DESIGN AND FABRICATION OF PNEUMATIC

JIG
SYNOPSIS
SINCE the design of drill jigs permits the adoption
of an almost unlimited range of new ideas it is curious to note the lack
of originality in the minor components. Most of the common
accessoriesclamps, screws, pins, bushings and the likehave
remained unaltered for years. And yet, in all of them, there is some
room for improvement. It is true that the measure of
possible
improvement is not great; often it is merely a pin here, a screw there,
an alteration of an existing part, or perhaps only a rearrangement of
some of the parts. But all these changes are within the scope of the
operator himself; he should not wait for the jig producer to furnish him
with ideas.
As a matter of fact, if any little defect is allowed to
continue unchecked it is the fault, not of the producer, but of the jig
operator who, because he is using the jig in actual practice, is in the
better position to see where it is wrong. At any rate, as far as the
present writer can ascertain, nothing on this subject has ever before
been published from the jig producing end. It
remains, therefore, for someone at the other endthe jig operating
endto point out some of the defects of small accessories and how
to correct them. These notes, although they chiefly concern the
operator, are directed to the producer as well, because many of the
ideas to be mentioned could well be incorporated in the jig before it is
delivered to the shop.

INTRODUCTION

PNEUMATICS
Pneumatics has long since played an important
role as a technology in the performance of mechanical work. It is also
used in the development of automation solutions. In the majority of
applications compressed air is used for one or more of

The following functions:

To determine the status of processors (sensors)
_ Information processing (processors)
_ switching of actuators by means of final control elements
_ carrying out work (actuators)

To be able to control machinery and installations

necessitates the construction of a generally complex logic
interconnection of statuses and switching conditions. This occurs as a
result of the interaction of sensors, processors, control elements and
actuators in pneumatic or partly pneumatic systems.
The technological progress made in material, design
and production processes has further improved the quality and
diversity of pneumatic components and thereby contributed to their
widely spread use in automation

The pneumatic cylinder has a significant role as a linear

drive unit, due to its
Relatively low cost,
_ ease of installation,
_ Simple and robust construction and
_ Ready availability in various sizes and stroke lengths
The pneumatic cylinder has the following general characteristics:
_ Diameters 2.5 to 320 mm
_ Stroke lengths 1 to 2000 mm
_ Available forces 2 to 45000 N at 6 bar
_ Piston speed 0.1 to 1.5 m/s

PNEUMATIC SYSTEMS

How Pneumatic Systems Works

Filtered Air is pulled through system by vacuum pump
Evacuated air passes through instrument case causes gyro to
spin
Spinning gyros provide rigidity in space for instrument
references
Air exhausts through Gyro Pressure Gauge exhaust port
Gauge measures system pressure
Failure Warning System

Pneumatics in review
Pneumatics has long since played an important role as a
technology in the performance of mechanical work. It is also used in
the development of automation solutions. In the majority of
applications compressed air is used for one or more of the following
functions:
_ To determine the status of processors (sensors)
_ Information processing (processors)
_ Switching of actuators by means of final control elements
_ Carrying out work (actuators)
To be able to control machinery and installations necessitates the
construction of a generally complex logic interconnection of statuses
and switching conditions. This occurs as a result of the interaction of
sensors, processors, control elements and actuators in pneumatic or
partly pneumatic systems.
The technological progress made in material, design and production
processes has further improved the quality and diversity of pneumatic
components and thereby contributed to their widely spread use in
automation.
The pneumatic cylinder has a significant role as a linear drive
unit, due to its
_ relatively low cost,
_ ease of installation,
_ simple and robust construction and
_ ready availability in various sizes and stroke lengths.
The pneumatic cylinder has the following general characteristics:
_ Diameters 2.5 to 320 mm

_ Stroke lengths 1 to 2000 mm

_ Available forces 2 to 45000 N at 6 bar
_ Piston speed 0.1 to 1.5 m/s

Elements of a Basic Compressed Air

Pneumatic System
A. Air Compressor
B.Check Valve
C.Accumulator
D.Directional Valve
E.Actuator

Elements of a Basic Compressed Air

Pneumatic System
Advantages of Pneumatic Systems
Light weight
Safe
Reliable
Eco-friendly
Small (can be)
Unaffected by atmospheric changes
Inexpensive components
Pressure seals are usually problem free
Forces transmitted are easy to manage (within
acceptable PSI limits)

The Advantages of Using Pneumatics

Fluid power technology encompasses both
hydraulics and pneumatics. Hydraulic applications use pressurized
fluids, mostly oil, while pneumatic applications use pressurized
gases, mostly air. Mobile construction equipment uses a hydraulic
pump mounted on the engine.
The outlet of the pump is plumbed to a set of valves.
Each valve is then plumbed to a cylinder. This allows you to distribute
power from the engine all around the equipment. The same is true for
a FIRST robot.
Once you install the compressor and are operating one
valve and cylinder combination, youve done most of the work. To add
an additional valve and cylinder combination, you just tee into
The pressure line and add in the additional circuit
Why use pneumatics in your FRC application? Here are some design
considerations for your review:
Weight
Compare the weight of several valves and cylinders to that of
the motors, gears, belts, and chains used on some lift mechanisms
and you will find the weight comparable, if not much lighter.
Simple to Design
Using pneumatics is much easier than building a motor; gear, chain
and sprocket lift mechanism. Once you have reviewed the layout on
page 15, you will find it very easy to build a circuit.
Adjustable Force
To adjust the force of the cylinder, all you have to do is
adjust the regulator in front of it. The force is equal to the area of the

cylinder piston times the pressure. Remember that the valves need at
a minimum of 15-30psi to work properly.
Durable
All of us have problems burning up motors from time to time.
You can stall an air cylinder against a load indefinitely and turn off the
compressor. These are industrial grade products.
Power
If you look at the force table on page 12, you have the option
of using a small 3/4 bore cylinder at 20psi, which will produce a force
of around 9 pounds. If you use a 2 bore cylinder at 60psi, you can
get 180 pounds of force. As you can see, your options are wide open.
Custom Cylinders and a Rotary Actuator
You may order the exact cylinder or rotary actuator you need
for the job from Bimba again this year, and get them in a few days via
regular UPS.
Last Minute Additions
At the last minute, you can add a cylinder and valve very
quickly.

Air Pump
Air Pump Heart of pneumatic system is pressure or
vacuum air pump (Usually engine driven)

Two basic types:

Wet air pumps use engine oil to lubricate pump internally
Dry air pumps-more common have graphite vanes inside
pump casing -self-lubricate as pump rotates

A Compressor
Pump that compresses air, raising air pressure to above
ambient pressure for use in pneumatic systems.

Pressure in Pneumatic Systems

The science of compressed air
We live at the bottom of a sea of air. The upper limit of the
earths atmosphere is not clearly defined, but it is safe to say that most of the
earths atmospheric mass lies within 100km or about 60 miles above the
surface.
Air has mass, and therefore it is affected by gravity. Gravity
acts on the particles of air and gives them weight. The weight of the air
above us creates a pressure around us. When you push down on the handle
of a bicycle pump, you are putting a force equal to some of your weight on
the handle.
The handle is attached to a rod and piston within the pump.
The force of your weight pushing down on the piston reduces the volume of
air in the pump, and raises the pressure. The weight of the air above us does
the same thing to the air around us.
We are not aware of the weight of the ocean of air above us,
because we were born into it. We have never been without it. Without the
pressure of this ocean of air around us, we would not be able to breathe.
Hold your hand on your chest and inhale deeply. Can you
feel your chest expand? As you expand your chest muscles, your lungs
increase in volume and the pressure of the ocean of air around us forces air
into your lungs! Without the pressure of the ocean of air, you would not be
able to breathe.
Climbing higher into the atmosphere reduces the depth of air
above you and thus reduces the mass and weight of the air above you. This
results in a lower air pressure and makes it hard to breathe. Climbers on the

worlds highest peaks bring bottles of oxygen with them in order to survive
at high altitudes.

Pressure is a Force Acting Over an Area

Pressure is described as the amount of Force acting on a specified
Area. Mathematically pressure
looks like this.
Area

Pressure is a force exerted by a fluid or a gas and it is

transmitted in all directions equally throughout the fluid/gas. Pressure
acts on the surface area of the vessels or chambers in which it is
confined.

The Advantages of Using Pneumatics

Fluid power technology encompasses both hydraulics
and pneumatics. Hydraulic applications use pressurized fluids, mostly
oil, while pneumatic applications use pressurized gases, mostly air.
Mobile construction equipment uses a hydraulic pump mounted on
the engine. The outlet of the pump is plumbed to a set of valves.
Each valve is then plumbed to a cylinder. This allows you to distribute
power from the engine all around the equipment. The same is true for
a FIRST robot. Once you install the compressor and are operating
one valve and cylinder combination, youve done most of the work. To
add an additional valve and cylinder combination, you just tee into the
pressure line and add in the additional circuit.

Weight

Compare the weight of several valves and cylinders to

that of the motors, gears, belts, and chains used on some lift
mechanisms and you will find the weight comparable, if not much
lighter.

Simple to Design
Using pneumatics is much easier than building a motor; gear, chain
and sprocket lift mechanism. Once you have reviewed the layout on
page 15, you will find it very easy to build a circuit.
Adjustable Force
To adjust the force of the cylinder, all you have to do is adjust the
regulator in front of it. The force is equal to the area of the cylinder
piston times the pressure. Remember that the valves need at a
minimum of 15-30psi to work properly.
Durable
All of us have problems burning up motors from time to time. You can
stall an air cylinder against a load indefinitely and turn off the
compressor. These are industrial grade products.
Power
If you look at the force table on page 12, you have the option of using
a small 3/4 bore cylinder at 20psi, which will produce a force of
around 9 pounds. If you use a 2 bore cylinder at 60psi, you can get
180 pounds of force. As you can see, your options are wide open.
Custom Cylinders and a Rotary Actuator
You may order the exact cylinder or rotary actuator you need for the
job from Bimba again this year, and get them in a few days via
regular UPS.

Last Minute Additions

At the last minute, you can add a cylinder and valve very quickly.
COMPRESSOR
With financial support from the Fluid Power
Education Foundation, we have the same compressor provided by
Thomas Industries that weve had for the last few years. The
compressor will put out approximately 120psi before the Norgren
relief valve opens (that would give you 376 pounds of output force on
a 2.00 bore cylinder). Because the compressor can produce a
significant amount of vibration, we have included vibration isolation
mounts donated by the Lord Corporation.

They can be screwed directly into the feet of the

compressor as shown on the following picture. In order for these to
isolate the vibration, they need to be mounted to a stiff piece of metal
such as a 1/4 aluminum plate. The distance between the front feet is
3.5. The distance from the centerline of these feet to the rear foot is
5.19. A spike relay must be used to control the power to the
compressor using a 20amp breaker, not a fuse. Ensure that the relay
is programmed to provide forward power only to the compressor. Do
not reverse the compressor! Norgren has supplied the pressure relief
valve. It is shown installed on the compressor.

Pressure - Absolute & Gage

Pressure = matter pushing against matter
Object pushing against another object
Absolute (psia) => True matter based pressure
0 psia => no matter present to press against objects
Not too important in our designs
Gage (psig) => Relative to Atmosphere
0 psig => pressure in equilibrium with atmosphere
All regulators and gauges based on this

Force, Pressure & Area

Pressure = Force / Area
Force = Pressure X Area
Example: 30 psig in 2 diameter cylinder

Pneumatics vs. DC Motors

Our ability to control the position of mechanisms actuated by
cylinders is very limited
We are not given integrated, dynamic airflow or pressure
controls
We are given much more versatile electronic controls for
motors
Cylinders can be stalled without damage to the pneumatic
system

 Motors will draw large current and let out the magic smoke
Cylinders absorb shock loads rather well and bounce back
However, be careful of over pressure conditions caused by
flowcontrol valves
Motors have to be actively held with feedback controls or
locked

TWIST DRILLS:
Twist drills are the most common cutting tools used
with drilling machines. Twist drills are designed to make round holes
quickly and accurately in all materials. They are called twist drills
mainly because of the helical flutes or grooves that wind around the
body from the point to the neck of the drill and appear to be twisted
(Figure 4-7). Twist drills are simply constructed but designed very
tough to withstand the high torque of turning, the downward pressure
on the drill, and the high heat generated by friction

There are two common types of twist drills, highspeed steel drills, and carbide-tipped drills. The most common type
used for field and maintenance shop work is the high-speed steel
twist drill because of its low cost. Carbide-tipped metal drills are used
in production work where the drill must remain sharp for extended
periods, such as in a numerically controlled drilling machine. Other
types of drills available are: carbide tipped masonry drills, solid
carbide drills, TiN coated drills, parabolic drills and split point drills.
Twist drills are classified as straight shank or tapered shank (Figure
4-7). Straight shank twist drills are usually l/2-inch or smaller and tit
into geared drill chucks, while tapered shank drills are usually for the
larger drills that need more strength which is provided by the taper
socket chucks.

Common twist drill sizes range from 0.0135 (wire

gage size No. 80) to 3.500 inches in diameter. Larger holes are cut by
special drills that are not considered as twist drills. The standard
sizes used in the United States are the wire gage numbered drills,
letter drills, fractional drills, and metric drills (See Table 4-1, in
Appendix A). Twist drills can also be classified by the diameter and
length of the shank and by the length of the fluted portion of the twist
drill. Wire gage twist drills and letter twist drills are generally used
where other than standard fractional sizes are required, such as
drilling holes for tapping. In this case, the drilled hole forms the minor
diameter of the thread to be cut, and the major diameter which is cut
by tapping corresponds to the common fractional size of the screw.
Wire gage twist drills range from the smallest to the largest size; from
No 80 (0.01 35 inch) to No 1 (0.2280 inch).

The larger the number, the smaller the diameter of

the drill. Letter size twist drills range from A (0.234 inch) to Z (0.413
inch). As the letters progress, the diameters become larger. Fractional
drills range from 1/64 to 1 3/4 inches in l/64-inch units; from 1/32 to 2
1/4 inches in 1/32-inch units, and from 1/1 6 to 3 1/2 inches in 1/16inch units. Metric twist drills are ranged in three ways: miniature set,
straight shank, and taper shank. Miniature metric drill sets range from
0.04 mm to 0.99 mm in units of 0.01 mm. Straight shank metric drills
range from 0.05 mm to 20.0 mm in units from 0.02 mm to 0.05 mm
depending on the size of the drill. Taper shank: drills range in size
from 8 mm to 80 mm in units from 0.01 mm to 0.05 mm depending on
the size of the drill.
The drill gage (Figure 4-8) is used to check the
diameter size of a twist drill. The gage consists of a plate having a
series of holes. These holes can be numbered, lettered, fractional, or
metric-sized twist drills. The cutting end of the drill is placed into the
hole to check the size. A micrometer can also be used to check the
size of a twist drill by measuring over the margins of the drill (Figure
4-9). The smaller sizes of drills are not usually marked with the drill
size or worn drills may have the drill size rubbed off, thus a drill gage
or micrometer must be used to check the size.

DRILL POINT

When grinding the lip angle, use the drill point gage
and grind one lip perfectly straight and at the required angle (usually
590). Then flip the drill over and grind the other lip. Once the angle is
established, then the lip clearance angle and lip length can be
ground. If both lips are not straight and of the same angle, then the
chisel edge (Figure 4-14) will not be established. It is it important to
have a sharp and centered chisel edge or the drill will not rotate
exactly on its center and the hole will be oversized. If the drill point is
too flat, it will not center properly on the work piece. If the drill point is
too steep, the drill will require more power and cut slowly. When the
angles of the cutting lips are different, then the drill will only have one
lip cutting as it revolves. The hole will be oversized and the drill will
wear very rapidly

GENERAL DRILLING OPERATIONS

THE DRILLING PROCESS:
After a work piece is laid out and properly
mounted, the drilling process can begin. The drilling process, or
complete operation, involves selecting the proper twist drill or cutter
for the job, properly installing the drill into the machine spindle, setting
the speed and feed, starting the hole on center, and drilling the hole
to specifications within the prescribed tolerance. Tolerance is the
allowable deviation from standard size. The drilling process must
have some provisions for tolerance because of the over sizing that
naturally occurs in drilling. Drilled holes are always slightly oversized,
or slightly larger than the diameter of the drills original designation.
For instance, a l/4-inch twist drill will produce a hole that may be
several thousandths of an inch larger than l/4-inch.
Over sizing is due to several factors that affect
the drilling process: the actual size of the twist drill, the accuracy of
the drill point, the accuracy of the machine chuck and sleeve, the
accuracy and rigidity of the drilling machine spindle, the rigidity of the
entire drilling machine, and the rigidity of the work piece and setup.
Field and maintenance shop drilling operations allow for some
tolerance, but over sizing must be kept to the minimum by the
machine operator

Drilling
Equipment
Drills
Any commercially available, power-driven equipment is acceptable.
This includes portable drills, drill presses, Lathes, automatic multiple
spindle drilling units, CNC routers and machining centers.

Drill Bits
Several manufacturers offer drill bits designed especially for plastics.
Drill bits are commonly made of high-speed steel (HSS), cobalt, HSS
with carbide tips or solid carbide. Metal-working high-speed steel
twist drill bits can be used with some modification. Standard metalworking drill bits are designed to aggressively cut into metal as they
are fed into it. If used on acrylic without modification, these bits will
chip and cause other damage to the plastic. These drill bits must be
reground in order to scrape the plastic instead of sharply cutting into
the material and gouging it. There are three points to consider when
modifying a standard metal-working twist drill for plastics.

1. Tip angles on standard drill bits are commonly 118-130. This

point angle must be ground to 60-90. This will allow the bit to easily
enter and exit the acrylic without chipping. Larger tip angles
commonly cause cracking and blow out as the bit exits the sheet. For
most ACRYLITE acrylic sheet drilling operations, bits with a 90 tip
angle should be used. A bit with a 90 tip angle will generate smaller
chips which are easier to evacuate, reducing melting and improving
hole quality. Care must be taken at the points of entry and exit.
Generally, bits with a 90 tip angle are recommended. Bits with 60 tip
angles are also used, especially for holes with diameters of 1/2" and
greater.

2. The cutting edge must be ground flat to a 0-4 rake angle. This
cutting edge will scrape the acrylic, not gouge it.

3. The surface behind the cutting edge must be ground away to

clearance angles of 12-15. This back relief reduces metal/plastic
contact and heat build-up. This modification is standard on most high
quality twist drill bits.

Bit geometry affects the quality of drilled holes since it affects chip
size and chip evacuation. Larger diameter bits and bits with smaller
tip angles produce larger chips. If hole depth (H) is less than bit
diameter (D), large chips are easily ejected. As the depth of the hole
increases, i.e. H>D, larger chips become more difficult to eject
because of the close clearance between the bit and the hole walls.
Increasing bit tip angle decreases the size of generated chips,
facilitating chip ejection. However, as mentioned above, if the tip
angle is too large, larger than 90, blow out and chipping may be a
problem when the bit exits the acrylic. The helix angle on a bit is the
angle between the cutting edge and a vertical line along the center of
the bit. Bits with a moderate helix angle aid in chip ejection and are
recommended for drilling of plastics. Small helix angles interfere with
chip ejection, increasing melting. Helix angles, which are too large,
can cause cracking around the hole edges. Typically a helix angle of
15-30 is recommended

Types and Functions of Jigs and Fixtures:

JIGS AND FIXTURES
Jigs and fixtures are production-work holding devices used to
manufacture duplicate parts accurately. The correct relationship and
alignment between the cutter, or other tool, and the work piece must be
maintained. To do this, a jig or fixture is designed and built to hold, support,
and locate every part to ensure that each is drilled or machined within the
specified limits. Jigs and fixtures are so closely related that the terms are
sometimes confused or used interchangeably. The difference is in the way
the tool is guided to the work piece.
A jig is a special device that holds, supports, or is placed on a part
to be machined. It is a production tool made so that it not only locates and
holds the work piece but also guides the cutting tool as the operation is
performed. Jigs are usually fitted with hardened steel bushings for guiding
drills or other cutting tools (Figure 21A).

As a rule, small jigs are not fastened to the drill press table. If, however,
holes above .25 inch in diameter are to be drilled, it is usually necessary to
fasten the jig to the table securely.

A fixture is a production tool that locates, holds, and

supports the work securely so the required machining operations can be
performed. Set blocks and feeler or thickness gauges are used with fixtures
to reference the cutter to the work piece (Figure 21B). A fixture should be
securely fastened to the table of the machine upon which the work is done.
Though largely used on milling machines, fixtures are also designed to hold
work for various operations on most of the standard machine tools. Fixtures
vary in design from relatively simple tools to expensive, complicated
devices. Fixtures also help to simplify metalworking operations performed
on special equipment.

CLASSES OF JIGS
Jigs may be divided into two general classes: boring jigs and
drill jigs. Boring jigs are used to bore holes that either are too large to drill or
must be made an odd size (Figure 22). Drill jigs are used to drill ream, tap,
chamfer, counterbore, countersink, reverse spotface, or reverse countersink
(Figure 23). The basic jig is almost the same for either machining operation. The only difference is in the size of the bushings used.

TYPES OF JIGS:
Drill jigs may be divided into two general types, open and closed. Open jigs
are for simple operations where work is done on only one side of the part.
Closed , or box, jigs are used for parts that must be machined on more than
one side. The names used to identify these jigs refer to how the tool is built.
Template jigs are normally used for accuracy rather than speed. This type of
jig fits over,on,or into the work and is not usually clamped (Figure 24).
Templates are the least expensive and simplest type of jig to use. They may
or may not have bushings. When bushings are not used, the whole jig plate
is normally hardened.

Plate jigs are similar to templates (Figure

25). The only difference is that plate jigs have built-in clamps to hold
the work. These jigs can also be made with or without bushings,
depending on the number of parts to be made. plate jigs are
sometimes made with legs to raise the jig off the table for large work.
This style is called a table jig (Figure 26). Sandwich jigs are a form
of plate jig with a back plate (Figure 27). This type of jig is ideal for
thin or soft parts that could bend or warp in another style of jig. Here
again, the use of bushings is determined by the number of parts to be
made. Angle-plate jigs are used to hold parts that are machined at
right angles to their mounting locators (Figure 28). Pulleys, collars,
and gears are some of the parts that use this type of jig. A variation is
the modified angle-plate jig , which is used for machining angles other
than 90 degrees (Figure 29). Both of these examples have
clearance problems with the cut- ting tool. As the drill exits the
product being drilled, it has little or no room for the drill point to clear
the product completely, produce a round hole all the way through the
part wall, and avoid drilling the part locator.
This is most noticeable in Figure 29, where an
angled hole requires additional clearance to the relieved portion of
the part locator. Additional clearance here would allow the drill to
complete the hole and avoid drilling the relieved portion of the locator.
The part locator will most likely be hardened and the drill will be lost
as a result of any attempted drilling. Additional clearance on the
relieved diameter of the part locator may be possible. A larger
clearance hole in the locator could also be added if the relieved
diameter cannot be reduced. The additional design consideration
added to the locator would include the feature to provide the correct
orientation of this clearance hole or machined relief to line up with the
bushing location. Box jigs, or tumble jigs , usually totally surround the
part (Figure 210). This style of jig allows the part to be completely
machined on every surface without the need to reposition the work in
the jig.

PNEUMATIC JIG

WORKING:
SINCE the design of drill jigs permits the adoption of an
almost unlimited range of new ideas it is curious to note the lack of
originality in the minor components. Most of the common accessories
clamps, screws, pins, bushings and the likehave remained unaltered for
years. And yet, in all of them, there is some room for improvement. It is true
that the measure of possible improvement is not great; often it is merely a
pin here, a screw there, an alteration of an existing part, or perhaps only a
rearrangement of some of the parts.

But all these changes are within the scope of the operator
himself; he should not wait for the jig producer to furnish him with ideas. As
a matter of fact, if any little defect is allowed to continue unchecked it is the
fault, not of the producer, but of the jig operator who, because he is using the
jig in actual practice, is in the better position to see where it is wrong. At any
rate, as far as the present writer can ascertain, nothing on this subject has
ever before been published from the jig producing end. It remains, therefore,
for someone at the other endthe jig operating endto point out some of
the defects of small accessories and how to correct them. These notes,
although they chiefly concern the operator, are directed to the producer as
well, because many of the ideas to be mentioned could well be incorporated
in the jig before it is delivered to the shop.

ADVANTAGES:
Automatic drilling

To fabricate the improved design of Drill Jig.

DISADVANTAGES:
Automatic may be difficult to handle

Incase of Pneumatic operation fails whole entire system will

affected
APPLICATIONS:
Auto mobile Industries
Drilling tool