UNIVERSITI PUTRA MALAYSIA COMPARISON OF COST, SURFACE ROUGHNESS AND TIME USING STEREO LITOGRAPHY AND 3D PRINTER FOR THE DESIGN OF COMPOSITE PEDAL

Transcription

1 UNIVERSITI PUTRA MALAYSIA COMPARISON OF COST, SURFACE ROUGHNESS AND TIME USING STEREO LITOGRAPHY AND 3D PRINTER FOR THE DESIGN OF COMPOSITE PEDAL LEE HO BOON FK

2 COMPARISON OF COST, SURFACE ROUGHNESS AND TIME USING STEREO LITOGRAPHY AND 3D PRINTER FOR THE DESIGN OF COMPOSITE PEDAL By LEE HO BOON Thesis Submitted to the School of Graduate Studies, Universiti Putra Malaysia, in Fulfilment of the Requirement for tne Degree of Master of Science October 2003

3 Abstract of thesis presented to the Senate ofuniversiti Putra Malaysia in fulfilment of the requirement for the degree of Master of Science COMPARISON OF COST, SURFACE ROUGHNESS AND TIME USING STEREO LITOGRAPHY AND 3D PRINTER FOR THE DESIGN OF COMPOSITE PEDAL By LEE HO BOON October 2003 Chairman : Associate Professor Ir. Mohd Sapuan Sa lit, Ph.D. Faculty : Engineering This research presents the process of designing a non metal pedal box system for Proton Wira car. Closed form or non-numerical data analysis of non metal pedal box system is initially carried out. Calculations of bending stiffness and torsion strength to decide on the best pedal lever cross section were carried out. Similarly yield stress calculation for pedal lever was performed. Comparison between non metal pedal box system and steel pedal box system was carried out. This research also includes the measuring process with a coordinate measuring machine of the currently used steel pedal box system and followed by modelling the design in Unigraphics. The design of three pedals namely an accelerator pedal, a brake pedal and a clutch pedal as well as a mounting bracket was carried out. Rapid prototyping models using stereo lithography (gla 3500) by 3D System and 3D Printer Z40L. by Z-corp were produced. Stereolithography and 3D printing were compared in terms of cost, speed of the process, user friendliness and model quality. The purpose of rapid prototyping models is to facilitate easy communication of product to the customers. 11

4 methods of rapid prototyping using various approaches and to decide on the best methods in term of quality, cost and speed of processing. Design communication using rapid prototyping is one of the important elements of concurrent engineering technique. The pedal box' system was designed to meet the final objective of weight reduction produced using injection moulding process. iii

5 Abstrak tesis yang dikemukakan kepada Senat University Putra Malaysia sebagai memenuhi keperluan untuk ijazah Master Sa ins PERBANDINGAN KOS, KEKASARAN PERMUKAAN DAN MASA DENGAN MENGGUNAKAN STEREO LITOGRAPHY DAN PENCETAK 3D UNTUK REKABENTUK INJAK KOMPOSIT Oleh LEE HO BOON Oktober 2003 Pengerusi : Profesor Madya Ir. Mohd Sapuan Sa lit, Ph.D. Fakulti : Kejuruteraan Penyelidikan ini mempersembahkan proses mereka bentuk sistem kotak injak bukan logam untuk kereta Proton Wira. Analisis data bukan berangka atau analisis bent uk tertutup bagi sistem kotak injak bukan logam telah dijalankan pada permulaan. Pengiraan-pengiraan kekukuhan lenturan dan kekuatan kehelan bagi menentukan keratan rentas injak yang terbaik telah dijalankan. Begitu juga pengiraan tegasan alah bagi injak telah dilaksanakan. Perbandingan antara sistem kotak injak bukan logam dan sistem kotak injak keluli telah dijalankan. Ia juga meliputi proses mengukur sistem injak keluli yang sedia ada dengan mesin pengukur kordinat dan diikuti dengan pemodelan reka bentuk dengan peri sian Unigraphics. Reka bentuk bagi tiga injak iaitu injak pecut, injak brek dan injak cekam serta pendakap cagak telah dijalankan. Reka bentuk itu digunakan untuk membentuk model contoh sulung cepat dengan stereolitografi (SLA 3500) oleh 3D System dan 3D Printer Z402 oleh Z-corp. Kedua-dua cara ini dinilai dari segi kos, kecepatan proses, kemesraan kepada IV

6 ialah bagi memudahkan komunikasi produk dengan pelanggan-pelanggan. Kedua-dua kaedah telah digunakan bagi tujuan mempelajari pelbagai kaedah contoh sulung cepat menggunakan pelbagai pendekatan dan menentukan kaedah-kaedah terbaik dalam sebutan mutu, kos dan kecepatan pemprosesan. Komunikasi reka bentuk menggunakan contoh sulung cepat adalah salah satu unsur penting dalam kaedah kejuruteraan setemu. Sistem kotak injak ini direka bentuk dengan bertujuan memenuhi objektif akhir iaitu, pengurangan berat dengan menggunakan proses pengacuan suntikan. v

7 ACKNOWLEDGEMENTS I would like to express my gratitude to the chairman of the supervisory committee Associate Professor Ir. Dr. Mohd Sapuan Salit for his advice and guidance throughout the duration of this research. I would also like to thank all lecturers and laboratory and administrative staff of Department of Mechanical and Manufacturing Engineering, Universiti Putra Malaysia especially Associate Professor Dr. Shamsuddin Sulaiman and Associate Professor Dr Megat Mohamad Hamdan Megat Ahmad who both acted as supervisory committee members. I would also like to express thanks to Mr Eyong Jantrik from Institute of Multimedia and Software Development, Universiti Putra Malaysia in assisting me in the stereolithography process and staff from Rapid Technology Solutions Sdn. Bhd., which is situated in Technology Park Malaysia in providing the 3D printing service. I would like also to thank Ministry of Science, Technology and Environment, Malaysia for providing the fund for this project under the vot number Further appreciation is extended to my parents Mr Lee Kok Siang and Madam Tan Chen Kim who have supported me with their encouragement and financially. Vi

8 I certify that an Examination Committee met on 5th November 2003 to conduct the final examination of Lee Ho Boon on his Master of Science thesis entitled "Comparison of Cost, Surface Roughness and Time Using Stereo Lithography and 3D Printer for the Design of Composite Pedal" in accordance with Universiti Pertanian Malaysia (Higher Degree) Act 1980 and Universiti Pertanian Malaysia (Higher Degree) Regulations The Committee recommends that the candidate be awarded the relevant degree. Members of the Examination Committee are as follows: Ir. Barkawi Sahari, Ph.D. Professor Faculty of Engineering Universiti Putra Malaysia (Chairman) Ir. Mohd. Sapuan Salit, Ph.D. Associate Professor Faculty of Engineering Universiti Putra Malaysia (Member) Megat Mohamad Hamdan Megat Ahmad, Ph.D. Associate Professor Faculty of Engineering Universiti Putra Malaysia (Member) Shams uddin Sulaiman, Ph.D. Associate Professor Faculty of Engineering Universiti Putra Malaysia (Member) ProfessorlDepu Dean School of Graduate Studies Universiti Putra Malaysia Date: 1 1 FEB 1004 vii

9 This thesis submitted to the Senate of Universiti Putra Malaysia has been accepted as fulfilment of the requirements for the degree of Master of Science. The members of the Supervisory Committee are as follows: Ir. Mohd. Sapuan Sa lit, Ph.D. Associate Professor Faculty of Engineering Universiti Putra Malaysia (Chairman) Megat Mohamad Hamdan Megat Ahmad, Ph.D. Associate Professor Faculty of Engineering Universiti Putra Malaysia (Member) Shams uddin Sulaiman, Ph.D. Associate Professor Faculty of Engineering Universiti Putra Malaysia (Member) k2.. t-" J AINI IDERIS, Ph.D. ProfessorlDean School of Graduate Studies Universiti Putra Malaysia Date: 2 5 FEB 2004 viii

10 DECLARATION I hereby declare that the thesis is based on my original work except for quotations and citations which have been duly acknowledged. I also declare that it has not been previously or concurrently submitted for any other degree at UPM or other institutions. LEE HO BOON Date: IX

11 TABLE OF CONTENTS ABSTRACT ABSTRAK ACKNOWLEDGEMENTS APPROVAL DEC LARA non LIST OF TABLES LIST OF FIGURES LIST OF PLATES LIST OF ABBREVIA nons II IV VI VII IX XII Xlll xv xvi CHAPTER Page 1 INTRODUCTION 1.1 Background 1.2 Statement of problem 1.3 Objectives of the research 1.4 Scope of the research 1.5 Structure of the thesis LITERATURE REVIEW 2.1 Introduction 2.2 Polymeric-Based composite 2.3 Automotive pedal box system 2.4 Application of polymeric-based composite in automotive industries 2.5 Review of current application of polymeric-based composite in automotive pedal box system 2.6 Rapid prototyping 2.7 Recent development in rapid prototyping 2.8 Injection moulding The injection moulding machine The injection mould 2.9 Recent developments in plastic injection mould design 2.10 Summary of literature review METHODOLOGY 3.1 Structure of the research 3.2 Closed form and non numerical data analysis of non metal pedal box system 3.3 Data collection process with coordinate measuring machine MISTRAL motorized measuring machine X

12 Modelling the pedal system with Unigraphics The rapid prototyping process with SLA machine The SLA 3500 machine The transfer from CAD to RP model The rapid prototyping process with the 3D Printer The printing process Direct comparison of the rapid prototyping model with the existing metal pedal box system RESULTS AND DISCUSSIONS 4.1 Closed form and non- numerical data analysis of non metal pedal box system Pedal design cross-section calculation Bending stiffness Torsion strength Weight calculation Calculation of the yield stress for the pedal design Functional capability calculation The result from the modelling of the pedal component with Unigraphics The result of the rapid prototyping process with the SLA system The result of the rapid prototyping process with 3D Printer Z Comparison of SLA and 3D printing processes Comparison of the Non Metal Pedal Box with the Original Steel Pedal Box System 81 Discussion on the composite pedal design CONCLUSIONS AND RECOMMENDATIONS 5.1 Conclusions 5.2 Recommendations REFERENCES 90 BIODATA OF THE AUTHOR 94 Xl

13 LIST OF TABLES Table Page 4.1 The M section is ranked the 4 th in the bending stiffiless calculation The M section is ranked the 1 st in the torsion strength calculation The M section is ranked the 5 th in the weight calculation Maximum load of the different pedals Maximum bending moment of the different pedals Volume of each part calculated by Unigraphics based on the model Weight comparison of composite and steel pedals Comparison between the two rapid prototyping systems 80 xu

14 LIST OF FIGURES Figure 1.1 Concurrent engineering approach of pedal box design 2.1 Brake pedal housing from Solvay Automotive Ltd. UK. [Bradbury (18)] 2.2 Accelerator pedal by AlliedSignal Plastics for Ford (22) 2.3 AB Elektronik accelerator pedal module (30) 2.4 Stereo lithography model and metal casting model (32) 2.5 Example of stereolithography model (32) 2.6 A typical injection moulding machine component (35) 2.7 Injection moulding machine-operating sequence (35) 2.8 Typical example of a plastic injection mould block (38) 3.1 Flowchart of the methodology 4.1 Cross section shape suggested in this study 4.2 The M cross section with four areas. (All dimensions are in millimetres) Page The approximate dimensions of the newly design pedal in millimeters The M cross section with the increase in size (All dimension in mm) The M cross section with the increase of ribbing thickness The graphical result of the finite element analysis of the brake pedal The graphical image of the accelerator pedal in Unigraphics The graphical image of the brake pedal in Unigraphics 62 xiii

15 4.9 The graphical image of the clutch pedal in Unigraphics The graphical image of the mounting bracket in Unigraphics The graphical image of accelerator pedal with the support structure The graphical image of brake pedal with support structure The graphical image of clutch pedal with support structure The graphical image of mounting bracket with the support structure The first built process consists of the whole brake pedal and half of the accelerator pedal The second built process The graphical image of the assembly of the pedal box system in Unigraphics 80 XIV

16 LIST OF PLATES Plate Page 3.1 The front view of the existing steel pedal box system The bottom view of the existing steel pedal box system The mounting bracket inside the pea undergoing postprocessmg The accelerator pedal SLA model in its fmal form The brake pedal SLA model in its final form The clutch pedal SLA model in its final form The mounting bracket SLA model in its fmal form The whole assembly SLA model in its final form The completed accelerator pedal 3D Printer model The completed brake pedal 3D Printer model The completed clutch pedal 3D Printer model The completed mounting bracket 3D Printer model The completed assembly pedal system 3D Printer model The comparison of the existing metal pedal box systems on the left with the SLA rapid prototyping model on the right 82 xv

17 LIST OF ABBREVATIONS 2D 3D - ABS C Acry Two-dimensional Three-dimensional lonitrile-butadiene-styrene Section with C shape CAD - Computer aided design CAE - Computer aided engineering ClM - Computer-integrated manufacture CMM - Coordinate measuring machine - CNC CO2 E - FEA I I IPC Finite Computer numerical control Carbon dioxide Elastic modulus element analysis Second moment of area Section with I shape Intelligent process control KBS - Knowledge based system KEE - Knowledge Engineering Environment LOM - M M NC - NVH Noise, p Laminated object manufacturing Section with M shape Bending moment Numerical control Vibration and Harshness Load in Newton XVi

18 PA Polyamide PBT - Polybutylene terephthalate PC Polycarbonate PCB - Printed circuit board PDS PEl Product design specifications Pol yetherimide PP Polypropylene PPS Polyphenylene sulfide RP Rapid prototyping Rz Mean roughness depth SGC - Solid ground curing SLiSLA- Stereo lithography SLS Selective laser sintering SOl Standard Operator Interface STL Standard triangle language U Section with U shape Z-corp - em Z Corporation Torsion strength (J' Yield stress () y Deflection Centre of geometry Z Y/I XVll

19 CHAPTER 1 INTRODUCTION 1.1 Background Business worlds nowadays often experience rapid change especially in the market place. Consumers were expecting more value added feature from the products they buy with the trend of cheaper prices. These have driven industrialists to search for more advanced methodologies and technologies to satisfy consumer demands. One of the potential areas is weight saving through the use of polymeric based composite to substitute metal component. By using composite as material the product can achieve lower weight. And this has been demonstrated for quite some time especially in automotive industries. The major weights saving examples so far are sheet body panel, body frames and even chassis. The advantages of polymeric-based composite are innumerable. It has high strength, high stiffness, and aesthetically pleasing, corrosion resistance and light weight due to low density. It also provided manufacturer flexibility in design. The manufacturing cost is also lower due to the ability of moulding several parts in one process thus shortens manufacturing lead-time and also reduces assembly time with part reduction. Injection moulding is a very good example. It is essential that more development and study on replacing more components in automobile to light weight composite to be carried out. 1

20 1.2 Statement of Problem There are over 286 million cars in the world and about 10% is replaced or scraped every year. This means that 28.6 million vehicles need to be scraped each year. The components of the vehicle were usually recycled but not 100 percent of the vehicles can be recycled easily. Vehicle needs fuel every time in operation. The limited petroleum reserves have urged manufacturer of vehicle to come up with more and more fuelefficient vehicle. One of the tactics they currently interested in is to 'slim' down the vehicle or to reduce the weight of the vehicle. It is common sense that lighter weight vehicle always consume lesser fuel. In order to have a lighter weight and easier recyclable vehicle, the manufacturer found their answer in composite material especially fibre reinforced polymeric composite material. A lot of work has been carried out in the past on the application of polymeric composite material in automotive industries. Composite has been used for some components such as bumper, tailgate, and door panel, just to name a few. A number of applications of pedal box system using composite material were also found. But currently there is no example that deals with the design of the whole pedal box system. The manufacturer only design parts of the pedal box system and especially there is no work has been carried out on the development of composite 2

21 brake pedal. In addition there is no work carried out on the use of rapid prototyping for composite pedal box system Therefore, there is a need to carry out design of the whole pedal box system from polymeric-based composite material and to develop rapid prototyping models using methods like SLA and 3D Printer. 1.3 Objectives of the Research The main objectives of this research are: i) to carry out a process of redesigning a pedal box system with a specific model of car. The vehicle selected is Proton Wira 1.5 litre manual transmission configuration. The pedal box must be able to be fitted in to a real vehicle. The performance is equal to its steel counterpart with the additional advantage of weight saving. ii) to develop rapid prototyping models of the redesigned pedal system using stereolithography and 3D printing methods to facilitate design communication which is the essence of concurrent engineering. iii) to compare both rapid prototyping methods in terms of cost, surface finishing and speed of the processes, in order to determine the optimum method of rapid prototyping process for a non metal automotive pedal box system. 3

22 1.4 Scope of the Research The research focuses on the manufacturing process of the pedal box system. Previous work have already included the material selection using knowledge-based system (KBS) (I), concept design with product design specifications (PDS) (1), detail design process by 3D CAD (1) and finite element analysis (FEA) (1), and cost estimation using KBS (1). By using the available data and information from previous work, this research work on the redesigning the models based on Proton Wira 1.5 model and on the development of the rapid prototyping models for pedal box system is presented. The redesigning process is carried out using conventional calculations such as torsion strength, bending stiffness and yield stress. It is to decide on the best cross section of pedal lever. Comparison between the design from non metal pedal box system and steel pedal box system is carried out. Basically, the size and location of both designs do not differ but the main difference is on some of the design features such as incorporation of ribbing, part integrations and others. Two different methods of rapid prototyping are used in this research and the models developed are compared. The criteria for comparison includes user friendliness, cost, time and other issues in both rapid prototyping methods. Two different rapid prototyping methods used were the Stereolithography and the 3D Printer. The former is a liquid based laser cure system and the latter is a powder-based system. Both of the systems are based on the Stereo lithography (SLA) technique. This technique is always referred to as building a solid model by tracing a profile of a 4

23 previously sliced digital model and stacking them layer by layer in their proper position to form the final solid model The selection of the optimum method is essential to facilitate the design communication, which is the essence of concurrent engineering. It is shown in Figure

24 DESIGN CALCULATIONS DESIGN FEATURES COORDINA1E V) ON TORSION STRENGTH, DETERMINA non: MEASURING BENDING STIFFNESS 4-t PART INTEGRATION,... SYSTEM. AND YIELD STRESS. RIBBING STRUC O h U CAD DESIGN STA GE MODELLING. COMPARISON OF NON 2DDRAWING. ftaetal PEDAL BOX 3D SOUD MODEL SYS1EM AND ftaet ALLIC WEIGHT CALCULATION PEDAL BOX SYS1EM ::>- -QIGN 3DPRrnTER SLAMODEL COMMUNICATION STAGE. MODEL O m I I <z RAPID PROTOTYPlNG U COMP AlUSON AND SELECTION A MANUFA=mG PROTOTYPE < I PEDAL BOX SYSTEM I i 1 STAGE INSTRUCTION Figure 1.1: Concurrent engineering approach of pedal box design 6

25 1.5 Structure of the Thesis The objectives and scope of the research are presented in chapter I.A literature review is presented in Chapter 2. Literature review begins with some general background of polymeric-based composite and automotive pedal box system, and it is followed by the review of current development in the applications of polymeric-based composite in various parts of automobile especially the pedal box system. It also includes some review on rapid prototyping and injection moulding technologies with particular emphasis on plastic injection moulding of thermoplastic materials. In Chapter 3 the methodology a closed form non-numerical data analysis of the designed pedal box system is presented. Application and procedure to produce the rapid prototyping with the Stereolithography and 3D printer are explained in detail. This includes collecting the data and dimensions of the existing steel pedal system with the use of coordinate measuring machine and modelling the new design of the pedal box system by using Unigraphics package the results from the modelling were used to carry out the development of rapid prototyping models. Two different rapid prototyping methods were used namely the SLA 3500 by 3D System and the 3D Printer by Z-corp. The results, discussion and comparisons of both models are made in Chapter 4. Finally conclusions and recommendations are presented in Chapter 5. 7