Design A Casing For Air Pressure Plug Rapid Prototype

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

Design A Casing For Air Pressure Plug

Rapid Prototype

Thesis submitted in accordance with the requirements of the University Technical of Malaysia Malacca for the Degree of Bachelor of Engineering (Honours) Manufacturing (Design)

By

Mohd Haffizzi B Md Idris

UTeM Library (Pind.1/2005)

SULIT

TERHAD

TIDAK TERHAD

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)

(TANDATANGAN PENULIS) Alamat Tetap:

NO 11-A ,JALAN MURNI 2, TAMAN MAS MERAH,

75350 BT. BERENDAM , MELAKA Tarikh: _______________________

Disahkan oleh:

(TANDATANGAN PENYELIA) Cop Rasmi:

BORANG PENGESAHAN STATUS TESIS* UNIVERSITI TEKNIKAL MALAYSIA MELAKA

JUDUL: DESIGN A CASING FOR AIR PRESSURE PLUG – RAPID PROTOTYPE

SESI PENGAJIAN: 2/2006-2007

Saya _____________________________________________________________________

mengaku membenarkan tesis ( PSM / Sarjana/Doktor Falsafah ) ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka ( UTeM ) dengan syarat-syarat kegunaan seperti berikut:

1. Tesis adalah hak milik Universiti Teknikal Malaysia Melaka.

2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan untuk tujuan pengajian sahaja.

3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi.

4. **Sila tandakan (√)

MOHD HAFFIZZI BIN MD IDRIS

DECLARATION

I hereby, declare this thesis entitled

“Design A Casing for Air Pressure Plug – Rapid Prototype” is the result of my own research except as cited in the reference.

Signature : ……….

Author Name : ………

Date : ………

MOHD HAFFIZZI MD IDRIS

APPROVAL

This thesis submitted to the senate of UTeM and has been accepted as fulfillment of the requirement for the degree of Bachelor of Manufacturing Engineering (Honours) (Manufacturing Design). The members of the supervisory committee are as follows:

……… Main supervisor

ABSTRACT

ABSTRAK

DEDICATION

Specially dedicated to; My beloved Father, Md Idris Bin Md Hushin and My

Mother, Khatijah Bte Hitam who are very concern, understanding, patient and

supporting. Thanks for everything. To My Respectful Supervisor; Mr. Nik Mohd

Farid Bin Che Zainal Abidin for his constructive guidance, encouragement and

patience in fulfilling our aspiration in completing this project. To the Team who

design and develop Air Pressure Plug, My Siblings; Ikha Nadia Bt Md Idris , Ikha

Fadhzila Bt. Md Idris , Mohd Fadhzil Md Idris , Ikha Nurain Md Idris and All My

Friends, I also would like to say thanks. The Work and Success will never be

ACKNOWLEDGEMENTS

In The Name of Allah Almighty and The Most Merciful and Blessings Be Upon His Messenger Prophet Muhammad S.A.W and His Companions.

Alhamdullillah, I would like to express my thankfulness to Allah S.W.T the almighty for his divine inspirational guidance, which had helped me in completing this final year project. All the praise and selawat is upon to The Prophet Muhammad S.A.W. And I would like to convey my sincere thanks to my supervisor, Mr. Nik Mohd Farid Bin Che Zainal Abidin for his constructive guidance and patience in fulfilling our aspiration in completing this project. Same goes to Mrs. Seri Rahayu Bt. Kamat for guidance and patience.

I would like to thanks to technicians involved; Mr. Mohd Fairus B Ninggal, and Mr. Nizamul Ikbal B. Khaeruddin for their explanation, experiment and demonstration of the lab equipments and machineries regarding to this lab work. Not forgiven, the team whom design and develop product Air Pressure Plug, My friends for their support and understanding during the completion this final year project report.

Last but not least, I would like to thank all those who had contributed to my final year project, directly or indirectly and special thanks also go to my parents and sisters for their support throughout in completing my project.

TABLE OF CONTENTS

Abstract………..….……….i

Abstrak……….………...ii

Dedication ……….……….iii

Acknowledgement ……….………iv

Table of Contents ……….………..v

List of Figures ...ix

List of Tables ……….………xi

1. INTRODUCTION……….………...1

1.1 Introduction of the research………..……….…………....1

1.2 Objective of the research………...……….…………....2

1.2.1 Purposes of study………...…….………..2

1.2.2 Significance of the problem……….………..3

1.2.3 Problem statement……….…………....3

1.3 Applications of the research……….………..3

1.4 Conclusions……….………...4

2. LITERATURES REVIEW………...5

2.1 Introductions ……….……..……….5

2.2 Product Concept Selection...………...5

2.2.1 Concept Screening……….………..….…………...11

2.2.2 Concept Scoring……….………..11

2.3 Prototypes and Rapid Prototypes……….……..…….…....12

2.3.1 Type of Rapid Prototypes……….…….……….13

2.3.1.1 Stereolithography (SLA)………..…..………….13

2.3.1.1.1 Process of SLA………...……....………….14

2.3.1.1.2 Equipment SLA………....…….….….15

2.3.1.1.4 Advantage and Disadvantage SLA…………..…...16

2.3.1.1.5 Suitable Material on SLA……….……....…..16

2.3.1.2 Selective Laser Sintering (SLS)……….……….17

2.3.1.2.1 Process of SLS……….…...18

2.3.1.2.2 Equipment SLS……….………..19

2.3.1.2.3 Application range……….….…..19

2.3.1.2.4 Advantage and Disadvantage SLS………….…….19

2.3.1.2.5 Suitable Material on SLS……….….……..20

2.3.1.3 Fused Deposition Manufacturing (FDM)………….…...20

2.3.1.3.1 Process of FDM……….…….………22

2.3.1.3.2 Application range…….……….….…….23

2.3.1.3.3 Advantage and Disadvantage FDM…….……...23

2.3.1.3.4 Suitable Material on FDM……….……….…23

2.3.1.4 3D Printing (3DP)……… ……….24

2.3.1.4.1 Process of 3DP………..…...25

2.3.1.4.2 Application range………..……..26

2.3.1.4.3 Advantage and Disadvantage 3DP…………...26

2.3.1.4.4 Suitable Material on 3DP……….……..27

2.3.2 Advantage of Rapid Prototype……….…...27

2.3.3 Disadvantage of Rapid Prototype……….……..28

2.3.4 Application of Rapid Prototype………...…...28

2.4 Rapid Prototypes Engineering………..………..29

2.5 Software used in study Rapid Prototypes ………....………….…30

2.5.1 Solidworks………..…....30

2.5.1.1 COSMOSXpress………...………….……....31

3. METHODOLOGY OF THE RAPID PROTOTYPE ENGINEERING FOR

THE PART DESIGN………....33

3.1 Introduction………..33

3.2 Product Air Pressure Plug………..….………....35

3.3 Product Design Specification………..………37

3.4 Concept Sketching Ideas……... ………..………...38

3.5 Concept Selection………..……….……….………43

3.5.1 Introduction concept selection method………..……….…43

3.5.2 Rate Concept for each method……….……….…..44

3.4.2.1 Rate for Concept Screening……….……...44

3.4.2.2 Rate for Concept Scoring………….……….……..44

3.6 Drawing Procedure..………..……….47

3.6.1 Introduction to SolidWorks………47

3.6.2 Casing air pressure plug product design procedures…………..47

3.6.2.1 Revolve boss/base……….………..48

3.7 Convert CAD file to .STL file………..………..53

3.8 Analysis on Research………..………….………...54

3.9 Measurement equipment……….……….……..54

3.9.1 Vernier Caliper………...55

3.10 Rapid Prototype Machine……….56

3.11 The flow of the process……….….………..58

4. PRODUCING AND ANALYSIS PROTOTYPE…..……….………....59

4.1 Introduction………..……..………….59

4.2 Method of Producing Prototype………..………59

4.2.1 Set up Product on Software………..………59

4.2.2 Set Up Machine………..….……….61

4.2.3 Results Project………..………..62

4.3 Analysis on Prototype and Design……….…..64

4.3.1 Analysis Using COSMOSXpress……….………...64

4.3.1.1 Analysis Process Method……….……..…….65

4.3.1.1.1.1 Concept 1………..…....………..66

4.3.1.1.1.2 Concept 2………..…………..66

4.3.1.1.1.3 Concept 3………..……..67

4.3.1.1.2 Different Loads………..……….67

4.3.1.1.3 Step of Analysis…………..…...……….67

4.3.1.2 Results of Analysis……….………71

4.3.1.3 Data of Analysis………..…….………..74

4.3.2 Analysis of The Measurement………..74

4.3.2.1 Result from the Data of Measurement………..……..77

4.3.3 Simple Study On Tolerance Linear Case……….….………79

5. DISCUSSION………...………80

5.1 Introduction………...………..80

5.2 Overview of Design and Analysis………..………80

5.3 Data Collection and Study Tolerance………..……….…...……82

6. CONCLUSION………..….………..83

6.1 Conclusion………...83

6.2 Recommendations………...85

REFERENCES………86

APPENDICES

A Gantt Chart PSM I B Gantt Chart PSM II

C Detail Drawing for Cap And Body

D Drawing of Assembly , Casing Air Pressure Plug E Result of Analysis COSMOSXpress

LIST OF FIGURES

2.1 Concept Selection In Design Product Development 5

2.2 Application of Concept Selection 8

2.3 Stereolithography Apparatus Machine ( 3D System ) 14 2.4 Stereolithography Apparatus Machine Principle 15

2.5 Selective Laser Sintering Machine 17

2.6 Selective Laser Sintering Principle 18 2.7 Fused Deposition Modeling Principle 21

2.8 Fused Deposition Modeling Machine 22

2.9 3 D Printing Machine ( MIT ) 25

3.1 Methodology Flow 34

3.2 Image of the Air Pressure Plug 35

3.3 Illustration of Shape Air Pressure Plug 36

3.4a Sketches of Model A 38

3.4b Sketches of Model B 39

3.4c Sketches of Model C 40

3.4d Sketches of Model D 40

3.4e Sketches of Model E 41

3.4f Sketches of Model F 42

3.5 Final Drawing ( Isometric View ) Casing 48

3.6 Sketch by Plane for Cap of Casing 49

3.7a Revolve Boss/Base Process 49

3.7b Result of Revolve For Cap 50

3.8 Sketcher Process for Body of Casing 50 3.9 Important Point for Body of Casing 51 3.10a Revolve Boss/Base process for Body of Casing 51 3.10b Result Revolved for Body of Casing 52 3.11a Part being Insert in Assembly process 52

3.13 Picture of ZPrinter 310 Plus Rapid Prototype machine 57

3.14 Flow Chart of Process 58

4.1 Screen of ZPrint Software 60

4.2 The gantry movement and the manually spread both box 61 4.3 Final product finishing – prototype 62

4.4 Log taken from the Software. 63

4.5 Software estimated of Volume, Surface and Ratio both parts 63

4.6 Part Body Restraints 68

4.7 Part Cap Restraint 69

4.8 Loads applied Cap 69

4.9 Loads applied Body 70

4.10 Process of COSMOSXpress 70

LIST OF TABLES

3.1 Standard Scale Rate of Concept Scoring 44 3.2 Show the result of Concept Screening 45 3.3 Show the result of Concept Scoring 46 3.4 General Specification Mitutoyo Vernier Caliper 55 3.5 Specification of ZPrint 310 Plus RP machine 57

4.1 Result Analysis COSMOSXpress for CAP 71 4.2 Result Analysis COSMOSXpress for Body 71 4.3 Data for measurements of the Vernier caliper for Body 76 4.4 Data for measurement of Vernier caliper for CAP 76

CHAPTER 1

INTRODUCTION

1.1 INTRODUCTION OF THE RESEARCH

In this study, it clearly shown that the rapid prototype engineering application had many benefit on the product development. By using CAD/CAM application and machine in the lab, the cost of the research will be low and more efficiently. In the industry, rapid prototype is a rapidly developing technology. Its application cover all of industry and academic and using a high technology of equipments. The design of cap and body as a main part for producing a casing air pressure plug product was the aim of the objectives. The product that is design is needed to be referring a product (Air Pressure Plug). The problem of producing the product can be easily overcome when the final design of casing is produce.

For this research, I’m using the application of rapid prototype in producing a casing of air pressure plug. The main focused on this research was a methodology and the using of rapid prototype in real situation of making a product rapidly. The methodologies that involve in this research also consist of design selection and follow on how to create or producing a new product. .

By taking the product properties such as shape and dimension, the design of casing can be produce. There fore in the rapid prototype, application for this study will find out how to produce the casing product. The final sample will be use as a final casing of air pressure plug.

1.2 OBJECTIVE OF THE RESEARCH

The objective of this study is to apply the rapid prototype engineering method in a real

situation and discover how this engineering application can be implement in making a prototype for casing air pressure plug. The main focused in this study was the design of Casing Air Pressure Plug. The part which going to produce were cap and body which can be fit together, do some analyze the aspect of the product during manufacturing process and get the final product ( casing Air Pressure Plug )

1.2.1 PURPOSES OF STUDY

1.2.2 SIGNIFICANCE OF THE PROBLEM

Rapid Prototype is a rapidly developing technology. It application cover all industrial and academic field [1]. Many of company in this industries use the rapid prototype approach because it can decrease costly mistakes but need a high cost in term of machining and tool. It can produce a prototype easily in short time and save analysis time on the product. By this process, the product can be re innovation or redesign after done the analysis process. Therefore, by taking this approach as method, the manufacture of product can reduce the Research and Develop program and producing a product. By this, the company or manufactured did not need to asked other industry to produce the part or analyze the part.

1.2.3 PROBLEM STATEMENT

The Casing Air Pressure Plug need to be design and need to develop or manufacture, but there are no other easily way or method for produced it than rapid prototype. The casing consists of a cap and body. The Air Pressure Plug is needed to be in the market for the next year. The casing must be suitable with the customer needs and the product specification and also the design of air pressure plug itself. The requirement related to the product air pressure plug. So by using rapid prototype engineering, the casing of product can be produced and have to do some analysis. If the casing failed, we need to improve it and make it a new product or prototype. The cost will not so high if using the rapid prototype engineering approach.

1.3 APPLICATIONS OF THE RESEARCH

produce more and more prototype to analyze and test. By implementing this approach, material, manufacturing cost and other factors can be decrease easily. This will decrease development time by allowing the correction to a product to be made easily in the process flow. Thus the manufacture can changes the design and do some correction before produce the real product.

1.4 CONCLUSIONS

CHAPTER 2

LITERATURES REVIEW

2.1 INTRODUCTION

This chapter describe about the related source and history of the research which had been done by others in rapid prototyping engineering field. This will include some of their idea for the method that I used in this study. In this chapter also told us the summarized a several of the rapid prototyping engineering and the application of it’s depend on the field related to. From the related research (previous). The example can be taken as guidance to apply in this research.

2.2 PRODUCT CONCEPT SELECTION

All designer use some method for choosing a concept. Whether or not the concept selection process is explicit, all of them use same method to choose among concept. The method varies in their effectiveness and includes the following:

External decision: Concept is turned over to the customer, client, or some other external entity for selection.

• Product champion: An influential member of the product development team

chooses a concept based on personal preference.

• Intuition: The concept is chosen by its fell. Explicit criteria or trade-offs are not used. The concept just seems better.

• Multivoting: Designer votes for several concepts. The concept with the most

votes is selected.

• Pros and cons: The designer lists the strengths and weaknesses of each

concept and makes a choice based upon group opinion.

• Prototype and test: The designer builds and tests prototypes of each concept,

making a selection based upon test data.

• Decision matrices: The designer rates each concept against pre-specified

selection criteria, which may be weighted.

A structured concept selection process helps to maintain objectivity throughout the concept phase of the development process and guides the product development team through a critical, difficult, and sometimes emotional process. Certainly the response of the market to a product depends critically on the product concept, but many practitioners and researchers also believe that the choice of a product concept dramatically constrains the eventual manufacturing cost of the product. Specifically, a structured concept selection method offers the following potential benefits:

• A customer- focused product: Because concepts are explicitly evaluated

against customer-oriented criteria, the selected concept is likely to be focused on the customer.

• A competitive design: By benchmarking concepts with respect to existing

• Better product-process coordination: Explicit evaluation of the product with

respect to manufacturing criteria improves the product’s manufacturability and helps to match the product with the process capabilities of the firm.

• Reduced time to product introduction: A structured method becomes a

common language among design engineers, manufacturing engineers, industrial designer, marketers, and project managers, resulting in decreased ambiguity, faster communication, and fewer false starts.

• Effective group decision making: Within the development team,

organizational philosophy and guidelines, willingness of members to participate, and team member experience may constrain the concept selection process. A structured method encourages decision making based on objective criteria and minimizes the likelihood that arbitrary or personal factors influence the product concept.

• Documentation of the decision process: A structured method results in a readily understood archive of the rationale behind concept decision. This record is useful for assimilating new team members and for quickly assessing the impact of changes in the customer needs or in the available alternatives.

We present a two-stage concept selection methodology, although the first stage may suffice for simple design decisions. The first stage is called concept scoring. Each is supported by a decision matrix which is used by the team to rate, rank, and selects the best concept(s). Although the method is structured, we emphasize the role of group insight to improve and combine concepts. The application of these two methods is illustrated in Figure 2.2 below. Screening is a quick, approximate evaluation aimed at producing a few viable alternatives. Scoring is a more careful analysis of these relatively few concepts in order to choose the single concept most likely to lead to product success.

quantitative evaluations of the remaining concepts using the scoring matrix as a guided must be taken.

Figure 2.2: Illustrated application of concept selection.[11]

Both, concept screening and concept scoring follow a six-step process which leads the team through the concept selection activity. The steps are:[11]

1. Prepare the selection matrix.

concept is best portrayed by both a written description and a graphical representation. A simple one-page sketch of each concept greatly facilitates communication of the key features of the concept. The concepts are entered along the top of the matrix, using graphical or textual labels of some kind.

These criteria are chosen based on the customer needs, we has identified, as well as on the needs of the enterprise, such as low manufacturing cost or minimal risk of product liability. The criteria at this stage are usually expressed at a fairly high level of abstraction and typically include from 5 to 10 dimensions. The selection criteria should be chosen to differentiate among the concepts.

For the concept scoring, after the criteria are entered, we needs add importance weights to the matrix. Several different schemes can be used to weight the criteria, such as assigning an importance value from 1 to 5, or allocating 100 percentage points among them. However, for the purpose of concept selection the weights are often determined subjectively by us.

2. Rate the concepts.

For Screening method, a relative score of “better than”(+), “same as”(0), or “worse than”(-) is placed in each cell of the matrix to represent how each the concept rates in comparison to the reference concept relative to the particular criterion.