Innovative Product Design & Manufacture Report on Three Wheeler Cart
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This report focuses on the design process, design concept, design specification, design evaluation, DFMA principles & analysis, design validation, conclusion, detailed design, assembly drawing, and G code of a three-wheeler cart. The report includes the material properties of the components used in the cart.
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INNOVATIVE PRODUCT DESIGN & MANUFACTURE REPORT ON THREE WHEELER CART 1|P a g e
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INNOVATIVE PRODUCT DESIGN & MANUFACTURE Table of Contents..................................................................................................2 1.Abstract....................................................................................................3 2.Introduction.............................................................................................4 4.Design Process.........................................................................................4 5.Design Concept........................................................................................4 6.DesignSpecification................................................................................5 6.DesignEvaluation..................................................................................17 6.DFMA principles & analysis.................................................................18 7.Design Validation..................................................................................19 8.Conclusion.............................................................................................24 9.Detailed design.......................................................................................25 9.Assembly Drawing.................................................................................28 9.G code...................................................................................................29 10.Reference...............................................................................................36 2|P a g e
INNOVATIVE PRODUCT DESIGN & MANUFACTURE Partial Product Design Specification (PPDS) ElementDescriptionDeman d or Wish WeightNot more than 7 KilogramsDeman d ErgonomicsDesign to be key activation of cart motion. Design to be self steering ability. Handle to accommodate by anyone. Deman d Deman d Deman d SafetyDesign to justify standards. Design to have no sharp corners or edges. All the moving components are covered by frame. Deman d Deman d Deman d MaterialsBody of design to be made of lightweight material such as acrylic . Chosen acrylic material should be resistant to wear and tear. Deman d Deman d Product CostDesign to fit into the $50.Wish Life in Service A minimum of 2 years is required.Deman d MaintenanceDesign is maintenance free.Deman d AestheticsFrame of cart coloured with blue , red or green .Deman d SizeOverall length is maximum to 600 mm. Width to be no more than 400 mm. Deman d Deman 3|P a g e
INNOVATIVE PRODUCT DESIGN & MANUFACTURE Height to be no more than 400 mmd Deman d PerformanceDesign must be easy to operate. Design must be easy to attach and remove attachments. Deman d Deman d ABSTRACT Under this report ,design of 3 wheeler cart is done by using Computer aided design .This cart is first created byLeonardo da Vinci and he named this vehicle as self propelling cart .The prototype of this cart is recreated in this report .The manual spring mechanism is used to power this cart as a key is directly connected to spring .When the key is rotated then spring get compressed and absorb the energy then spring transfers the energy to gear arrangement which is directly connected to wheels of cart .The front wheel is design in such a way to steer it accordingly . 4|P a g e
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INNOVATIVE PRODUCT DESIGN & MANUFACTURE INTRODUCTION Da Vinci was not only designer but also an artist and a painter and that also reflect in his work as well .His one of the best work was propelling cart and this cart was impossible of design at that time without necessary resources .This cart is a masterpiece having perfect use of gears .All the parts of cart were recreated using solidworks CAD software . Rendering and detailed drawing of all parts are prepared for manufacturing purpose . Analysis of wheel of cart is done and comparing it for prototyping purpose and cnc manufacturing . DESIGN PROCESS The main focus of design process is to recreate the prototype of 3 wheeler cart effectively considering all design aspects . DESIGN CONCEPT/SKETCH Wheel 5|P a g e
INNOVATIVE PRODUCT DESIGN & MANUFACTURE Wheel provide the rolling motion to cart , the spokes present on its centre balance center of gravity of wheel . Frame Frame cover all the mechanical components used in cart and support the weight of it . Gears Gear transfer the motion from one part to other . Cart 6|P a g e
INNOVATIVE PRODUCT DESIGN & MANUFACTURE Figure 1.1 Cart design concept Under the design concept , a rough sketch of 3 wheeler cart is obtained. This sketch gives us the basic idea about the product visualization. The above sketch shows that gears assembly is surrounded by frame .This frame not only kept all the parts together but also carry out all the load act upon it .1 1Davinci, Leonardo (2011).The Notebooks of Leonardo Da Vinci. Lulu. p.736. 3 Wheeler cart should be designed similar to propelling cart and all the main components like spring , gears and frame should be used accordingly . 3 Wheels are used in this cart , front single wheels is used for direction purpose and backward two wheels provide the motion .2 DESIGN SPECIFICATION Under design specification all the parts of 3 wheeler car should be specify accordingly . All the component are explained below . 1)Truss/Frames 7|P a g e
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INNOVATIVE PRODUCT DESIGN & MANUFACTURE Truss/Frames are the structure members generally used to carry loads and coupled multiple parts in single unit for smooth operation of assembly. To carry the weight of multiple gear units , here two types of truss are used . Truss/Frames used are:- a)Bottom Truss/frame b)Top Truss/frame a)Bottom truss According to its name suggest ,bottom truss present at the bottom of gear assembly .The load of all mechanical components are directly act on this truss .At the surface of bottom truss , multiple threaded holes are present .These holes are used for mounting and rotating gear shafts . Other holes are used to fastened the bolts with other frame . Fillets are present at corners of truss for stress reduction. 2Fernando(2010).TechnologicalConceptsandMathematicalModelsintheEvolutionofModernEngineering Systems.Birkhäuser.ISBN978-3-7643-6940-8. Manufacturing process - The shape of frame is non uniform , So all the linear parts are joined together with fasteners , at necessary places holes of required diameter are drilled . Fillets are provided by using grinding operation .3 8|P a g e
INNOVATIVE PRODUCT DESIGN & MANUFACTURE Figure 1.2 Bottom truss The material used for frame is Wood .Some properties of wood is given below . Major properties of Wood is shown below PropertyValueUnits Elastic Modulus3000N / mm^2 Poisson's Ratio0.29N / A Shear Modulus300N / mm^2 Mass Density160kg / m^3 Yield Strength20N / mm^2 Thermal Conductivity0.05W / (m·K) Table 1.1 Material Properties 3Plesha, Michael E (2013).Engineering Mechanics: Statics(2nd ed.). New York: McGraw-Hill Companies Inc. pp.364– 407.ISBN0-07-338029 b)Top truss/frame Top truss is present at the top of gear arrangement and lock the linear motion of all gears . The top truss share the load of all components with bottom truss .At its surface, multiple threaded holes are present .These holes 9|P a g e
INNOVATIVE PRODUCT DESIGN & MANUFACTURE are used for mounting and rotating gear shafts. Fillets are present at corners of truss for stress reduction.4 Figure 1.3 Top truss/frame Manufacturing process - The shape of top truss is similar to bottom truss as compare in area covered but it is also non uniform , So all the linear parts are joined together with fasteners , at necessary places holes of required diameter are drilled . Fillets are provided by using grinding operation . 4Jacob;Papadopoulos(Oct 2016).Introduction to Solid Mechanics: An Integrated Approach. Springer.ISBN9783319188782. The material used for frame is Wood .Some properties of wood is given below . Major properties of Wood is shown below PropertyValueUnits 10|P a g e
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INNOVATIVE PRODUCT DESIGN & MANUFACTURE Elastic Modulus3000N / mm^2 Poisson's Ratio0.29N / A Shear Modulus300N / mm^2 Mass Density160kg / m^3 Yield Strength20N / mm^2 Thermal Conductivity0.05W / (m·K) Table 1.2 Material Properties 2)Wheel There are 3 wheels in this vehicle , front wheel adjust itself according to direction of cart and two back wheels are assembled with the gear arrangement and provide motion to the cart . The material used for wheel is Acrylic .Some properties of acrylic is given below . Major properties of Acrylic is shown below PropertyValueUnits Elastic Modulus3000000000N / m^2 Poisson's Ratio0.35N A Shear Modulus890000000N / m^2 Mass Density1200kg / m^3 Tensile Strength73000000N / m^2 Yield Strength45000000N / m^2 Thermal Conductivity0.21W / (m·K) Specific Heat1500J/(kg·K) Table 1.3 material properties5 11|P a g e
INNOVATIVE PRODUCT DESIGN & MANUFACTURE Figure 1.4 Front wheel Manufacturing process All 3 wheels are similar and have uniform cross-section so it is manufactured by machining process .Back wheels have taper tube on its inner face which is joined separately to it . Figure 1.5 Back wheel 5Wingerter, R., and Lebossiere, (Feb 2011) P.,ME 354, Mechanics of Materials Laboratory: Structures, University of Washington The material used for Back wheel is Acrylic .Some properties of acrylic is given below . Major properties of Acrylic is shown below PropertyValueUnits 12|P a g e
INNOVATIVE PRODUCT DESIGN & MANUFACTURE Elastic Modulus3000000000N / m^2 Poisson's Ratio0.35N A Shear Modulus890000000N / m^2 Mass Density1200kg / m^3 Tensile Strength73000000N / m^2 Yield Strength45000000N / m^2 Thermal Conductivity0.21W / (m·K) Specific Heat1500J/(kg·K) Table 1.4 material properties 3)Gear arrangement The gear arrangement shows the combination of different gears , shafts , winding unit , hub connecting in such a way to obtain desired output . Figure 1.6 Gear arrangement This gear arrangement having following parts explained below - 13|P a g e
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INNOVATIVE PRODUCT DESIGN & MANUFACTURE a)WINDING UNIT The winding unit is input link in which a key is present .This unit is connected with the spring .As the key is rotated manually or by external means then this rotational motion stored in spring and then further transfer to gears . Figure 1.7 Winding unit The material used for winding unit is Acrylic .Some properties of acrylic is given below . Major properties of Acrylic is shown below PropertyValueUnits Elastic Modulus3000000000N / m^2 Poisson's Ratio0.35N A Shear Modulus890000000N / m^2 Mass Density1200kg / m^3 Tensile Strength73000000N / m^2 Yield Strength45000000N / m^2 Thermal Conductivity0.21W / (m·K) Specific Heat1500J/(kg·K) 14|P a g e
INNOVATIVE PRODUCT DESIGN & MANUFACTURE Table 1.5 material properties b)INPUT GEAR A The winding unit is directly connected to the input gear a and both are having common shaft .6 Figure 1.8 Input gear 1 The material used for input gear a is Acrylic .Some properties of acrylic is given below . Major properties of Acrylic is shown below PropertyValueUnits Elastic Modulus3000000000N / m^2 Poisson's Ratio0.35N A Shear Modulus890000000N / m^2 Mass Density1200kg / m^3 Tensile Strength73000000N / m^2 Yield Strength45000000N / m^2 Thermal Conductivity0.21W / (m·K) Specific Heat1500J/(kg·K) Table 1.6 material properties 6Sclater, Neil. (2011). "Gears: devices, drives and mechanisms."Mechanisms and Mechanical Devices Sourcebook.5th ed. NewYork:McGrawHill.pp.131–174.ISBN9780071704427.Drawingsanddesignsofvarious gearings. c)STEPPEDGEAR SHAFT AND CAM GEAR 15|P a g e
INNOVATIVE PRODUCT DESIGN & MANUFACTURE The input gear A is connected with stepped gear shaft which is further connect with wheel brake hub , other part of gear A is connected Cam gear which help in completing the circuit and provide motion to other gear. Figure 1.9 Stepped shaft gear Figure 1.10 Cam gear The material used for gear a is Acrylic .Some properties of acrylic is given below . Major properties of Acrylic is shown below PropertyValueUnits Elastic Modulus3000000000N / m^2 Poisson's Ratio0.35N A Shear Modulus890000000N / m^2 16|P a g e
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INNOVATIVE PRODUCT DESIGN & MANUFACTURE Mass Density1200kg / m^3 Tensile Strength73000000N / m^2 Yield Strength45000000N / m^2 Thermal Conductivity0.21W / (m·K) Specific Heat1500J/(kg·K) Table 1.7 material properties d)CLUTCH SHAFT The clutch shaft is directly connected with wheels tube which help the 3 wheeler assembly to stop . The material used for clutch is Acrylic .Some properties of acrylic is given below . Major properties of Acrylic is shown below PropertyValueUnits Elastic Modulus3000000000N / m^2 Poisson's Ratio0.35N A Shear Modulus890000000N / m^2 Mass Density1200kg / m^3 Tensile Strength73000000N / m^2 Yield Strength45000000N / m^2 Thermal Conductivity0.21W / (m·K) Specific Heat1500J/(kg·K) Table 1.8 material properties 17|P a g e
INNOVATIVE PRODUCT DESIGN & MANUFACTURE Figure 1.11 Clutch gear Gear Assembly Figure 1.12 Complete gear arrangement Figure 1.13 gear arrangement 18|P a g e
INNOVATIVE PRODUCT DESIGN & MANUFACTURE DESIGN EVAUATION As a prototype , consider the cart having speed of 10 m/second . V =10 m/s Cart Weight = 1000 Grams Formula Kinetic energy = ½ x mass of cart x velocity^2 KE = ½ * 1000/1000 * 10*10 K.E= 50 Joules So this cart need 50J to reach speed of 10 m/s But spring energy is equal to kinetic energy S.E = K .E ½ * k *x = 50 k = spring constant= 800 N/m Apply values we get x =125 mm Dia meter of coil = 12 mm So its Perimeter = 12 x pi= 12*3.14 =37.7 mm No . of rotations = 125 /37.7 = 4 So maximum 4 rotations needed to reach the cart to 10 m /second . 7Mahadevan K and Reddy K.Balaveera, (2015), 'Design data hand book', CBS publishers and Distributors (P) ltd., New- Delhi,ISBN9788123923154 19|P a g e
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INNOVATIVE PRODUCT DESIGN & MANUFACTURE DFMA PRINCIPLES & ANALYSIS DFMA refers to design for manufacture and assembly .DMFA is technique that focus on efficiency in manufacturing and assembly of a product by simplifying all process include under it .It main motives to manufacture and assembly the product in minimum time and at least cost . Main principles of DFMA Simplify the automation process by reducing number of parts in assembly .The 3 wheeler assembly is completely automated . Encourages to use standard parts that are easily available rather than complex manufacturing that increase cost of product .In 3 wheeler assembly ,standard parts like gear ,spring , shaft hub are used . Reduce the use of flexible components like gaskets, seal ,rubber . As assembly of these parts are more difficult .No flexible part used in 3 wheeler assembly . Use adhesive and snap type fitting for assembly rather than fasteners . To simplify manufacturing , parts design should be simple and unnecessary features on parts should be avoided . Advantages of DFMA Cost of assembly and manufacturing becomes low . Time required for assembly and manufacturing is less . As numbers of parts reduces then chances of parts failure also reduces therefore reliability increases . High quality of product is achieved . 8Boothroyd, G., Dewhurst, P. and Knight, W., “Product Design for Manufacture and Assembly, 2nd Edition”, Marcel Dekker, New York, 2012. 20|P a g e
INNOVATIVE PRODUCT DESIGN & MANUFACTURE DESIGN VALIDATION Consider the factor of safety is 2 and design the wheel of cart , considering its weight of 7000 grams. Weight on wheels = 7*9.81 N = 70 N ,To maintain factor of safety is 2 , load applied should be 70 x 2 = 140 N As Applied load is 140 N on wheels centre and check the maximum stress and deflection produced by the wheels .Diameter of shaft is 3 mm. Solid partProperties Revolve1Mass:0.4 kg Volume:6.e-007 m^3 Density:1200 kg/m^3 Weight:4 N Material Properties Model ReferenceProperties Name:Acrylic (Medium-high impact) Model type:Isotropic Default failure criterion:von Mises Stress Yield strength:45 MPA 21|P a g e
INNOVATIVE PRODUCT DESIGN & MANUFACTURE Loading As discussed below , applied load is 140 N while considering the factor of safety of 2 .Applied load is the total weight of cart acting on the wheels , so this load is applied at centre of wheel . Mesh information Mesh typeSolid Mesh Mesher Used:Standard mesh Jacobian points4 Points Element Size2 mm Tolerance0.01 mm Mesh QualityHigh Mesh information - Details Total Nodes33998 Total Elements18454 Maximum Aspect Ratio14 % of elements with Aspect Ratio < 318.1 % of elements with Aspect Ratio > 100.001 % of distorted elements(Jacobian)0 22|P a g e
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INNOVATIVE PRODUCT DESIGN & MANUFACTURE RESULT As all the input parts are completed now the run the analysis and obtained the output result . Stress STRESS Values of stress is given below Minimum :- 0 MPa 23|P a g e
INNOVATIVE PRODUCT DESIGN & MANUFACTURE Maximum :- 31.39 MPa Deflection DEFLECTION Value of deflection obtain is given below Minimum :- 0.00 mm Maximum :- 0.166 mm FACTOR OF SAFETY Factor of safety is the ratio of yield stress to maximum stress generated while applying load. Yield stress is maximum permissible stress for a particular material after which deformation takes plate. Here Yield stress is 45MPa and maximum stress generated is 31.39 MPa .Although this design is safe but factor of safety value of 2 is not achieved F.O.S = 45/31.39 =1.43 So changes need to be done to reduce the maximum stress value and achieve the factor of safety to 2 . 24|P a g e
INNOVATIVE PRODUCT DESIGN & MANUFACTURE CHANGES IN DESIGN To maintain the factor of safety of 2 and above , necessary changes need to be done accordingly .Earlier the shaft and hub of wheels having diameter of 3 mm . According to formula below , stress is inversely proportional to Moment of inertia(I) . For shaft I =3.14 *D^4 /32 This shows that to reduce the value of maximum stress ,diameter of shaft need to be increased . Now in new design diameter of shaft is increased from 3 mm to 4 mm due to which stress value will reduce . The below picture shows that diameter of shaft change to 4mm Now kept all the procedure same i.e fixtures , loading and run the result with new design. RESULT As all the input parts are completed now the run the analysis and new results are obtained shown below . 25|P a g e
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INNOVATIVE PRODUCT DESIGN & MANUFACTURE Stress STRESS Values of stress is given below Minimum :- 0 MPa Maximum :- 20.65 MPa Deflection 26|P a g e
INNOVATIVE PRODUCT DESIGN & MANUFACTURE DEFLECTION Value of deflection obtain is given below Minimum :- 0.00 mm Maximum :- 0.21 mm FACTOR OF SAFETY Here Yield stress is 45MPa and maximum stress generated in new design is 20.65 MPa . Although this design is safe and also factor of safety value of 2 is also achieved . F.O.S = 45/20.65 =2.17 So changes done are effective to achieve the factor of safety to 2 or more . Conclusion In 1stcase when the diameter of shaft is 3 mm and applied load is 140 N then although the design is safe but factor of safety of 2 need to be achieved .To increase the value of factor of safety , maximum stress occurs due to applied load need to be reduced . So in new design diameter of shaft is increased from 3 mm to 4 mm so that its moment of inertia get increased and maximum stress reduced . So after increasing the diameter of shaft to 4 mm the maximum stress value reduced to20.65 MPa and factor of safety of 2 is successfully achieved . So overall design is safe .9 9Fridtjov Irgens (2010),"Continuum Mechanics". Springer.ISBN3-540-74297-2 27|P a g e
INNOVATIVE PRODUCT DESIGN & MANUFACTURE DETAILED DESIGN 28|P a g e
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INNOVATIVE PRODUCT DESIGN & MANUFACTURE 10Lynch, Mike (2010-01-18),"When programmers should know G code",Modern Machine Shop(online ed.). References Davinci, Leonardo (2011).The Notebooks of Leonardo Da Vinci. Lulu. p.736. Fernando (2010).Technological Concepts and Mathematical Models in the Evolution of Modern Engineering Systems.Birkhäuser.ISBN978-3-7643-6940-8. Plesha,MichaelE(2013).EngineeringMechanics:Statics(2nded.).NewYork:McGraw-Hill Companies Inc. pp.364–407.ISBN0-07-338029 Jacob;Papadopoulos(Oct2016).IntroductiontoSolidMechanics:AnIntegratedApproach. Springer.ISBN9783319188782. Wingerter, R., and Lebossiere, (Feb 2011) P.,ME 354, Mechanics of Materials Laboratory: Structures, University of Washington Record,Samuel,2010.TheMechanicalPropertiesofWood.J.Wiley&Sons. p.165.ASINB000863N3W. Sclater, Neil. (2011). "Gears: devices, drives and mechanisms."Mechanisms and Mechanical Devices Sourcebook.5th ed. New York: McGraw Hill. pp.131–174.ISBN9780071704427. Drawings and designs of various gearings. Khurmi R S, (2014), 'A text book of machine design', Eurasia publishing house(P) ltd., New- Delhi,ISBN9788121925372 Mahadevan K and Reddy K.Balaveera, (2015), 'Design data hand book', CBS publishers and Distributors (P) ltd., New-Delhi,ISBN9788123923154 Boothroyd, G., Dewhurst, P. and Knight, W., “Product Design for Manufacture and Assembly, 2nd Edition”, Marcel Dekker, New York, 2012. Smid, Peter (2010),CNC Control Setup for Milling and Turning, New York: Industrial Press,ISBN978- 0831133504,LCCN2010007023. Lynch,Mike(2010-01-18),"WhenprogrammersshouldknowGcode",ModernMachine Shop(online ed.). Fridtjov Irgens (2010),"Continuum Mechanics". Springer.ISBN3-540-74297-2 Ramsay, Angus."Stress Trajectories".Ramsay Maunder Associates. RetrievedApril2017. 41|P a g e