Development of cutting technology for cutting polymer foam material

Che Roizimi, Muhamad Shafiq (2016) Development of cutting technology for cutting polymer foam material. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

This project focused to develop cutting technology in the form of vertical bandsaw machine for manufacturing polymer foam. The main function of the cutting technology is to cut large size of foam expected minimum of 2m (length) x1m (high) x 0.0254m (thickness). Early development of the cutting technology expressed the problem to cut the foam due to unavailable machine that suit to reduce the thickness of the foam. Therefore, the cutting technology has been developed involving with several engineering methods such as design, process and evaluation of the product. In term of design, the process involved with determination of machine specifications, select and analyse the design concept based on Pugh Method and develop the real drawing of the cutting technology based on the selected concept and specifications. Further, the cutting technology has been manufactured by machining, cutting, welding and assembly. As the whole cutting technology completed, the newly fabricated produce were evaluated based on function ability, belting performance and Finite Element Analysis (FEA). For function ability, the systems demonstrated adequate performance to cut the foam into reasonable thickness. For belting performance, observation of new and worn surface highlighted the mechanism of belting failure in the form of breakage, burr and deterioration of belting structure. For FEA analysis, the simulation using Solidwork shows the cutting technology enable to retain force up to 1000N with minimum stress and displacement. Overall, the cutting technology developed in this study manage to perform according to the intended objective and ready to be applied for real industry production.

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