SANDWICH JIG DRILL MANUFACTURING

Minor Project Report

Bachelor of Technology In

Mechanical Engineering

Submitted by: Supervisor:Osaama Ullah Khan Mr. Ram dayal Asst. LecturerMechanical Batch B

DEPARTMENT OF Mechanical ENGINEERINGMewar University,

NH - 79 Gangrar,Chittorgarh (Rajasthan) – 312901, India

ACKNOWLEDGEMENT

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I am very pleased to express my deep sense of gratitude to my esteem guide

“Mr. Ram dayal” for his valuable training, encouragement and facilities

provided during the project Work.

There were umpteen moments when I learned heavily from him. It is the fact,

without his construction and simulating criticism arduous but invaluable advice

sought time to time, masterly guidance deep personal interest and attention, this

work would not have seen the down of the day and could never have attend the

present stage. I am also heartily thanks to Mr. Ashok Gadiya(Honorable,

Chancellor), Mr. Harish Gurnani(Director, training and placement), Mr. D.K

Sharma (HOD, Department of MECH) and all faculty members for their co-

operation .I extend my sincere thanks to my friends who were there with me

directly or indirectly during the Work.

PLACE: Chittorgarh B.Tech, IVthyear

DATE : 21/11/2013 Mechanical Engineering

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Abstract

Jig and Fixtures setup is used to reduce the work load within the Company.The

jigs and fixtures are the economical ways to produce a component in mass. So

jigs and fixtures are used and serve as one of the most important facility of

mass production system. These are special work holding and tool guiding

device. Quality of the performance of a process largely influenced by the

quality of jigs and fixtures used for this purpose. What makes a fixture unique

is that each one is built to fit a particular part or shape. The main purpose of a

fixture is to locate and in the cases hold a workpiece during an operation. A jig

differs from a fixture in the sense that it guides the tool to its correct position

or towards its correct movement during an operation in addition to locating

and supporting the workpiece.

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CONTENTS

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Topic Page No.

ACKNOWLEDGEMENTS 03

ABSTRACT 04

CHAPTER:-1 INTRODUCTION

1.1 Definition 06

1.2 Purpose and Advantage 07

CHAPTER:-2 TYPES OF JIGS

2.1 Table. 08

2.2 Angle. 09

2.3 Plate. 10

2.4 Sandwich. 11

CHAPTER : - 3 MATERIAL USED & DIMENTIONS 12

CHAPTER:- 4 CONCLUSION

4.1 Conclusion of project 13

4.2 References 13

List of Figure

S.No. Figure no. Page No

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01 2.1.Table Jig 09

02 2.2. Angle Jig 10

03 2.3. Plate Jig 11

04 2.4.Sandwich jig 11

05 2.5. Load Curve 12

CHAPTER:-1

INTRODUCTION

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1.1Definition

The jigs and fixtures are the economical ways to produce a component in mass. So jigs and fixtures are used and serve as one of the most important facility of mass production system. These are special work holding and tool guiding device. Quality of the performance of a process largely influenced by the quality of jigs and fixtures used for this purpose. What makes a fixture unique is that each one is built to fit a particular part or shape. The main purpose of a fixture is to locate and in the cases hold a workpiece during an operation. A jig differs from a fixture in the sense that it guides the tool to its correct position or towards its correct movement during an operation in addition to locating and supporting the workpiece.

An example of jig is when a key is duplicated; the original key is used as base for the path reader which guides the movement of tool to make its duplicate key. The path reader of a CWC machine here works as a jig and the original is called template. Sometimes the template and jig both are the name of same part of a manufacturing system..

1.2 .PURPOSE AND ADVANTAGES OF JIGS AND FIXTURES

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(a) It reduces or sometimes eliminates the efforts of marking, measuring and setting of workpiece on a machine and maintains the accuracy of performance.

(b) The workpiece and tool are relatively located at their exact positions before the operation automatically within negligible time. So it reduces product cycle time.

(c) Variability of dimension in mass production is very low so manufacturing processes supported by use of jigs and fixtures maintain a consistent quality.

(d) Due to low variability in dimension assembly operation becomes easy, low rejection due to les defective production is observed.

(e) It reduces the production cycle time so increases production capacity. Simultaneously working by more than one tool on the same workpiece is possible.

(f) The operating conditions like speed, feed rate and depth of cut can be set to higher values due to rigidity of clamping of workpiece by jigs and fixtures.

(g) Operators working becomes comfortable as his efforts in setting the workpiece can be eliminated.

(h) Semi-skilled operators can be assigned the work so it saves the cost of manpower also.

(i) There is no need to examine the quality of produce provided that quality of employed jigs and fixtures is ensured.

2. Various types of Jigs :-

1. Table.

2. Angle (Modified and Normal)..

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3. Plate.

4. Sandwich.

2.1. Table jig : -

Table jig is plain plate jig with legs.

Main purpose is holding irregular or non-symmetrical work pieces that

cannot be held in other plate jig forms.

The part is referenced by the surface being machined rather than the

opposite side.

Table jigs can accommodate almost any shape work piece.

Limitations are the size of the part and availability of clamping surfaces.

Sample of a Table Jig

The part is clamped between jig plate and the clamping device

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Fig.2.1

2.2 Angle jig : -

Angle plate jigs are used to hold parts that are machined at right

angles to their mounting locators.

A variation is the modified angle plate jig, which is used for machining

angles other than 90 degrees.

Allow the drill to complete the hole .

avoid drilling the relieved portion of the locator.

Sample of Angle Jigs

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Fig.2.2

2.3 Plate Jigs : -

Plate jigs are basically modified or improve template jigs.

While performing the same locating function as template, they also

incorporate a mean of securing the part.

This added feature, clamping, is what allow plate jigs to locate part

with a high degree of accuracy and repeatability.

Plate jigs are actually a family of jigs rather than a single type of to

Sample of Plate Jigs

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Fig. 2.3

It is moveable on big plate type objects as a guide

2.4 Sandwich jigs

the sandwich jig is almost identical to a plain plate jigs.

the only difference is the backup plate found on the sandwich jigs.

this back up plate allows the jigs to hold very thin part that could

bend or distort under tool pressure.

another use of a sandwich jig is as a combination jig.

Sample of Sandwich Jig

Fig.2.4

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3. MATERIAL USED & DIMENSIONS : -

Mild steel plates are used each having dimensions as follows : -

Plates:-

Length = 16cm

Breath = 4.5cm

No. of Locating Pin Holes = 4 holes each of dia 6mm for drilling

operation.

= 4 holes each of dia 6mm for locating pins.

4 for nut and bolts for holding the job having dia. Of 6mm.

Load cuve : - stress-strain graph for mild steel plates.

Fig. 2.5

4 .1 CONCLUSION: -

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Open Jigs are convenient and simple.

Cheap to produce which is good for economical reasons.

Suitable for home and industrial.

Cheap and best for simple drilling operations.

Drilling upto 10 mm in dia. can be done on job on the sandwich jig

drill.

4.2 REFERENCES: -

www.wikipidea.com .

http://en.wikipedia.org/wiki/Stress%E2%80%93strain_curve .

P.N.Rao M.T-2.

www.slideshare.com .

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