DESIGN AND FABRICATIONS OF PNEUMATIC DRILL JIG

SYNOPSIS
This project work deals with the DESIGN AND FABRICATION
OF PNEUMATIC DRILL JIG FOR THE MOTOR COVER. This
Pneumatic Drill Jig shows reduction in the labor time, machining time
etc. This type of Jig is used for mass production for motor cover, bearing
cap and other mechanical and automobile equipment.
This pneumatic drill jig provided with pneumatic clamping
arrangement. This type of clamping arrangement saves the setting time,
marking time, punching time etc. when compressed air is taken from a
convenient medium to provide pope clamping force and good gripping
to the component. As the quantity to produce is large the proposed
pneumatic drill jigs fulfills the mass production requirement in the
shop. Clamping can be done by releasing the pressured air using valves.
INTRODUCTION
Jigs and Fixtures have become a necessary part of modern
manufacturing processes. The employment of Jig is an important aspect
of workshop Engineering field. So as understanding of the principles
involved is a necessity in every step. Jig is the economical means to
produce repetitive type of works by providing special work holding and
tool-guiding devices Jig is an appliance used to facilitate the operation
to which it is applied. The primary objects of its use might be to
facilitate the holding and support an awkward of trial article for some

machining operations, to position a component and guide the cutters, so

that every component will be uniform.
Jigs are designed mainly to save manufacturing time and for each
type of work where quantity of production is desired, to maintain
consistency in dimensioning and in facilitate quick and easy assembly
and also to reduce cost of manufacturing. The work may be clamped
and unclamped quickly using valves.
Holes may be drilled at the same relative positions on each of the
identical work pieces, without marking the work individually. The work
is clamped below the Jig and holes are located. The jig plate is rotated
for the required holes and kept it in position using locating pins. The
drill bushes provided on the jig plate guide the drill. When the work is
completed, the second work is clamped as per the procedure and
process is again repeated.

WORKING PRINCIPLE
The component is placed in between the Jig plate and the locator,
which is on the piston rod. When the valve is opened, the compressed air
from the compressor will enter into the cylinder through a hole at the
bottom of the cylinder. The piston inside the cylinder is made to push in
the upward direction. When the piston moves the locator clamps the
component rigidly. Now the component is ready for drilling operation.

When the two-way valve is closed the piston will return to bottom
position to release the clamps. When we close the valve, the piston will
come in very high force in downward direction. So these are chances for
the damage of piston. To avoid this, we are using FLOW CONTROL
VALVE to control the flow of piston. This cana be repeated with the
same procedure as described above.

ADVANTAGES
The main advantages of Pneumatic Drill Jig fir HP Motor cover
are termed as follows:
1. The use of air cylinder reduces operator effort
2. Operator effort was reduced considerably and the job made much
easier and faster
3. Air clamping device is quicker in action more constant in
clamping proper and more convenient than hand operated clamps
and save human energy
4. Increases the versatility of machining performed
5. Reduces waste motions which cause fatigues to worker
6. Considerable savings in time are possible from the use of air
clamps
7. The average ratio of clamping time for a component between
manual operation and air operation is approximately 4:1
8. Increases machining accuracy, because the work piece is
automatically located without any alignment to the machine tools.

9. Increases productivity due to increasing the speed, feed and depth

of cut. This becomes possible due to higher clamping rigidity.
10.Air clamping can be controlled more uniformly than manual
clamping, thus reducing tendencies for work piece breakage or
distortion and insufficient grip. The savings so far indicated in
addition to the energy and strain serve the operator; it has been
proved conclusively that operator fatigue can be greatly reduced
by the use of pneumatic clamping means where large exertions
not be made. Also operator straining himself on large manual
clamping device has caused physical impairment.
11.Decreases expenditure on quality control of the machined parts
12.This method is used for large production qualities pressures are
uniform, and are controlled by operator with minimum fatigue.