Design and Development of an Electromagnetic Portable Drill Guide for Improved Precision and Efficiency in DIY Applications

Anis Syazwani Aziz; Zammeri Abd Rahman; Razwan Rohimi; Mohd Shahir  Kasim; W Noor Fatihah W Mohamad; Mohd Sobri Hamid; Rodianah Alias; Zulkifli Abd Rahman; Madihah Maharof

doi:10.37934/ard.126.1.2641

Authors

Anis Syazwani Aziz Faculty of Innovative Design and Technology, Universiti Sultan Zainal Abidin, Kampus Gong Badak, 21300 Kuala Nerus, Terengganu, Malaysia
Zammeri Abd Rahman Faculty of Innovative Design and Technology, Universiti Sultan Zainal Abidin, Kampus Gong Badak, 21300 Kuala Nerus, Terengganu, Malaysia
Razwan Rohimi Faculty of Innovative Design and Technology, Universiti Sultan Zainal Abidin, Kampus Gong Badak, 21300 Kuala Nerus, Terengganu, Malaysia
Mohd Shahir Kasim Faculty of Innovative Design and Technology, Universiti Sultan Zainal Abidin, Kampus Gong Badak, 21300 Kuala Nerus, Terengganu, Malaysia
W Noor Fatihah W Mohamad Faculty of Innovative Design and Technology, Universiti Sultan Zainal Abidin, Kampus Gong Badak, 21300 Kuala Nerus, Terengganu, Malaysia
Mohd Sobri Hamid Faculty of Innovative Design and Technology, Universiti Sultan Zainal Abidin, Kampus Gong Badak, 21300 Kuala Nerus, Terengganu, Malaysia
Rodianah Alias Faculty of Innovative Design and Technology, Universiti Sultan Zainal Abidin, Kampus Gong Badak, 21300 Kuala Nerus, Terengganu, Malaysia
Zulkifli Abd Rahman Faculty of Engineering Technology, University College TATI (UC TATI), 24000 Kemaman, Terengganu, Malaysia
Madihah Maharof Department of Mechanical and Production Engineering, Islamic University of Technology, Board Bazar, Gazipur-1704, Bangladesh

DOI:

https://doi.org/10.37934/ard.126.1.2641

Keywords:

Electromagnetic drill guide, precision, technical education, DIY applications, finite element analysis

Abstract

This study investigates the design and performance of an electromagnetic portable drill guide aimed at enhancing precision, efficiency, and sustainability in educational and hobbyist applications. Using a combination of CAD modeling, Finite Element Analysis (FEA), and additive manufacturing, the developed drill guide demonstrated significant improvements in operational precision and portability. Circularity tests on different materials revealed minimal errors, with plywood exhibiting the lowest error rate of 0.40% and sheet metal the highest at 3.2%. FEA simulations confirmed the drill guide's structural integrity, with a maximum von Mises stress of 78.97 MPa (below the yield strength of the material), maximum displacement of 0.18 mm, and a safety factor of 3.48. The prototype, fabricated from mild steel and ABS plastic, was lightweight (5-7 kg) and versatile, supporting a wide range of materials including plywood, acrylic, and sheet metal. These findings highlight the drill guide's potential to improve precision tooling practices while promoting cost-effective and sustainable manufacturing, particularly in educational and DIY settings. Further enhancements are suggested to optimize ergonomic design and extend application versatility.