ABSTRACT

The target of the mass production is to increase the productivity and increase the
accuracy. This is done by reducing the set up cost and manual fatigue. Thus, mass
production can be achieved by the use of jigs. For large scale production of different
materials, a lot of time is wasted in set up of the device and clamping the device. Trial
and error method is usually practiced until the axis of the hole is properly aligned with
the axis of the drill. In such a situation a lot of time is being wasted to maintain the
accuracy. Eventually it increases the operator’s fatigue. Thus, drill jig increases
productivity by eliminating individual positioning, marking and frequent checking. The
main advantage of the jigs is interchangeability. The need of selective assembly is
eliminated. The parts of the jig will fit properly and, in the assembly, and all similar
components are interchangeable. Also, a jig reduces the repetitive nature required for
drilling holes, because the locating, clamping and guiding of the tool is done by the jig
itself. The tool guiding element is used whose chief work is to guide the tool in to the
correct position. Hence the requirement of skilled laborers is eliminated.

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1.INTRODUCTION
Increasing the productivity and accuracy are the two basic common way to
achieve this aim is mass production of component and mass production is achieved
economically by using jig and fixtures. Mass production ensures reduction in unit cost
by high productivity and interchangeability for ease of assembly. The productivity is
increased which is done by eliminating individual positioning, marking and frequent
checking. One does not need to repeatedly clamp and unclamp the object for various
purposes like positioning as the locating, and guiding of the tool is done by the jig itself.
Bushing which is a tool guiding tool is used. So, it reduces the presence of skilled
labourer. Drill jig helps to drill, ream and tap at a much faster speed and with great
accuracy as compared to holes done conventionally by hand. The responsibility of
maintain the accuracy of the hole is now shifted from the operator and given to the jig.

Table 1 Comparison of jig and fixture

Basis Jig Fixture
Definition It is a work holding It is also a device that
device that holds, holds supports and
supports and locates locates the workpiece.
the workpiece and But it differs from jig in
guides the tool for a way that it does not
very specific operation. guide the tool for the
operation.
Clamping Jigs are not clamped to Whereas fixtures should
the drill table unless and be securely clamped to
until large diameter the table of the machine
holes are to be drilled. upon which the work
Also, there is necessity needs to be done. Also,
to move the jig to bring there is no requirement
one bush directly under of alignment as bush is
the drill. absent in fixture.

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Operation Jigs are special tools in Fixtures are specific
operation particularly in tools used in milling,
reaming, tapping and shapers and slotting
boring. machine.
Gauge block Gauge blocks are not Gauge blocks are
necessary. necessary for effective
handling.
Weight Jigs are generally lighter Fixtures are usually
in construction. heavier in construction.

2. ELEMENTS OF JIG
2.1 Locating Elements
Locating elements includes pin, slot and recesses which locate the job on
jig. It may be fixed or adjustable. They are usually made up of hardened steel.

2.2 JIG BODY

Jig body is the main structural element of jig. The body is formed by
welding. It maintains relationship between locators, clamps, bushes and the
machine tool on which job is to be processed.

2.3 BUSHES
These are tool guiding elements usually made up of mild steel. They must
be interchangeable, precise and wear resistant. A bush is held in hole of jig
through which drill is to be passed. The bushes are classified as fixed bushes,
Renewable bushes and slip bushes.

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3. TYPES OF JIGS
3.1. PLATE JIG
Plate jigs are in many ways similar to template jig. The only difference is
that there is a location for built in clamps for holding the work in case of template
jig. Bushings may or may not be provided in template jig. The factor on which the
availability of the bushing depends is the number of jobs to be manufactured.
Plate jigs can also made with legs which help in raising the jig off the table for
machining of large work. This style is called table jig.

Figure 1 PLATE JIG

3.2 LEAF JIG

Leaf jig is also called as open type jig. Here the top plate which is used to
hold the job in its place is arranged in such a way that it swings about the fulcrum
point. Thus it helps in clearing the path completely for loading and unloading of
the job to the device. The plate which covers the jig is called leaf, latch or lid. It
also has drill bushes fitted into it which guides the tool to its right position while
machining the job.

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 Figure
2 LEAF JIG

3.3 BOX JIG

Box jigs is used where there is drilling at number of distinct angles. Hence
the part is to be held precisely while positioning the jig. Here there are multiple
locators placed on different walls of the box whose sole reason is to locate the
work piece securely while drilling is being carried out. Unlike leaf jig the box is
being closed by the pivot wall. One should always try to avoid placing bushings
on the moving walls of the jig. This helps in better accuracy.

Figure 3 BOX JIG

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4. PROBLEM DEFINITION
In industries components for pipe connecting flange drilling operation is
performed by manual marking. Hence manual error occurs in marking for drilling
operation. Also, we observed that production cycle time is maximum.

4.1 Due to Above Conditions Following Problem Occurs:

• Spacing between equi -spaced holes is not maintained.
• A problem occurs in assembly of such components.
• CDD (Contractual Delivery Date) is not maintained.
• Error observed in pcd of component at drilling operation.

PIPE CONNECTING FLANGE:

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5. JIG DESIGN
It is a work holding device that holds, supports and locates the workpiece and
guides the cutting tool for a specific operation. Jigs are usually fitted with hardened steel
bushings for guiding or other cutting tools. a jig is a type of tool used to control the
location and/or motion of another tool. A jig's primary purpose is to provide repeatability,
accuracy, and interchangeability in the manufacturing of products. A device that does
both functions (holding the work and guiding a tool) is called a jig.
5.1 BOX JIG DESIGN

SELECTION OF BUSH

Fixed bush

DDB (Page no: 5.100)

For 15 mm select d1 = 15 mm

d1 = 15 mm

d2 = 25 mm

l1 = 16 mm

l2 = 12 mm

l3 = 30 mm

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SELECTION OF LOCATOR

Thickness of the jig plate = Height of the bush

Thickness l2 = 12 mm

Round Locating Pin

DDB (Page no: 5.92)

D = 10 mm

d = 9.5 mm

d1 = 8 mm

d2 = 7.5 mm

h1= 8 mm

h2 = 16 mm

DESIGN OF JIG BODY

Type of Body: Cast Body

Width of the jig = 130 mm (as per w/p width)

Length of the jig body:

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Allowance taken as 15 mm

= 12+16+125+15+12= 180 mm

Height of the jig:

Clearance between w/p & jig plate:

For ductile material half of drill diameter

= 12+5+70+7.5+12= 106.5 mm

SELECTION OF CLAMP

DDB (page no: 5.104)

Select pressure pad:

d1 = 10 mm (because locator is 10 mm)

d4 = 3.8 mm f = 25 mm t1 = 4.5 mm

d5 = 8 mm h = 7 mm

d6 = 4 mm r1 = 1.2 mm

d7 = 1.5 mm r2 = 0.3 mm

e = 2.5 mm t2 = 0.5 mm

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SELECTION OF SCREW

DDB (Page no: 5.105)

Screw = M6

d2 = 4.5 mm l1 = 6.5 mm Z = 1.0 mm

d3 = 3 mm l2 = 2.2 mm

r = 3 mm l3 = 2.2 mm

r1 = 0.6 mm L = 30 mm

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5.2 CHANNEL JIG DESIGN:

SELECTION OF BUSH

Fixed bush
DDB (Page no: 5.100)
For 15 mm select d1 = 15 mm
d1 = 15 mm
d2 = 25 mm
l1 = 16 mm
l2 = 12 mm
l3 = 30 mm

JIG PLATE DESIGN

Thickness of plate = 12mm (from drill bush)

Length of the jig plate = 12+15+125+18(clearance)

= 170mm

Height of the jig plate = 12+70+12+6(clearance)

=100mm

CENTER PIN DESIGN

Dia of center pin = 50mm (bore dia)

Dia of pin head = 60mm

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CHANNEL JIG DESIGN:

EXPLODED VIEW

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6. SELECTION OF BETTER CONCEPT:
From the above jig designs, we select the channel jig because manufacturing the
channel jig is easier compared to box jig and the slot in the component is used for fool
proofing and the loading and removing of work piece in jig can be done easily compared
to the box jig.

FOOL PROOFING:

• In this the location system positively prevent the wrong loading of the work piece
in a fixture by fool proofing.
• It would be impossible to load the work piece wrongly due to a fool proofing slot.

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7. PROCESS PLANNING SHEET
7.1 PROCESS PLANNING SHEET FOR FLANGE WHEEL
PROCESS PLANNING SHEET FOR FLANGE WHEEL
Part no :
Part Name: Flange wheel
Material: Mild steel
Drawing no:
Operation Operation Department Machine Tool used Work Measuring
no used holding instrument
1. Flange Cutting Band saw Hacksaw Machine Ruler
wheel cutting vice
cutting machine
2. Turning Machine Lathe Single Chuck Vernier
shop point Calliper
cutting
tool
3. Facing Machine Lathe Single Chuck Vernier
shop point Calliper
cutting
tool
4. Drilling Machine Lathe Ø30mm Chuck Vernier
Ø30mm shop Drill Calliper
center
5. Boring Machine Lathe Single Chuck Vernier
shop point Calliper
cutting
tool
6. Drilling Machine Lathe Ø10mm Chuck Vernier
Ø10mmx4 shop Drill Calliper
holes

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7.2 PROCESS PLANNING FOR FLANGE HUB
PROCESS PLANNING SHEET FOR FLANGE HUB
Part no :
Part Name: Flange Hub
Material: Mild steel Drawing no:
Operation Operation Department Machine Tool used Work Measuring
no used holding instrument
1. Flange Cutting Band saw Hacksaw Machine Ruler
Hub blank cutting vice

cutting machine

2. Turning Machine Lathe Single point Chuck Vernier

shop cutting tool Caliper
3. Boring Machine Lathe Single point Chuck Vernier
shop cutting tool Caliper

7.3 PROCESS PLANNING FOR JIG

PROCESS PLANNING SHEET FOR JIG
Part no :
Part Name: Jig plate
Material: Mild steel
Drawing no:
Operation Operation Department Machine Tool used Work Measuring
no used holding instrument
1. Blank Cutting Gas - - Ruler
cutting cutting
[Rectangle] machine
2. Facing – Machine Lathe Single Chuck Vernier
1mm (up to shop point Calliper
flange Ø cutting
size) tool
3. Drilling Machine Lathe Ø30mm Chuck Vernier
shop Drill Calliper

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4. Boring Machine Lathe Single Chuck Vernier
shop point Calliper
cutting
tool
5. Drilling Machine Lathe Ø20mm Chuck Vernier
Ø20mmx4 shop Drill Calliper
holes
6. Grinding Machine Bench Grinding Chuck -
(Finishing) shop Grinder wheel

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