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

Modulus of Elasticity
(Gpa)
210

Breaking Strength

Ultimate Tensile 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

Modulus of Elasticity

(BHN)

(Gpa)

229

210

Breaking Strength

Ultimate Tensile 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