Design analysis of the X-axis assembly of a newly developed 3D router machine using finite element analysis

Mat Rozi, Muhammad Ibnur Ameerul (2023) Design analysis of the X-axis assembly of a newly developed 3D router machine using finite element analysis. Project Report. Melaka, Malaysia, Universiti Teknikal Malaysia Melaka. (Submitted)

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Abstract

The main objective of this research is to design and analyze a newly developed Computer Numerical Control (CNC) three-dimensional (3D) router machine. Six students are involved in the project, and each student is responsible for handling a certain aim related to product distribution. However, this study focuses on designing and applied static analysis on X-axis assembly or stucture using Finite Element Analysis (FEA). The research problem statement was built on ideas from the Ministry of Higher Education and industry opinions. The current market benchmark price of CNC routers made the existing machine incredibly expensive for several colleagues and students attending schools. Following that, one of the concepts in this study that can tackle the issues of expensive 3D router prices on the open market is the new design of a CNC 3D router machine. The development of this machine will solve the issues of cost, availability, and exposure for a 3D router machine for educational purposes. However, in order to succeed in the develop of this machine, research must be conducted so that issues with machine durability may be tackled and the machine can endure a long time. The design of X-axis and static analysis in 3D routers machine is the focus of this research. The research starts with the benchmarking of the selected router machine and generating the engineering design specification in the formulation stage. After that, the sub-function of the X-axis structure concept was generated by using the table of combinations. The final specification of the X-axis assembly was developed using the weighted rating approach after the number of potential concepts was obtained from the table of combinations and one of them was chosen in the concept selection phase. Using the SolidWorks 3D Computer-Aided Design (CAD) software, the final specification produced the special purpose component part, and the detailed design drawing was released. The CAD design was then imported into Solidwork Simulation which is one of FEA software to perform static analysis using three different load of 5 kg, 10 kg, and 15 kg. The outcomes were validated using comparisons with experimental testing. According to the collected data, load less than 10 kg is the maximum load that this structure's X-axis design can support. This means that redesign should be done to meet higher load criteria if the load is over 10 kg. Finally, applying a load more than 10 kg to the X-axis structure is not advised since the results of the static analysis indicate that there is a significant risk of failure or fracture. Overall, we conclude that the load of the Z-axis, which is attached to the X-axis structure, cannot be greater than 10 kg. This is because experimental testing and static analysis results show that the applied load are predicted to be positive.

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