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  • MALACCA TECHNICAL UNIVERSITY OF MALAYSIA

    DESIGN OF JIG AND FIXTURE FOR

    MILLING MACHINE,

    CASE STUDY: CYLINDRICAL PARTS

    Thesis submitted in accordance with the requirements of the Malacca Technical

    University of Malaysia for the Degree of Bachelor of Engineering (Honours)

    Manufacturing (Process)

    By

    FAIEZUL BIN ZAINAL

    Faculty of Manufacturing Engineering

    May 2007

  • DECLARATION

    I hereby, declare this thesis entitled Design Of Jig And Fixture For Milling Machine,

    Case Study: Cylindrical Parts is the results of my own research

    except as cited in the reference.

    Signature :

    Authors Name : Faiezul Bin Zainal

    Date : 11 May 2007

  • i

    ABSTRACT

    The final year project is start by the overview of jig and fixture. It is the briefly explanation

    about the perspective of project namely the jig and fixture. List the problem statement that can

    help to create an idea in order to prepare the solution of all the problems for cylindrical parts in

    milling machine. In order to determine the problem statement, the comparison between the

    milling machine and the lathe machine is needed. This is because both of these machines have

    significant difference in types of work piece, cutting tool and machining processes. Need to

    understand the objectives of this project and make sure the target is achieved. The scope of the

    project is totally for milling machine so need to give high focus in order to do the jig and fixture

    design. Besides, need to organize the works into several parts to make sure the works become

    more systematically. Divided the works into three main parts namely research, design and

    analysis. The purpose of this project is to do the case study about jig and fixture for milling

    machine in perspective of cylindrical work piece, a new design of jig and fixture and comes out

    with the jig and fixture product. Actually, there are many jigs and fixtures available in the

    manufacturing field so the development a new product of jig and fixture is needed. On the other

    hands, this design can improve the ability and characteristic of the milling machine. There are

    four designs of the jig and fixture for this project and all design are creating by Autodesk

    Inventor 9 software. By the four of the design, the analysis about the specification, safety factor,

    characteristic and other factor is needed then select one for the best design. The determination

    about the suitable material is in order to produce this jig and fixture also important. The result

    for this project can totally solve the problem for milling machine in perspective of cylindrical

    parts.

  • ii

    DEDICATION

    For

    My Family

    And

    Friends

  • iii

    ACKNOWLEDGEMENTS

    Valuable suggestions, criticisms and comments have been made by numerous

    individuals. Greatly appreciate the time and effort the following person gave in order to

    complete the final year project and thanks them for their help in improving the quality of

    this final year project:

    Mohd Faiz Bin Samsuddin

    Mohd Najib Bin Abd. Manan

    Raja Manisa Bt Raja Mamat

    Nazareha Bt Ramli

    Muslim Bin Wan Harun

    Mohd Noor Ikhwan Bin Mohd Fauzi

    Razif Bin Sidek

    Highly appreciate for supervisor, Mr. Taufik for his advices and guidelines and all

    lecturers who have ensured the successful completion of this project. Finally, thanks to

    brothers, Hafizam and Aszairi for their encouragement, support and patience throughout

    the process of creating this final year project.

  • iv

    TABLE OF CONTENTS

    Abstract...............................................................................................................................i

    Dedication..........................................................................................................................ii

    Acknowledgement.............................................................................................................iii

    Table of Contents..............................................................................................................iv

    List of Figures.................................................................................................................viii

    List of Tables.....................................................................................................................xi

    Sign and Symbols.............................................................................................................xii

    1. INTRODUCTION........................................................................................................1

    1.1 Overview / Background................................................................................................1

    1.2 Problem Statements......................................................................................................2 1.3 Objectives.....................................................................................................................3

    1.4 Scope of Project............................................................................................................3

    1.5 Project Organization.....................................................................................................4

    2. LITERATURE REVIEW............................................................................................8

    2.1 Introduction to the Jigs and Fixtures............................................................................8

    2.2 Definition of Jigs and Fixtures.....................................................................................8

    2.3 Production Devices.......................................................................................................9

    2.4 Elements in Jigs and Fixtures.......................................................................................9

    2.5 Advantages of Jigs and Fixtures.................................................................................10

    2.6 Inspection Devices......................................................................................................10

    2.7 Limits and Fits............................................................................................................11

    2.7.1 Classification of Fits.............................................................................................12

    2.7.2 Sample of Fits.......................................................................................................13

    2.8 Material Used.............................................................................................................13

    2.9 Work piece..................................................................................................................15

  • v

    2.9.1 Work piece Stops.................................................................................................15

    2.9.2 Work piece Supports............................................................................................17

    2.10 Essential Features of Jigs and Fixtures....................................................................18

    2.11 Differentiate Between Jigs and Fixtures..................................................................20

    2.12 Locators....................................................................................................................20

    2.12.1 Basic Principle of Locating................................................................................21

    2.12.2 Accuracy.............................................................................................................21

    2.12.3 Constraint...........................................................................................................22

    2.12.4 Motion Economy................................................................................................22

    2.12.5 Locating Devices................................................................................................23

    2.12.6 Locating Methods...............................................................................................23

    2.13 Typical Jigs Feet.......................................................................................................26

    2.14 Clamps......................................................................................................................26

    2.14.1 Basic Principles of Clamping.............................................................................27

    2.14.2 Types of Clamps.................................................................................................28

    2.14.3 Power Clamping.................................................................................................34

    2.14.4 Non-Conventional Clamping..............................................................................35

    2.15 Components of Jigs and Fixtures.............................................................................36

    2.16 Typical Dimensioning..............................................................................................37

    2.17 Bushes......................................................................................................................38

    2.18 Cost Estimat