UNIVERSITI MALAYSIA PAHANG

DECLARATION OF THESIS AND COPYRIGHT

Author’s Full Name : ALI ZULFAKAR BIN KHAIRUDIN

Identification Card No : 930118075763

Title : DESIGN AND DEVELOPMENT OF DRILL BIT

SHARPENING JIG FOR BENCH GRINDER

Academic Session : 2015/2016

I declare that this thesis is classified as:

CONFIDENTIAL

(Contains confidential information under the

Official Secret Act 1972)

RESTRICTED

(Contains restricted information as specified by

the organization where research was done)*

OPEN ACCESS

I agree that my thesis to be published as online

open access (Full text)

I acknowledge that Universiti Malaysia Pahang reserve the right as follows:

1. The Thesis is the Property of University Malaysia Pahang.

2. The Library of University Malaysia Pahang has the right to make copies for the purpose of

research only.

3. The Library has the right to make copies of the thesis for academic exchange.

Certified by:

_____________________________ _____________________________

(Author’s Signature) (Supervisor’s Signature)

ALI ZULFAKAR BIN KHAIRUDIN DR. MUHAMMED NAFIS BIN OTHMAN ZAHID

Date: 10 JUNE 2016 Date: 13 JUNE 2016

DESIGN AND DEVELOPMENT OF

DRILL BIT SHARPENING JIG FOR

BENCH GRINDER

ALI ZULFAKAR BIN KHAIRUDIN

Report submitted in partial fulfillment of the requirements

for the award of the degree of

Bachelor of Engineering in Manufacturing Engineering

Faculty of Manufacturing Engineering

UNIVERSITI MALAYSIA PAHANG

June 2016

i

SUPERVISOR’S DECLARATION

I hereby declare that I have checked this thesis/project and in my opinion, this thesis/project is

adequate in terms of scope and quality for the award of the degree of Bachelor of Engineering

In Manufacturing.

Signature :

Name of supervisor : DR. MUHAMMED NAFIS BIN OSMAN ZAHID

Position : SUPERVISOR

Date :29 May 2016

ii

STUDENT’S DECLARATION

I hereby declare that the work in this thesis/project is my own except for quotation and

summaries which have been duly acknowledged. The thesis/project has not been accepted for

any degree and is not concurrently submitted for award of other degree.

Signature :

Name : ALI ZULFAKAR BIN KHAIRUDIN

ID Number : FA12032

Date : 29 May 2016

vi

TABLE OF CONTENTS

Page

SUPERVISOR’S DECLARATION iii

STUDENT’S DECLARATION iv

ACKNOWLEDGEMENTS v

ABSTRACT vi

ABSTRAK vii

TABLE OF CONTENTS viii

LIST OF TABLES ix

LIST OF FIGURES x

LIST OF SYMBOLS xi

LIST OF ABBREVIATIONS xii

CHAPTER 1 INTRODUCTION

1.1 Introduction 1

1.2 Project Background 2

1.3 Problem Statement 2

1.4 Project Objectives 3

1.5 Project Scopes 3

CHAPTER 2 LITERATURE REVIEW

2.1 Introduction 4

2.2 Introduction of Jigs And Elements of Jigs 4

2.2.1 Jig Body 4

2.2.2 Locating Devices 5

2.2.3 Clamping Devices 5

2.3 Design Consideration In Fabrication of Jigs 5

2.4 Importance of Jigs 6

2.5 Introduction of Drill Bit Sharpening Jigs 7

2.6 Material Selection

vii

2.6.1 Phosphor Bronze 7

2.6.2 Die Steels 8

2.6.3 High Speed Steels 8

2.6.4 Carbon Steel 9

2.6.4 Mild Steel 10

2.7 Previous Research Of Jig Design 11

2.8 Previous Research Of Material 17

2.9 Conclusion `20

CHAPTER 3 METHODOLOGY

3.1 Introduction 21

3.2 Methodology Overview 21

3.3 Product Drawing Using CATIA softwaree 23

3.4 Analysis using CATIA-Generative Part Structural Analysis 23

3.5 Processes

3.5.1 Milling Process 24

3.5.2 Lathe Process 25

3.5.3 EDM Wirecut 26

3.5 Conclusions 26

CHAPTER 4 RESULT AND DISCUSSION

4.1 Introduction 32

4.2 Design Phase 33

4.2.1 Concept Screening 33

4.2.2 Concept Scoring 34

4.2.3 Finite Element Analysis 35

4.3 Fabrication Phase 36-37

4.4 Analysis Phase 38-39

CHAPTER 5 CONCLUSION AND RECOMMENDATION

5.1 Introduction 40

5.2 Recommendation 41

viii

REFERENCES 44

APPENDICES 45

ix

LIST OF TABLES

Table No. Title Page

2.1 Requirements for high-speed tool steels per ASTM 10

4.2.1 Concept Screening of Drill Bit Sharpening Jig 33

4.2.2 Concept Scoring of Drill Bit Sharpening Jig 34

4.4.1 Data from the surface roughness analysis 38

4.4.2 Average Minimum Surface roughness (µm) for both holes on the workpiece39

4.4.3 The difference of surface roughness(µm) 39

x

LIST OF FIGURES

Figure No. Title Page

2.1 Requirements for high-speed tool steels per ASTM 9

2.2 Drill bits sharpening jigs 11

2.3 Universal Device for Sharpening Drill Bits 12

2.4 Device for grinding the spiral drill 14

2.5 Drill grinding fixture 15

2.6 The Drill Bits Sharpening Device 16

2.7 Figures of lip angle, clearance angle and web angle 17

2.8 Influencing factors on the die life of die casting tools 19

3.1 Flow chart for final year project progress 22

3.2 The Von Mises stress distribution in ISO value 24

3.3 Milling machine Makino KE55 25

3.4 Lathe machine Romi C420 25

3.5 Example of wirecut process 25

xi

4.1 Design generated in CATIA software 32

4.2.3 The Finite Element Analysis (FEA) in CATIA Generative Stress Analysis 34

4.3.1 Milling process using Makino KE55 milling machine 35

4.3.2 Manual tapping for the adjust bolt fitting thread 36

4.3.3 The jig setup on bench grinder 37

4.3.4 Drill bit surface (Before resharpening) 37

4.3.5 Drill bit surface (After resharpening) 38

4.3.6 The continuous chips formed 38

4.3.7 Drilling holes on the aluminium block 39

4.3.8 Surface Roughness Analysis 39

4.4.1 Graph of the differences of the hole surface roughness 41

\

xii

LIST OF SYMBOLS

ω Natural frequency

ε Total strain, Bandwidth parameter

Raw rating of concept j for the ith criterion

Weighting for ith criterion

Total score for concept j

RM Ringgit Malaysia

xv

LIST OF ABBREVIATIONS

AA Aluminum alloy

Al Aluminum

ASTM American Society for Testing and Materials

CAD Computer-aided drafting

CAE Computer-aided engineering

DOF Degree-of-freedom

DTP Discretized turning point FE Finite element

FEA Finite Element Analysis

FFT Fast Fourier transform

FRF Frequency response function

MBD Multibody dynamics

PDF Probability density function