Title:

BORE CURVING JIG

Code & Paper:
MTP24103 (MANUFACTURING PROCESSES I)

Course:
B. TECH. (HONS) IN MANUFACTURING ENGINEERING TECHNOLOGY (PRODUCT
DESIGN)

Session:
4th SEMESTER

Lecture Name:
PN ROZIMAH BINTI YUSOF

Student Name & Matric:

MUHAMMAD LUQMAN BIN ISMAIL (051272)
 ABSTRACT
The purpose of this experiment is to create bore curving jig. Material removal involves
machine processes of one type or another. It involves starting with a piece of material then
removing any unwanted areas to create the desired shape and configuration. In this
experiment the desired part of the process is a bore curving jig. Which has five components
that has different complex shape each. Therefore each part need to be processed separately at
a certain accuracy. There is three main processes utilized which is, turning, milling, and
drilling. In turning, a part is shaped to a round configuration through various operations and
set-ups. Milling will create a part that is mainly square in nature utilizing various set-ups,
cutters, and operations. Drilling produces holes to various diameters utilizing drills and
reamers. The material removal process will produce the most precise work, but is extremely
time consuming and very waist full of material during the processing.
1.0 INTRODUCTION

Jigs and fixtures are manufacturing tools that are employed to produce interchangeable and
identical components. They are unique tool-guiding and work-holding devices designed
specifically for machining and assembling large number of parts.

Chennu (2014), listed the following as the purposes of jigs and fixtures reduction of
production cost, increase of production rate, high accuracy of products without any
manufacturing defects, provision of interchangeability, easy machining of complex shaped
parts, reduction of quality control costs, etc. According to Meduettaxila (2012), Jigs and
fixtures eliminate the necessity of a special set up for each individual part. He observed
that once a jig or fixture is appropriately set up, that any number of duplicate components
can be readily produced without additional set up.

A jig is a work-holding device that supports, holds, locates a work-piece and also guides
the cutting tool for the desired machining operations. Its main objective is to ensure high
degree of precision, interchangeability, and duplication in product’s manufacturing, it is
also applied to manipulate the location and movement of other tools.

Nanthakumar and Prabakaran (2014), explained that a jig is a type of custom-made tool
used for the location and motion of another tool. They observed that the primary purpose of a
jig is to provide repeatability, accuracy, and interchangeability in the manufacturing of
products. Although the most common jigs are the drilling and boring jigs, they are all
identical except for the shape, type, and the position of the bushings for drilling or boring.
While according to Joshi (2010), jigs are imparted with tool guiding elements such as drill
bushes, which regulate the tool to the right position in the work piece. He observed that they
are rarely clamped on the machine table as it is essential to push the jig on the table to align
the numerous bushes in the jig with the spindle of the machine.

Fixtures are rigid and sturdy mechanical devices which allow fast and precision machining
with reliable quality, interchangeability, and lead time reduction. As a work-holding device,
fixtures do not position, guide, and locate the cutting tool, as it is achieved by making
necessary adjustments on the machine. Kaija, and Heino (2006), explained that the main
purpose of a fixture is to locate and in some cases hold a work-piece during either a
machining operation or some other industrial processes. He pointed out that what makes
fixtures unique is that they are all manufactured to fit a particular shape or part.
 Jig boring is used to accurately enlarge existing holes and make their diameters highly
accurate. Jig boring is used for holes that need to have diameter and total run out controlled to
a high degree. Typically, a part has holes machined on regular equipment and then the part is
transferred to a dedicated jig boring machine for final operations on the especially accurate
holes. Jig boring can also maintain high accuracy between multiple holes or holes and
surfaces.

2.0 Objective

2.1 Understand material removal process.

2.2 Understand jig capability and different type of jig.

3.0 Materials and Procedures

3.1 Materials

Horizontal Bandsaw Machine.

Turrate Milling Machine

Up Right Drilling Machine. Lathe Machine
 Tubular Hacksaw

3.2 Procedures
To make the bore curving jig they had been divided in to three parts. Each part had
different procedures. They had additional part that been provided by lab due to limited of
time.
3.2.1 Part A (Base)
1. Mild steel width 100 mm, height 25 mm was cut using the horizontal band saw
machine by 135 mm length.
2. The part than set on lathe machine to begin facing process. The part was located
perpendicular from the centre of the part to dead centre of lathe machine. The part located in
spindle of lathe machine and was clamped tightly to avoid it slipped away.
3. A hole with 7.5 mm depth and 78 mm diameter are made from the centre.
4. Another hole with 24 mm diameter drilled through the part at the centre.
5. Another hole with 7.5 mm depth and 78 mm diameter was made from the part
6.