Design for assembly analysis for newly developed 3D router machine

Esmadee, Shahrul Akmal (2023) Design for assembly analysis for newly developed 3D router machine. Project Report. Melaka, Malaysia, Universiti Teknikal Malaysia Melaka. (Submitted)

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Abstract

CNC machines are widely used all over the world, and this CNC machine will undergo numerous improvements each year. As a result, there are numerous opportunities to learn, particularly for students studying Engineering Mechanical Technology. This thesis describes and applied the NPD process on creating a new product design idea by conducting research and studying the Engineering Design Phase. The ED process is critical, and being used to structure this newly developed CNC machine 3D router. This thesis are apply the ED phase, which consists of Formulation, Concept Design, Configuration Design, Parametric Design, and Detail Design. For Parametric Design, will not be covered because for this thesis only highligted DFA analysis which under the Configuration Design.Understanding the Problem Statement, which is this project's target market purpose on educational institutions such as technical high schools, vocational schools, and technology mechanical stream schools, before developing some new product. Beside to provide additional knowledge and exposure to students about CNC 3D routers, it will allow students to understand and be exposed to CNC machines more quickly. The primary goal of this research is to design and develop a new Y-axis sub assembly for a newly developed 3D router machine using CAD software and to compare DFA analysis using DFA 9.4 software on the Y-axis sub assembly between the current design (Original design) and the redesign (New design). For this report methodology, it consisted of ED phase in which responsible in designing the Original design and DFA analysis was responsible on redesign the current design which make into the new design of Y-axis sub-assembly. There are many information are used to evaluate all the existing CNC milling machine that was applied in benchmarking method for this project. Some of the benchmarked existing CNC milling machine such as the Genmitsu PROVerXL 4030 CNC Router, the stepper motor type will be the benchmark because it can holding torque up to 4Nm and medium size and design that suit nicely and give aesthetic to the design. Then, the VFH Cam220 Classic router, the benchmark on the material used will be more focused because the aluminum material was light in weight and durability. With the right material, the stepper motor on the Y-axis will be more smoothed in power transmission. Lastly, the Carbide 3D Shapeko Pro 4 the benchmark on the transmit movement because ball screw gives precise movement for the axis due to low friction loss and high transmission efficiency. Therefore, generated the alternative concept for the feature such as the movement guide include linear rail block and bushing, transmit movement having lead screw, ball screw, and rodless cylinder, and lastly stepper motor type which consist of NEMA 17, NEMA 23, and NEMA 34. Then, total number combination for each alternative concept was 18 of the alternative concepts. Next, concept selection using the weight rating method resulting number 5 was selected from the 18 alternative concept generation where linear rail block, ball screw, and NEMA 23 where total rate are 3.75, 4.05 and 3.95 respectively. Furthermore, the final specification from the result for movement guide is linear rail block because it was more lighted than the bushing and more in aesthetic and durability. Meanwhile for transmit movement is ball screw due to low friction loss and high transmission efficiency with high precision. Last but not least stepper motor is NEMA 23 because holding torque up to 4Nm come with medium size and design that suit nicely and give aesthetic to the design. Next, the Original 3D design was created by using Solidwork software The DFA methodology able giving understanding the problems in the total assemble time for the Y-axis sub-assembly. This Y-axis subassembly has the same number of parts on the left and right sides. For the right side, it has additional part which is the number of bill of material (BOM) is 29 parts rather than left side only have 25 parts. The additional parts are limit switch board, limit switch mount, cap screw m5x25, and spring washer M5. Limit switch function to detect limit workspace that stop automatically when it touches and act as safety factor on newly develop CNC 3D Router machine for the user used. Then, following with DFA analysis result conclude in generate report suggestion fro redesign. For redesign new design of Y-axis sub-assembly, some redesign methods are part combination application and redesign part are applied. As result, it make a better production total assembly time. The total assembly time are generated automatically by DFA 9.4 software from DFA executive summary comparison which reduced from 848.23s to 559.46s. It shortens the assembly time about 317.67s or 34.04%. The reduction of assembly time contributed by the combination and redesign of certain part components based on DFA analysis result. This reduction of the part will improve the design efficiency.Therefore, the result for design efficiency was calculated and shown at the Table 3 below, where resulted the design comparison between Original design and New design show the huge gap of the total assembly time that effected with the total number of part decreases 9 part, and poorly increase on design efficiency around 0.46% but still acceptable.

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