Modelling and analysis of a drilling jig for a electric motor mounting casing

Mass production is extremely vital to the machine tool industry, as it contributes to producing higher levels of precision, reduces the number of workers needed and any costs from automation as well as increase overall productivity. Specialized tools such as drill jigs and fixtures are used to precisely clamp and locate a work in place and guide the drill along a predetermined path, ensuring that the holes are drilled at the correct location and depth. This research aims to investigate the design and analysis of drill jigs. The design was successfully modelled using Autodesk Inventor and analyzed using ANSYS. The analysis results showed that the thrust force calculated has proved to be lesser than the clamping force, verifying the performance and rigidity of the designed jig. The maximum amount of total deformation found is 0.03772 mm, where the jig was under the highest load of 7000 N. The highest stress value obtained is around 75 MPa, much less than the ultimate tensile strength of the material, which is 310 MPa, giving us a safety factor value of 4. The modelled jig has proved to withstand different loads; the jig was tested under 4000 N, 5000 N, 6000 N and 7000 N. The different results were then tabulated and compared with the help of a stress vs load plot. The results showed that with increasing stress due to the increasing load, the jig showed very minimal deformation, strain and stress.