Lab Session: 07

Objective:
Design an indexing jig for the flange coupling of stainless steel to drill 4 holes of diameter
10mm on its pitch circle diameter to produce a lot of 1500 parts.

Figure 1: Component Diagram with Dimensions Solution:

1. Design of Indexing Pin:

2. Selection of Bush:
There should be adequate clearance for the chips removal otherwise it can affect the accuracy
as well as the overall process.

Clearance in Bush for chip disposal=0.5 Internal diameter

Internal Diameter=10mm

Clearance=5mm

Total Internal diameter after inclusion of chip clearance allowance =10+5

=15mm

3. Design of Nut and Bolt:

4. Design of Jig Body:

After the selection of indexing pin, bush, bolt and nut for the jig, the next step is to design an
appropriate Jig. The Cast iron has been used for building the jig because it offers a low-cost
solution as well as good base so that jig can easily support the whole operation. The length of
workpiece is 45mm.So, 6omm is taken as the height and 15mm is the clearance between the
bush plate and workpiece. The length is taken as 160 mm because the workpiece ha s a diameter
of 120 mm. The width of lower base plate is taken as 35mm so that it can provide a solid
foundation, the width of upper base plate is 10mm.
5. Assembly of Indexing Jig and Component:
6. Bill of Material (BOM):
Enlist the bill of material for the leaf jig designed in which specify the part name used in the
jig, its material and how many parts (e.g. clamps) are used in the assembly of jig.
Sr. No. Part Name Material Quantity
1 Indexing Pin Hardened Steel 1
2 Drill Bush Tungsten Carbide 1
3 Hex Nut Alloy Steel 1
4 Jig Body Cast Iron 1

a. Explain the reason for the selection of indexing pin, bush, bolt and nut
in designing indexing jig for the component shown above and the
material selected for each part.
Indexing pin, also known as locating stud is used to locate the position of hole. In
indexing jig, an already bored cylindrical workpiece is used. The first hole is used as
reference hole or datum hole, which is subsequently employed for drilling other holes.
The hardened steel has been selected for the indexing pin because indexing pin has to
be put in and out after drilling each hole. It would be facing a lot of wear and tear
especially if we take into account that there are 1500 parts and each part has 4 holes.
So, hardened steel is ideal material keeping in view the application.
Drill Bush is used to guide the drill bit to drill accurate holes. Their outer diameter is
typically unground, which allows for custom grinding. They are typically made up of
hardened steel, stainless steel, carbides, Tungsten carbide and Titanium nitride. There
are different types of bushes such as Press Fit, slip fit, with or without liner depending
upon the applicated and intended use. To ensure accuracy in work, following factors are
crucial.
• Alignment
• Diametral Interference fit
• Chip clearance
• The proximity of bush and workpiece

Tungsten Carbide is used for bush making because stainless steel is itself a hard
material. Similarly, Tungsten Carbide bushes have 50% more life as compared to
conventional steel bush.

Hex Nut or Nut and bolt, is used for subsequent loading and unloading of part after
drilling operation has been performed. It has to face a lot of wear and tear during this process.
So, its surface needs to be hardened so that it can bear the wear. Any alloy steel can be used for
making hex nut having higher hardness.