THE DESIGN AND MODELLING OF A BOX

DRILL JIG SYSTEM

GROUP C

MEE322: MANUFACTURING TECHNOLOGY

SUBMITTED TO:

Course Lecturer: Prof. Paul Ihom

Date: 21st May, 2021

 INTRODUCTION

• In the manufacturing industry, manufacturing time and cost

has been an important factor in determining its
productivity. Jigs are production tools used for
manufacturing of duplicate and interchangeable parts with
great accuracy. They are specifically designed in order to
machine a large number of components, assembled
identically and for easy interchangeability of components.
• A jig can be defined as a work part used in holding and
locating positions and guides or controls the drilling tool
during machining. Drill jig increases productivity and
eliminates individual, positioning and repetitive checking
that may cause a lot of errors. Interchangeability is one of
the advantages of a jig. A jig minimizes the repetitive
nature of work required for drilling a hole, as the locating,
clamping and guiding are done by jig itself. The tool
guiding element helps to set a tool in correct position as
compared to conventional hand methods. The drill jig helps
in drilling, reaming and tapping holes at higher speed with
a high degree of accuracy.
PROBLEM STATEMENT / SCOPE
• The workpiece to be drilled is a rectangular workpiece
and the drill jig to be designed is a box type jig where
the workpiece can be drilled from the top and as well
as the two ends.
• In this design, special clamping mechanism like leaf
clamp, quarter-turn screw has been incorporated. The
drill bushing, jig feet and solid locators are also the
components of this jig.
 FORCE ANALYSIS
The forces acting on the system are ;
• The clamping force due to the leaf clamp and the thumb
screw
• Thrust force (feed force due to the vertical movement of the
drill bit)
• The drilling torque due to the rotation of the drill bit: this
result in the vibration of the workpiece and also the jig itself
• The reaction forces due to base supports and locators
The clamping force acting during this operation occurs between the Leaf clamp, thumb screw and the jig body.
The Torque, T = (F×d)/20
The clamping force, Q = Torque(T) * Safety factor (per unit length)

The Thrust force and the Drilling torque are the feed force due to the vertical movement of the drill bit. To
exert this force the power of the upright vertical drilling machine (Model: DB-12; Flow capacity: 12L/min;
Specification: 380V, 50Hz) is considered which is 0.75/0.55kWatts.
The feed (drill bit) rotating rate, s = mm/rev
Diameter of the drill bit, d = 6mm
k= material factor
Force acting on each of the lips of the drill bit, F = (k×d×s)/4
The Torque, T = (F×d)/20
Maximum spindle travel, L = 140mm (5½ inches)

The reaction force is the frictional force acting between the weight of the work piece and drilling force on the
base and side locators. Therefore all the locators must be capable of resisting both forces exerted by the work
piece and drill force.
 MATERIAL SELECTION
• During recent years the selection of the materials that are to be
used in the design and manufacture has assumed great
importance and for numerous reasons, it is certain that it’s
importance is going to continue to increase. Material selection is
both complex and a continuing process.
• Jigs are made from variety of materials to resist wear and tear,
the materials are often tempered and hardened. The various
components of the jig are made up of different materials chosen
based on the forces acting on each parts.
• In designing a drill jig the thought pertaining to material
selection is to know the available materials that will provide the
essential properties required for quality design.
• For the design of a good drill jig the functional requirements for
each components with the material used are considered;
• For the jig body (Box body type) , The body is constructed by casting out
the jig body (frame) and metals. i.e mild steel(<0.3% carbon) and then heat
treated for stress reduction .It is required to be resistive on impact, strength,
hardened and tempered.
• For the drill bushing it is required to be resistive to vibrations, wearing and
the torque force induced during the drilling operation. Cast iron containing
(2%-2.5%) carbon.
• For the solid locators it is required to be of adequate strength and rigidity
,for this purpose hardened steel is to be used to withstand the extreme
vibrations attained. Mild steel with diameter of 16mm was chosen for the
design which contains (0.85%-1.18%) carbon and when tempered with oil
are very resistive to tear and wear of the locators.
• For all the screws (fasteners) used in the design it is required to be resistive
to tear, shear and wear. High tensile steel which contains (0.45%-0.65%)
carbon and alloys of Ni2CrMo28 (40%).
 EQUIPMENTS USED
• The type of machine required for the drilling operation is an Upright
vertical drilling machine; Model: DB-12; Power: 0.75/0.55kWatts;
Flow capacity: 12L/min; Maximum drilling diameter: 25mm(1inch);
Maximum spindle travel: 140mm(5½ inches); Motor power: 0.75 or
0.55kW; Specifications: 380V, 50Hz.
• The specifications for the drill bit used are; a 6mm diameter drill bit
made of a high speed steel required to withstand wear and tear during
the operation, the temperature induced and to prolong the tool life of
the drill bit. The length and cutting angle of the drill bit is also
considered.
• The specified material of the work piece to be used for the drilling
operation is mild steel which is of good quality to overcome the
resistant force implemented by the work piece.
 METHOD OF CONSTRUCTION
• The jig is first obtained by casting of mild steel into an hollow rectangular box
• Recesses are machined out of the four corners of the hollow cast box; these serve as relief area
for chips form during the drilling operation to escape
• The bottom plate contains rest pads or support the workpiece and as well position the workpiece
in respect to the machine table
• The jig feet is welded on the bottom plate and as well the two ends of the jig; this help to support
the jig itself during the operation
• The jig body is designed in such a way to accommodate excessive metal chips that are produced
during the operation and also easy removal of the excess metal chips.

• The locating system comprises of: Two side locators and a single locators which are button
locators are mounted on the two side of the jig which are perpendicular to each other
• The clamping system consists of: (a) The leaf clamp which comes with a thumb screw that
tighten the workpiece against the bottom rest pads; this screw is located on the top plate. (b)
Quarter-turn screw which enhance the locking of the leaf clamp against the top plate. (c) And also
there is one thumb screw at the side which helps in locating the workpiece against the opposite
locators.
Figure 3: A Vertical drilling machine
 WORKING PROCESS
• Installation of the box drilling jig on the upright vertical drilling machine bed
(inbuilt fixture).
• Open the box jig and place the workpiece properly on the base locators relative
to the cutting tool and the workpiece should also lap with the side locators
which will hold the workpiece firmly.
• Align the box jig with the vertical drilling bit. The diameter of the drill bit (6mm)
used must be of a clearance tolerance with the drill bushing of the jig.
• Start the drilling machine and slowly adjust the drill handle to fit properly into
the drill bushing unto the workpiece.
• While drilling into the work piece (top) observe the stopper attached to the drill
bit in order not to exceed the specified hole depth. Once the limit is attained the
drill bit is removed gently all in one stroke of operation (i.e. a to and from
operation) and the machine is turned off.
• Uninstall the box jig and reposition it fitly installed on the vertical drilling
machine to the side to enable the end drilling of the work piece.
 CONCLUSION
• In this project the drill jig is designed for a rectangular
workpieces. The box jig was modeled using AutoCAD
and AutoCAD INVENTOR. The proposed box jig is a
reliable device which will enhance maximum
productivity and save production time during
machining operation and also to enhance maximum
metal chippings.
 References
1. Jigs and fixtures by Joshi P. , Tata McGraw Hill Publishers (2010)
2. Jigs and fixtures and their purposes, Chennu V. (2014)
3. Mini Project on Jigs and Fixtures by Spogel (2014).
4. Design of Jigs and Fixtures- Online
(https://www.en.m.wikibooks.org).