DESIGN OF WATER BIKE FOR UMP PEKAN LAKE CHANG CHUN KIT

DESIGN OF WATER BIKE FOR UMP PEKAN LAKE CHANG CHUN KIT Report submitted in partial fulfilment of the requirements for the award of Diploma in Mechanical Engineering Faculty of Mechanical Engineering UNIVERSITI MALAYSIA PAHANG DECEMBER 2011

v ABSTARCT The objective of this thesis is to design a water bike which can be manufacture in UMP and also can be used in UMP Pekan s lake in the future. This water bike is easy to operate and easy to fabricate. This water bike will be design by using software. This water bike will purposely design for UMP Pekan s Lake use. A prototype will be build and the structure of the water bike will be analyze. The main material for this project is mild steel hollow bar. The fabrication type will be more to cutting and welding to form the shape designed. Solidworks Simulation Xpress software is used to simulate the stress analysis on critical part of the water bike. Lastly, the objective of this project has been achieved where the water bike can be manufacture in UMP and used in UMP Pekan s lake in the future.

vi ABSTRAK Objektif projek ini adalah untuk mereka dan membuat satu basikal atas air yang boleh dibuat di UMP dan juga boleh diguan pakai di tasik UMP pada masa depan. Basikal atas air ini senang diguna pakai dan senang diperbuat. Basikal atas air ini akan direka dengan menggunakan perisian. Basikal atas air ini direka untuk penggunanan tasik UMP. Prototaip akan dibuat dan reka bentuknya akan dianalisa. Bahan terutama bagi projek ini adalah keluli lembut bar beronggar. Cara untuk menghasilkan projek ini ialah memotong dan kimpalan. Solidwork Simulation Xpress juga digunakan untuk menganalisa tekanan di tempat kritikal basikal atas air tersebut. Akhir sekali, objektif projek ini telah tercapai di mana basikal atas air ini boleh diperbuat di UMP and dipergunakan di tasik UMP pada masa akan datang.

vii TABLE OF CONTENTS SUPERVISOR S DECLARATION STUDENT S DECLARATION ACKNOWLEDGEMENTS ABSTRACT ABSTRAK TABLE OF CONTENTS LIST OF TABLES LIST OF FIGURES Page ii iii iv v vi vii x xi CHAPTER 1 INTRODUCTION 1.1 Introduction 1 1.2 Project Background 1 1.3 Problem Statement 2 1.4 Objective 2 1.5 Scope 2 1.6 Project Flow Chart 3 1.7 Project Gantt Chart 4 1.8 Thesis Organization 5 CHAPTER 2 LITERATURE REVIEW 2.1 Introduction 6 2.2 Archimedes Principle 6 2.3 Gear 7 2.4 Torque 8 2.5 Dimension of Hull 10

viii 2.6 Market Existing Product 11 2.6.1 Product A 12 2.6.2 Product B 13 2.7 Fabrication Equipment 2.7.1 MIG Welding Machine 14 2.7.2 Drill Press 15 2.7.3 Disk Cutter Machine 16 CHAPTER 3 METHODDOLOGY 3.1 Introduction 17 3.2 Synopsis 17 3.2.1 Methodology Flow Chart 18 3.3 Concept Design 19 3.3.1 Concept A 19 3.3.2 Concept B 20 3.3.3 Concept C 22 3.3.4 Concept D 22 3.3.5 Concept E 23 3.4 Evaluation Process 24 3.4.1 Concept Screening 24 3.5 Finalize Concept 25 3.6 Bill of Material 26 3.7 Fabrication Process 27 CHAPTER 4 RESULTS AND DISCUSSION 4.1 Introduction 30 4.2 Result 30 4.2.1 Product Specification 33 4.2.2 Working Mechanism 34 4.2.3 Material Required 35 4.2.4 Stress Analysis 35 4.3 Discussion 37

ix 4.3.1 Advantages and Disadvantages 37 4.3.2 Type of Defect 37 4.3.3 Problem Faced 38 CHAPTER 5 CONCLUSION AND RECOMMENDATION 5.1 Introduction 39 5.2 Conclusion 39 5.3 Recommendation 40 REFERENCES 41 APPENDICES 42 A1 Frame 42 A2 Hull 43

x LIST OF TABLES Table No. Page 2.1 Specification of hydrobike explorer 1 12 2.2 Specification of hydrobike explorer 2 13 3.1 Bill of material 26 4.1 Product specifications 33 4.2 Material Required 35 4.3 Result of stress analysis of the frame 36 4.4 Tensile test analysis of the frame 36

xi Figure No. LIST OF FIGURES Page 1.1 Project flow chart 3 1.2 Project gantt chart 4 2.1 Hull dimension for LOA & LWL 10 2.2 Hull dimension under waterline 10 2.3 Hydrobike Explorer 1 12 2.4 Hydrobike Explorer 2 13 2.5 MIG Welding Machine 14 2.6 Drill Press Machine 15 2.7 Disk Cutter Machine 16 3.1 Methodology Flow Chart 18 3.2 Concept A 19 3.3 Concept B 20 3.4 Concept C 21 3.5 Concept D 22 3.6 Concept E 23 3.7 Concept Screening 24 3.8 Finalize Concept 25 3.9 Disk Cutter Machine 27 3.10 Drill Press 28 3.11 MIG Welding Machine 28 3.12 Finishing Process 29 3.13 Mould 29 3.14 Fibre Glass Hull 29 4.1 Isometric View 31 4.2 Steering System 31 4.3 Paddling System 32 4.4 Impeller 32 4.5 Hull 32 4.6 Solidworks Estimation 33 4.7 Stress analysis of the frame on single part 36

CHAPTER 1 INTRODUCTION 1.1 INTRODUCTION The purpose of this chapter is to explain about the project background, problem statement, project objectives, project scopes, flow chart of the project as well as Gantt chart to present the flow and overall process for this project. 1.2 PROJECT BACKGROUND Water bike is a transport that can move on the surface of the water. Usually people ride it for entertainment or exercise purpose. Water bike applies the cycling principle or mechanism to move the water bike. People will cycle on the pedal and this will move the propeller which is connected with it. By this, the water bike will move forward. There are many types of water bike exist around the world. For different environment or condition, we need to design different type of water bike which suits to it. The water bikes that already exist in the market can be classified into two way

2 which are differentiated by the number of hull or differentiated by the number of user can ride on it. Some of the designs can be used in two types of condition or environment. For example, some water bikes can move on the beach and also on the sea. This enable users to cycle the water bike from the beach direct into the sea surface without any change to the water bike. 1.3 PROBLEM STATEMENT UMP Pekan has a lake which is popular among the people here. Usually, every evening students and staffs go there for exercising or to relaxing their mind. There are only few types of activity that can be done there, which are cycling, jogging and canoeing. The lake is quite wasted since it is only used for canoeing. Besides, another problem is there are too less activity for UMP Pekan s student to exercise during the evening. To overcome these problems we need to add on some activity which can be held in the lake. So, manufacture of water bike is the most suitable way to solve these problems. 1.4 OBJECTIVE 1. To design a water bike which can be manufactures at UMP for UMP Pekan s lake. 2. To design a water bike which can be uses at UMP Pekan s lake in the future. 1.5 SCOPE 1. Designing of water bike by using software. 2. Designing of water bike for UMP Pekan s lake use in the future. 3. Building a prototype based on the design. 4. Analysing for the structure of the water bike designed.

3 1.6 PROJECT FLOW CHART Figure 1.1 shows the project flow chart which indicates the overall flow in conducting out this project. Start Literature Review Identify Problem Statement Identify Objective &Scope Concept Selection Design & Sketching No Yes Finalize Design Fabricate of Prototype Design & Sketching No Yes Project Report End Figure 1.1: Project flow chart

4 1.7 PROJECT GANTT CHART Figure 1.2: Gantt chart

5 1.8 THESIS ORGANIZATION Chapter 1 will explains about the introduction, project background, problem statement, objective, scope, project flow chart and project Gantt chart. This chapter planned about the flow of my project. Chapter 2 which is the literature review mainly will explain about the definition, formulas and market existing products. Chapter 3 which is the methodology and this chapter will explains about the concept design and also the finalize concept of the design. It also explains about the fabrication process and machining used. Chapter 4 which is the results and discussion and this chapter will explains about the finalize product that have been made. The product is then being analysed by using software to find out its specification. Chapter 5 mainly explains about the conclusion and recommendation that can be made to the product.

CHAPTER 2 LITERATURE REVIEW 2.1 INTRODUCTION This chapter will explain about the definition and formulas that needed to know before I start designed a water bike. This chapter will also explain about the literature review of some of the market existing products. These existing water bikes have their own advantages and disadvantages. Water bike is a transport that we use on the surface of water. Usually people ride it as entertainment purpose. 2.2 ARCHIMEDES PRINCIPLE Archimedes principle relates buoyancy to displacement (Yunas A. Cengel, 2010). This principle name came from the discoverer s name which is Archimedes of Syracuse. Archimedes principle suggests that any floating object displaces its own weigh of fluid. This means any object either it is wholly or partially immersed in a fluid is buoyed up by a force equal to the weight of the fluid displaced by the object (Yunas A. Cengel, 2010). So, buoyancy is equal to weight of displaced fluid.

7 In Archimedes principle, the weight of the displaced fluid is directly proportional to the volume of the displaced fluid. Which mean, the buoyant force on the object is going to be equal to the weight of the fluid displaced by the object (Yunas A. Cengel, 2010). So, comparing objects with the same masses, the greater volume object has a greater buoyancy force. In term of buoyancy, it is a force exerted by a fluid that opposes an object s weight. Buoyancy force can keep an object afloat on the fluid surface if the object is less denser than the fluid or the object is shaped appropriately like a boat (Yunas A. Cengel, 2010). Consider any object of arbitrary shape and volume V surrounded by a liquid, the force that the liquid exerts on the object is equal to the weight of the liquid displaced by the same volume. However, the force acting on the object by the buoyancy force is opposite in direction with the gravitational force. The above formula is used to calculate magnitude of buoyancy force where B is the magnitude of buoyancy force acts on the body, is volume of fluid displaced by the object s body. is the density of the fluid and g is the gravitational acceleration at the location. To let an object float on the fluid surface, the volume of the object must be greater than the volume of the fluid displaced. 2.3 GEAR Gear is a rotating machine part having cut teeth which mesh with another toothed part in order to transmit torque (R.C. Hibbeler, 2010). Torque will be explained by the next sub-topic. Transmission is where two or more gear work together. This can produce a mechanical advantage through a gear ratio (R.C. Hibbeler, 2010). So gear system is considering a simple machine. By using gear system, we can change the speed, torque, and direction of the power source.

8 Normally a gear will mesh with another gear. However a gear also can be meshed with a non-rotating toothed part, called a rack. By this it can produce a translation instead of rotation. The advantage of using a gear is we can prevent slipping to happen (R.C. Hibbeler, 2010). The gears in a transmission are analogous to the wheels in a pulley. To perform mechanical advantage by using gear, we need to combine two gears which have unequal number of teeth. By doing this, both gear s rotational speeds and the torque will be different. The simplest gear train is a pair of meshing gears. The input gear will drive the output gear. The velocity between two gears will be the same. With this statement we can form an equation. From the equation v represents velocity, r represents the gear radius of the pitch circle and w represents angular velocity. Besides, the number of teeth on a gear is proportional to the radius of its pitch circle. This means the ratio of the radius is equal to the ratio of the number of teeth. The formula below will show the gear ratio R of a simple gear train with two gears connected together. 2.4 TORQUE Torque is the tendency of a force to rotate an object about an axis or pivot. It can be thought as a twist (R.C. Hibbeler, 2010). For an example, pushing or pulling

9 the handle of a wrench connected to a nut or bolt can produce a torque. This torque is used either to loosen or tighten the nut or bolt. The SI unit for torque is newton meter (N.m.). The symbol for torque is τ. It was a Greek letter called as tau. However when we called moment, the symbol will be denoted by M, The magnitude of the torque depends on three quantities which are force applied, the length of the lever arm connecting the axis to the point of force application and the angle between the force vector and the lever arm. In the formula above, τ represents the torque vector, r represents the displacement vector and F represents the force vector. However in this formula, τ represents the magnitude of the torque, r represents the length of the lever arm vector, F represents the magnitude of the force and θ represents the angle between the force vector and the lever arm vector. We can also convert torque to power. This is very important in engineering calculation if we wish to provide other energy source. For example, if rotational speed is used in place of angular speed, we need to multiply factor of 2π radians per revolution as shown below. Power = torque X 2π X rotational speed By using this formula, it will help us to get the power in the unit of Watt(W). So we can get to know how much power it consumes to finish the work.

10 2.5 DIMENSION OF HULL The most important thing to understand in designing any water bike is how to measure the dimension of a hull. The exact hull s dimension is needed in order to calculate all the forces and resistances. Figure 2.1: Hull dimension for LOA & LWL Source: http://upload.wikimedia.org/wikipedia/commons/2/2f/loa-lwl.svg Figure 2.2: Hull dimension under waterline (Sv. Aa. Harvald, 1983)

11 Figure 2.1 and Figure 2.2 shows the way to take the measurement of a hull properly. The symbol used in the figure will be explained as below. I. Length overall (LOA) is the extreme length from one end to the other II. Length at the waterline (LWL) is the length from the forward most point of the waterline measured in profile to the stern-most point of waterline. III. Draft (D) is the vertical distance from the bottom of the hull to the waterline. IV. Length between perpendiculars (LPP) is the length of the summer load waterline from the stern post to the point where it crosses the stem. V. Beam water line (BWL) is the maximum beam at the water line. Normally in designing a hull, we only need to consider the parameter showns in Figure 2.2 because only the hull s portion which immersed under the water or exactly on the surface of water is needed. The length between perpendiculars is the length between the foremost perpendicular, which is usually a vertical line passing through the stem s intersection with the waterline. Normally, it coincides with the rudder axis. Thus, this length is slightly less than the waterline length (Sv. Aa. Harvald, 1983). It can be expressed as: LPP = 0.97 X LWL 2.6 MARKET EXISTING PRODUCT This topic will explain about the market existing product and some comparison about their specification. At this topic, there are two type of product that being show.

12 2.6.1 Product A Figure 2.3: Hydrobike Explorer 1 Source: http://www.funwatercraft.com/water-bike/hydrobike/hydrobike-explorer-1 Table 2.1: Specification of hydrobike explorer 1 Item Specification Width (hull to hull) Weight Capacity Length Height 44 inches 125 lbs. 400 lbs. 10 feet 53 inches Gear Ratio 8.6:1 Propeller Diameter Hull Draft Hull Frame Steering Adjustments 12 inches 9 inches Seamless, Molded polyethylene 17 in. Powder-Coated Aluminium Front Rudder Quick-Release Clamp Cost RM 4500

13 2.6.2 Product B Figure 2.4: Hydrobike Explorer 2 Source: http://www.funwatercraft.com/water-bike/hydrobike/hydrobike-explorer-2 Table 2.2: Specification of hydrobike explorer 2 Item Specification Width (hull to hull) Weight Capacity Length Height 84 inches 211 lbs. 600 lbs. 10 feet 53 inches Gear Ratio 8.6:1 Propeller Diameter Hull Draft Hull Frame Steering Adjustments 12 inches 9 inches Seamless, Molded polyethylene 17 in. Powder-Coated Aluminium 2 Front Rudder Quick-Release Clamp Cost RM 9000

14 2.7 FABRICATION EQUIPMENT There are various types of machining that will be used in carry out the fabrication process. Below are the details about the two main machining equipments that needed. 2.7.1 MIG Welding Machine Figure 2.5: MIG Welding Machine MIG welding machine is one of the welding machines that available in our lab. MIG welding can perform work faster if compared to arc welding. MIG welding machine is used to join two objects with same type material together. Not every material can be weld by using MIG welding machine.

15 2.7.2 Drill Press Figure 2.6: Drill Press Machine Drill press is a fixed style of drill that are mounted on a stand or bolted to the floor or workbench. A drill press consists of a base, pillar, table, spindle and drill head which is driven by an induction motor. The head has a set of handles radiating from a central hub that when turned move the spindle and chuck vertically parallel to the axis of the column. The table can be adjusted vertically and is rely on the operator to lift and re-clamp the table in position.

16 2.7.3 Disk Cutter Machine Figure 2.7: Disk Cutter Machine Disk cutter machine is a machine that can be used to cut hollow tube, bar, flat plate and so on. This is the machine that I will be needed to cut the raw material into the dimension that I needed. Before we cut the material we need to measure and marking on the material. After that we clamp the material on the disk cutter machine. After make sure the material is being clamp firmly we start to cut the material.

CHAPTER 3 METHODOLOGY 3.1 INTRODUCTION This chapter will explain about the concept design that has been made in order to solve the problem statement. This chapter also will explain about how all the concept design being evaluated in order to get the finalize concept. Material selection and fabrication process also being discuss in this chapter about how the raw material being cut and shape into desired design. 3.2 SYNOPSIS This topic will explain about the flow or step involve in designing out the finalize concept. The flows of the project methodology are as follow: i. Identify the problem statement ii. Concept design and evaluation iii. Finalize concept iv. Material selection v. Fabrication process and finishing

18 3.2.1 Methodology Flow Chart Start Identify the problem Concept design and evaluation Finalize concept Yes No Material selection Fabrication Finishing End Figure 3.1: Methodology flow chart From the methodology flow chart in Figure 3.1, the project started with identifying the problem which is the problem statement. After the problem have been identified, concept design is carry out. In this project, five concept designs have been sketch out and after that evaluation is carry out. Concept screening is the method of evaluation that are being carry out to design out the finalize concept.

19 After finalize concept have been identified, material selection is the next process. For this project I had choose the material of mild steel hollow bar due to its ease of fabrication and the appearance of the final product. After material is being select, fabrication process is then carry out. Here several of tool and machining process is carry out like cutting, welding and much more. After that, finishing process is carry out. At this process the product is being paint. 3.3 CONCEPT DESIGN 3.3.1 Concept A Steering Steering Propeller Seat Hull Steering plate Figure 3.2: Concept A Figure 3.2 shows the first concept design. It is designed for single user. Only one pedal and propeller is needed. The steering is connected to the steering plate to control the direction of the water bike to go. This design consists of only one hull which will cause the stability to decrease. The advantage of this design is ease of operating. However the disadvantages are the stability is less and the manufacturing process will be quite hard.

20 3.3.2 Concept B Steering Hull Seat Steering plate Pedal Propeller Figure 3.3: Concept B Figure 3.3 shows second concept design. It is multi-user, can be ride up to 3 people. The front rider will be the one who control the direction while the rear riders will be the one who pedal to move the water bike. This water bike required team work to move to a destination. This concept consists of two propellers which can move the water bike faster. The stability of the hull is still low.

21 3.3.3 Concept C Steering Hull Steering Plate Seat Propeller Pedal Figure 3.4: Concept C Figure 3.4 shows the third concept design. It is for single user. This concept consists of single hull. The pedal will connect to the propeller by using helix gear. This water bike is very easy for operating. This is the concept that I take it as the reference when evaluating process.

22 3.3.4 Concept D Steering Steering plate Chassis Pedal Propeller Hull Seat Figure 3.5: Concept D Figure 3.5 shows the fourth concept design. This concept is very stable since it consists of three hulls. This water bike can be ride by two people. Each people have his own steering and pedal. Again, this concept needed cooperation of both the rider to move the water bike to the destination. The chassis designed is for lifting the seat to a higher place to avoid the water being reach to the rider.

23 3.3.5 Concept E Steering Steering plate Seat Chassis Pedal Propeller Handle Hull Figure 3.6: Concept E Figure 3.5 shows the fifth concept design. This concept is stable since it consists of two hulls. This water bike can be ride by two people. Each people have his own pedal. Front rider can control the direction while the rear rider can hold on the handle as a support. The chassis designed is for support the seat to a higher place. Both the pedal force will join together to rotate the propeller behind to move the water bike.

24 3.4 EVALUATION PROCESS After five concept designs have been sketch out, the next process will be evaluation process to sort out the criteria of each concept. Screening concept will be carry out in this section. At here, the process will determine which concept or design will be developed. 3.4.1 Concept Screening Figure 3.7 below shows the concept screening process. Each concept design will be evaluate according to the selection criteria which is multi-user, stability, durability, ease of operating, space optimization, cost of fabrication and ease of manufacture. Concept C is taken as the reference in screening out the design concept. Design concept that has the same selection criteria to the reference will be given a (0) sign, (-) is given to the design that has bad criteria than the reference and (+) is given to the design that has better criteria than the reference. Then the sum of (+), (-) and (0) is calculated. Net score is obtained by minus away the (+) sign with the (-) sign then the concept is ranked. Here concept design E ranked the first followed by D, C, A, and finally B. Concept B is decided not to continue as it only has the net score of -2. Concept E is the only designed that will be continue. Figure 3.7: Concept screening