FACULTY OF MANUFACTURING & MECHATRONIC

ENGINEERING TECHNOLOGY

SEMESTER I 2019/2020

PROJECT REPORT

BFF3632 DESIGN FOR JIGS AND FIXTURES

GROUP 1

GROUP MEMBERS

NAME ID
NUR NADIA BINTI MUHD NOR FA17087
MUHAMMAD FARIS BIN MOHD ZAIDI FA17092
NIK MUHAMMAD SHAHIR B NIK ROSLI FA18021
MUHAMAD ALIFF ASYRAF BIN CHE ROSLI FA17083

Submission Date : 16/4/2021

Lecturer : Dr. Ahmad Rosli Bin Abdul Manaf
 CONTENTS
......................................................................................................................................... 1
INTRODUCTION............................................................................................................. 3
PROBLEM STATEMENT .............................................................................................. 3
OBJECTIVES ................................................................................................................... 4
DESIGN DEVELOPMENT ............................................................................................. 4
DESIGN CONSIDERATIONS ........................................................................................ 4
MACHINING PROCESS PLANNING (VIRTUAL) .................................................... 6
MACHINING PROCESS FLOW CHART .................................................................... 6
PROCESS FLOW CHART FOR FABRICATING JIGS & FIXTURES WITH
WORKPIECE ................................................................................................................... 7
WORKPIECE (BOTTLE OPENER WITH JOYSTICK DESIGN) ........................... 8
JIGS BASE ........................................................................................................................ 9
CLAMP ............................................................................................................................ 10
INTRODUCTION

Jigs and fixtures are commonly used in manufacturing companies to improve product
efficiency during development. In general, jigs and fixtures are capable of increasing efficiency,
decreasing running time due to increased speed, lowering costs, and many other benefits. Jigs and
fixtures are usually constructed of reinforced materials such as cast iron and die steel. It is done to
prevent any harm to the workpieces. In reality, jigs and fixtures are two distinct concepts that must
be understood in the context of manufacturing.

Jigs is a work holding device that will holds, supports and locates the workpiece and guides
the cutting tool for a specific . They are not fixed to the machine table. Aside from that, jigs are the
type of tool used to monitor the position or motion of another tool. Its aim is to provide accuracy
and repeatability in product manufacturing. The setting of the device is done by machine adjustment,
setting block or slip gauges. Fixtures are used to locate and hold a workpiece during a machining
procedure or another industrial process.

To gain a better understanding, we as students must delegate design jigs and fixtures to team
members to ensure that it can clamp or keep our product later.

PROBLEM STATEMENT

Based on our project of designing a jig and fixture for our chosen design, a bottle opener
design, we must weigh many factors in order to complete this task successfully. The considerations
that we must remember include the identifying, supporting, and clamping methods that are truly
suitable and can provide us with a simple way out during the machining phase of the bottle opener
design. In addition, we must determine their locating points and outline structure before
considering the adjustable locating points. Aside from that, we must avoid complicated clamping
arrangements in our jig and fixture design. It will improve the final product's efficiency.

We also design our jig and fixture to minimise running time in order to shape better machining.
The locators and clamp can be adjusted in order to reduce the number of locators while also
lowering the cost. Finally, in order to have an effective design, we must create a locator
arrangement that is ideally suited to the workpiece.
OBJECTIVES

1. To design a jig and fixture that can fit with our design.
2. To identify the best clamping, locating and also supporting method that can give an easy
way in machining process of our products.
3. To ensure that the complex parts can be easily machined
4. To provide safety during the machining later

DESIGN DEVELOPMENT

The calculations and descriptions for the jigs and fixtures design were based on the
six jig and fixture design principles, which are clamping, clearance, stability, rigidity,
handling, and other considerations.

Based on the consideration factors, the concept of the designs of workpieces, jigs,
and fixtures is created. The designs drawn were proposed for improvement, and team
members would choose the best design based on jigs and fixtures consideration factors.
CATIA V5 can be used to draw on this product. The CATIA V5 software can be used to
model the design and generate the programming that will be sent to the CNC machine to
execute the operation.

DESIGN CONSIDERATIONS

Jigs and fixtures are made up of many components that serve different functions, including a
locating element, a clamping element, and a tool guiding or setting element. This design is based
on various factors that are studied to produce the best possible performance, such as the fact that
jigs and fixtures should be made of rigid materials to allow for easy handling. The factors to be
considered for design of jigs and fixtures are as below:

I. Component

⚫ Ensure function of the jig is performed in a proper sequence.

 ⚫ Maximum operations should be performed on a machine in single setting.

II. Capacity of the machine

⚫ Type of machine on which the operation is to be performed needs careful consideration.

III. Production requirements

⚫ Design should be made on basis of actual production requirements.

⚫ Decision for use of manual and automatic tooling arrangements.

IV. Location

⚫ Ensure equal distribution of clamping forces throughout all sequence of operation.

⚫ Should be easily removable.

⚫ Ensure the movement of workpiece should be restricted.

V. Loading and unloading arrangements

⚫ Should be adequate clearance for loading and unloading.

⚫ Size variation must be accepted.

VI. Clamping arrangement

⚫ Used as far as possible.

⚫ Should be always arranged directly above the points supporting the work.

VII. Clearance between Jigs and Components

⚫ Leave enough clearance to accommodate variable sizes of work.

VIII. Rigidity and vibration

⚫ Must possess enough rigidity.

⚫ The product should not vibrate during process.

IX. Safety device

⚫ Assure full safety to the operation.

X. Cost

⚫ Make sure the product is low cost.

⚫ Initial investment required to design and build should be optimum

MACHINING PROCESS PLANNING (VIRTUAL)

MACHINING PROCESS FLOW CHART

Startt

Generate Idea

Product Specification

Product Design

Select Design

No
Design satisfying.

Yes

Process Planning

Testing

No
Product considered as
successful.
Yes

Production Planning

End
Manufacture
PROCESS FLOW CHART FOR FABRICATING JIGS & FIXTURES WITH
WORKPIECE
WORKPIECE (BOTTLE OPENER WITH JOYSTICK DESIGN)

Material Aluminum
Tool Process Max Depth of cut Feed Rate Shape
0.5mm(Total depth: hole
Flat end mill 4 Drilling 5252mm/min
5mm)
0.5mm(Total depth: cross
Flat end mill 4 Roughing 5252mm/min
5mm)
0.5mm(Total depth: hole
Flat end mill 7 Drilling 1909mm/min
5mm)
0.5mm(Total depth: contouring
Flat end mill 4 Roughing 5252mm/min
5mm)
 JIGS BASE

Material Bakelite
Tool Description Process Depth of cut Spindle Speed
5mm Drill bit Screw Drilling 20mm 1500 rpm
Screw & fool
6mm Drill bit Drilling 20mm 1500 rpm
proofing
7mm Drill bit Locator Drill bit 12mm 1500 rpm
Flat end mill 8 U-shape Pocketing 40mm(15x15) 1000 rpm
CLAMP

Material Aluminum
Tool Process Depth of cut Spindle Speed
4mm flat end mill Pocketing 12mm 1500 rpm
6mm Drill bit Drilling 39mm(through) 1500 rpm