DESIGN AND FABRICATION OF STATIONERY RACK

AHMAD HAZURY BIN HAMID

A report submitted in partial fulfillment of the

requirement for the award of the Diploma

of Mechanical Engineering

Faculty of Mechanical Engineering

Universiti Malaysia Pahang

NOVEMBER 2007

ABSTRACT

Development of this stationery rack is for stationeries such as pen, pencil and

ruler on the table. With more stationeris case, this rack can store numbers of

stationeries and easy to find. This stationery rack is made from mild steel sheet metal.

It has rotating boxes which is use as place to store stationeries. This rack will help to

store stationeries in place and easy to take stationeries from it.

Whole of this project is particular involves the stationery rack. Diploma final

year project will allocate one semester to complete the project. This project also

required the adequate student to finish a task given. The tasks division need to apply,

for the entirely two part will be make that is a process to development of parts and

assemble the stationery rack.

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ABSTRAK

Penghasilan rak alat tulis mi adalah untuk digunakan sebagai tempat

meyimpan alatan tulis seperti pen, pensil dan pembaris di atas meja. Dengan tempat

menyimpan yang banyak, rak mi dapat menyimpan banyak alat tulis dan mudah

dicari. Rak alat tulis mi dibuat dan kepingan besi dan karbon lembut. Rak mi juga

mempunyai rak yang boleh diputar yang dijadikan sebagai tempat menyimpan alat

tulis. Rak mi membantu menyimpan alat tulis dan memudahkan untuk mencari alat

tulis.

Kesuluruhan projek mi adalah melibatkan mereka bentuk yang sesuai bagi rak

alat tulis. Projek tahun akhir bagi diploma mi mempunyai tempoh satu semester

untuk disiapkan. Projek mi juga memerlukan pelajar untuk menyiapkannya tugasan

yang diberi. Di dalam projek mi, pembahagian tugasan diperlukan. Secara

kesuluruhannya, projek mi dipecahkan kepada dua bahagian iaitu proses

menyediakan bahagian-bahagian rak dan mencantunikan rak itu.

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TABLE OF CONTENTS

CHAPTER TITLE PAGE

FRONT PAGE i

SUPERVISOR DECLARATION

DECLARATION in

DEDICATION iv

ACKNOWLEDGEMENTS v

ABSTRACT vi

ABSTRAK vii

TABLE OF CONTENTS viii

LIST OF FIGURES xii

LIST OF TABLES xv

LIST OF APPENDICES xvi

INTRODUCTION 1

1.1 Project Synopsis I

1.2 Problem Statement I

1.3 Project Scope 2

1.4 Project Objective 2

1.5 Project Planning 3

2 LITERATURE REVIEW 5

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2.1 Introduction 5

2.2 Stationery rack and Description 6

2.3 Manufacturing Method 7

2.4 Turret Punch Machine 7

2.5 Bending Machine 9

i. CNC bending 10

ii. Bending design guidelines 10

iii. Specification for CNC bending 11

2.6 Welding process 11

i. Basic Theory of Metal Inert Gas(MIG) Welding 11

ii. Metal Inert Gas (MIG) Welding 12

iii. The Advantages of MIG Welding 13

iv. The Disadvantages of M1G Welding 13

V. Welding Gun and Wire Feed Unit 13

vi. Process of MIG Welding 14

PROJECT METHODOLOGY 15

3.1 Project Flow Chart 15

3.2 Design and Sketching 18

i. Material 18

ii. Size 18

iii. Cost 18

3.3 Drawing 19

i. Sketching 19

ii. Solidworks Software 19

iii. Autocad 19

3.4 Sketching and drawing selection 19

i. Design A 20

ii. Design B 20

iii. Design C 21

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iv. Design D (datum concept) 21

V. Design E 22

vi. Design F 22

3.5 Pugh Selection Method 22

3.6 Conclusion of Pugh Selection Method 24

3.7 Solidwork Software Design 24

3.8 Part Design 26

3.9 Fabrication 27

i. Material 27

ii. Joining Method 28

iii. Functional Performance 28

iv. New or Special Feature 28

V. Manufacturing Process 28

a) Punching 29

b) Bending 31

c) Welding 33

d) Finishing 34

e) Painting 34

RESULTS AND DISCUSSION 35

4.1 Introduction 35

4.2 Result 35

4.3 Product Specification 37

4.4 Types of Defects 38

i. Gap 38

ii. Bead 39

iii. Unsmooth Rotating 39

4.5 Discussion 40

5 CONCLUSION AND RECOMMENDATION 42

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5.1 Introduction 42

5.2 Conclusion 42

5.3 Recommendation for Future Work

43

i. Facilities and Student requirement 43

ii. Work progress and management 44

REFERENCES 45

APPENDICES 46

LIST OF FIGURES

FIGURE NO. TITLE PAGE

2.1 Typical stationery rack in the market 6

2.2 Turret punch machine 8

2.3 Example of punching product 8

2.4 CNC Bending machine 10

2.5 Example of bending product 10

2.6 Basic Structure of Metal Inert Gas (MIG) Welding. 12

2.7 GMAW torch nozzle cutaway image 13

2.8 Basic equipment used in MIG operations 14

3.1 Project Flow Chart 16

3.2 Design A 19

3.3 Design B 20

3.4 Design C 20

3.5 Design D(datum concept) 21

3.6 Design 21

3.7 Design F 22

3.8 Solidwork design 25

3.9 Solidwork part by part design 26

3.10 Material selection 27

3.11 Turret Punch machine 29

3.12 Convert the drawing 29

3.13 Select sheet metal and bring to Turret Punch machine 30

3.14 Setting the tools 30

3.15 Run the machine 30

3.16 Products from punching process 31

3.17 Setting the dimension for bending process 31

3.18 Choosing suitable bending tool 32

3.19 Bending process 32

3.20 Products from bending process 32

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3.21 MIG welding 33

3.22 Welding process with safety equipments 33

3.23 Result from MTG welding 34

3.24 Painting process 34

4.1 Isometric view 36

4.2 Front view 36

4.3 Top view 37

4.4 Side view 37

4.5 Gap between each walls of the box 39

4.6 Bead at the chassis 39

4.7 Holder for rotating boxes 40

4.8 Round shape steel is not flat surfaces 40

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xv

LIST OF TABLES

TABLE NO. TITLE PAGE

1.1

Gantt chart 5

3.1 Pugh selection method table

23

4.1 Product specification

38

5.1 Gantt chart with actual and planning progress 43

xv:

LIST OF APPENDICES

APPENDIX TITLE PAGE

A Design and picture 46

B 3D drawing of stationery rack 48

C Apparatus

49

D Fabrication process 50

CHAPTER 1

INTRODUCTION

1.1 Project Synopsis

My project title is Design and Fabrication of Stationery Rack. The project

involves small analysis of the Stationery Rack requirement and fabrication of the

rack itself with concerns regarding strength, durability and ergonomic factor. New

concept of stationery rack is required to improve its durability and functions.

Overall, the project will meet acquire skills of design, analysis, and fabrication.

The concept of the stationery rack is to help user to store their stationeries in

place. Thus, with the fabrication of stationery rack, it is hope that it can contribute to

help them to store stationeries at exact places.

1.2 Problem Statement

The common problems that student faces with stationeries;

i. Mostly students put their stationeries anywhere they want.

ii. Since there is no specific place to store stationeries.

iii. Their stationeries cannot be found and lost.

iv. Stationeries mix with other items.

1.3 Project Scopes

The scope of the project as limited to the below parameter, equipments and

materials;

i. Software that has been used to design the stationery rack is solidwork and

autoCAD.

ii. Fabrication process will use all necessary manufacturing method including

cutting, bending and welding.

iii. Material that has been used to fabricate this stationery rack are sheet metals

and bearing.

1.4 Project Objective

There are two objective of this project;

i. Design a stationery rack that will help people to store their stationeries.

ii. Fabricate a stationery rack that is easy to handle and much better.

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1.5 Project Planning

According to the gantt chart from figure below, this project start with briefing

about the flow of the project from start till the end and followed by collecting

literature review. These include research about project title and gathering raw data

from internet, book and other source. The planning process is from week 1 until a

week 5.

After that, this project continued with design and measurement process from

week 3 to week 6. This includes sketching the design until the final design is chosen.

The design then transfer to solidwork software to create 3D look of the design. This

includes the actual dimension to fabricate the product.

From week 5 to week 8, material those needs to be use is search and gather.

Each raw material will be cut into dimension before the fabrication process.

Methodology study about manufacturing process from start of project until

finish fabrication is done by week 4 to week 7. It includes study on how to control

machines and which machine is suitable to use.

Fabrication process starts from week 7 to week 10. In this period of time, raw

material will undergo manufacturing process until the product is finish.

Evaluation stage has been implemented after fabrication stage. The

evaluation counted by considering the strength, durability, safety, and workability

factors of the rack. During the evaluation, if problem occur such as not functioning,

modification will be done.

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After the product is finish, report writing need to be complete before the

period of time. The report start from planning of the project until the design is

complete.

Finally, preparation slide for final presentation and show the project that

produce.

Table 1.1: Gantt chart

Project

Activities Weeks

1 2 3 4 5 6 7 8 9 1011 12 13 14 15

Literature

Review

Design &

Measurement

consideration

Acquisition &

Material

preparation

Methodology

study

Fabrication

Evaluation &

Improvement

Report writing

Presentation

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CHAPTER 2

LITERATURE REVIEW

2.1 Introduction

Stationery rack basically used as a place to store stationeries. It will help to

store stationeries in proper place and easy to find. Stationeries that usually use in

daily include pencil, pen, ruler, rubber, staplers and paper clips. This is the basic

meaning of stationeries rack and its function.

A stationery rack consists of 2 major parts. The parts are base and storage

box or cases. The base is the bottom part of a stationery rack. It is used as the place

to put the storage box or cases.

Most of stationery rack is put on the desk. Therefore, the design and size are

really important and must be consider as the factors to create it. Too much space will

limit the usage of a table. Stationery rack also used as something that could be made

as decoration on the table.

2.2 Stationery Rack and Description

Study about stationery rack show that this product already exists in the

market. However, based on the design, it only focused on it function to keep

stationeries. Below are examples of the product that can be seen in the market;

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Figure 2.1: Typical stationery rack in the market

2.3 Manufacturing Method

Manufacturing method that is use to fabricate the product include punching

process by using Turret Punch Machine. This process is to cut sheet metal into

desired shape. Bending process using Bending Machine. This process is to bend

sheet metal to part before joining process. Lastly joining process by using Metal

Inert Gas (MIG).

2.4 Turret Punch Machine

In line with industry trends, producing quality parts, lowering costs and better

scheduling of production to meet customer demands. At HSM Engineering we

provide many such solutions. The Plasma! Punch shop is equipped with the

technological solutions to cater for this high productivity environment.

Boasting state of the art equipment such as the Turret Punch Press, designed

for fast operator set-up and cycle times. With 58 tool stations 4 of which are

indexible (with an accuracy of 0.01 degrees). A series of tool configurations can be

set-up on the turret and only removed for maintenance, thus set-up time is drastically

reduced. The machine equipped with a Fanuc 1 8PC Multi-Axis CNC Control, which

is used to motion the carriage and table in the X, Y direction as well as I (tool

selection) and C (tool rotation). With feed-rate, ram speed and ram position controls

this machine can process jobs at a faster rate than others would take to set-up tooling

alone. Using the PHNC (Power Hydraulic Numerical Control) feature to set depths

of the form required can control specialised forming actions. Hence a single tool can

be set-up to perform several different tasks using this feature. The high-speed brush

type table has reduced noise levels and back scratch of sheets. This is just another

feature, which will ensure the quality of component produced for this demanding

global community in which we live.

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The Turret Punch Press has a 30 tonne press capacity, can handle a sheet size

of 1270mm x 4000mm with one reposition to a maximum of 3.2mm gauge material.

A hit rate of 360 hits per minute based on a 3mm stroke @ 25.4mm pitch or 290 hits

per minute based on an 8mm stroke @25.4mm pitch. This speed can be achieved

while still maintaining a high level of accuracy 0.1mm.

The world renowned software, JetCAM being the package software used to

program for this machine is able to interact with various CAD (Computer Aided

Draughting)/ CAM (Computer Aided Manufacture) software packages. The

flexibility of this software allows for geometric files produced in a DXF or IGES

format to be imported, edited, tooled and output in a GCD format to the machine.

This allows maximum production time for the machine to run, while other

components are being programmed. A variety of material types and gauges can be

processed, thus expanding its compatibility throughout many industries.

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Figure 2.2: Turret punch machine

Figure 2.3: Example of punching product

2.5 Bending Machine

Press brakes and bending machines are used to bend and fold metal by

pressing it into a die. There are several types of press brakes and bending machines.

Examples include a hydraulic press brake, folding equipment, bending machine,

press brake tooling, CNC brake press, and a sheet metal press brake. A hydraulic

press brake is designed for both specialized sheet metal work and continuous

production applications. A hydraulic press brake is designed to handle tough

industrial production jobs from single-cycle operations to automated cell

components. Folding equipment can be used to stiffen new metal panels that would

otherwise flap around, and to put lips on pieces of sheet that would normally need

screws passed through the front face. A bending machine forms angles in sheet

metal. Press brake tooling is used in cold-forming metal sheets or strips into desired

sections. A CNC brake press is a computer numerically controlled, filly automated

brake press with extensive bending capacity and networking function. A sheet metal

press brake is used to bend.

1. CNC Bending

Metal bending forms angles in sheet metal. A workpiece is positioned

over a die block and formed by the punch as it is forced into the die cavity.

Figure 2.4: CNC bending machine

ii. Bending Design Guidelines;

• The minimum inner radius recommended is approximately one material

thickness for most materials.

• The minimum flange width should be at least 4 times the material

thickness plus the bending radius.

• Holes or slots should be located a minimum of 3 stock thickness plus

the bend radius. If it is necessary to have holes closer, then the hole or

slot should be extended beyond the bend line.

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Figure 2.5: Example of bending product

iii. Specification for CNC Bending;

. Material - most ductile metals.

• Alternative machines - none.

• Tooling - CNC Bending requires only software program tooling. Intricate

designs may require custom tooling to shape your part.

• Reducing costs - reduce the number of bends used in your design. Design parts to pack efficiently. For example, in designing a large box consider making the sides of the box separate with bolted flanges. Avoid complex bend combinations. You can avoid the cost of bending by adding slots in place of the bends. You can then bend the part manually. This lowers cost further because items are flat and take less shipping volume. Such parts also take less storage space.

2.6 Welding Process

i. Basic Theory of Metal inert Gas(MIG) Welding

This stationery rack will be joined by using the permanent joint which is

welding process. The method joining that be able to fabricate and assembled the

Part is Metal Inert Gas (MIG) Welding.

ii

Nozzle

ntact Tube Electrod

ieIding Gas Arc Weld Pool

Base Metal

Figure 2.6: Basic structure of Metal Inert Gas (MlG) welding.

ii. Metal Inert Gas (MIG) Welding

An arc is struck between a consumable electrode and the sheet metal to

be welded. The consumable electrode is in the form of continuous filler metal.

An inert gas surrounds the are and shields it from the ambient to prevent

oxidation. Carbon steels, low alloy steels, stainless steels, most aluminum alloys,

zinc based copper alloys can be welded using this process.

Gas Metal Arc Welding (GMAW) is frequently referred to as MIG

welding. MIG welding is a commonly used high deposition rate welding

process. Wire is continuously fed from a spool. MIG welding is therefore

referred to as a semiautomatic welding process. The shielding gas, forms the arc

plasma, stabilizes the arc on the metal being welded, shields the arc and molten

weld pool, and allows smooth transfer of metal from the weld wire to the molten

weld pool. There are three primary metal transfer modes which are spray

transfer, globular transfer and short circuiting transfer.

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