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Lab Report

Tool & Fixture Design

Design a drill jig for drilling on cylindrical surface.

Group Members:
Shubham Abrol
Aviruddh Jain
Jaswant Nag
Shanukh Dhrona Kankanala
Harsh Bhalani
Valiveti Vivek Bhargav

Aims of the Project:


Our aim is to design a drill jig to drill on the curved surface of the cylindrical
surface.

Objectives:
Our objective was to design a drill jig to drill on the
curved surface of the cylindrical surface. The jig will
hold the work piece rigidly during drilling operation and
reduce the operational difficulty in drilling on the
curved surface of the cylindrical work-piece.

Design Considerations:
1. Modularity: In order to accommodate the work-pieces of different lengths
and diameters the design is made up of several small components so that
they can be changed according to the dimensions of work-piece.
2. Simple design: The design of individual components is kept relatively simple
for the ease of manufacturing the drill jig. There is no intricate shape.
3. Low cost: This is one of the major considerations taken into account while
finalising the design. The overall cost is very less due to the simplicity of
design and components.
4. Ease of loading and unloading: In order to reduce setup time and time of
loading and unloading latch has been inculcated in the design.
5. Safety: There should be no projections of the fixture which may causes
injury to the operator.
6. The drill should be rigid and overhang of work-piece is to be kept minimum
possible by use of a V block so that there is no bending action.
7. The drill should be as light weight as possible.

Design:

The objective of the drill jig is to support, locate and clamp the work-piece as well
as guide the drill bit. All these objectives are carried out by the design efficiently
and are explained below:
Locating and Supporting:
The primary support and locator of the work-piece is the vblock. It is tailored such that it provides ample chip clearance
below the work-piece as well as provides a rigid support to
prevent defects.
A secondary support is provided in the form of a
mandrel. The mandrel has a smaller diameter compared
to the hollow work-piece which establishes a line contact
between the former and the latter. The mandrel
counters the cutting force acting on the work-piece and
prevents buckling. Play in the work-piece is avoided
using both supports.

Clamping:
We have used the Lead screw mechanism to clamp
the work-piece. It is a very efficient clamping
method in this situation because the axial force
provided by the lead screw, is not in the direction
of the cutting forces.
Easy placement and removal of work-piece is
facilitated using dowel pins to rotate the plate on
which the lead screw is attached.
Guiding the Cutting Tool:
A fixed leaf plate is present above the work-piece. It
consists of a drill bushing to guide the drill bit
accurately. The distance between the leaf plate and the
work-piece is very less to avoid vibration of the drill bit.
Renewable slip bushings can be used for quick
replacement of bushings as well as to drill different
sized holes.

Design Iterations:
The design iterations have been implemented on Solidworks.
First Iteration: At the initial stage of design, i.e. the first iteration, we constructed
a design similar to the final design with an exception of the v-block. The job of
supporting and locating the work-piece was to be carried out by the mandrel only.
Second Iteration: After construction of the design created in the first iteration,
we got to know that the mandrel cannot perform the operation of locating and
supporting the work-piece efficiently. Hence, to overcome this issue, we had to
think of a change in the design which can be implemented easily to the already

existing design so that no major changes have to be made. Upon further


discussion, we decided to add a v-block to locate and support the work-piece
from the bottom.

Scope for Improvements:


1. Dowell pins can be used instead of screws for easy removal of components, so
that whenever a work-piece of different size and dimension has to be
accommodated, the time to setup is minimal.
2. The movement of lead screw and latch can be automated to reduce overall
time of operation.
3. The V-block can be custom made in such a way that there are 2 v sticks on
both the ends and 2 plates to support them to accommodate work pieces of
different sizes.
4. A proper mechanism of coolant flow and chip removal can be incorporated.

Conclusion and Remarks:


It was observed that the improved design would be better in a large production
scenario as it incorporates features like much easier loading and unloading of
work piece and high level of accuracy. Although its cost may be marginally higher
than the drill jig that has been designed, use of standard parts and the benefits of
higher production rates offset the effects of this higher cost.