SELF CLEANING MECHANISM CALCULATION ON THE WEIGHT OF THE SILICONE USED THE MATERIAL THE DESIGN

CHAPTER 5 75 ANALYSIS AND DISCUSSION 75

5.0 INTRODUCTION

75 5.1 ANALYSIS 76 5.1.1 Manual Static Analysis 76 5.1.2 Computer Simulation 77 5.1.2.1 Result on the upper casing 77 5.1.2.2 Result on the lower casing 78

5.2 SELF CLEANING MECHANISM

80 5.3 ROTATION OF CUTTING DISC 81

5.4 CALCULATION ON THE WEIGHT OF THE SILICONE USED

81 5.5 CALCULATION ON THE WEIGHT OF POLYURETHANE USED 82 5.5.1 Lower Casing 82 5.5.2 Upper Casing 82

5.6 THE MATERIAL

83 5.7 FUSED DEPOSITION MODELLING 83

5.8 THE DESIGN

83 CHAPTER 6 84 CONCLUSION 84 BIBLIOGRAPHY 85 APPENDIX 88 LIST OF FIGURES CHAPTER 2 Figure 2. 1: Malaysia had produced 41.3 of world palm oil production in 2008 8 Figure 2. 2: Export trend of major oil until 2008 MPOB, 2008 9 Figure 2. 3: The Six Wheeler MPOB, 2008 11 Figure 2. 4: The grabber MPOB, 2008 11 Figure 2. 5: Leaf emission rate varies with palm age MPOB, 2008 14 Figure 2. 6: Canopy form of oil palm leaves MPOB, 2008 14 Figure 2. 7: The spikelets MPOB, 2008 15 Figure 2. 8: Fresh fruit bunch MPOB, 2008 15 Figure 2. 9: Short oil palm trees stem MPOB, 2008 16 Figure 2. 10: Cylindrical shape stem of oil palm MPOB, 2008 17 Figure 2. 11: Thick superficial adventitious mat of oil palm root MPOB, 2008 18 Figure 2. 12: The fibrous superficial root system MPOB, 2008 18 Figure 2. 13: Traditional harvesting method using sickle cutter MPOB, 2008 19 Figure 2. 14: Latest technology developed by MP OB known as CANTAS™ 20 CHAPTER 3 Figure 3. 1: Flow Chart 25 Figure 3. 2: Basic structure of House of Quality 32 Figure 3. 3: House of Quality of Pneumatic Mini Disc Cutter 35 Figure 3. 4: Morphological Chart 38 Figure 3. 5: Objective Tree 42 Figure 3. 6: Final Concept 44 CHAPTER 4 Figure 4. 1: Prototype Developement Process 46 Figure 4. 2: Isometric View of Exterior Look 48 Figure 4. 3: Isometric View of Interior Look 48 Figure 4. 4: Isometric View of Exterior Look 49 Figure 4. 5: Isometric View of Interior Look 49 Figure 4. 6: Isometric View of Axial Impeller 50 Figure 4. 7: Isometric View of Impeller Sub 51 Figure 4. 8: Fused Deposition Modelling Machine 52 Figure 4. 9: Interior Look of FDM Machine 52 Figure 4. 10: The for segments of upper casing 54 Figure 4. 11: Joint segments 54 Figure 4. 12: Box construction 56 Figure 4. 13: Modelling Clay Base 57 Figure 4. 14: Leakage Inspection 57 Figure 4. 15: The completed model is kept on flat and safe place 58 Figure 4. 16: Completed Male Mold 59 Figure 4. 17: Mixing Machine 60 Figure 4. 18: The Silicone 60 Figure 4. 19: Pouring hardener intothe silicone 60 Figure 4. 20: Completed female mold 62 Figure 4. 21: Setting up sprue on upper casing 62 Figure 4. 22: Setting up sprue on the lower casing 63 Figure 4. 23: Cured Lower Casing Part 64 Figure 4. 24: Cured Upper Casing Part 64 Figure 4. 25: Lathe machine is used in producing impeller sub 65 Figure 4. 26: Safety precaution in handling lathe machine 65 Figure 4. 27: Continuous measurement 66 Figure 4. 28: Drill Press Machine 68 Figure 4. 29: Bandsaw Machine 69 Figure 4. 30: Inner besring insertion 71 Figure 4. 31: Back bearing insertion 71 Figure 4. 32: Bearing insertion in upper casing 71 Figure 4. 33: Axial impeller respective slots 72 Figure 4. 34: Supporting pad with axial impeller 72 Figure 4. 35: Pressuruzed air distributor 73 Figure 4. 36: Installing pressurized air distributor 73 Figure 4. 37: Complete product 73 CHAPTER 5 Figure 5. 1: Force Distribution in Static Analysis 76 Figure 5. 2: Von Mises Stress in Upper Casing 77 Figure 5. 3: Deformation Analysis in Upper Casing 78 Figure 5. 4: Von Mises Stress in Lower Casing 78 Figure 5. 5: Deformation Analysis in Lower Casing 79 Figure 5. 6: Air Distribution Along the Hose 80 Figure 5. 7: Self-Cleaning Working Principle 80 Figure 5. 8: Rotation of Cutting Disc 81 LIST OF TABLES CHAPTER 2 Table 2. 1: The increasing need of labour throughout years until 2008 10 CHAPTER 3 Table 3. 1: Product Design Specification PDS 37 Table 3. 2: Concept Generation 40 Table 3. 3: Scoring Method 43 CHAPTER 4 Table 4. 1: Technical Detail on Fused Deposition Modelling 53 Table 4. 2: Typical properties of silicone mixture 61 CHAPTER 5 Table 5. 1: Mechanical properties of Aluminium Alloy 77 LIST OF SYMBOLS F P = Pulling Force N F R = Reaction Force N F C = Cutting Force N W = Weight N x = Maximum distance where the force can be aplliedmm Ʃ = The sum of δ x = Change in distance mm η = Safety factor s ut = Ultimate tensile strength Nm 2 σ max = Maximum stress Nm 2 W = Wide cm H = Height cm L = Long cm CHAPTER 1 INTRODUCTION