DRILL JIG (Final One)

PROJECT PRESENTATION ON
DESIGN & MANUFACTURING OF DRILL JIG FOR

END YOKE USED IN UNIVERSAL JOINT
SUBMITTED BY ,
EXAM SEAT NO
1. KHEMNAR PRADEEP
B80690814
2. LASALKAR SARVESH
B80690816
3. PATIL BY
BHUSHAN
SPONSORED
MAHINDRA SONA LTD.
SATPUR, NASHIK-422007
B80690818
PROF. M. A. AHIRE (INSTITUTE GUIDE)
Mr. S.V. BHUSAL &
Mr. D.J. BHADANE (COMPANY GUIDE)
Dept. of Mech. Engg.- GESs R. H. Sapat C.O.E., M.S. & R , Nashik-5
PROBLEM STATEMENT:Design and development of Drill Jig for

elimination of broach repass operation by changing
process sequence.
Present operation sequence
Proposed operation sequence
Broaching
Drilling and Tapping
Keyway Milling
Broaching
Drilling and Tapping

Broaching re-pass
Keyway Milling
STEPS IN JIG DESIGN :1)PRODUCT ANALYSIS :

Product Name - End yoke
Product No
- 3204533F
Product Weight - 1.2 kg
Product Material - SAE1141
Composition
- C-0.37-0.45% ; Mn-1.35- 1.65%
P- 0.060% ;
S-0.08-0.35%
Heat Treatment - HND & TEM :-229-269 BHN
2)OPERATION CONSIDERATIONS: Operation

Hole size
Drill bit diameter
Speed
Depth of cut
Feed
- Drilling on circular cross section.

- 7.8mm - 8.1mm
- 7.8 mm
- 700 rpm
- 10 mm
- Manual
Study of old jig & available other jig & fixture.
Machining Time(tm):tm= Length of drill travel(L) ,mm

Feed rate(s) * Rpm(n)
tm= l+0.3d
tm= 10+0.3(7.8)
s*n
0.15*700
tm= 0.1175 minute.
Machining Time(tm) = 7.05
sec.
Ref:- Westerman Table ; Pg. No :- 106
0.3d
Fig no. 1. Drill bit
3)MACHINE STUDY:Drilling Machine:

Available Space For Jig:1. Bed Size = 680 mm x 330 mm
Bed consist of two slots at a distance of 255mm from each side of
bed. These slots provide clamping arrangement for jig & fixture
2. Distance from tip of tool to base = 175 mm
3. Drill bit length =100 mm
Motor Specifications:1. Rating = 1HP / 0.75Kw
2. Rpm = 940 rpm
3. Torque = 7620 N/mm^2
Side butting
blocks
VBlock
Jig
Plate
Drill
Bush
Support
Plate
Support
Plate
Main Hole
Locater
CWasher
Base
Plate
Fig no. 2. Assembly of drill jig
CUTTING FORCE IN DRILLING:Power (K w) = 1.25*d^2*k1*n*(0.056+1.5s)

10^5
P = 0.3141 Kw
Where, k1= Material factor ; Ref - (P.T hmt; pg. no- 141)
s = Feed rate, mm/rev; Ref- (As above)
Drill Thrust(kg f) = 1.16*k1*d*(100*s)^0.85
= 173.49 kg f
Ref - (P.T hmt; pg. no- 141)
Thrust = 1702.02 N
Torque(T):T= P*60*1000 = 0.3141*60*1000

2*3.14*n
2*3.14*700
T= 4.2849 N-m
Cutting Speed(V):Ref :- T.O.M. By Khurmi Gupta
V = 3.14* d* n = 3.14* 7.8* 700
60*1000
60*1000
V= 0.2858 m/sec
Ref :- P.T ; By R.K JAIN
Tooling Force(F):F= Power

= 314.13
Velocity
0.2858
F=
N Gupta
Ref :- 1099.13
T.O.M. By Khurmi
4)LOCATION:-
Fig no. 3. Main hole locater
Fig no. 4. V-Block
5)CLAMPING FORCE CALCULATION:=
Nf*Tooling Force (F)

= 1.5*1099.13
Coeff. of friction of w/p material
0.3
Clamping Force = 5495.65 N

Ref:- Care lane cutting & clamping force (pdf) ; Pg.No- 2
www.reidsupply.com(pdf) ; Pg. No- 7
From Clamping Force range Screw/Bolt size is selected from book is,
Selected Size = M16

Ref:- Jig & Fixture Design; By Edwrd.G. Hoffman
Care lane cutting & clamping force (pdf) ; Pg.No- 2
For Clamping we used, C-Washer & M 16 Nut.
Material Chart
Component No
Component Number
Component Material
1.
Base Plate
Mild-Steel
2.
Support Plate
Mild-Steel
7.
Washer
Mild-Steel
9.
C-washer
Mild-Steel
11.
Jig plate
Mild-Steel
Composition in %
C
Si
Mg
0.2-0.3
0.25
0.05
0.05
0.57
Properties
Density
Hardness
Modulus of Elasticity
(Kg/m^3)
(BHN)
(Gpa)
7850
140
190
Breaking Strength
(N/mm^2)
430
Ultimate Tensile Strength

(N/mm^2)
555
Remarks
Above mentioned parts are not subjected to much stresses & wear. Hence Mild-steel is selected for these
components. Mild-Steel have following advantages: Easily available, Cheap cost, Economical,
Most widely used.
Material Chart
Component No
Component Number
Component Material
3.
Vee-Block
SAE 8620
4.
Main hole locator
SAE 8620
8.
Hinge pin
SAE 8620
12.
Side butting block
SAE 8620
Composition in %
C
Mn
Si
Ni
Cr
Mo
0.17-0.23
0.60-0.95
0.20-0.35
0.35-0.75
0.35-0.65
0.15-0.25
Properties
Density
(Kg/m^3)
7859
Hardness
(BHN)
220
(Gpa)
210
Breaking Strength
(N/mm^2)
690
(N/mm^2)
821.8
Remarks
Above mentioned parts are subjected to the stresses & friction, hence material have wear resistance property.
Thus, SAE8620 materials selected for these components.
SAE 8620 have following advantages: Used for high resistance surface, High hardness .
Resist shock load, High strength.
Material Chart
Component No
Component Number
Component Material
5.
Drill Bush
EN 31
6.
Linear Bush
EN 31
Composition in %
C
Mn
Si
Cr
0.9-1.2
0.3-0.75
0.10-0.35
1-1.6
0.5
0.5
Properties
Density
(Kg/m^3)
7810
Hardness
(BHN)
(Gpa)
229
210
Breaking Strength
(N/mm^2)
(N/mm^2)
1102.45
1158
Remarks
Above mentioned parts Drill bush, Linear bush required to be hardened material, for that we have selected EN
31 Material. It has following advantages: High hardness,
Used for high resistance surface,
Resist shock load,
High strength.
COST ESTIMATION
Raw Material Cost = Rs 2273
Operation Cost
= Rs 11545
Standard Part Cost = Rs 320

Total Cost of Project := Raw Material Cost + Operation Cost + Std. Part Cost
= 2273 + 11545 + 320
= Rs 14138
Cost Analysis for Broach Re-pass : Lot Size Selected (Ls)

Parts per Hour (Ph)
Cost per Part (Cp)
Cost Saving per Hour
Total Saving for A Lot Size (Ts)
Cost Saving per Day (approximate)
Cost Saving Per Year (approximate)
Operation Cost Saved per Year (actual)
= 500 Parts
= 75 parts/hr
= 8.50 Rs/part
= 638 Rs/hr
= 4250 Rs
= 4785 Rs/day
= 14,35,500 Rs/year
= 17000 Rs/year
All Formulas are mentioned in Project Report

Ref : Jig & Fixture Design; By Edwrd.G. Hoffman;Pg no. 91,94.
Time Analysis for Broach Re-pass : Operation Time for Single Batch (Ot)
= 7 hr
Job Handling Time (Ht)
= 0.5 hrs
Total Time Saved Per Batch
= 10.5 hrs
Total Time Saved Per Year
= 42 hrs
Total Time Saving/Year in Terms of money =18900 Rs/year
Total Yearly Benefits
= Rs 35900
Payback Period
Break Even Point
= 4 Months
= 1664 Parts
Ref : Jig & Fixture Design; By Edwrd.G. Hoffman; Pg no. 91,94
Benefits of Project: Save Electricity,

Save Oil,
Increased Productivity,
Save Machining Cost,
Broaching Machine is free for another job.
Result: The complete process of broach re-pass is eliminating, with

increasing productivity & rejection make zero.
CONCLUSION
Yearly profit earned by company is actually of Rs.
35,900/ If parts are continuously manufactured for whole year;
then profit will be of Rs. 14,35,500/ The total machining time saved for a batch of 500 parts is
around 10.5 Hrs.
Rejection tends to zero & productivity increases.
Customers satisfaction by obtaining their required surface
finish & dimensions.
REFERENCES
1. Jig and Fixture Design, By Edwrd G. Hoffman; Delmar Cengage Learning; 5th Edition;
2. Production Technology, By HMT; TATA McGraw Hill; 24th Edition2006;
3. Westermann Tables, By Hermann Jutz &Eduard scharkus; New Age International(P)Ltd.; 3rd Edition
2008;
4. Design Data, By PSG College of Technology; Kalaikathir Achchagam; 2nd Edition 2010;
5. Material science & Metallurgy, By O. P. Khanna; Dhanpat Rai Publications; 11th Edition; 2007;
6. Jigs and fixtures, By P.H.Joshi; Tata Mc-GrawHill company limited; 6th Edition 2010;
7. Material Analysis, By Mahindra & Mahindra Steel Division; Industrial and Engg Journals;
8. Design of a 5-Axis Fixture System, By Brian Dorchik, Steven Feroli, Ryan McGlone, Ryan McLaughlin;
Worcester Polytechnic Institute, Worcester, Massachusetts; 2007;
9. Dedicated Fixture Design for Polishing of Silicon, By Taufif Bin Zakaria; Report submitted in partial
fulfillment of the requirements for the award of the degree of Bachelor of Mechanical Engineering;
November 2008;
10. Manufacturing Tooling (Jig Design) By Nageswara Rao Posinasetti; February 12, 2008;
11. Introduction of Jig & Fixture (Pdf).
12. Care lane cutting & clamping forces (Pdf).
13. http://www.mahindrasona.com/about.htm
THANKS

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PROJECT PRESENTATION ON

DESIGN & MANUFACTURING OF DRILL JIG FOR

Dept. of Mech. Engg.- GESs R. H. Sapat C.O.E., M.S. & R , Nashik-5

PROBLEM STATEMENT:Design and development of Drill Jig for

Proposed operation sequence

Drilling and Tapping

Drilling and Tapping

STEPS IN JIG DESIGN :1)PRODUCT ANALYSIS :

- C-0.37-0.45% ; Mn-1.35- 1.65%

2)OPERATION CONSIDERATIONS: Operation

- Drilling on circular cross section.

Study of old jig & available other jig & fixture.

Machining Time(tm):tm= Length of drill travel(L) ,mm

3)MACHINE STUDY:Drilling Machine:

Fig no. 2. Assembly of drill jig

CUTTING FORCE IN DRILLING:Power (K w) = 1.25*d^2*k1*n*(0.056+1.5s)

Torque(T):T= P*60*1000 = 0.3141*60*1000

Ref :- P.T ; By R.K JAIN

Tooling Force(F):F= Power

Fig no. 3. Main hole locater

Fig no. 4. V-Block

5)CLAMPING FORCE CALCULATION:=

Nf*Tooling Force (F)

Clamping Force = 5495.65 N

Selected Size = M16

For Clamping we used, C-Washer & M 16 Nut.

Ultimate Tensile Strength

Main hole locator

Side butting block

Ultimate Tensile Strength

Ultimate Tensile Strength

Standard Part Cost = Rs 320

Cost Analysis for Broach Re-pass : Lot Size Selected (Ls)

All Formulas are mentioned in Project Report

Benefits of Project: Save Electricity,

Result: The complete process of broach re-pass is eliminating, with

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CUTTING FORCE IN DRILLING:Power (K w) = 1.25d^2k1n(0.056+1.5s)

Torque(T):T= P601000 = 0.3141601000