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JIG
SYNOPSIS
SINCE the design of drill jigs permits the adoption
of an almost unlimited range of new ideas it is curious to note the lack
of originality in the minor components. Most of the common
accessoriesclamps, screws, pins, bushings and the likehave
remained unaltered for years. And yet, in all of them, there is some
room for improvement. It is true that the measure of
possible
improvement is not great; often it is merely a pin here, a screw there,
an alteration of an existing part, or perhaps only a rearrangement of
some of the parts. But all these changes are within the scope of the
operator himself; he should not wait for the jig producer to furnish him
with ideas.
As a matter of fact, if any little defect is allowed to
continue unchecked it is the fault, not of the producer, but of the jig
operator who, because he is using the jig in actual practice, is in the
better position to see where it is wrong. At any rate, as far as the
present writer can ascertain, nothing on this subject has ever before
been published from the jig producing end. It
remains, therefore, for someone at the other endthe jig operating
endto point out some of the defects of small accessories and how
to correct them. These notes, although they chiefly concern the
operator, are directed to the producer as well, because many of the
ideas to be mentioned could well be incorporated in the jig before it is
delivered to the shop.
INTRODUCTION
PNEUMATICS
Pneumatics has long since played an important
role as a technology in the performance of mechanical work. It is also
used in the development of automation solutions. In the majority of
applications compressed air is used for one or more of
PNEUMATIC SYSTEMS
Pneumatics in review
Pneumatics has long since played an important role as a
technology in the performance of mechanical work. It is also used in
the development of automation solutions. In the majority of
applications compressed air is used for one or more of the following
functions:
_ To determine the status of processors (sensors)
_ Information processing (processors)
_ Switching of actuators by means of final control elements
_ Carrying out work (actuators)
To be able to control machinery and installations necessitates the
construction of a generally complex logic interconnection of statuses
and switching conditions. This occurs as a result of the interaction of
sensors, processors, control elements and actuators in pneumatic or
partly pneumatic systems.
The technological progress made in material, design and production
processes has further improved the quality and diversity of pneumatic
components and thereby contributed to their widely spread use in
automation.
The pneumatic cylinder has a significant role as a linear drive
unit, due to its
_ relatively low cost,
_ ease of installation,
_ simple and robust construction and
_ ready availability in various sizes and stroke lengths.
The pneumatic cylinder has the following general characteristics:
_ Diameters 2.5 to 320 mm
cylinder piston times the pressure. Remember that the valves need at
a minimum of 15-30psi to work properly.
Durable
All of us have problems burning up motors from time to time.
You can stall an air cylinder against a load indefinitely and turn off the
compressor. These are industrial grade products.
Power
If you look at the force table on page 12, you have the option
of using a small 3/4 bore cylinder at 20psi, which will produce a force
of around 9 pounds. If you use a 2 bore cylinder at 60psi, you can
get 180 pounds of force. As you can see, your options are wide open.
Custom Cylinders and a Rotary Actuator
You may order the exact cylinder or rotary actuator you need
for the job from Bimba again this year, and get them in a few days via
regular UPS.
Last Minute Additions
At the last minute, you can add a cylinder and valve very
quickly.
Air Pump
Air Pump Heart of pneumatic system is pressure or
vacuum air pump (Usually engine driven)
A Compressor
Pump that compresses air, raising air pressure to above
ambient pressure for use in pneumatic systems.
worlds highest peaks bring bottles of oxygen with them in order to survive
at high altitudes.
Weight
Simple to Design
Using pneumatics is much easier than building a motor; gear, chain
and sprocket lift mechanism. Once you have reviewed the layout on
page 15, you will find it very easy to build a circuit.
Adjustable Force
To adjust the force of the cylinder, all you have to do is adjust the
regulator in front of it. The force is equal to the area of the cylinder
piston times the pressure. Remember that the valves need at a
minimum of 15-30psi to work properly.
Durable
All of us have problems burning up motors from time to time. You can
stall an air cylinder against a load indefinitely and turn off the
compressor. These are industrial grade products.
Power
If you look at the force table on page 12, you have the option of using
a small 3/4 bore cylinder at 20psi, which will produce a force of
around 9 pounds. If you use a 2 bore cylinder at 60psi, you can get
180 pounds of force. As you can see, your options are wide open.
Custom Cylinders and a Rotary Actuator
You may order the exact cylinder or rotary actuator you need for the
job from Bimba again this year, and get them in a few days via
regular UPS.
Motors will draw large current and let out the magic smoke
Cylinders absorb shock loads rather well and bounce back
However, be careful of over pressure conditions caused by
flowcontrol valves
Motors have to be actively held with feedback controls or
locked
TWIST DRILLS:
Twist drills are the most common cutting tools used
with drilling machines. Twist drills are designed to make round holes
quickly and accurately in all materials. They are called twist drills
mainly because of the helical flutes or grooves that wind around the
body from the point to the neck of the drill and appear to be twisted
(Figure 4-7). Twist drills are simply constructed but designed very
tough to withstand the high torque of turning, the downward pressure
on the drill, and the high heat generated by friction
There are two common types of twist drills, highspeed steel drills, and carbide-tipped drills. The most common type
used for field and maintenance shop work is the high-speed steel
twist drill because of its low cost. Carbide-tipped metal drills are used
in production work where the drill must remain sharp for extended
periods, such as in a numerically controlled drilling machine. Other
types of drills available are: carbide tipped masonry drills, solid
carbide drills, TiN coated drills, parabolic drills and split point drills.
Twist drills are classified as straight shank or tapered shank (Figure
4-7). Straight shank twist drills are usually l/2-inch or smaller and tit
into geared drill chucks, while tapered shank drills are usually for the
larger drills that need more strength which is provided by the taper
socket chucks.
DRILL POINT
When grinding the lip angle, use the drill point gage
and grind one lip perfectly straight and at the required angle (usually
590). Then flip the drill over and grind the other lip. Once the angle is
established, then the lip clearance angle and lip length can be
ground. If both lips are not straight and of the same angle, then the
chisel edge (Figure 4-14) will not be established. It is it important to
have a sharp and centered chisel edge or the drill will not rotate
exactly on its center and the hole will be oversized. If the drill point is
too flat, it will not center properly on the work piece. If the drill point is
too steep, the drill will require more power and cut slowly. When the
angles of the cutting lips are different, then the drill will only have one
lip cutting as it revolves. The hole will be oversized and the drill will
wear very rapidly
Drilling
Equipment
Drills
Any commercially available, power-driven equipment is acceptable.
This includes portable drills, drill presses, Lathes, automatic multiple
spindle drilling units, CNC routers and machining centers.
Drill Bits
Several manufacturers offer drill bits designed especially for plastics.
Drill bits are commonly made of high-speed steel (HSS), cobalt, HSS
with carbide tips or solid carbide. Metal-working high-speed steel
twist drill bits can be used with some modification. Standard metalworking drill bits are designed to aggressively cut into metal as they
are fed into it. If used on acrylic without modification, these bits will
chip and cause other damage to the plastic. These drill bits must be
reground in order to scrape the plastic instead of sharply cutting into
the material and gouging it. There are three points to consider when
modifying a standard metal-working twist drill for plastics.
2. The cutting edge must be ground flat to a 0-4 rake angle. This
cutting edge will scrape the acrylic, not gouge it.
Bit geometry affects the quality of drilled holes since it affects chip
size and chip evacuation. Larger diameter bits and bits with smaller
tip angles produce larger chips. If hole depth (H) is less than bit
diameter (D), large chips are easily ejected. As the depth of the hole
increases, i.e. H>D, larger chips become more difficult to eject
because of the close clearance between the bit and the hole walls.
Increasing bit tip angle decreases the size of generated chips,
facilitating chip ejection. However, as mentioned above, if the tip
angle is too large, larger than 90, blow out and chipping may be a
problem when the bit exits the acrylic. The helix angle on a bit is the
angle between the cutting edge and a vertical line along the center of
the bit. Bits with a moderate helix angle aid in chip ejection and are
recommended for drilling of plastics. Small helix angles interfere with
chip ejection, increasing melting. Helix angles, which are too large,
can cause cracking around the hole edges. Typically a helix angle of
15-30 is recommended
As a rule, small jigs are not fastened to the drill press table. If, however,
holes above .25 inch in diameter are to be drilled, it is usually necessary to
fasten the jig to the table securely.
CLASSES OF JIGS
Jigs may be divided into two general classes: boring jigs and
drill jigs. Boring jigs are used to bore holes that either are too large to drill or
must be made an odd size (Figure 22). Drill jigs are used to drill ream, tap,
chamfer, counterbore, countersink, reverse spotface, or reverse countersink
(Figure 23). The basic jig is almost the same for either machining operation. The only difference is in the size of the bushings used.
TYPES OF JIGS:
Drill jigs may be divided into two general types, open and closed. Open jigs
are for simple operations where work is done on only one side of the part.
Closed , or box, jigs are used for parts that must be machined on more than
one side. The names used to identify these jigs refer to how the tool is built.
Template jigs are normally used for accuracy rather than speed. This type of
jig fits over,on,or into the work and is not usually clamped (Figure 24).
Templates are the least expensive and simplest type of jig to use. They may
or may not have bushings. When bushings are not used, the whole jig plate
is normally hardened.
PNEUMATIC JIG
WORKING:
SINCE the design of drill jigs permits the adoption of an
almost unlimited range of new ideas it is curious to note the lack of
originality in the minor components. Most of the common accessories
clamps, screws, pins, bushings and the likehave remained unaltered for
years. And yet, in all of them, there is some room for improvement. It is true
that the measure of possible improvement is not great; often it is merely a
pin here, a screw there, an alteration of an existing part, or perhaps only a
rearrangement of some of the parts.
But all these changes are within the scope of the operator
himself; he should not wait for the jig producer to furnish him with ideas. As
a matter of fact, if any little defect is allowed to continue unchecked it is the
fault, not of the producer, but of the jig operator who, because he is using the
jig in actual practice, is in the better position to see where it is wrong. At any
rate, as far as the present writer can ascertain, nothing on this subject has
ever before been published from the jig producing end. It remains, therefore,
for someone at the other endthe jig operating endto point out some of
the defects of small accessories and how to correct them. These notes,
although they chiefly concern the operator, are directed to the producer as
well, because many of the ideas to be mentioned could well be incorporated
in the jig before it is delivered to the shop.
ADVANTAGES:
Automatic drilling
DISADVANTAGES:
Automatic may be difficult to handle
affected
APPLICATIONS:
Auto mobile Industries
Drilling tool