from a basic indexing fixture with the work piece held in a chuck. The single drill bushing can be adjusted to different heights and allow holes to be drilled on the pitch circle of different sizes.

Universal or pump jigs:
These jigs are produced commercially as basic unit and are adapted to specific jobs by tool designers and tool makers. Many fine types are available and the outstanding feature of these jigs is their rigidity, low height, ample chip clearance, and ease of operation. The moving parts are completely protected from chips. Some pump jigs incorporate a swing-away feature.

Vise jigs:
Vise jigs are constructed by attaching special inserts to the jaws of a regular machine vise. The inserts can be made quickly with a minimum amount of expense. They are usually used for low volume and short production runs but may be used for long production runs of single parts.

Chip Formation in Drilling
The tool designer must be acquainted with the process to design the most effective tools for use with a drilling operation. In drilling to flute drill passes through to a piece of metal, the metal is displaced by two parts of the drill point, the drill lips and the chisel edge of the drill. The cutting process of the drill lip is essentially the same as that of a lathe cutting tool. But at the chisel the process is quite different. After the metal is displaced by the chisel edge and the cutting lips of the drill, it must be ejected_______ from the hole. The drill flutes act as an auger to remove the chips. Chip c

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