Zulkeflee Abdullah

Warpage Analysis of Different Number Cooling Channels for Dumbbell Plastic Part in Injection Moulding

Warpage deflection is one of the common pitfalls in plastic injection moulding which is always affected the quality and accuracy of the plastic products. It occurs due to the influences of mould temperature during injection moulding process and it is related to the number of cooling system existed in the mould. Therefore, this paper studies the effect of cooling channels on warpage of dumbbell plastic part having different number of cooling channel using Moldflow software. Warpage analysis was run using four and eight cooling channels. Parameters involved in this study are injection time, packing time, melt temperature and mould temperature. The result of warpage from simulation analysis was projected on the graphic having different colour which is presented the actual value of warpage. It is found from warpage simulation result that the maximum warpage for four cooling channels is 1.283mm and the maximum warpage for eight cooling channels is 1.280mm. It shows that the increasing of the number of cooling channel from four to eight channels in the injection mould reduces the warpage deflection about 0.2%. Thus, the result shows that the number of cooling system in the mould plays an important role on the quality of plastic part during injection moulding process.

Optimization design and analysis of an underactuated dexterous robotic hand system

This paper presents the optimization of three-dimensional (3D) Printed Underactuated Dexterous Robotic Hand (UDRH) design and the analysis of the UDRH material. The UDRH design consists of three fingers and a thumb at which each finger has two links and two degrees of freedoms (DOF) and each joint of the finger is actuated by the DC Micromotor. The thumb has 3DOF to allow for adduction and abduction of the thumb. The robot hand is designed to be like human hand whereby higher performances in accuracy, stability and consistency can be achieved. The actuators are placed directly in each finger link so that the robot hand has several degrees of freedoms to achieve dexterous grasping. The angular rotation, speed, and torque have to be controlled for each individual joint to enable a more precise control. The structure of the UDRH robot hand is printed by using Flashforge Creator Pro 3D printer machine. In this paper, the optimization and analysis of fused deposition modeling (FDM) printed materials which are Acrylonitrile Butadiene Styrene (ABS), Polylactid Acid (PLA), Nylon, and Polycarbonate (PC) plastic are accomplished by testing for their stress and deformation through finite element analysis by using Solidworks software. From the analysis, the critical points and the parts of the UDRH design that are prone to damage under high force and temperature can be detected. In this study, ABS plastic material is chosen for UDRH prototype due to its properties which are resistance to heat which is 5.47 × 106N/m2, and high melting point of 210°C compared to the other materials.

Development of Database for Checking Fixtures for Automotive Parts

The purpose of this study is to develop a database for checking fixtures for automotive parts. The parts used in the fixture checking process were automotive parts such as clamper, stand and toggle. The goal of this project is to implement a database of checking fixtures parts. The project started with identifying the current problems that were faced by the designer at a design department, in a support service for automotive industries. Idle time has been the major problem that designer have to faced. All the data and information related to this project has been sought and explored in the literature review. Catia software is used as the CAD software to construct three-dimensional models for the design of all the parts in the parts library. All the parts are organized in three different sizes which are determined by the size of car body panel. Referring to the result, new libraries were developed and created using the Catia software to aid designers in the checking fixture design process. The validation of the new libraries had been conducted with the company’s design engineer to test the effectiveness, usability and relevancy. In summary, this database and method can potentially accelerate the checking fixtures design process to be faster and more efficient.

Design and Development of Weaving Aid Tool for Rattan Handicraft

The main purpose of this project is to design and develop an assisting tool in manufacturing of rattan handicraft. Rattan is a non-timber forest resource which has a variety of functions in the making of handicrafts and furniture. The production of rattan handicraft typically carried out using manual and traditional methods. However, there are some problems to be faced by the craftsman in making the handicrafts such as the time constraints for the creation of products, due to the difficulty in term of the size, and the pain in the hands while making the handicraft products. Therefore, assisting tools or devices in manufacturing of rattan handicraft are needed to solve the problem. The methods used are questionnaire survey, CATIA software for RULA analysis and SolidWork software for FEA analysis.

Effect of Different Coolant Medium on Warpage Deflection Using Moldflow Insight Analysis

The effect of mould temperature on warpage using water and oil as coolant fluid was studied using flow software analysis. Mould temperature was controlled using two types of coolants; where cold mould was controlled by water and hot mould was controlled by oil. The simulation analysis was performed using flow software analysis Moldflow Plastics Insight (MPI). Taguchi method was used to design the planning matrix and to find the optimum levels of input variables. Then, to find the percentage contribution of input variables on output variables, analysis of variance (ANOVA) was used. It is found that mould temperature controlled by water shows less warpage analysis compared to oil. The minimum and maximum percentage of warpage analysis between cold mould and hot mould are 3.1% and 7.1% respectively. In addition, ANOVA analysis shows that the most significant parameters affected the warpage analysis for both moulds using oil and water are melt temperature (255°C) followed by mould temperature (water 15°C and oil 70°C) and cooling time (water 8s and oil 6s). Thus, it shows that coolant medium used in mould cooling system contributes the quality of plastic parts.

Design Analysis of Motion Simulation for Development of Rehabilitation Device

A current study regarding the development of a rehabilitation device for lower extremity is presented. The device is specifically designed for rehabilitation of post-stroke patients who encounter walking weakness. The rehabilitation device is categorized as an active device that is power-driven by a DC motor. Its design was the outcome of improvements to counter the problems existed in the a newly developed prototype. A motion simulation was used to ratify the motion capability of the proposed design in the modelling design process. Analysis of kinematic and dynamic behavior of the motion simulation has been carried out. The smoothness of the mechanical movement and the linear velocity provided by the device are acceptable as additional work of the design process. Based on a statistical analysis, the study found that there is no significant difference from the motor torque requirement even though the angular velocity of the motor was changed substantially.