Design And Analysis For Development Of Bicycle Helmet Moulding Process

Mohd Zulkarnain, Fatin Syazana (2017) Design And Analysis For Development Of Bicycle Helmet Moulding Process. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

Mould is a container that is used to gives shape to a product with various media. With the help of CAD/CAM technique available nowadays together with advance machining, the mould production time and cost of manufacturing can be reduced. Also, the limitation of the conventional moulding technique can be improvised. Open mould is one of the mould that is suitable for hand lay-up technique of moulding where rapid product development cycle can be developed. Hand lay-up technique is suitable for fabricating composites product which is the epoxy resin with kenaf fiber reinfored. Air pollution due to industrialisation is the biggest concerned nowadays. In order to achieved greener manufacturing practice, synthetic material used by manufacturer to produced a product is replaced by non- synthetic material such as epoxy resin with kenaf fiber reinforment. The use of material like ABS plastics going through injection moulding process will affect both operators and end users health and also environment. This project designed an open mould suitable for the hand lay-up moulding of kenaf fiber with epoxy resin adhesion. Furthermore, the propose of the project is to analysed the mould designed for its mechanical properties such as plasticity, hand lay- up problem and sharp edges effect upon the product. In order to get the most suitable mould for hand lay-up moulding, the mould is first being analyzed with ANSYS software analysis. From the Pugh concept selection method, open mould design was selected as it is satisfy all the criteria needed for the fabrication process. After the mould is validated where from the analysis shown that the design is strong and have safety factor of 0.71722. Thus, the fabrication process of outer shell of the helmet can be used with this mould repeatedly, the outermost bicycle helmet shell is fabricated using hand lay-up technique by concerning about curing time to achieved better result.

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