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CHAPTER 1

INTRODUCTION

1.1 JIG

A Jig is a work-holding and tool guide used in the manufacturing

industry. Jig are used to securely locate (position in a specific location or
orientation) and support the work, ensuring that all parts produced using the
fixture will maintain conformity and interchangeability. Using a jig improves
the economy of production by allowing smooth operation and quick transition
from part to part, reducing the requirement for skilled labour by simplifying
how work pieces are mounted, and guide the tool in constant path. A jig differs
from a fixture in that when a fixture is used, the tool must move relative to the
work piece, the jig is a tool that guides the cutting (or machining) tool.

A Jig’s primary purpose is to provide repeatability, accuracy and

interchangeability in the manufacturing of products. A jig is often confused with
a fixture; a fixture holds the work in a fixed location. A device that does both
functions (holding the work and guiding a tool) is called a jig.

An example of a jig is when a key is duplicated; the original is used as a

 jig so the new key can have same path as the old one since the advent of
“automation” and “computer numerical control (CNC)” machines, jigs are often
not required because the tool path is digitally programmed and stored in
memory.

Jigs may be made for reforming plastics. Jigs or templates have been
known long before the industrial age. There are many types of Jigs, and each
one is custom-tailored to do a specific job.

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Jig also allow for a higher degree of operator safety by reducing the

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concentration and effort required to hold a piece steady. Economically speaking
the most valuable function of a jig is to reduce labour costs.

Millions of titles at your fingertips Many jigs are created because there is a necessity to do shown by the
tradesmen. Some are made to increase productivity thought consistency, to do

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activities or to do job more accuracy. Jig may be well made for
frequent use or may be improvised from scrap for a single project, defending on
the task.

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drill days
jig is a type of jig that expedites repetitive hole centre location on
multiple interchangeable parts by acting as a template to guide the twist drill or
other boring device into the precise location of each intended hole centre. In

Learnmetalworking
more practice, typically a hardened drill bushing lines each hole on the
 jig plate to keep the tool from damaging the jig.

Drill jig started falling into disuse with the invention of the jig borer.
Since the widespread penetration of the manufacturing industry by CNC
machine tool, in which servo controls are capable of moving the tool to the
current location automatically, the need for drill jigs is much less than it used to
 be.

Most jigs have a solid component, affixed to the floor or to the body of
the machine and considered immovable relative to the motion of the machining
 bit, and one or more movable components known as clamps. These clamps
(which may be operated by many different mechanical means) allow work
 pieces to be easily placed in the machine or removed, and yet stay secure during
operation. Many are also adjustable, allowing for work pieces of different sizes
to be used for different operations

Jigs are in many different types, in a drilling process majorly ten types.
They are briefly explained below. Our industrial project is designing a indexing
type of Jig.

1.2 TYPES OF JIG

   Closed Jig
   Plate Jig
   Sandwich Jig
   Angle Plate Jig
   Box Jig
   Channel Jig
   Turnnion Jig
   Pump Jig
   Indexing Jig
   Template Jig

1.2.1 INDEXING JIG

Indexing jig is used to drill holes which are spaced equally along a circle.
in this example four equally spaced holes are to be drilled on the periphery of
the work piece. The work piece has a machined bore. The work piece is located
 by a C-washer and a nut. A drill bush is fitted in the bush plate. The drill is fed
through the bush to drill the first hole. After this, by rotating the hand wheel, the
work piece is indexed for drilling the next hole. The indexing is done with the
help of an index plate and an indexing device(Shown in figure 1.2.1)

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Fig 1.2.1 Indexing Jig

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The Figure 5.1 shows the flowchart for the construction of automated
drill jig.

Component study machine details

machining operation required

Jig layout planning

Design of jig elements, clamping system,

locator and jig body and tool guiding
system

Assembly and evaluation of jig,

completion of design

Fig 5.1 Flow chart on the Automated drill jig construction

5.2.4 ASSEMBLY

The assembly can be done in this automated drill jig as the sequential
order of arrangement and can be explained as follows.

Step 1: At first, the Drill bush can be mounted on the bush plate and then the
 bush plate can be tightened in the Vertical plate at the top portion of it.

31

Step 2:  At the centre of the Vertical plate, a ball bearing can be attached in
which the component locator have been mounted and the locator pin has been
used to hold the component locator and can disable the movement.

Step 3: The threaded screw can be used here to adjust the C-Washer, which can
hold the work piece tightly and firmly.

Step 4: Then, the completed Vertical plate assembly can be fixed on the Base
 plate by the means of Bolts.

Step 5: Atlast, this automated drill jig unit has been mounted strongly at the
Table of the Drilling machine.

Fig 5.2Assembly of Automated Drill Jig

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5.3 WORKING

5.3.1 PRINCIPLE

Work piece will be completely controlled when positioned against three

 points in one plane, two points in another plane and one point in third plane. 

5.3.2 WORKING PROCEDURE

The working of the Automated drill jig can be very simple and can be
explained easily as follows. 

   The Workpiece can be fixed in the component locator and then the C-
washer can be used to hold tightly the workpiece. The tightness can be
adjusted by the Threaded screw.
   Before the drilling process gets start, the locator pin in the bush plate can
 be used to fix the Component locator and can disable its movement
further after the workpiece gets fixed.
   After the Drilling operation initiated, the drill pit can be guided by the
drill bush provided in the bush plate to workout a proper drilling process
in a given workpiece.
   For drilling different points on the same workpiece, the screw can be
adjusted and the workpiece can be turned and fixed again for the desired
 position.
   Finally, the most accurate Drilling process in the workpiece can be
successfully executed.

33

5.4PRODUCTION (TIME TAKING)

Table 5.4 Time Table for Production

WORK PIECE / 1 HOUR 8HOUR 24HOUR

TIME
Before Jig Used 6 to 8 50 to 65 175 to 190
After Jig Used 15 to 18 125 to 146 380 to 430

Before Jig Used = One Piece Take Time 7 to 10 minutes

After Jig Used =One Piece Take Time 3.5 to 4 minutes

5.5 ADVANTAGES 

The advantages of jigs can be given in the following:

   Production increase.
   Low variability in dimension, thereby leading to consistent quality of
manufactured products.
   Cost reduction.
   Ensures interchangeability and high accuracy of parts.
   Reduces the need for inspection and quality control Expenses.
   Reduces accident, as safety is improved.
   Semi-skilled machine operators can easily use them thereby saving the
cost of manpower.
   The machine tool can be automated to an appreciable extent.
   Complex and heavy components can be easily machined.
   Easy assembly operations saves labour, and also lead to reduction of

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   They eliminate the need for measuring, marking out, punching,
 positioning, alignments, and setting up for each work-piece thereby
reducing the cycle and set up time.
   Increases technological capacities of machine tools.
   The application of more than one tool simultaneously on a work-piece
can be achieved.
   Setting of higher values of some operating conditions like depth of cut,
speed, and rate of feed can be attained because of the increased clamping
capability of jigs.

35

CHAPTER 6

COST ESTIMATION

Table 6.1 Cost Estimation

S.NO COMPONENT SHIPPING MACHINING TOTAL

COST COST COST

1. Base plate 500 1300 1800

2. Vertical plate 500 2100 2600

3. Bush plate 50 1350 1400

4. Drill plate 30 400 430

5. Component locator 330 970 1300

6. Locator pin 65 170 235

7. C-Washer 120 320 440

8. Ball bearing 330 - 330

9. Worker cost 2500 - 2500

TOTAL 4425 6610 11035

(RUPEES ELEVEN THOUSAND THIRTY FIVE ONLY)  

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CHAPTER 7

CONCLUSION AND FUTURE SCOPE

7.1 CONCLUSION
These automated drill Jigs 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. They eliminate the need for a special set-up
for every work-piece thereby facilitating production and also ensuring that
every work piece is manufactured within a predetermined tolerance.
The design of jigs is dependent on the operation type as well as the
machine tool to be used for the operation. They are fabricated with heat-treated
steel that are corrosion and wear resistant.
7.2 FUTURE SCOPE
   The design can be made more modular i.e. more PCD combination can be
done.
   Other than steel material, Plastics also used in fabricating the jigs.
   Instead of Acrylic Plastic and other material can be used.
   We can fix bush size and interchange the liner size according to the drill
size.

37

REFERENCES 

1.  Joshi, P. “Jigs and Fixtures” Tata McGraw Hill Education, New
Delhi, India.
2.  Nanthakumar, K. and Prabakaran, V. “Design and Fabrication Testing
of Combined Multipurpose Jig and Fixture” IOSR Journal of
Mechanical and Civil Engineering(www.iosrjournals.org)
3.  Lin, Q., Burdick, J., and Rimon, E “Constructing Minimum
Deflection Arrangements Using Invar iant Norms” IEEE Transactions
on Automation Science and Engineering, Vol. 3, No. 3. Science
Research.
4.  Blogspot “Introduction to Jigs and Fixtures” [Online]
engineeringhut.blogspot.com/jigs-andfixtures.html
5.  Spogel “Mini project on Jigs and Fixtures” [Online]
http://files.spogel.com/miniprojectsin-mech/p-0027--Jigs-and-
Fixtures.pdf  
6.  Kaija, T. and Heino, P. “The Optimization of OnwaferShield -Based
Test Fixture Layout” IEEE  Transactions on Microwave Theory and
Techniques, Vol. 54, No. 5.
7.  Meduettaxila. “Jigs and Fixtures Module” [Online]
https://2k9meduettaxila.files.wordpress.com/2012/04/scanjigs-and-
fixtures.pdf  
8.  Mechnol. “Applications of Jigs and Fixtures” [Online]
http://www.mechnol.com/applications-of-jigs-andfixtures.html 

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9.  Pachbhai, S. and Raut, L. “A Review on Design of Fixtures”
International Journal of Engineering Research and General Science,
Vol. 2, Issue 2.
10. Chennu, V “Jigs and Fixtures and their Purposes”[Online]
http://www.memechanicalengineering.com/2015/02/jigs-and-
fixtures.html 

39

PROJECT IMAGE

WITH WORK PIECE

WITH OUT WORK PIECE

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SIDE VIEW

TOP VIEW

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