viii
TABLE OF CONTENTS
CHAPTER
1
TITLE
PAGE
ACKNOWLEDGEMENT
v
ABSTRACT
vi
ABSTRAK
vii
TABLE OF CONTENTS
viii
LIST OF TABLES
xiv
LIST OF FIGURES
xv
LIST OF SYMBOLS
xviii
LIST OF APPENDICES
xx
INTRODUCTION
1
1.1
Introduction to the Problem
1
1.2
Objective of Project
2
1.3
Scope of Project
2
1.4
Project Methodology
3
1.5
Significant of Findings
5
1.6
Report Structure
5
1.7
Summary
7
ix
2
LITERATURE REVIEW
8
2.1
Introduction
8
2.2
Thermodynamics Systems and Boundary
9
2.3
The 1st Law of Thermodynamics
11
2.4
Energy Balance
11
2.5
Energy Change in System
12
2.6
Mechanism of Energy Transfer, Ein and Eout
14
2.6.1
Heat Transfer
14
2.6.2
Work
14
2.6.3
Mass Flow
15
2.7
1st Law of Thermodynamics in
15
Piston Cylinder Analysis
2.8
Product Development Process
22
2.9
Identifying Customer Needs
24
2.10
Product Design Specifications (PDS)
25
2.11
Engineering Design Process
26
2.12
Concept Generation
27
2.13
Concept Selection
29
2.13.1 Concept Screening
30
2.13.2 Concept Scoring
32
2.14
Design for Manufacture and Assembly (DFMA)
35
2.15
Overview of Design For Manufacture (DFM)
36
2.16
DFM Methodology
37
2.17
Boothroyd-Dewhurst DFM Methodology
38
2.17.1 General Shape Attribute
40
2.17.2 Process Capabilities
41
DFM Guidelines
42
2.18.1 Design for Ease of Fabrication
42
2.18.2 Design within Process Capabilities
42
2.18
2.18.3 Simplify the Design and
Reduce Parts Number
43
2.18.4 Standardize and use common
parts and materials
2.19
Overview of Design For Assembly (DFA)
43
43
x
2.20
DFA Methodologies
44
2.20.1 The Boothroyd-Dewhurst DFA Method
44
2.20.1.1 Theory of Evaluation
45
2.20.1.2 Evaluation Procedure
45
2.20.2 The Hitachi Assemblablility
Evaluation Method
49
2.20.2.1 Theory of Evaluation
49
2.20.2.2 Evaluation Procedure
50
2.20.3 The Lucas DFA Method
2.21
2.22
3
51
2.20.3.1 Theory of Evaluation
51
2.20.3.2 Evaluation Procedure
51
DFA Guidelines
53
2.21.1 Reduce Part Count and Part Types
55
2.21.2 Eliminate Adjustments
56
2.21.3 Self Locating and Aligning
56
2.21.4 Consider Handling Part from Bulk
57
2.21.5 Consider Ease for Handling
58
2.21.6 Eliminate Threaded Fasteners
59
2.21.7 Minimize Variations, Use Standard Part
59
2.21.8 Easy Serviceability and Maintainability
59
2.21.9 Minimize Assembly Directions
60
2.21.10 Provide Easy Insertion and Alignment
60
Summary
61
CONCEPTUAL DESIGN DEVELOPMENT
62
3.1
Introduction
62
3.2
User Requirements
63
3.3
Prepare Product Design Specification
64
3.4
Concept Generation
65
3.4.1
Concept No. 1
65
3.4.1.1
Concept Description
66
3.4.1.2
The Advantage and Disadvantage
67
3.4.2
Concept No. 2
68
3.4.2.1
68
Concept Description
xi
3.4.2.2
3.4.3
3.4.4
3.5
4
The Advantage and Disadvantage
69
Concept No. 3
70
3.4.3.1
Concept Description
70
3.4.3.2
The Advantage and Disadvantage
71
Concept No. 4
72
3.4.4.1
Concept Description
72
3.4.4.2
The Advantage and Disadvantage
73
Selection Criteria
74
3.5.1
Ease of Handling
74
3.5.2
Low Cost
75
3.5.3
Safety
75
3.5.4
Ease of Manufacture
75
3.5.5
Lightweight
76
3.5.6
Portability
76
3.5.7
Ease of Maintenance
76
3.6
Concept Screening
77
3.7
Concept Scoring
78
3.8
Final Concept Selection
80
3.9
Summary
81
DESIGN FOR MANUFACTURE AND
ASSEMBLY (DFMA) ANALYSIS
82
4.1
Introduction
82
4.2
Product Structure and Part Quantity
83
4.2.1
Assembly Drawing
84
4.2.2
Exploded Drawing
85
4.2.3
Bill Of Material (BOM)
86
4.2.4
Part Function and Critics
87
4.3
Boothroyd-Dewhurst DFM Analysis
90
4.4
Boothroyd-Dewhurst DFA Analysis
93
4.5
Apparatus Animation
96
4.6
Summary
97
xii
5
FABRICATION AND ASSEMBLY
98
5.1
Introduction
98
5.2
Development –Phase 1
99
5.2.1
Cylinder Liner
99
5.2.2
Piston
101
5.2.3
Cylinder Liner Cover
103
5.3
5.4
6
103
5.3.1
Base Support
104
5.3.2
Cylinder Liner Support
105
Development – Phase 3
106
5.4.1
Cylinder Assembly
106
5.4.2
Thermometer Installation
108
5.4.3
Piston Indicator Assembly
109
5.4.4
Piston Installation
110
5.5
Complete Assembly
112
5.6
Summary
113
TESTING AND OPERATION WORK PROCEDURE
114
6.1
Introduction
114
6.2
Apparatus Preparation
115
6.3
Safety Instruction
117
6.4
Work Procedure
118
6.5
Data Collection
126
6.6
1st Law of Thermodynamics Analysis
128
6.6.1
Work Analysis, W
130
6.6.2
Total Internal Energy Analysis,
6.6.3
Net Heat Enter to System, Q
6.7
7
Development – Phase 2
U
Summary
131
134
135
DISCUSSION
136
7.1
Introduction
136
7.2
Product Development Approach
137
7.3
Design For Manufacture and Assembly Methodology
137
7.4
Fabrication and Assembly
141
xiii
8
7.5
Apparatus Testing and Functionality
142
7.6
Summary
142
CONCLUSIONS
143
8.1
Conclusion
143
8.2
Recommendation And Future Work
144
REFERENCES
APPENDICES
145
A1 - E
146 - 156
xiv
LIST OF TABLES
TABLE NO.
TITLE
PAGE
2.1
Example of customer needs for the suspension fork
24
2.2
Example of concept screening matrix
30
2.3
Example of concept scoring matrix table
32
2.4
Concept rating
33
2.5
Shape Generation Capabilities of Processes
41
2.6
Boothroyd-Dewhurst DFA Evaluation table
46
2.7
Evaluation table of old piston assembly
47
2.8
Evaluation table of new design piston assembly
48
3.1
Product Specification
64
3.2
Screening matrix
77
3.3
Relative performance rating
78
3.4
Concept scoring matrix
79
4.1
Bill of Material of developed apparatus
86
4.2
Part functions
87
4.3
Shape attributes and material requirement data for cylinder
91
4.4
Process elimination for cylinder
92
4.5
Alpha ( ) and beta ( ) angle for each part
94
4.6
Computation Design Efficiency of the apparatus
95
6.1
Work Procedure for operating the apparatus
119
6.2
Table for data record
127
6.3
Testing data
128
xv
LIST OF FIGURES
FIGURE NO.
TITLE
PAGE
1.1
Project flowchart
3
2.1
Close system
10
2.2
Open system
10
2.3
Piston cylinder apparatus
15
2.4
Lifting the piston by steam pressure
16
2.5
Concept development phase
22
2.6
Five steps of concept generation
28
2.7
Generation of new concepts of potato peeler
29
2.8
Design flow in DFM
37
2.9
Compatibility matrix between processes and materials
39
2.10
Old design of piston assembly
47
2.11
New design of piston assembly
48
2.12
Example of AEM symbols and penalty scores
50
2.13
Application of DFA guidelines
54
2.14
Part reduction using DFA guidelines
55
2.15
Self locating and aligning parts
56
3.1
Design Concept No. 1
65
3.2
Design concept No. 2
68
3.3
Design concept No. 3
70
3.4
Design concept No. 4
72
3.5
Final design concept
80
4.1
Product structure
83
4.2
Assembly drawing of final design concept
84
4.3
Exploded drawing of final design concept
85
xvi
LIST OF FIGURES – CONTINUED
4.4
Step 1, piston at rest position
96
4.5
Step 2, piston start lift-up
96
4.6
Step 3, piston still lifting
96
4.7
Step 4, piston reach to final position
96
5.1
Cylinder Liner
99
5.2
Flow Chart of Cylinder Liner Fabrication Process
100
5.3
The Piston
101
5.4
Piston after modification
102
5.5
Aluminum sheet
103
5.6
Base support
104
5.7
Two inches angle iron
104
5.8
Cylinder liner support
105
5.9
Cylinder liner before assembly
106
5.10
Cylinder liner after assembly
106
5.11
Cylinder liner after wrapping with woven
107
5.12
Cylinder liner after assembled with aluminum cover
108
5.13
Thermometer installation
108
5.14
The assembly of indicator on piston
109
5.15
Ring Expander
110
5.16
Piston and ring
110
5.17
Special tool to insert piston to cylinder liner
111
5.18
Method to insert piston into cylinder
111
5.19
Complete Assembly of Apparatus
112
6.1
Lubrication oil is applied on the cylinder liner inner wall.
115
6.2
Complete apparatus arrangement
116
6.3
Hot surface sign on cylinder liner
117
6.4
Hot surface sign on base support
118
6.5
Complete Apparatus
119
6.6
Checking all fittings
119
6.7
Applying lubrication oil
119
xvii
LIST OF FIGURES – CONTINUED
6.8
Close bottom valve
120
6.9
Water is filled to cylinder
120
6.10
Initial temperature
120
6.11
Initial pressure
121
6.12
Initial piston position
121
6.13
Butane gas weight measurement
121
6.14
Installation of Butane gas container to gas stove burner
122
6.15
Placing gas stove burner
122
6.16
Flame directed to bottom of cylinder liner
122
6.17
Observation of temperature increasing
123
6.18
Temperature at 90° C
123
6.19
Ready to shut down gas burner
123
6.20
Piston slowly lifts up
124
6.21
Shut down gas burner
124
6.22
Piston lift to new position
124
6.23
Final water temperature
125
6.24
Piston final position
125
6.25
Final Pressure
125
6.26
Measurement final butane gas weight
126
6.27
Illustration of experimental process
129
7.1
Percentage of theoretical minimum parts
138
7.2
Comparison between parts that need special tool to total part
139
7.3
Percentage of assembly time
139
xviii
LIST OF SYMBOLS
E1
=
Initial energy
E2
=
Final energy
Ein
=
Total energy entering the system
Eout
=
Total energy leaving from system
∆Esystem
=
Change in the total energy in the system
Efinal
=
Energy at final state
Einitial
=
Energy at initial state
∆U
=
Change in internal energy
∆PE
=
Change in potential energy
∆KE
=
Change in kinetic energy
m
=
Mass of system, kg
u2
=
Specific internal energy at final state
u1
=
Specific internal energy at initial state
V2
=
Final velocity, m/s
V1
=
Initial velocity, m/s
g
=
Gravity acceleration, m/s2
z2
=
Final height, m
z1
=
Initial height, m
Q
=
Heat supplied to system, Joule
W
=
Work done by system, Joule
X1
=
Initial position, m
X2
=
Final Position, m
P
=
Pressure, Pa
V
=
Volume, m3
A
=
Area, m2
F
=
Force, kg / ms-2 or Nm
xix
LIST OF SYMBOLS (CONTINUED)
vf
=
Specific volume: Saturated liquid, m3/kg
vg
=
Specific volume: Saturated vapour, m3/kg
vfg
=
Specific volume: Evaporation, m3/kg
uf
=
Internal energy : Saturated liquid, kJ/kg
ug
=
Internal energy : Saturated vapour, kJ/kg
ufg
=
Internal energy : Evaporation, kJ/kg)
v1
=
Specific volume at initial state, m3/kg
v2
=
Specific volume at final state, m3/kg
x
=
Quality
Cv
=
Specific heat of Ideal gas, kJ/kg
T1
=
Temperature at initial state, ºC
T2
=
Temperature at final state., ºC
xx
LIST OF APPENDICES
APPENDIX
TITLE
PAGE
A1
Gantt Chart for Semester 1
146
A2
Gantt Chart for semester 2
146
B1
Te Standard Thermodynamics Properties
147
Table for water
B2
Example of Product Design Specification
148
B3
General Capabilities of a range of commonly
150
used manufacturing processes.
C
Data for estimated times for manual handling
154
(Boothroyd-Dewhurst)
D
Data for estimated times for manual insertion
155
(Boothroyd-Dewhurst)
E
Lucas DFA method - Manual Handling and
Manual Fitting Analysis
156