Design of Drill Jigs

02-08-2018
Design of Jigs & Fixtures

Construction of Drill Jig
Jigs & Fixtures
Module 3
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Drill Jig
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Overview of the Lecture

• Introduction
• Selection of location, supporting and clamping faces /points,
cutting tools and means of guiding and supporting Jigs
• Various types of Jig Bushes

• Commonly used drill jigs
• Case Study on Design of Drill Jig
Selection of Locators
• Button Locators • Adjustable Support Pins
• Pin Locators • Jack Pins
• Pad Locators
• Location Post
• Locator Pots
• V Block
• Adjustable
• Fixed
• Nesting Block
• Diamond Pin Locator
• Dowel Pins 4
• Conical Locators
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Selection of Clamps
• Mechanical • Wedge Clamps
• Screw Clamps • ‘U’ Clamp
• Strap Clamps • Equalizer
• Retractable • Fluid Power
• Swinging • Pneumatic
• Edge • Hydraulic
• Bridge

• Special • Magnetic Clamping
• Pivoted Clamps • Vacuum Power Clamping
• Hinged Clamps • Electrostatic Clamping
• Swinging Clamps • Electrical Actuator Clamping
• Cam Clamps • Adhesive clamping
• Toggle Clamps • Fusion clamping
• ‘C’ Washer Clamp
• Without Chain
• With Chain
• Captive
• Bayonet Clamps 5
• Quarter Turn Screw
General Considerations
Rigidity:
• Jig must be strong enough to withstand all forces applied to it.
• It must also resist deflections that may be the result of
excessive tightening of clamps that hold the w/p in place.
• The work must also be supported so that it does not bend

under drilling pressure.
• Cast iron is generally used because it absorb shocks and
compressive forces.
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Chip Control:
• Types of chips: segmental and continuous.
• The segmental chip is preferred.
• Space should be kept between the w/p and bottom of drill

bushings to allow chips to pass between the work and busing
plate (1-1/2” dia. Of drill).
• Three ways of chip removal: coolant, manually with brush or
hook, compressed air.
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Jig feet and legs:
• A drill jig should stand on four feet (Or legs) rather than a flat
surface.
• Jig feet may be built into the jig body or purchased as

standard parts.
• They are usually placed on the extremities of the jig body.
• Feet should be ground so that they are all in one plane after
they are mounted on the jig base.
Standard Jig Feet

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• The type of machine in which operation is performed needs
careful considerations.
• The layout of the jig must provide adequate hand clearance
for easily loading and unloading and process for loading and
unloading must be quick.

• Errors arise in components due to wear. Therefore wear
resistance surfaces should be small and easily replaceable.
• To increase tool life and keep the components cool, a coolant
is provided in cutting edge in sufficient quantity. Provisions
should be made for the coolant to get to the drill and holes or
passages for escape of the coolant.
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• Design considerations require easy ejection of the component
from jig (particularly for heavy ones) to save the operation
time and increase the productivity, pneumatic devices are very
suitable for easy and quick ejection.
• Sharp corners should be eliminated.
• Gripping surfaces should be knurled.

• The jig should be large enough to hold it against the torque of
the drilling machine.
• It must be easy to handle.
• Normally jigs are made of hardened steel, which are wear
resistant, corrosion resistant and thermally insensitive.
• Their dimensional accuracy directly influences the accuracy
of performance of the operations where these are used. 12
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Drill Bushes
• Drill bushes are used to guide drills,
reamers and other cutting tools to the
workpiece.
• They are made of hardened carbon
steel, so as to minimize wear due to

contact with hard, rotating tools.
• The inside diameter of the bush is
ground precision running fit with the
drill/reamer to be guided.
• While the outer diameter is made press
fit, precision location fit or precision
running fit depending on the function
and application of the bush.
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Drill Bush Materials

• Bushes are made of hardened Carbon Steel with 0.85 - 1%
Carbon, 0.5 - 0.9% Manganese.
• They are hardened to RC60 – 64 to minimise wear due to
contact with hard, rotating tools.
• Bushes are finished by grinding the inside and outside
diameters within 0.001 mm concentricity.

• The inside diameter has precision running fit (F7) with the
drill / reamer
• The outside diameter is made press fit (p6), precision location
fit (h6) or precision running fit (f6) depending upon
application of the bush.
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Types of Drill Bushes

• Different types of Drill Bushes are mentioned below:
• Press Fit / Liner Bushes
• Renewable Bushes
• Slip Bushes

• Threaded Bushes
• Special Bushes
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Bushings
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Drill Bushings

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Drill Bush Designation

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Drill Bush Installation

• Stationary drill bushings are mounted or installed by press fit.
• In any press fit installation, metal is displaced and distortion
occurs in the busing and the jig plate.
• It is recommended to always use the minimum interference

necessary to retain the bushing in the jig plate.
• Head type bushings are particularly recommended for
installation in relatively thin jig plates.
• Where a headless bushing would require an excessive
interference fit for adequate retention.
• The hole in the jig plate must be finished by means of a
reamer, jig borer or jig grinder, never a twist drill.
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Arbor Press
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Drill Bush Installation

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Bushing Installation - Wrench

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Bushing Installation - Vise

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Bushing Installation – C clamp

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Press Fit / Liner Bushes

• They are most common types of bushes used and are pressed
interference fit in the jig plates.
• They are used for batch production where the bushes often
outlast the life of the jig.
• Bushes with collars are called as headed bushes and used to

provide a positive stop for the bushes.
• However when the bushes are spaced close together,
collarless bushes are used.
• Press fit / Liner bushes are used as liners for Renewable and
Slip bushes.
• Serrations are sometimes provided on the bush to prevent
rotation in softer materials like, aluminum, wood , etc. 25
Press Fit / Liner Bushes

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Press Fit Bushing

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Extended Drill Bush

• It is used when the
hole to be drilled in
a face that is at
some distance from
the drill plate.

• When the drill bush
is long, its bore is
relieved so that only
end near the
workpiece controls
the tool. 28
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Extended Drill Bush

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Renewable Bushes
• When the bush is subjected to severe wear to due to
continuous contact with the cutting tool, especially during
large batch productions, the bush needs to replaced
frequently.
• For this purpose renewable bushes are used. They can be
assembled manually without any press and are place over a

liner in the jig plate.
• The renewable bush is prevented from rotation and getting
lifted out when the cutting tool is coming out, by the
provision of a flat on the collar of the bush.
• A retainer shoulder screw is provided over this flat to prevent
rotation and lifting out, of the bush. 30
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Renewable Bush
Renewable Bushes
Design of Jigs & Fixtures Design of Jigs & Fixtures
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Renewable Bush - Locking

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Slip Bushes
• When a hole in the workpiece requires two different
operations such as drilling and reaming, it is necessary to use
two different guide bushes.
• The hole is first drilled using a bush having a bore suitable for
the drill, then it is removed.
• And next a reaming bush is installed on the jig plate and is

used to guide the reamer.
• During mass production, the change of the bushes have to be
effected quickly. This is done by using slip bushes.
• The slip bush is provided with a flat on the head similar to the
renewable bush and a circular cutout in the flange to
facilitate quick assembly and removal. 34
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Slip Bush
Slip Bushes
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Slip Bush
Slip Bush - Locking

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Threaded Bushes
• The bushings used for clamping the workpiece are
threaded on the outside.
• The collar of the liner bushing is usually placed on the
opposite side to take the axial thrust of the screw.

• The liner bushing is prevented from rotation by a flat on
the collar. The flat mates with machined step on the jig
plate.
• Alternatively, an unthreaded bushing can be clamped
with a spring loaded lever. The pressure of the spring
holds the bushing pressed against the workpiece.
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Threaded Bushes
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Threaded Bush

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Special Bushes
• Sometimes work-pieces require unusual drill bushes. These
are made by simple modifications to existing drill bush
designs.
• While trying to drill inclined or curved surfaces, bending or
breaking of the drill occurs frequently.
• To counter this, the shape of the drill bush is altered by

matching the end of the bush with the profile of the
workpiece.
• Sometimes the centers of the drilled holes are placed very
close. In such instances, plate-type bushes are used. This plate
bush is screwed and dowelled to the jig plate.
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Special Bushes
• Sometimes the centre of
the drilled holes are placed
so close to each other that
it is impossible to provide
any drill bushes in the jig
plate.

• Under such circumstances,
a combined plate – type of
bush is used.
• The plate bush is made of
Tool Steel.
• A number of bushes can be
combined into a single
plate bush. The plate bush
is screwed and dowelled to
the jig plate. 45
Special Bushes
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Castable Drill Bushes

• In Jigs made of made of
cast or laminated plastics,
bushings are either cast
or potted in cavities, that
are formed by cores as
the jig is laminated.

• In either case, the
bushings ae made with an
outer surface texture or
pattern that permits the
metal or plastic to grip
and lock the bushing.
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Castable & Chip-breaker Bushings

Castable bushings provide Chip-breaker bushings are
excellent holding strength against renewable bushings specially
rotational forces designed to break up chips from 49
tough and stringy materials while
reducing friction and heat build-up.
Directed Coolant & Oil-Groove Bushings

Directed-coolant bushings Oil Groove bushings feature

feature internal passages to grooves specifically designed to
direct coolant to the cutting provide a coolant passageway in 50
area designed to wash away a bushing’s ID wall.
chips.
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Circuit Board Drill Bushing

Circuit Board Drill
Bushings are small
bushings for guiding
drills of 6 mm diameter
down to 0.35 mm

diameter for the drilling
of circuit boards.
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Gun Drilling Bushing Template Bushing

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Circuit Board – drill Bushing Air feed – Drill Bushing
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Drill Jig
• Definition:
They are the most common types of jigs used. Drill jigs
are used to hold the workpiece when drilling, reaming,
counter-boring, countersinking, spot-facing and tapping.

They incorporate locating, clamping and tool guiding
elements in their designs depending on the workpiece and
cutting action required.
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Drill Jigs
• Types of Drill Jigs
• Template Jigs
• Angle Plate Jigs & Plate Jigs
• Box Jigs

• Channel Jigs
• Leaf or Latch Jigs
• Pot Jigs
• Pump Jigs
• Post jigs
• Sandwich Jigs
• Table or Turn-over Jigs
• Trunnion Jigs 55
Template Jigs
• This is the simplest type of jig.
• It is simply a plate made to the shape and size of the work
piece, with the required number of holes made in it.
• It is placed on the work piece and the hole will be made by
the drill; which will be guided through the holes in the

template plate
• The plate should be hardened to avoid its frequent
replacement
• This type of jig is suitable if only a few parts are to be made.
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Template Jig
Template Jigs
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Angle Plate Jigs & Plate Jigs

• Plate-type jigs consist mainly of a single bush plate with
provision for location and clamping of a workpiece.
• The workpiece profile is located by using locating pins and
clamped using knurled screw clamps.

• The workpiece should be adequately supported against
bending due to the downward thrust of the drill.
• In angle plate jigs, locators are generally fixed to the vertical
wall of the angular body.
• Here the central locator must have clearance for the passage
of the drill after breaking though the workpiece.
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Angle Plate Jigs & Plate Jigs

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Plate Drill Jig
Plate Drill Jig
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Box Jigs
• Workpieces having holes on a number of sides can be drilled
economically with drill jigs.
• The jig body is generally shaped like a box with one side open
for loading and unloading the workpiece.
• The open side is provided with a hinged latch which often

houses bushes and clamping screws.
• The jigs is fitted with bushes on various sides and suitable jig
feet on the opposite sides.
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Box Jigs
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Box Jig
Box Jig – Angular Hole

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Box Jig – Angular Hole

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Channel Jigs
• The channel jig is a slightly more elaborate jig made from
channel section as compared to the plate type jig.
• Here part of the location is provided by the sides of the
channel.
• Its is generally more economical to make jigs channel shaped
in order to simplify location and clamping.
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Channel Jigs
Channel Jigs
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Channel Jigs

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Leaf or Latch Jigs

• The leaf or latch jig is an elaboration of the latch clamp, that
we have already seen.
• They generally have a hinged jig (bush ) plate.
• The jig plate is swung out to provide a clear path for loading
and unloading the workpiece from the top.

• The jig plate is clamped against the resting face by an eyebolt.
• The hand knob needs to be loosed by only a half turn and the
eyebolt is swung out in order to permit swinging of the jig
plate.
• They are particularly suitable for workpieces having location
surfaces and holes to be drilled on opposite sides.
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Leaf Jig
Leaf or Latch Jigs
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Leaf Jig

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Pot Jigs
• To provide for ample clearance of drill after drilling through
the workpiece, pot jigs are used.
• The drill bush is located on the top jig plate of the pot and the
jig plate is clamped to the top of the pot base.
• A clamp (usually a nut with C-washer) is used to clamp down
the jig plate to the pot base.
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Pot Jigs
Pot Jigs
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Pot Jig

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Pump Jigs
• These are smaller versions of sandwich jigs.
• Here two jig plates are positioned one above the other and
guided using guide pillars.
• Then the top plate is raised for loading and unloading of the
workpiece.
• The up and down motion of the plates is facilitated by rack
and pinion arrangement.
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Pump Jigs
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Post Jigs
• The post jig is used to locate the workpiece from its bore by
means of a locating post.
• This post is also used to locate the drill plate.
• The swing washer enables the drill plate to be removed

without removing the hand nut.
• This jig is used mostly for drilling and reaming.
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Post Jigs
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Sandwich Jigs
• Here two jig plates are positioned one above the other and
guided using guide pillars.
• Then the top plate is raised for loading and unloading of the
workpiece.
• Sandwich type of jigs are particularly suitable for workpieces

having parallel machined surfaces, square with the axis of
drilling.
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Sandwich Jigs
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Sandwich Jig
Sandwich Jigs
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Sandwich Jigs

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Table or Turnover Jigs

• Workpieces having no suitable resting surfaces are drilled with
this type of jigs.
• They are plate jigs with jig feet.
• The jig is first turned over and the workpiece is clamped to it
and then the whole jigs is again turned over

• Then the drilling process is completed and the jig is turned
over again and the workpiece is unclamped.
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Table or Turnover Jigs

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Turnover Jig
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Trunnion Jigs
• Here the entire workpiece is clamped and located in a box
which is pivoted using some indexing mechanism.
• This allows for large workpieces to be easily rotated to provide
for easy access to drill holes on the different sides.

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Trunnion Jigs
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Trunnion Jig
Open Drill Jig

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Angle Plate Jig

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Modified Angle Plate Jig

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V-Block Drill Jig

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V-Block Drill Jig

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Drill Jig Design

Jig design procedure
• Assumptions regarding earlier performed operations,
• Selection of type of jig with justifications,
• Selection and conceptual finalization of the location system,

• Selection and conceptual finalization of the clamping system,
• Designing the liner bush system,
• Any other specific features to be adopted,
101
Drill Jig Design

• Design and draw a jig for 2 holes M14 at 60 +/- 0.1 C.D. for
the component shown in figure.
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Drill Jig Design

• Operations performed earlier
• Facing of Ø 150 base
• Facing of opposite face maintaining 70 mm dia.
• Drilling of 16 dia. Holes at the base.
• Selection of type of jig
• For this component, base is suitable for the location , so it shall be

required to be loaded/unloaded in vertical direction. The processing
of the component is at opposite side of the locating surface.
Therefore a Leaf Jig is suitable for this component.
• Selection of locating system
• The component can be given a two pin location at a any pair of
opposite holes at the base. One pin shall be cylindrical with a
diameter 16f7 and clear length of 18 mm. Other pin shall be a
diamond shaped.
• For resting purpose 4 pads are preferred of size 30 mm dia. and 15
mm height. These pads can be placed on the same PCD, but in 103
between a pair of holes.
Drill Jig Design

• Selection of clamping system
• The clamping of work piece shall be preferred from upper side
centrally. Hence an adjustable clamping pad can be provided at
the swinging jig plate. Hence latch clamp is preferred.
• Design of Bush / Liner system.
Item I. D. O. D. Quantity
Component M14 - 2 tapped holes
Tapping Bush 14 F7 24 g6 1 slip bush
Drilling Bush 12 F7 24 g6 1 slip bush
Liner 24 H7 34 p6 2 nos.
Jig Plate 34 H7 2 bored holes
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Drill Jig Design

• Specific Features
• The height of the fulcrum pin shall be responsible for
maintaining the horizontally of the jig plate. So it is selected
as H = Rest pad thickness (15 mm) + Component Height (70
mm) + Chip removal gap (10 mm) + ½ X Jig plate thickness =

105 mm
• On the other side, there shall be a similar clamping post
with its clamping surface height = 15 + 70 + 10 = 95 mm
• The clamping pad preferably softer than Mild steel, shall be
adjustable to impart required clamping pressure.
• All items of the jig shall be of mild steel expect the liner
bushes. 105
• The clamping pad shall be of semi-circular shape.
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Design of Drill Jigs

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02-08-2018

Design of Jigs & Fixtures

Overview of the Lecture

Design of Jigs & Fixtures

Design of Jigs & Fixtures

• The work must also be supported so that it does not bend

Design of Jigs & Fixtures

Design of Jigs & Fixtures

Standard Jig Feet

Design of Jigs & Fixtures

• Gripping surfaces should be knurled.

Design of Jigs & Fixtures

Drill Bush Materials

diameters within 0.001 mm concentricity.

Types of Drill Bushes

Design of Jigs & Fixtures

Design of Jigs & Fixtures

Drill Bush Designation

Drill Bush Installation

Design of Jigs & Fixtures

Drill Bush Installation

Design of Jigs & Fixtures

Bushing Installation - Wrench

Bushing Installation - Vise

Design of Jigs & Fixtures

Bushing Installation – C clamp

Press Fit / Liner Bushes

Design of Jigs & Fixtures

Press Fit / Liner Bushes

Press Fit Bushing

Design of Jigs & Fixtures

Extended Drill Bush

the drill plate.

Extended Drill Bush

Design of Jigs & Fixtures

assembled manually without any press and are place over a

Design of Jigs & Fixtures Design of Jigs & Fixtures

Renewable Bush - Locking

Design of Jigs & Fixtures

• And next a reaming bush is installed on the jig plate and is

Design of Jigs & Fixtures Design of Jigs & Fixtures

Slip Bush - Locking

Design of Jigs & Fixtures

Design of Jigs & Fixtures

• To counter this, the shape of the drill bush is altered by

Design of Jigs & Fixtures

Design of Jigs & Fixtures

Castable Drill Bushes

the jig is laminated.

Castable & Chip-breaker Bushings

Design of Jigs & Fixtures

Directed Coolant & Oil-Groove Bushings

Directed-coolant bushings Oil Groove bushings feature

Circuit Board Drill Bushing

Design of Jigs & Fixtures

Gun Drilling Bushing Template Bushing

Design of Jigs & Fixtures

Design of Jigs & Fixtures

Design of Jigs & Fixtures

the drill; which will be guided through the holes in the

Design of Jigs & Fixtures Design of Jigs & Fixtures

Angle Plate Jigs & Plate Jigs

Design of Jigs & Fixtures