Design A Casing For Air Pressure Plug Rapid Prototype.

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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

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UTeM Library (Pind.1/2005)

SULIT

TERHAD

TIDAK TERHAD

(Mengandungi maklumat yang berdarj ah keselamat an at au kepent ingan Malaysia yang t ermakt ub di dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang t elah dit ent ukan oleh organisasi/ badan di mana penyelidikan dij alankan)

(TANDATANGAN PENULIS)

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

SESI PENGAJIAN: 2/ 2006-2007

Saya _____________________________________________________________________

mengaku membenarkan t esis ( PSM / Sarj ana/ Dokt or Falsaf ah ) ini disimpan di Perpust akaan Universit i Teknikal Malaysia Melaka ( UTeM ) dengan syarat -syarat kegunaan sepert i berikut :

1. Tesis adalah hak milik Universit i Teknikal Malaysia Melaka.

2. Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat salinan unt uk t uj uan pengaj ian sahaj a.

3. Perpust akaan dibenarkan membuat salinan t esis ini sebagai bahan pert ukaran ant ara inst it usi pengaj ian t inggi.

4. **Sila t andakan (√)

MOHD HAFFIZZI BIN MD IDRIS

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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

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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

Faculty of Manufacturing Engineering

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ABSTRACT

The rapid prototyping term is very familiar with the rapid technology

development. Most of the product existing in the industry nowadays used this

technology as their main roots. The product had been developed by using this

technology has higher quality and most commercialized by many company. There

are a lot of advantages in this field such as the cost and time can be reduce in product

manufacture and also we can integrate the product into a high level usage after a few

research been made. In this project, the scope mostly been specified to find the

manufacturing process of the casing of ‘Air Pressure Plug’ and to analyze it. The

product produced by the rapid prototype machine used a sketch as a guide to get the

shape. The 3D sketches in .stl format existed being the guided to make the casing.

The design begin with identifying the product ( air pressure plug ) specification and

then followed with construct some sketches of the casing. The next step was

analyzing the sketching by using concept selection method and next final selection

will be draw with exactly dimension. After the drawing finished, the file will convert

into .stl format to slice the drawing to easy the machine doing the process. After

completely done, it will through some analyze. The analysis will be using

COSMOSXpress software bundle from SOLID WORKS software. It analyzes the

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ABSTRAK

Kaedah ‘rapid prototype engineering’ lebih dikenali dengan teknologi

pemprosesan secara berterusan dan cepat. Hampir di dalam semua bidang

perkilangan menggunakan kaedah ini dimana ianya banyak menghasilkan produk

yang bermutu dan dikomersialkan daripada kaedah ini. Dalam bidang kejuruteraan

dan bidang kesihatan sekalipun, teknologi ‘rapid prototyping’ mempunyai banyak

kelebihan dan manfaat pengunaannya seperti pengurangan kos kaji selidik dari segi

bahan mentah, aspek pemprosesan dan masa pembuatan sesuatu produk dan juga

meningkatkan keupayaan produk berdasarkan kajian yang telah dijalankan. Projek

ini melibatkan skop yang lebih menjurus kepada merekabentuk dan cara pembuatan

bekas untuk produk air pressure plug dan analisa produk(bekas) berkenaan. Ini

melibatkan dan mempengaruhi keputusan serta proses penghasilan produk untuk

mendapatkan bentuk yang dikehendaki. Proses kerja bermula dengan mengenal pasti

bentuk produk ( air pressure plug ) dan seterusnya memulakan lakaran serta

menganalisa menggunakan Concept Selection dan seterusnya merekabentuk produk

terakhir. Setelah itu, dengan mengunaakan mesin yang bersesuian dengan konsep

rapid prototype, produk akan dihasilkan dan akan dianalisa. Analisa ini akan

menggunakan perisian komputer bantuan graphic COSMOSXpress yang di

datangkan sekali bersama SOLID WORKS. Ia nya akan menganalisa sebarang

kegagalan yang terdapat dalam produk. Selain itu, analisa berbentuk ukuran akan

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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

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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.

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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

3.7a 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

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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

4.11 Result of ABS material with 25N force applied 72

4.12 Result Analysis for Body Material base ABS, force 0.394N applied. 73

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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

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CHAPTER 1 INTRODUCTION

1.1INTRODUCTION 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. .

Air Pressure Plug Product has been created by Mr. Nik Mohd Farid Che Zainal

Abidin , Mr. Hambali Arep and Mr. Mohd Najib Abd Manan representation for

Faculty of Manufacturing innovation product for competition of ITEX 2005 and

EKSPO IPTA R&D 2005. The Air Pressure Plug is created to substitute the ordinary

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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.

1.2OBJECTIVE 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

The purpose of this study is to develop the Casing Air Pressure Plug which is a cap

and body part and study the manufacturing process and analyze for the product. The

Air Pressure Plug did not have any casing yet to protect it from any factor that can

make it damage. And to product it in the market level, the product need a casing. The

other of most proposes is to know the rapid prototype engineering approach and it

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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

This study has many applications especially in designing a mold cavity and any

prototype in automotive field and also many other process. The sketcher by 2D and

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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

Finally in this chapter brief directly the purpose, objective and what is the main

focused of this study. The rapid prototype engineering for my product, casing air

pressure plug will be focused on how the product being manufactured. In this chapter

also told that application and problem that to be manufactured the product. The cap

and the body is the part to be produce using rapid prototype engineering approach

and it will be focused on the study. The selection of rapid prototype approach is the

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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

Concept selection is an integral part of the product development process. Concept

selection is the process of evaluating concepts with respect to customer needs and

other criteria, comparing the relative strengths and weaknesses of the concept, and

selecting one or more concepts for further investigation, testing, or development.

Figure 2.1. Illustrates how the concept selection activity is related to the other

activities that make up the concept development phase of the product development

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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 designs, designers push the design to match or exceed their competitors’

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• 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.

During concept screening, rough initial concepts are evaluated relative to a common

reference concept using the screening matrix. At this preliminary stage, detailed

quantitative comparisons are difficult to obtain and may be misleading, so a coarse

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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.

To prepare the matrix, selects a physical medium appropriate to the problem

at hand. Individuals and small groups with a short list of criteria may use

matrices on paper for their selection process. For larger groups a chalkboard

or flip chart is desirable to facilitate group discussion. Next, the inputs

(concepts and criteria) are entered on the matrix. Although possibly

generated by different individuals, concepts should be presented at the same

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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.

And for concept scoring, a single reference concept can be used for the

comparative ratings, as in the screening stage; however, this is not always

appropriate. Unless by pure coincidence the reference concept is of average

performance relative to all of the criteria, the use of the same reference

concept for the evaluation of each criterion will lead to “scale compression”

Design A Casing For Air Pressure Plug Rapid Prototype.

UNIVERSITI TEKNIKAL MALAYSIA MELAKA