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UNIVERSITI TEKNOLOGI MALAYSIA FAKULTY OF MECHANICAL ENGINEERING SMR-4723 - 01 TOOLING FOR PRODUCTION
PROJECT 1 (JIG AND FIXTURE DESIGN)
LECTURER: PM. ZAINAL ABIDIN AHMAD
GROUP : 1.
KIONG KHEE HUI
AM090074
2.
LEONG THYE JIEN
AM090082
TABLE OF CONTENTS
Chapter
1
2
3
4
5
Title
Page
TABLE OF CONTENTS
i
LIST OF FIGURES
iii
LIST OF TABLES
iv
INTRODUCTION
1
1.1 Project Title
1
TOOL DESIGN
2
2.1 Introduction to Tool Design
2
2.2 Design Process
3
JIG AND FIXTURE
6
3.1 Introduction to Jig and Fixture
6
3.2 Jig
7
3.3 Fixture
8
MACHINING
10
4.1 Introduction to Machining
10
4.2 Drilling
10
4.3 Milling
11
4.3.1 Horizontal Milling Machine
12
4.3.2 Vertical Milling Machine
12
, LOCATOR AND BUSHING
14
5.1 Types of
14
5.1.1 Solid
14
5.1.2 Adjustable
15 i
5.2 Types of Locator 5.2.1 Pin-Type
15
5.2.2 Diamond or Relieved Locator
16
5.2.3 Vee Locator
17
5.3 Types of Bushing
6
17
MODULAR FIXTURE AND CLAMP
19
6.1 Modular Fixture
19
6.2 Type of Modular Fixturing Systems
21
6.2.1 Subplate System
21
6.2.2 "T"-Slot System
22
6.2.3 Dowel-Pin System
23
6.3.1 Strap Clamp
8
17
5.3.1 Press-Fit Bushing
6.3 Clamp
7
15
25 25
OPERATIONS
26
7.1 Operation Description
26
7.2 Tool
28
7.3 Production Plan
28
7.4 Part Drawing
30
7.5 Drilling Operation
32
7.6 Milling Operation 1
39
7.7 Milling Operation 2
43
CONCLUSION
48
REFERENCES
49
APPENDICES
50
ii
LIST OF FIGURES
FIGURE NO.
TITLE
PAGE
1.1
Part
1
2.1
Tool design process
3
3.1
Box jig
7
3.2
Angle plate fixture
8
4.1
Drilling machine
11
4.2
Horizontal milling machine
12
4.3
Vertical milling machine
13
5.1
Rest button
14
5.2
Adjustable
15
5.3
Pin-type locator
16
5.4
Diamond locator
16
5.5
Schematic diagram of the method of using diamond locator
16
5.6
Vee locator
17
5.7
Different types of press-fit bushing
18
6.1
Modular fixture
20
6.2
Subplate system
22
6.3
"T"-slot system
23
6.4
Dowel-pin system
24
6.5
Special-purpose locating screw
24
6.6
Strap clamp
25
iii
LIST OF TABLES
TABLE NO.
TITLE
PAGE
7.1
Types of cutting tools chosen
28
7.2
Production Plan
28
iv
CHAPTER 1
INTRODUCTION
1.1
Project Title
The component in figure 1.1 shown needs to be drilled all holes and machined on the surface marked. Design a suitable jig or jigs and a fixture or fixtures. Make a process plan in the form of a table. Decide the processing sequence and type of machining processes. Use modular fixture design approach for machining the surface marked.
Figure 1.1: Part 1
CHAPTER 2
TOOL DESIGN
2.1
Introduction to Tool Design
Tool design is one of the four processes in product-planning process, together with product design, manufacturing, and marketing. Tool design is the process of deg and developing the tools, methods, and techniques necessary to improve manufacturing efficiency and productivity. Tool design provides industry the machines and unique tooling necessary for today’s high-speed, high-volume production. Since there is not a single tool or process that can serve all forms of manufacturing, thus tool design is an ever-changing, growing process of creative problem solving. The main objective of tool design is to reduce overall manufacturing cost while maintaining the quality of products and increase production rate. In order to accomplish this, a tool designer must satisfy the following objectives: i.
Provide protection in design of tools for maximum safety of operators
ii.
Design the tool to make it foolproof and prevent improper usage.
iii.
Select the materials that will give adequate tool life.
iv.
Provide simple, easy-to-operate tools for maximum efficiency.
v.
Reduce manufacturing expenses by producing parts at the lowest possible cost.
vi.
Design tools that consistently produce parts of high quality.
vii.
Increase the rate of production with existing machine tools.
2
2.2
Design Process
Tool design is essentially an exercise in problem solving. The five-step process is illustrated in the flow chart below:
Figure 2.1: Tool design process
1.
Defining requirements
Defining requirements or statement of problem is the first step of tool design process. A designer must first identify all the requirements or specifications in the problems to be solved. The requirements must be stated broad but clear enough to define the scope of the design project.
3
2.
Gathering and Analyzing Information
All of the data will be collected and assembled for evaluation. When collecting the information, ensure that the part documents and records such as part print, process sheets, and machine specifications are current or the latest. Note-taking is essential part of this step because it allows the designer to record or collect the important information which is important for future references. Note-taking also prevent the lost of good ideas or thoughts. Four categories have to be taken into considerations: i.
Workpiece Consideration
Usually the most important factors
Have the largest influence on the work-holder's final design
Considerations include: Part size and shape Required accuracy Part material properties Locating and clamping surfaces Number of pieces
ii.
Manufacturing Operations Consideration
Considerations include: Type of operations required Number of operation performed Sequence of operations Inspection requirements Time restrictions
iii.
Equipment Consideration
Controls the type of equipment needed for machining, assembly, and inspection operations
Determines whether the work-holder is designed for single or multiple parts
Typically, equipment criteria include factors such as: Types and sizes of machine tools Inspection equipment Scheduling 4
Cutting tools General plant facilities iv.
Personnel Consideration
Deal with the end or operator
The first and most important consideration in this phase is safety. Therefore, all tools must be designed with complete safety to protect to operator
Operator fatigue, efficiency, economy of motion, and operation speed should be considered too
Designer must understand well the general aspects of design safety and all appropriate government and company safety rules and codes
3.
Developing Several Options
Creativity is most needed in this step since a workpiece can be located and clamped in different ways. Brainstorming is an important strategy for successful tool design. Several good tooling alternatives should be brainstormed. Besides, more options should be added during this phase to ensure that they are feasible.
4.
Choosing the Best Options
This step is a cost or benefit analysis of different tooling options such as tooling durability, operator comfort and safety, and etc.
5.
Implementing the Design
This phase consists of turning the chose design approach into reality. Final details will be decided, detailed drawings will be made, and the tooling will be built and tested.
5
CHAPTER 3
JIG AND FIXTURE
3.1
Introduction to Jig and Fixture
In manufacturing duplicate parts accurately, jigs and fixtures are used to hold workpiece during the processes. Jigs and fixtures are designed and built to hold, , and locate every part to ensure that each is drilled or machined within the specified limits. A jig is a special device that holds, s, or is placed on a part to be machined while fixture is a production tool that locates, holds, and s the work securely so the required machining operations can be performed. The design of jigs and fixtures are usually unique for particular part or shape. There are a few other components are used together with jigs and fixtures in order to locate and position workpiece securely during machining operations to ensure precision and accuracy, such as: i. ing and locating elements To position the workpiece accurately with respect to the tool guiding or setting elements. er is locators that positioned underneath a part while locators are positioned by the edge of part ii. Clamping and workholding elements To hold and clamp the workpiece securely at a position and prevent movement during machining operations
6
iii. Tool guiding and setting elements To aid the setting or guiding of the tools in the correct position with respect to the workpiece
3.2
Jig
Jig is usually used for drilling, boring, reaming, counterboring and other drilling operations. Bushing is used to guide and align drilling operations. There are many types of jigs such as template jigs, plate jigs, sandwich jigs, angle-plate jigs, box jigs and others depending on the part shape and drilling operations required. Figure 3.1 shows the example of box jig.
Figure 3.1: Box Jig
Requirements of a Good Jig: i.
Quick and accurate location of the workpiece.
ii.
Easy loading and unloading of the workpiece and prevention of wrong loading. 7
iii.
Prevention of bending or movement of the workpiece during drilling.
iv.
Ample chip clearance with facilities for metal fillings removal and cleaning.
v.
Light weight to minimize operator fatigue due to repeated handling.
vi.
Prevention of loss of loose parts by chaining them to the jig body.
vii.
Clearance for overshoot of the drill.
3.3
Fixture
Fixture on the other hand is generally used for milling operations. It is used together with set blocks and feeler or thickness gauges as reference to cutter and workpiece. Due to the larger tool forces, fixtures are generally built stronger, and heavier than jigs. Fixture can also be classified into different categories such as plate fixtures, angle-plate fixtures, vise-jaw fixtures, indexing fixtures and many more. Figure 3.2 shows the example of angle plate fixture.
Figure 3.2: Angle plate fixture
8
Essentials of Fixture: i.
Strength to withstand heavy forces.
ii.
Thrust should be directed towards a strong solid structure.
iii.
Cutter setting piece should be provided.
iv.
Milling fixtures should be aligned with locating tennons.
v.
Rigid clamping.
vi.
Motion economy through multiple/power clamping.
vii.
Gates for chip removal.
9
CHAPTER 4
MACHINING
4.1
Introduction to Machining
Machining is a process that remove the material from a workpiece. This is a process using power-driven tools, such as lathes, milling machines, and drill presses, and a sharp cutting tool to cut the material mechanically to achieve the desired geometry. Metal cutting is the term used when the material process is metallic. Material is very expensive for high volume production. However, machining has very low set-up cost compared to forming, moliding and casting processes. Machining is use when tight tolerances on dimensions and finishes are required.
4.2
Drilling
Drilling process is one of the most common machining processes. Drilling process is so common that is estimated that 75% of all metal-cutting material removed come from drilling operations. Drilling is known as a creation of right circular cylinders by using a twist drill. The chips of the material must exit through the flutes to the outside of the tool. Drilling machine has different shapes and sizes. It has small hand-held power drills, bench mounted and floor-mounted models. The drilling machine can perform many of operation other than
10
drilling process likes countersinking, counter boring, reaming, and tapping large or small holes. Figure 4.1 shows the example of drilling machine.
Figure 4.1: Drilling machine
4.3
Milling
Milling process is explain as a process of cutting away material by feeding a workpiece past a rotating multiple tooth cutter. This machining method is providing by the cutting action of many teeth around the milling cutter. There are varieties of the machined surface like flat, angular, or curved or any combination of shapes. A milling machine is a machine tool used to machine solid materials. The milling machines are often classed in two basic forms, horizontal and vertical which refers to the orientation of the main spindle.
11
4.3.1 Horizontal Milling Machine
This kind of machine is very robust and sturdy. They are variety of cutters available to mill the material which is normally held in a strong machine vice. This kind of miller is used when the vertical miller is less suitable. Horizontal milling machine normally used when a lot of material has to be removed by the cutters or there is less of need for accuracy for the shape material. Figure 4.2 shows the example of horizontal milling machine.
Figure 4.2: Horizontal milling machine
4.3.2 Vertical Milling Machine
This kind of milling machine produce machined surfaces by progressively removing material from a work piece uses a rotating milling cutter. The vertical milling machine also
12
can function like a drill press because the spindle is perpendicular to the table and can be lowered into the work piece. Figure 4.3 shows the example of vertical milling machine.
Figure 4.3: Vertical milling machine
13
CHAPTER 5
, LOCATOR AND BUSHING
5.1
Types of
5.1.1 Solid
Solid is the easiest type of to use on tool base. This type of can be machined or installed into the tool base. It is use when a machined surface acts as a locating point. Figure 5.1 shows the rest button that can be used as s, side locator pads, and jig feet.
Figure 5.1: Rest button 14
5.1.2 Adjustable
Adjustable is used when the surface is rough or uneven. Normally used with one or more solid locator to allow any adjustment needed to level the work. Figure 5.2 shows the examples of adjustable .
Figure 5.2: Adjustable
5.2
Types of Locator
5.2.1 Pin-Type
Pin-type locator is a precision locating pins with a tapered tip for easy part loading, and a shoulder to resist downward forces (superior to standard dowel pins). Figure 5.3 shows the example pin-type locator.
15
Figure 5.3: Pin-type locator
5.2.2 Diamond or Relieved Locator
Diamond pins and round pins are often used together to locate from two holes in a workpiece, it reduce the time it takes to load and unload the tool. The diamond pin also acts to restrict the movement of the part as shown in the figure 5.5 below. Figure 5.4 shows the example of diamond locator.
Figure 5.4: Diamond locator
Figure 5.5: Schematic diagram of the method of using diamond locator 16
5.2.3 Vee Locator
Vee locator is mainly used for round work. It also can locate flat work with rounded or angular ends and flat discs. The advantage of the vee locator is it have centralizing feature. Figure 5.6 shows the examples of vee locator.
Figure 5.6: Vee locator (left: horizontal vee locator, right: vertical vee locator)
5.3
Types of Bushing
5.3.1 Press-Fit Bushing
There are 3 types of press-fit bushing which are head, headless and serrated. It is permanently pressed into the jig plate, usually flush with the top surface. They are generally used for single-operation drilling or reaming. Press-fit bushings can be mounted closer together than headed bushings, but offer less resistance to heavy axial loads. Figure 5.7 shows the examples of different press-fit bushing.
17
Figure 5.7: Different types of press-fit bushing
18
CHAPTER 6
MODULAR FIXTURE AND CLAMP
6.1
Modular Fixture
The two major categories of workholding tool that have developed over the years are general-purpose workholders and special-purpose workholders. Although these two forms of fixtures cover almost every tooling requirement, but neither of it is economically suited for every product. Thus, the third form of fixture called modular fixture is introduced to fill the gap between general-purpose and special-purpose fixtures. Modular fixturing is a workholding system that uses a series of reusable standard components to build a wide variety of special-purpose workholding devices. It is designed to be versatile and interchangeable to a number of different industrial applications. Modular fixturing provide quick application changeover without sacrificing accuracy when holding a work piece in place. Figure 6.1 shows the example of modular fixture.
19
Figure 6.1: Modular fixture
Unlike dedicated fixturing, a modular workholding system is comprised of many interchangeable components that allow flexibility when deg custom fixtures from one application to the next. The modular fixturing components can be assembled in different combinations to build almost unlimited number of jigs and fixtures as desired. The modular system can be used with other modular fixturing devices or independently with existing tooling to immediately increase productivity while reducing setup times and fixture costs. Modular fixturing components include items such as:
grid plates
tooling blocks
versatile clamps
adjustable stops
modular risers
spring loaded work s
The process of building modular workholders is quite easy. Since the various components are designed to work together, building a workholder is merely a process of assembling necessary elements according to machining process and suitability. Once the 20
assembler has mastered basic assembly methods with simple jigs and fixtures, the assembler can use his or her imagination and experience to build more detailed workholders. Therefore, modular tooling systems can provide fixturing devices for just about any type of part.
6.2
Type of Modular Fixturing Systems
Modular-component workholding systems available can be categorized to three basic types: subplate, "T"-slot, and dowel pin. There are some variations as well as slightly different accessories made by different manufacturers within each of these categories. It is normally depend upon the designer's requirements and machining operations that will be performed in choosing specific type of modular-component workholding system.
6.2.1 Subplate System
Subplate system is the most elementary and basic type of modular fixturing system which uses a series of flat grid plates, angle plates, multisided tooling blocks, and similar components as major structural elements. These components can be used individually or combined to assemble different workholders. Although it is cheaper in price compare to "T"-slot and dowel-pin systems, it is less versatile. However, by using master plate tooling method, this can be overcome. A tooling plate acts as an adapter between workpiece and modular workholding elements. Rather than being mounted directly to the modular elements, the workpiece is first attached to a dedicated tooling plate, which is then mounted to the modular elements. The result is a combination of modular and dedicated tooling elements, used together to fixture the workpiece. Figure 6.2 shows the example of subplate system.
21
Figure 6.2: Subplate system
6.2.2 "T"-Slot System
The "T"-slot systems uses a series of precisely machined base plates, mounting blocks and other elements having machined and ground "T"-slots. These are used to mount and attach the additional accessories. Regardless the shapes of the base plates or the types of component, these "T"-slots are machined exactly perpendicular and parallel to each other. The principal advantages of the "T"-slot system are its adaptability, strength and ease of positioning the components. The "T"-slot permits more movement of the components on the base plate and this ease the fixturing. Besides, it is also stronger than dowel pins. The disadvantage of "T"-slot systems is in its repeatability from one tool to the next. The repositioning of the elements in a "T"-slot system require precise measurement due to it only have references point at the intersections of the "T"-slot systems. Figure 6.3 shows the example of "T"-slot system.
22
Figure 6.3: "T"-slot system
6.2.3 Dowel-Pin System
Dowel-pin system is very similar in basic design with "T"-slot system, mainly the overall size capabilities and range of components. The major difference is the grid pattern of holes used to locate and mount the other accessories. The major advantage of dowel-pin system is in the automatic positioning of the components from one tool to the other. It is faster and easier to locate with dowel pins if a tool must be built more than once. The major problem with this type of system is in clamping. This is caused by the spacing between the holes, the components, and arrangements made for clamping. The fixed locating points in the base plates provided by the dowel pins, while desirable for repeatability, do not permit movement of the components. In order to overcome this, the elements are used with slots in individual components to achieve adjustability. Figure 6.4 shows the example of Dowel-pin system.
23
Figure 6.4: Dowel-pin system
Dowel-pin systems are made with two different types of holes. One uses alternating tapped holes separated with dowel-pin holes while the other combines both the locating functions and mounting functions in the same hole by mounting a locating bushing on top of a tapped hole. The first hole style permits both dowel pins and screws to be used to locate and mount the components while the second requires a special-purpose locating screw which capable in locating and holding the components. Figure 6.5 shows the example of specialpurpose locating screw.
Figure 6.5: Special-purpose locating screw 24
6.3
Clamp
The function of a clamp is to hold a part against the locators during the machining cycle. To be effective and efficient, clamps must be planned into the tool design. Clamp should always the work at its most rigid point. This prevents the clamping force from bending or damaging the part. In modular fixture that used, strap clamp is chosen.
6.3.1 Strap Clamp
Strap clamp is the simplest clamp used for jigs and fixtures. In order to function this clamp, first is to place it into position, then applied clamping force by fasten the clamp stud until the workpiece is been firmly clamp. Figure 6.6 shows the example of strap clamp.
Figure 6.6: Strap clamp
25
CHAPTER 7
OPERATIONS
7.1
Operation Description
The part as shown from the figure 1.1 above is formed by casting. The part has to be gone through drilling process by using CNC drilling machine. A total of 4 holes have to be drilled to the part. For an easier loading method, box jig is selected to hold the workpiece for drilling process. After all the drilling operations are done on the workpiece, the finishing process on six selected surfaces of workpiece will be completed by using CNC milling machine. In order to perform finishing milling process on all six surfaces, two milling modular fixtures have been designed. Standard parts were chosen from Carrlane catalogue and a few parts were customized to suit the processes. Both jigs and fixtures are designed to hold workpiece and restrict any degree of freedom to achieve required surface specifications. The following operations will be performed using the box jig and designed fixtures.
1.
Drilling Operation using customized box jig: i.
Drilling of two Ø 0.3750 inches hole thru
ii.
Drilling of Ø 0.7500 inches hole thru
iii.
Drilling of Ø 1/4-20 UNF inches hole 5/8 deep
26
2.
3.
Milling Operation 1 using Fixture 1: i.
Milling of surface of two Ø 0.3750 inches holes
ii.
Milling of surface of Ø 0.7500 inches hole
Milling Operation 2 using Fixture 2: i.
Milling of two surfaces 3.500 × 0.800 inches
ii.
Milling of surface 2.500 × 0.800 inches
iii.
Milling of surface 3.500 × 2.500 inches
Box Jig is used to perform the drilling operations. The box jig is designed with three different bushings for the drilling of four holes (two holes with Ø 0.3750 inch, one hole with Ø 0.7500 inch and one hole with Ø1/4-20 UNF 5/8 deep). Box jig is chosen because the part can be completely machines on every surface without the need to reposition the part in the jig. This can reduce the inaccuracy caused by the reposition of part. Fixture 1 locates the part by using a round pin and a diamond pin. This reduces the time it takes to load and unload the tool. The combination of round pin and diamond pin can restrict eleven direction of movement of the workpiece. The last vertical degree of freedom is restricted by using a strap clamp. A customized er is used to the workpiece. Fixture 2 utilizes the holes drilled in earlier process. A round pin and diamond pin is used as in Fixture 1 to restrict eleven direction of movement of the workpiece. A customized part with a pin welded is used to restrict the last vertical direction of movement. This is because the length of diamond and round pin with this diameter is not suitable for the design. Another customized er is used to the workpiece.
27
7.2
Tool
The drilling cutting tool is selected from Mitutoyo catalogue. We choose three drill bit from the catalogue which are shown in table 7.1 below. On the other hands, the milling cutting tool is selected from ITS catalogue. We choose one of finishing end mills cutters from the catalogue. Detail specification of all cutting tools are shown in table 7.1.
Table 7.1: Types of cutting tools chosen Ø1/4' Drill Bit
Ø3/8' Drill Bit
Ø3/4' Drill Bit
End Mill Cutter
Catalogue
Mitutoyo
Mitutoyo
Mitutoyo
ITS
Part No.
48516
24070
24310
S314DU
Diameter
0.2500'
0.3750'
0.7500'
20mm
No. of Flute
2
2
2
4
Total
2-1/2'
3-1/8'
5'
110mm
1-3/8'
1-13/16'
3-1/8'
45mm
Length Flute Length
7.3 Production Plan
Table 7.2 below shows a production plan for the operations. PRODUCTION PLAN P/N 1234-1 DWG NO. D-8975-1-1 OPERATION
PART NAME COMPONENT A
QUANTITY
ORDER NO
PROCESS PLANNER REVISION NO: KIONG KHEE HUI 0 LEONG THYE JIEN DESCRIPTION
DATE: 14/11/2012
PAGE 1
DEPT.
MACH. TOOL
OF 1
28
NO 1
2
3.
4.
5.
6.
7.
8.
8.
DRILL 2 - Ǿ 3/8 INCH HOLES THRU DRILL 1 - Ǿ 3/4 INCH HOLES THRU DRILL 1 - Ǿ 1/4-20 UNF 5/8 DEEP MILL FACE 2 - Ǿ 0.75 INCH TOP SURFACE MILL END - Ǿ 1.5 + Ǿ 0.5 INCH RIGHT SURFACE
MILL END 2 - 0.745×3.375 INCH
MILL END - 0.745×2.500 INCH
MILL FACE - 3.375×2.5 INCH
HORIZONTAL MILL CUTTER
*10
DRILL PRESS
DRILLING
*10-01
*10
DRILL PRESS
DRILLING
*10-02
*10
DRILL PRESS
DRILLING
*10-03
*20
HORIZONTAL MILL
MILLING
*20-10
*20
HORIZONTAL MILL
MILLING
*20-10
*20
HORIZONTAL MILL
MILLING
*20-10
*20
HORIZONTAL MILL
MILLING
*20-10
*20
HORIZONTAL MILL
MILLING
*20-10
Ø 20mm
M. FIXTURE F-A-02
7.
HORIZONTAL MILL CUTTER
Ø 20mm
M. FIXTURE F-A-02
6.
HORIZONTAL MILL CUTTER
Ø 20mm
M. FIXTURE F-A-02
5.
HORIZONTAL MILL CUTTER
Ø 20mm
M. FIXTURE F-A-01
4.
HORIZONTAL MILL CUTTER
Ø 20mm
M. FIXTURE F-A-01
3.
Ǿ 1/4'
DRILL BIT
BOX JIG J-A-01
2.
DRILL BIT
Ø 3/4'
BOX JIG J-A-01
1.
DRILL BIT
Ø 3/8'
BOX JIG J-A-01
OPERATION NO
TOOL DESCRIPTION
SIZE
SPECIAL TOOL NO.
29
7.4 Part Drawing
30
31
7.5 Drilling Operation
32
33
34
35
36
37
38
7.5 Milling Operation 1
39
40
41
42
7.6 Milling Operation 2
43
44
45
46
47
CHAPTER 8
CONCLUSION
Throughout this project, we know that we should be able to design a simple and yet effective tool that simplified the work of operator. A tool that is functioning well will lower the cost while maintaining the quality of the product and also increasing the production rate. Other than that, certain basic knowledge such as machine tool and cutter for different operation should be familiarize so that we are prepare to put these knowledge into practice during our future career. We able to design one drilling operation and two milling operation that could function properly. We have applied all the basic principles that we have learnt into this project. This helps us to get a better understanding of deg jigs and fixtures.
48
REFERENCES
1.
Edward G.Hoffman, Jig and Fixture Design, 2004, Delmar Cengage Learning
2.
http://www.carrlane.com/Articles/StPartCL.cfm
3.
http://www.manufacturinget.org/home/tech-4571-tool-design/introduction-to-tool-
design/ 4.
http://pdf.directindustry.com/pdf/arno/drill-system-shark-drill/17568-22485-_12.html
5.
ITS_cutting_tools_catalogue
6.
http://www.fastenal.com/web/search/product/cutting-tools-metalworking/holemaking-
and-drilling/screw-machinedrills/_/Navigation?searchterm=&sortby=webrank&sortdir=descending&searchmode=&refin e=~|categoryl1:%22601071%20Cutting%20Tools%209and%20Metalworking%22|~%20~|ca tegoryl2:%22601075%20Holemaking%20and%20Drilling%22|~%20~|categoryl3:%2260234 7%20Screw%20Machine%20Drills%22|~
49
APPENDICES
Standard Device Used in Drilling Operation No.
Device
Standard
Quantity
1.
Rest button
CL-7-RB
1
2.
Rest button
CL-14-RB
15
3.
Thumb screw
CLM-6-KHS
2
4.
Veeblock
CL-MF25-6002
1
5.
Quarter turn screw
CL-3-QTS
1
6.
Press-fit bushing
HC-32-12
1
7.
Press-fit bushing
HC-48-12
2
8.
Press-fit bushing
HC-88-12
1
1.
Rest button: CL-7-RB
2.
Rest button: CL-14-RB
50
3.
Thumb screw: CLM-6-KHS
4.
Veeblock: CL-MF25-6002
51
5.
Quarter turn screw: CL-3-QTS
6.
Press-fit bushing: HC-32-12
7.
Press-fit bushing: HC-48-12
8.
Press-fit bushing: HC-88-12
52
53
Fixture 1
Standard Device Used in Milling Operation 1 No Part Name
Part Number
Quantity
1
Rectangular Tooling Plate CL-MF25-0151
1
2
0.375 Round Pin
CL-3-RP
1
3
0.375 Diamond Pin
CL-3-DPX
1
4
Slotted-Heel Clamp Strap
CL-6A-CS
1
5
Clamp Rest
CL-4-CR
1
6
Clamp Spring
CL-9-SPG
1
7
Flat Washer
CL-2-FW
1
8
Stud
CL-1/2-13 x 4.00 1
9
Hand Knob
CL-40-HK-4
1
10
Spherical Washer
CL-3-SW
2
11
Nut
CL-8-JN
2
1. Rectangular Tooling Plate : CL-MF25-0151
54
2. 0.375 Round Pin : CL-3-RP
3. 0.375 Diamond Pin : CL-3-DPX
55
4. Slotted-Heel Clamp Strap : CL-6A-CS
5. Clamp Rest : CL-4-CR
56
6. Clamp Spring : CL-9-SPG
7. Flat Washer : CL-2-FW
57
8. Stud : CL-1/2-13 x 4.00
9. Hand Knob : CL-40-HK-4
58
10. Spherical Washer : CL-3-SW
11. Jam Nut : CL-8-JN
59
Fixture 2
Standard Device Used in Milling Operation 2 No Part Name
Part Number
Quantity
1
Rectangular Tooling Plate CL-MF25-0151
1
2
0.375 Round Pin
CL-3-RP
1
3
0.375 Diamond Pin
CL-3-DPX
1
4
Socket Head Cap Screw
CL-1/2-13x2.00-SHCS 1
4. Socket Head Cap Screw : CL-1/2-13x2.00-SHCS
60
Drill Bit: Ø1/4'
Drill Bit: Ø3/8'
61
Drill Bit: Ø3/4'
Milling Cutter: Dc = 20 mm
62
PROJECT 1 (JIG AND FIXTURE DESIGN)
LECTURER: PM. ZAINAL ABIDIN AHMAD
GROUP : 1.
KIONG KHEE HUI
AM090074
2.
LEONG THYE JIEN
AM090082
TABLE OF CONTENTS
Chapter
1
2
3
4
5
Title
Page
TABLE OF CONTENTS
i
LIST OF FIGURES
iii
LIST OF TABLES
iv
INTRODUCTION
1
1.1 Project Title
1
TOOL DESIGN
2
2.1 Introduction to Tool Design
2
2.2 Design Process
3
JIG AND FIXTURE
6
3.1 Introduction to Jig and Fixture
6
3.2 Jig
7
3.3 Fixture
8
MACHINING
10
4.1 Introduction to Machining
10
4.2 Drilling
10
4.3 Milling
11
4.3.1 Horizontal Milling Machine
12
4.3.2 Vertical Milling Machine
12
, LOCATOR AND BUSHING
14
5.1 Types of
14
5.1.1 Solid
14
5.1.2 Adjustable
15 i
5.2 Types of Locator 5.2.1 Pin-Type
15
5.2.2 Diamond or Relieved Locator
16
5.2.3 Vee Locator
17
5.3 Types of Bushing
6
17
MODULAR FIXTURE AND CLAMP
19
6.1 Modular Fixture
19
6.2 Type of Modular Fixturing Systems
21
6.2.1 Subplate System
21
6.2.2 "T"-Slot System
22
6.2.3 Dowel-Pin System
23
6.3.1 Strap Clamp
8
17
5.3.1 Press-Fit Bushing
6.3 Clamp
7
15
25 25
OPERATIONS
26
7.1 Operation Description
26
7.2 Tool
28
7.3 Production Plan
28
7.4 Part Drawing
30
7.5 Drilling Operation
32
7.6 Milling Operation 1
39
7.7 Milling Operation 2
43
CONCLUSION
48
REFERENCES
49
APPENDICES
50
ii
LIST OF FIGURES
FIGURE NO.
TITLE
PAGE
1.1
Part
1
2.1
Tool design process
3
3.1
Box jig
7
3.2
Angle plate fixture
8
4.1
Drilling machine
11
4.2
Horizontal milling machine
12
4.3
Vertical milling machine
13
5.1
Rest button
14
5.2
Adjustable
15
5.3
Pin-type locator
16
5.4
Diamond locator
16
5.5
Schematic diagram of the method of using diamond locator
16
5.6
Vee locator
17
5.7
Different types of press-fit bushing
18
6.1
Modular fixture
20
6.2
Subplate system
22
6.3
"T"-slot system
23
6.4
Dowel-pin system
24
6.5
Special-purpose locating screw
24
6.6
Strap clamp
25
iii
LIST OF TABLES
TABLE NO.
TITLE
PAGE
7.1
Types of cutting tools chosen
28
7.2
Production Plan
28
iv
CHAPTER 1
INTRODUCTION
1.1
Project Title
The component in figure 1.1 shown needs to be drilled all holes and machined on the surface marked. Design a suitable jig or jigs and a fixture or fixtures. Make a process plan in the form of a table. Decide the processing sequence and type of machining processes. Use modular fixture design approach for machining the surface marked.
Figure 1.1: Part 1
CHAPTER 2
TOOL DESIGN
2.1
Introduction to Tool Design
Tool design is one of the four processes in product-planning process, together with product design, manufacturing, and marketing. Tool design is the process of deg and developing the tools, methods, and techniques necessary to improve manufacturing efficiency and productivity. Tool design provides industry the machines and unique tooling necessary for today’s high-speed, high-volume production. Since there is not a single tool or process that can serve all forms of manufacturing, thus tool design is an ever-changing, growing process of creative problem solving. The main objective of tool design is to reduce overall manufacturing cost while maintaining the quality of products and increase production rate. In order to accomplish this, a tool designer must satisfy the following objectives: i.
Provide protection in design of tools for maximum safety of operators
ii.
Design the tool to make it foolproof and prevent improper usage.
iii.
Select the materials that will give adequate tool life.
iv.
Provide simple, easy-to-operate tools for maximum efficiency.
v.
Reduce manufacturing expenses by producing parts at the lowest possible cost.
vi.
Design tools that consistently produce parts of high quality.
vii.
Increase the rate of production with existing machine tools.
2
2.2
Design Process
Tool design is essentially an exercise in problem solving. The five-step process is illustrated in the flow chart below:
Figure 2.1: Tool design process
1.
Defining requirements
Defining requirements or statement of problem is the first step of tool design process. A designer must first identify all the requirements or specifications in the problems to be solved. The requirements must be stated broad but clear enough to define the scope of the design project.
3
2.
Gathering and Analyzing Information
All of the data will be collected and assembled for evaluation. When collecting the information, ensure that the part documents and records such as part print, process sheets, and machine specifications are current or the latest. Note-taking is essential part of this step because it allows the designer to record or collect the important information which is important for future references. Note-taking also prevent the lost of good ideas or thoughts. Four categories have to be taken into considerations: i.
Workpiece Consideration
Usually the most important factors
Have the largest influence on the work-holder's final design
Considerations include: Part size and shape Required accuracy Part material properties Locating and clamping surfaces Number of pieces
ii.
Manufacturing Operations Consideration
Considerations include: Type of operations required Number of operation performed Sequence of operations Inspection requirements Time restrictions
iii.
Equipment Consideration
Controls the type of equipment needed for machining, assembly, and inspection operations
Determines whether the work-holder is designed for single or multiple parts
Typically, equipment criteria include factors such as: Types and sizes of machine tools Inspection equipment Scheduling 4
Cutting tools General plant facilities iv.
Personnel Consideration
Deal with the end or operator
The first and most important consideration in this phase is safety. Therefore, all tools must be designed with complete safety to protect to operator
Operator fatigue, efficiency, economy of motion, and operation speed should be considered too
Designer must understand well the general aspects of design safety and all appropriate government and company safety rules and codes
3.
Developing Several Options
Creativity is most needed in this step since a workpiece can be located and clamped in different ways. Brainstorming is an important strategy for successful tool design. Several good tooling alternatives should be brainstormed. Besides, more options should be added during this phase to ensure that they are feasible.
4.
Choosing the Best Options
This step is a cost or benefit analysis of different tooling options such as tooling durability, operator comfort and safety, and etc.
5.
Implementing the Design
This phase consists of turning the chose design approach into reality. Final details will be decided, detailed drawings will be made, and the tooling will be built and tested.
5
CHAPTER 3
JIG AND FIXTURE
3.1
Introduction to Jig and Fixture
In manufacturing duplicate parts accurately, jigs and fixtures are used to hold workpiece during the processes. Jigs and fixtures are designed and built to hold, , and locate every part to ensure that each is drilled or machined within the specified limits. A jig is a special device that holds, s, or is placed on a part to be machined while fixture is a production tool that locates, holds, and s the work securely so the required machining operations can be performed. The design of jigs and fixtures are usually unique for particular part or shape. There are a few other components are used together with jigs and fixtures in order to locate and position workpiece securely during machining operations to ensure precision and accuracy, such as: i. ing and locating elements To position the workpiece accurately with respect to the tool guiding or setting elements. er is locators that positioned underneath a part while locators are positioned by the edge of part ii. Clamping and workholding elements To hold and clamp the workpiece securely at a position and prevent movement during machining operations
6
iii. Tool guiding and setting elements To aid the setting or guiding of the tools in the correct position with respect to the workpiece
3.2
Jig
Jig is usually used for drilling, boring, reaming, counterboring and other drilling operations. Bushing is used to guide and align drilling operations. There are many types of jigs such as template jigs, plate jigs, sandwich jigs, angle-plate jigs, box jigs and others depending on the part shape and drilling operations required. Figure 3.1 shows the example of box jig.
Figure 3.1: Box Jig
Requirements of a Good Jig: i.
Quick and accurate location of the workpiece.
ii.
Easy loading and unloading of the workpiece and prevention of wrong loading. 7
iii.
Prevention of bending or movement of the workpiece during drilling.
iv.
Ample chip clearance with facilities for metal fillings removal and cleaning.
v.
Light weight to minimize operator fatigue due to repeated handling.
vi.
Prevention of loss of loose parts by chaining them to the jig body.
vii.
Clearance for overshoot of the drill.
3.3
Fixture
Fixture on the other hand is generally used for milling operations. It is used together with set blocks and feeler or thickness gauges as reference to cutter and workpiece. Due to the larger tool forces, fixtures are generally built stronger, and heavier than jigs. Fixture can also be classified into different categories such as plate fixtures, angle-plate fixtures, vise-jaw fixtures, indexing fixtures and many more. Figure 3.2 shows the example of angle plate fixture.
Figure 3.2: Angle plate fixture
8
Essentials of Fixture: i.
Strength to withstand heavy forces.
ii.
Thrust should be directed towards a strong solid structure.
iii.
Cutter setting piece should be provided.
iv.
Milling fixtures should be aligned with locating tennons.
v.
Rigid clamping.
vi.
Motion economy through multiple/power clamping.
vii.
Gates for chip removal.
9
CHAPTER 4
MACHINING
4.1
Introduction to Machining
Machining is a process that remove the material from a workpiece. This is a process using power-driven tools, such as lathes, milling machines, and drill presses, and a sharp cutting tool to cut the material mechanically to achieve the desired geometry. Metal cutting is the term used when the material process is metallic. Material is very expensive for high volume production. However, machining has very low set-up cost compared to forming, moliding and casting processes. Machining is use when tight tolerances on dimensions and finishes are required.
4.2
Drilling
Drilling process is one of the most common machining processes. Drilling process is so common that is estimated that 75% of all metal-cutting material removed come from drilling operations. Drilling is known as a creation of right circular cylinders by using a twist drill. The chips of the material must exit through the flutes to the outside of the tool. Drilling machine has different shapes and sizes. It has small hand-held power drills, bench mounted and floor-mounted models. The drilling machine can perform many of operation other than
10
drilling process likes countersinking, counter boring, reaming, and tapping large or small holes. Figure 4.1 shows the example of drilling machine.
Figure 4.1: Drilling machine
4.3
Milling
Milling process is explain as a process of cutting away material by feeding a workpiece past a rotating multiple tooth cutter. This machining method is providing by the cutting action of many teeth around the milling cutter. There are varieties of the machined surface like flat, angular, or curved or any combination of shapes. A milling machine is a machine tool used to machine solid materials. The milling machines are often classed in two basic forms, horizontal and vertical which refers to the orientation of the main spindle.
11
4.3.1 Horizontal Milling Machine
This kind of machine is very robust and sturdy. They are variety of cutters available to mill the material which is normally held in a strong machine vice. This kind of miller is used when the vertical miller is less suitable. Horizontal milling machine normally used when a lot of material has to be removed by the cutters or there is less of need for accuracy for the shape material. Figure 4.2 shows the example of horizontal milling machine.
Figure 4.2: Horizontal milling machine
4.3.2 Vertical Milling Machine
This kind of milling machine produce machined surfaces by progressively removing material from a work piece uses a rotating milling cutter. The vertical milling machine also
12
can function like a drill press because the spindle is perpendicular to the table and can be lowered into the work piece. Figure 4.3 shows the example of vertical milling machine.
Figure 4.3: Vertical milling machine
13
CHAPTER 5
, LOCATOR AND BUSHING
5.1
Types of
5.1.1 Solid
Solid is the easiest type of to use on tool base. This type of can be machined or installed into the tool base. It is use when a machined surface acts as a locating point. Figure 5.1 shows the rest button that can be used as s, side locator pads, and jig feet.
Figure 5.1: Rest button 14
5.1.2 Adjustable
Adjustable is used when the surface is rough or uneven. Normally used with one or more solid locator to allow any adjustment needed to level the work. Figure 5.2 shows the examples of adjustable .
Figure 5.2: Adjustable
5.2
Types of Locator
5.2.1 Pin-Type
Pin-type locator is a precision locating pins with a tapered tip for easy part loading, and a shoulder to resist downward forces (superior to standard dowel pins). Figure 5.3 shows the example pin-type locator.
15
Figure 5.3: Pin-type locator
5.2.2 Diamond or Relieved Locator
Diamond pins and round pins are often used together to locate from two holes in a workpiece, it reduce the time it takes to load and unload the tool. The diamond pin also acts to restrict the movement of the part as shown in the figure 5.5 below. Figure 5.4 shows the example of diamond locator.
Figure 5.4: Diamond locator
Figure 5.5: Schematic diagram of the method of using diamond locator 16
5.2.3 Vee Locator
Vee locator is mainly used for round work. It also can locate flat work with rounded or angular ends and flat discs. The advantage of the vee locator is it have centralizing feature. Figure 5.6 shows the examples of vee locator.
Figure 5.6: Vee locator (left: horizontal vee locator, right: vertical vee locator)
5.3
Types of Bushing
5.3.1 Press-Fit Bushing
There are 3 types of press-fit bushing which are head, headless and serrated. It is permanently pressed into the jig plate, usually flush with the top surface. They are generally used for single-operation drilling or reaming. Press-fit bushings can be mounted closer together than headed bushings, but offer less resistance to heavy axial loads. Figure 5.7 shows the examples of different press-fit bushing.
17
Figure 5.7: Different types of press-fit bushing
18
CHAPTER 6
MODULAR FIXTURE AND CLAMP
6.1
Modular Fixture
The two major categories of workholding tool that have developed over the years are general-purpose workholders and special-purpose workholders. Although these two forms of fixtures cover almost every tooling requirement, but neither of it is economically suited for every product. Thus, the third form of fixture called modular fixture is introduced to fill the gap between general-purpose and special-purpose fixtures. Modular fixturing is a workholding system that uses a series of reusable standard components to build a wide variety of special-purpose workholding devices. It is designed to be versatile and interchangeable to a number of different industrial applications. Modular fixturing provide quick application changeover without sacrificing accuracy when holding a work piece in place. Figure 6.1 shows the example of modular fixture.
19
Figure 6.1: Modular fixture
Unlike dedicated fixturing, a modular workholding system is comprised of many interchangeable components that allow flexibility when deg custom fixtures from one application to the next. The modular fixturing components can be assembled in different combinations to build almost unlimited number of jigs and fixtures as desired. The modular system can be used with other modular fixturing devices or independently with existing tooling to immediately increase productivity while reducing setup times and fixture costs. Modular fixturing components include items such as:
grid plates
tooling blocks
versatile clamps
adjustable stops
modular risers
spring loaded work s
The process of building modular workholders is quite easy. Since the various components are designed to work together, building a workholder is merely a process of assembling necessary elements according to machining process and suitability. Once the 20
assembler has mastered basic assembly methods with simple jigs and fixtures, the assembler can use his or her imagination and experience to build more detailed workholders. Therefore, modular tooling systems can provide fixturing devices for just about any type of part.
6.2
Type of Modular Fixturing Systems
Modular-component workholding systems available can be categorized to three basic types: subplate, "T"-slot, and dowel pin. There are some variations as well as slightly different accessories made by different manufacturers within each of these categories. It is normally depend upon the designer's requirements and machining operations that will be performed in choosing specific type of modular-component workholding system.
6.2.1 Subplate System
Subplate system is the most elementary and basic type of modular fixturing system which uses a series of flat grid plates, angle plates, multisided tooling blocks, and similar components as major structural elements. These components can be used individually or combined to assemble different workholders. Although it is cheaper in price compare to "T"-slot and dowel-pin systems, it is less versatile. However, by using master plate tooling method, this can be overcome. A tooling plate acts as an adapter between workpiece and modular workholding elements. Rather than being mounted directly to the modular elements, the workpiece is first attached to a dedicated tooling plate, which is then mounted to the modular elements. The result is a combination of modular and dedicated tooling elements, used together to fixture the workpiece. Figure 6.2 shows the example of subplate system.
21
Figure 6.2: Subplate system
6.2.2 "T"-Slot System
The "T"-slot systems uses a series of precisely machined base plates, mounting blocks and other elements having machined and ground "T"-slots. These are used to mount and attach the additional accessories. Regardless the shapes of the base plates or the types of component, these "T"-slots are machined exactly perpendicular and parallel to each other. The principal advantages of the "T"-slot system are its adaptability, strength and ease of positioning the components. The "T"-slot permits more movement of the components on the base plate and this ease the fixturing. Besides, it is also stronger than dowel pins. The disadvantage of "T"-slot systems is in its repeatability from one tool to the next. The repositioning of the elements in a "T"-slot system require precise measurement due to it only have references point at the intersections of the "T"-slot systems. Figure 6.3 shows the example of "T"-slot system.
22
Figure 6.3: "T"-slot system
6.2.3 Dowel-Pin System
Dowel-pin system is very similar in basic design with "T"-slot system, mainly the overall size capabilities and range of components. The major difference is the grid pattern of holes used to locate and mount the other accessories. The major advantage of dowel-pin system is in the automatic positioning of the components from one tool to the other. It is faster and easier to locate with dowel pins if a tool must be built more than once. The major problem with this type of system is in clamping. This is caused by the spacing between the holes, the components, and arrangements made for clamping. The fixed locating points in the base plates provided by the dowel pins, while desirable for repeatability, do not permit movement of the components. In order to overcome this, the elements are used with slots in individual components to achieve adjustability. Figure 6.4 shows the example of Dowel-pin system.
23
Figure 6.4: Dowel-pin system
Dowel-pin systems are made with two different types of holes. One uses alternating tapped holes separated with dowel-pin holes while the other combines both the locating functions and mounting functions in the same hole by mounting a locating bushing on top of a tapped hole. The first hole style permits both dowel pins and screws to be used to locate and mount the components while the second requires a special-purpose locating screw which capable in locating and holding the components. Figure 6.5 shows the example of specialpurpose locating screw.
Figure 6.5: Special-purpose locating screw 24
6.3
Clamp
The function of a clamp is to hold a part against the locators during the machining cycle. To be effective and efficient, clamps must be planned into the tool design. Clamp should always the work at its most rigid point. This prevents the clamping force from bending or damaging the part. In modular fixture that used, strap clamp is chosen.
6.3.1 Strap Clamp
Strap clamp is the simplest clamp used for jigs and fixtures. In order to function this clamp, first is to place it into position, then applied clamping force by fasten the clamp stud until the workpiece is been firmly clamp. Figure 6.6 shows the example of strap clamp.
Figure 6.6: Strap clamp
25
CHAPTER 7
OPERATIONS
7.1
Operation Description
The part as shown from the figure 1.1 above is formed by casting. The part has to be gone through drilling process by using CNC drilling machine. A total of 4 holes have to be drilled to the part. For an easier loading method, box jig is selected to hold the workpiece for drilling process. After all the drilling operations are done on the workpiece, the finishing process on six selected surfaces of workpiece will be completed by using CNC milling machine. In order to perform finishing milling process on all six surfaces, two milling modular fixtures have been designed. Standard parts were chosen from Carrlane catalogue and a few parts were customized to suit the processes. Both jigs and fixtures are designed to hold workpiece and restrict any degree of freedom to achieve required surface specifications. The following operations will be performed using the box jig and designed fixtures.
1.
Drilling Operation using customized box jig: i.
Drilling of two Ø 0.3750 inches hole thru
ii.
Drilling of Ø 0.7500 inches hole thru
iii.
Drilling of Ø 1/4-20 UNF inches hole 5/8 deep
26
2.
3.
Milling Operation 1 using Fixture 1: i.
Milling of surface of two Ø 0.3750 inches holes
ii.
Milling of surface of Ø 0.7500 inches hole
Milling Operation 2 using Fixture 2: i.
Milling of two surfaces 3.500 × 0.800 inches
ii.
Milling of surface 2.500 × 0.800 inches
iii.
Milling of surface 3.500 × 2.500 inches
Box Jig is used to perform the drilling operations. The box jig is designed with three different bushings for the drilling of four holes (two holes with Ø 0.3750 inch, one hole with Ø 0.7500 inch and one hole with Ø1/4-20 UNF 5/8 deep). Box jig is chosen because the part can be completely machines on every surface without the need to reposition the part in the jig. This can reduce the inaccuracy caused by the reposition of part. Fixture 1 locates the part by using a round pin and a diamond pin. This reduces the time it takes to load and unload the tool. The combination of round pin and diamond pin can restrict eleven direction of movement of the workpiece. The last vertical degree of freedom is restricted by using a strap clamp. A customized er is used to the workpiece. Fixture 2 utilizes the holes drilled in earlier process. A round pin and diamond pin is used as in Fixture 1 to restrict eleven direction of movement of the workpiece. A customized part with a pin welded is used to restrict the last vertical direction of movement. This is because the length of diamond and round pin with this diameter is not suitable for the design. Another customized er is used to the workpiece.
27
7.2
Tool
The drilling cutting tool is selected from Mitutoyo catalogue. We choose three drill bit from the catalogue which are shown in table 7.1 below. On the other hands, the milling cutting tool is selected from ITS catalogue. We choose one of finishing end mills cutters from the catalogue. Detail specification of all cutting tools are shown in table 7.1.
Table 7.1: Types of cutting tools chosen Ø1/4' Drill Bit
Ø3/8' Drill Bit
Ø3/4' Drill Bit
End Mill Cutter
Catalogue
Mitutoyo
Mitutoyo
Mitutoyo
ITS
Part No.
48516
24070
24310
S314DU
Diameter
0.2500'
0.3750'
0.7500'
20mm
No. of Flute
2
2
2
4
Total
2-1/2'
3-1/8'
5'
110mm
1-3/8'
1-13/16'
3-1/8'
45mm
Length Flute Length
7.3 Production Plan
Table 7.2 below shows a production plan for the operations. PRODUCTION PLAN P/N 1234-1 DWG NO. D-8975-1-1 OPERATION
PART NAME COMPONENT A
QUANTITY
ORDER NO
PROCESS PLANNER REVISION NO: KIONG KHEE HUI 0 LEONG THYE JIEN DESCRIPTION
DATE: 14/11/2012
PAGE 1
DEPT.
MACH. TOOL
OF 1
28
NO 1
2
3.
4.
5.
6.
7.
8.
8.
DRILL 2 - Ǿ 3/8 INCH HOLES THRU DRILL 1 - Ǿ 3/4 INCH HOLES THRU DRILL 1 - Ǿ 1/4-20 UNF 5/8 DEEP MILL FACE 2 - Ǿ 0.75 INCH TOP SURFACE MILL END - Ǿ 1.5 + Ǿ 0.5 INCH RIGHT SURFACE
MILL END 2 - 0.745×3.375 INCH
MILL END - 0.745×2.500 INCH
MILL FACE - 3.375×2.5 INCH
HORIZONTAL MILL CUTTER
*10
DRILL PRESS
DRILLING
*10-01
*10
DRILL PRESS
DRILLING
*10-02
*10
DRILL PRESS
DRILLING
*10-03
*20
HORIZONTAL MILL
MILLING
*20-10
*20
HORIZONTAL MILL
MILLING
*20-10
*20
HORIZONTAL MILL
MILLING
*20-10
*20
HORIZONTAL MILL
MILLING
*20-10
*20
HORIZONTAL MILL
MILLING
*20-10
Ø 20mm
M. FIXTURE F-A-02
7.
HORIZONTAL MILL CUTTER
Ø 20mm
M. FIXTURE F-A-02
6.
HORIZONTAL MILL CUTTER
Ø 20mm
M. FIXTURE F-A-02
5.
HORIZONTAL MILL CUTTER
Ø 20mm
M. FIXTURE F-A-01
4.
HORIZONTAL MILL CUTTER
Ø 20mm
M. FIXTURE F-A-01
3.
Ǿ 1/4'
DRILL BIT
BOX JIG J-A-01
2.
DRILL BIT
Ø 3/4'
BOX JIG J-A-01
1.
DRILL BIT
Ø 3/8'
BOX JIG J-A-01
OPERATION NO
TOOL DESCRIPTION
SIZE
SPECIAL TOOL NO.
29
7.4 Part Drawing
30
31
7.5 Drilling Operation
32
33
34
35
36
37
38
7.5 Milling Operation 1
39
40
41
42
7.6 Milling Operation 2
43
44
45
46
47
CHAPTER 8
CONCLUSION
Throughout this project, we know that we should be able to design a simple and yet effective tool that simplified the work of operator. A tool that is functioning well will lower the cost while maintaining the quality of the product and also increasing the production rate. Other than that, certain basic knowledge such as machine tool and cutter for different operation should be familiarize so that we are prepare to put these knowledge into practice during our future career. We able to design one drilling operation and two milling operation that could function properly. We have applied all the basic principles that we have learnt into this project. This helps us to get a better understanding of deg jigs and fixtures.
48
REFERENCES
1.
Edward G.Hoffman, Jig and Fixture Design, 2004, Delmar Cengage Learning
2.
http://www.carrlane.com/Articles/StPartCL.cfm
3.
http://www.manufacturinget.org/home/tech-4571-tool-design/introduction-to-tool-
design/ 4.
http://pdf.directindustry.com/pdf/arno/drill-system-shark-drill/17568-22485-_12.html
5.
ITS_cutting_tools_catalogue
6.
http://www.fastenal.com/web/search/product/cutting-tools-metalworking/holemaking-
and-drilling/screw-machinedrills/_/Navigation?searchterm=&sortby=webrank&sortdir=descending&searchmode=&refin e=~|categoryl1:%22601071%20Cutting%20Tools%209and%20Metalworking%22|~%20~|ca tegoryl2:%22601075%20Holemaking%20and%20Drilling%22|~%20~|categoryl3:%2260234 7%20Screw%20Machine%20Drills%22|~
49
APPENDICES
Standard Device Used in Drilling Operation No.
Device
Standard
Quantity
1.
Rest button
CL-7-RB
1
2.
Rest button
CL-14-RB
15
3.
Thumb screw
CLM-6-KHS
2
4.
Veeblock
CL-MF25-6002
1
5.
Quarter turn screw
CL-3-QTS
1
6.
Press-fit bushing
HC-32-12
1
7.
Press-fit bushing
HC-48-12
2
8.
Press-fit bushing
HC-88-12
1
1.
Rest button: CL-7-RB
2.
Rest button: CL-14-RB
50
3.
Thumb screw: CLM-6-KHS
4.
Veeblock: CL-MF25-6002
51
5.
Quarter turn screw: CL-3-QTS
6.
Press-fit bushing: HC-32-12
7.
Press-fit bushing: HC-48-12
8.
Press-fit bushing: HC-88-12
52
53
Fixture 1
Standard Device Used in Milling Operation 1 No Part Name
Part Number
Quantity
1
Rectangular Tooling Plate CL-MF25-0151
1
2
0.375 Round Pin
CL-3-RP
1
3
0.375 Diamond Pin
CL-3-DPX
1
4
Slotted-Heel Clamp Strap
CL-6A-CS
1
5
Clamp Rest
CL-4-CR
1
6
Clamp Spring
CL-9-SPG
1
7
Flat Washer
CL-2-FW
1
8
Stud
CL-1/2-13 x 4.00 1
9
Hand Knob
CL-40-HK-4
1
10
Spherical Washer
CL-3-SW
2
11
Nut
CL-8-JN
2
1. Rectangular Tooling Plate : CL-MF25-0151
54
2. 0.375 Round Pin : CL-3-RP
3. 0.375 Diamond Pin : CL-3-DPX
55
4. Slotted-Heel Clamp Strap : CL-6A-CS
5. Clamp Rest : CL-4-CR
56
6. Clamp Spring : CL-9-SPG
7. Flat Washer : CL-2-FW
57
8. Stud : CL-1/2-13 x 4.00
9. Hand Knob : CL-40-HK-4
58
10. Spherical Washer : CL-3-SW
11. Jam Nut : CL-8-JN
59
Fixture 2
Standard Device Used in Milling Operation 2 No Part Name
Part Number
Quantity
1
Rectangular Tooling Plate CL-MF25-0151
1
2
0.375 Round Pin
CL-3-RP
1
3
0.375 Diamond Pin
CL-3-DPX
1
4
Socket Head Cap Screw
CL-1/2-13x2.00-SHCS 1
4. Socket Head Cap Screw : CL-1/2-13x2.00-SHCS
60
Drill Bit: Ø1/4'
Drill Bit: Ø3/8'
61
Drill Bit: Ø3/4'
Milling Cutter: Dc = 20 mm
62
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