Lab Session:11

Objective:
Design and draw a channel jig for stainless steel component as shown in the figure
for drilling a hole of 18mm to produce a lot of 2000 of parts.

Figure No 1: Workpiece

1. Selection of Bush:
We select the type H press fit bush as shown in following figure:

Figure No 2: Bush

Drill Diameter = 18 mm
For 18 mm diameter,
The tolerance for the inner diameter of bush is d1F7 running fit.
d1 = 18 mm (+0.441, +0.020) d2
= 30 mm (0, -0.016)
The tolerance for the outer diameter of bush is d2h6 pushes fit.
l1 = 20 mm l2
= 15 mm d3
= 35 mm
3D Design View: -
 Figure No 3: 3D View of Bush

Figure No 4: 2D View in 1st Angle of Projection

2. Selection of Locator:
Locators are used to ensure that the workpiece is properly referenced, if the process is
repeatable. The locator is made up of steel, due to its good surface finish.

Figure No 5: Locator

d = 16 mm h1
= 14 mm h2 =
22 mm d1 =
12 mm d2 =
11.5 mm
The distance h1 can be less than or equal to the thickness of jig plate.

Figure No 6: 3D View of Locator

Figure No 7: 2D View in 1st Angle of Projection

3. Selection of Clamp:

Figure No 8: Clamp

d1 = 20 mm d4 = 6 mm,
f = 8 mm d5 = 14 mm, h
= 28 mm d6 = 7 mm d7
= 2 mm
The size of screw with thread is M8.

Figure No 9: 3D View of Clamp and Bolt

Figure No 10: 2D View of Clamp in 1st Angle of Projection

 Figure No 11: 2D View of Bolt in 1st Angle of Projection

4. Design of Jig Body:

Width of the jig plate (W) = 45 mm
Length of the jig plate = 2Tp + Lw + h2 + allowance
Where,
Tp – thickness of jig plate = 15 mm
Lw – length of workpiece = 75 mm
h2 – Locator pin head length = 22
mm
Allowance = 13 mm
Length of jig plate = (2 x 15) + 75 + 22 + 13 =140 mm
But we take
Length of Jig plate = 165 mm
Height of Jig Plate = Hw + Tp + clearance for chip removal
Where,
Hw – height of workpiece = 52 mm
Tp – thickness of jig plate = 15 mm
It noted that
Clearance between workpiece and top jig plate
1. For ductile material = ½ of the drill diameter
2. For brittle material = equal to the diameter of drill
Clearance = ½ x 18 9 mm
Therefore,
Height of jig plate = 52 + 15 + 9 = 76 mm
 Figure No 12: Channel Jig

Figure No 13: 2D View in 1st Angle of Projection

Figure No 14: Base Plate

 Figure No 15: 2D View in 1st Angle of Projection

5. Bill of Materials (BOM):

Sr. No. Part Name Material Quantity
1 Bush Gun Metal 1
2 Jig Plate Steel 1
3 Screw Clamp with Pressure Pad Steel 1
4 Locator Steel 2
5 Base Plate Cast Iron 1

6. Assembly of Leaf Jig and Components:

Figure No 16: Assembly of Channel Jig

The diagram of 1st angle of projection of assembly of channel jig and its components is
following:

Figure No 17: 2D View in 1st Angle of Projection