FACULTY OF MANUFACTURING

ENGINEERING
BFF 3632 DESIGN OF JIGS AND FIXTURES
SEM 2 2016/2017
ASSIGNMENT 4 : MINI PROJECT
MATRIC NO.

STUDENTS NAME

FA 14030

NUR SYAMIZA BINTI ZAMRI

SECTION :
TOPIC :
LECTURER
S NAME :
DATE :

01P
MINI PROJECT
MUHAMMED NAFIS BIN OSMAN ZAHID
5th DECEMBER 2016

TABLE OF CONTENTS
NO
1
2
3
4

TITLE
INTRODUCTION
OBJECIVE
MACHINING PROCESS
DESIGN FOR MILLING AND DRILLING JIGS

PAGE
3
3
3
4

AND FIXTURES
MILLING PROCESS

4-6

a) PART IN VICE
b) MILLING OPERATION

TO

SHAPE

(146X45)MM AREA
c) MILLING OPERATION

TO

SHAPE

(146X60)MM AREA
d) MILLING OPERATION TO SHAPE THE
6

ACTUAL SIZE
DRILLING PROCESS

7-8

a) DRILL 18MM HOLE

b) DRILL 2 X 20MM HOLES
7
8
9

CONCLUSION
REFRENCES
APPENDIX

9
9
9-18

1. INTRODUCTION

The aluminum block in figure below shown needs to be drilled all holes and machined on the
surface marked. We need to design a suitable jig and fixtures and make a process plan . We
also need to decide the processing sequence and type of machining processes. the figure
illustrates the machined part which fabricated from the aluminum block with 150mm length,
50mm width and 65mm height.

2. OBJECTIVE
-

To design jig and fixture that is suitable for this operation

To visualize the design in CADCAM software

3. MACHINING PROCESSES
The list of operations required are as follow:
1. Milling operation to shape (146x45)mm area
2. Milling operation to shape (146x60)mm area
3. Drill 18mm hole
4. Drill 2 x 20mm holes

4. DESIGN FOR MILLING AND DRILLING JIGS AND FIXTURES

1) For milling processes , we use common vise to complete operation 1 and 2 :

2) While for the drilling operation which is I applied in operation 3 and 4 , I use box jigs
and fixtures as shown in figure :

5. MILLING PROCESSES
Milling is the machining process of using rotary cutters to remove material[1] from a
workpiece by advancing (or feeding) in a direction at an angle with the axis of the tool. [2]
Milling is a cutting process that uses a milling cutter to remove material from the surface of a
workpiece. The milling cutter is a rotary cutting tool, often with multiple cutting points. By
using common vise , we can complete the milling operation .
a) PART IN VICE
There are seven parts in the common vise which are :

1)
2)
3)
4)
5)
6)
7)

Stationary jaw
Sliding jaw
Screw
Handle
Base
Adjustable Cylinder
Support for Sliding Jaw

b) MILLING OPERATION TO SHAPE (146X45)MM AREA

PROCESS : FACING
The block given is 150 x 50 x 60 mm . We need to reduce the block size before doing
drilling machine . So, we clamp the block between stationary jaw and sliding jaw .The first
process we do is done facing on a surface which area will become ( 146 x 45 ) mm . Face
mill is used to complete this process .

c) MILLING OPERATION TO SHAPE (146X60)MM AREA

PROCESS : FACING
After that , we unclamp the block and rotate it to the different surface . We still use the
same face mill as before .Then, the area after facing will become (146 x 60) mm as shown in
figure :
5

d) MILLING OPERATION TO SHAPE THE ACTUAL SIZE

PROCESSES : ROUGHING AND FINISHING
A roughing operation is used to remove large amounts of material rapidly and to
produce a part geometry close to the desired shape. So we use roughing end mill to make it
geometry close the true shape . A finishing operation follows roughing and is used to achieve
the final geometry and surface finish. In finishing operation , we use ball nose cutting to
make is smooth and achieve final geometry .

6. DRILLING PROCESS
Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in solid
materials. The drill bit is usually a rotary cutting tool, often multipoint. Drilled holes are
characterized by their sharp edge on the entrance side and the presence of burrs on the exit
side (unless they have been removed). Also, the inside of the hole usually has helical feed
6

marks.[3] There are many jigs and fixtures that can be used in completing this process . For
this mini project I prefer to use box jigs , some supporter component and bush to guide the
cutting tool . The cutting tool we use is drill bit with diameter 14mm .
a) PART BOX JIG
There are seven parts in the box jig which are :
1) Handle to rotate the cylinder rotator .
2) Cylinder rotator .- we workpiece can be place on it as supporter . Other than that , we
use cylinder shape because , the material that have been remove not stuck under the
workpeice .
3) Stationary supporter it is there to clamp the cylindrical rotator . So that . the
4)
5)
6)
7)

cylindrical rotator not move when the operation run .

Drill bushes to guide cutting tolls .
Body to place all component inside it .
Base support the body .
Top cover close the jigs

b) DRILL 18MM HOLE

The first operation is drill diameter 18mm hole . We use the front hole of box jig to make the
18mm diameter hole .

So we can get this shape :

c) DRILL 2 X 20MM HOLES

The last operation is to make 2 hole with diameter 20mm . So we use the top hole on the top
cover with have the bushes . The bushes will guide the cutting tool and prevent it from
damage .

So we can get this shape :

7. CONCLUSION
From this mini project , we can conclude that there are many design for jigs and fixtures that
can be use in doing this process . But for me , the Box Jigs is more suitable and easy to
8

complete this operation . We also can visualize this design in CADCAM software which is I
use software Catia V5R21 .

8. REFERENCES
1) Practical treatise on milling and milling machines. Brown & Sharpe Manufacturing
Company. 1914. Retrieved 2013-01-28.
2) A treatise on milling and milling machines. Cincinnati, Ohio: Cincinnati Milling
Machine Company. 1922. Retrieved 2013-01-28.
3) Todd, Robert H.; Allen, Dell K.; Alting, Leo (1994), Manufacturing Processes
Reference Guide, Industrial Press Inc., pp. 4348, ISBN 0-8311-3049-0.
9. APPENDIX

FINAL WORKPIECE

10

COMMON VICE
11

12

BOX JIGS

13

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15

16

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