International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 03 | Mar 2025
p-ISSN: 2395-0072
www.irjet.net
Design and Analysis of Drill Jig for Lap Joint Flange (ANSI B16.5) Rahul P. Shekokar1, Krunal M. Patel2, 1Engineer, Indo German Tool Room, Ahmedabad
2PG Student, Indo German Tool Room, Ahmedabad
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Abstract - This paper presents the design and analysis of an
Table -1: Mechanical Properties of Materials Used in Jig Analysis
automatic indexing drill jig for lap joint flanges (ANSI B16.5). The jig enhances efficiency by allowing multiple hole sizes to be drilled on a single setup, reducing part rejections and production time. Designed in SolidWorks and analyzed using ANSYS 2022 R1, the study evaluates the jig’s structural performance, focusing on stress and deformation in the clamping system. The results confirm the jig's effectiveness in improving accuracy, minimizing setup changes, and optimizing manufacturing costs. Key Words: Drill Jig, ANSI B16.5, ASTM A105, Finite Element Analysis, Machining, Structural Analysis
1.INTRODUCTION Drilling jigs are essential tool in precision machining operations, ensuring accurate hole placement and reducing setup time. This study focuses on the development and analysis of a drilling jig for Lap Joint Flange (ANSI B16.5) machining ASTM A105 material, commonly found in piping applications. The objective is to assess the jig's performance using FEA and validate its structural integrity.
Material
Yield Strength (MPa)
Tensile Strength (MPa)
Modulus of Elasticity (GPa)
ASTM A105
250
485
AISI 1045
310
565
EN-8
280
AISI 52100
Poisson’s Ratio
Density (kg/m³)
200
0.3
7850
205
0.29
7870
550
210
0.29
7855
1520
2410
215
0.28
7810
SAE 1050
440
760
205
0.29
7850
4135-Steel
1034
1158
205
0.29
7850
AISI 4140
415
655
207
0.3
7850
HSS (M2)
2000
4100
225
0.28
8200
Stainless Steel
205
515
193
0.3
7930
3. Cutting and Clamping Force Analysis for Drilling To determine the cutting force and clamp force for drilling a 19 mm diameter hole in ASTM A105 carbon steel to a depth of 20 mm, the following calculations and assumptions are made: 3.1 Cutting Force Calculation
Figure 1 : 3D-Cad Model of Lap Joint Flange (ANSI B16.5)
F=K× 𝑓×D where: K is the specific thrust coefficient (600–700 N/mm² for medium carbon steel) 𝑓 is the feed rate (0.25 mm/rev, typical for 19 mm drill in steel) 𝐷 is the drill diameter (19 mm) Substituting values: F=600×0.25×19= 2.85 kN F=700×0.25×19= 3.3 kN Thus, the cutting force is estimated between 2.85 kN to 3.3 kN. 3.2 Clamp Force Calculation The clamp force should be three times the cutting force:
2. Materials Used in Analysis
Fclamp=3×F
The drilling jig consists of multiple materials selected based on mechanical strength, wear resistance, and machining properties. The following materials were used in the analysis:
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Impact Factor value: 8.315
Using the calculated cutting forces: Fclamp=3×2.85=8.55 kN
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