UNIVERSITI PUTRA MALAYSIA

COMPARISON OF COST, SURFACE ROUGHNESS AND TIME USING STEREO LITOGRAPHY AND 3D PRINTER FOR THE DESIGN

OF COMPOSITE PEDAL

LEE HO BOON

FK 2003 69

COMPARISON OF COST, SURFACE ROUGHNESS AND TIME

USING STEREO LITOGRAPHY AND 3D PRINTER FOR THE DESIGN OF COMPOSITE PEDAL

By

LEE HO BOON

Thesis Submitted to the School of Graduate Studies, Universiti Putra Malaysia, in Fulfilment of the Requirement for tne Degree of Master of

Science

October 2003

Abstract of thesis presented to the Senate ofUniversiti Putra Malaysia in fulfilment of the requirement for the degree of Master of Science

COMPARISON OF COST, SURFACE ROUGHNESS AND TIME USING STEREO LITOGRAPHY AND 3D PRINTER FOR THE DESIGN

OF COMPOSITE PEDAL

By

LEE HO BOON

October 2003

Chairman : Associate Professor Ir. Mohd Sapuan Sa lit, Ph.D.

Faculty : Engineering

This research presents the process of designing a non metal pedal box system

for Proton Wira car. Closed form or non-numerical data analysis of non metal

pedal box system is initially carried out. Calculations of bending stiffness and

torsion strength to decide on the best pedal lever cross section were carried out.

Similarly yield stress calculation for pedal lever was performed. Comparison

between non metal pedal box system and steel pedal box system was carried

out. This research also includes the measuring process with a coordinate

measuring machine of the currently used steel pedal box system and followed

by modelling the design in Unigraphics. The design of three pedals namely an

accelerator pedal, a brake pedal and a clutch pedal as well as a mounting

bracket was carried out. Rapid prototyping models using stereo lithography

(gLA 3500) by 3D System and 3D Printer Z40L. by Z-corp were produced.

Stereolithography and 3D printing were compared in terms of cost, speed of the

process, user friendliness and model quality. The purpose of rapid prototyping

models is to facilitate easy communication of product to the customers.

11

methods of rapid prototyping using various approaches and to decide on the

best methods in term of quality, cost and speed of processing. Design

communication using rapid prototyping is one of the important elements of

concurrent engineering technique. The pedal box' system was designed to meet

the final objective of weight reduction produced using injection moulding

process.

iii

Abstrak tesis yang dikemukakan kepada Senat University Putra Malaysia sebagai memenuhi keperluan untuk ijazah Master Sa ins

PERBANDINGAN KOS, KEKASARAN PERMUKAAN DAN MASA DENGAN MENGGUNAKAN STEREO LITOGRAPHY DAN

PENCETAK 3D UNTUK REKABENTUK INJAK KOMPOSIT

Oleh

LEE HO BOON

Oktober 2003

Pengerusi : Profesor Madya Ir. Mohd Sapuan Sa lit, Ph.D.

Fakulti : Kejuruteraan

Penyelidikan ini mempersembahkan proses mereka bentuk sistem kotak injak

bukan logam untuk kereta Proton Wira. Analisis data bukan berangka atau

analisis bent uk tertutup bagi sistem kotak injak bukan logam telah dijalankan

pada permulaan. Pengiraan-pengiraan kekukuhan lenturan dan kekuatan

kehelan bagi menentukan keratan rentas injak yang terbaik telah dijalankan.

Begitu juga pengiraan tegasan alah bagi injak telah dilaksanakan. Perbandingan

antara sistem kotak injak bukan logam dan sistem kotak injak keluli telah

dijalankan. Ia juga meliputi proses mengukur sistem injak keluli yang sedia

ada dengan mesin pengukur kordinat dan diikuti dengan pemodelan reka

bentuk dengan peri sian Unigraphics. Reka bentuk bagi tiga injak iaitu injak

pecut, injak brek dan injak cekam serta pendakap cagak telah dijalankan. Reka

bentuk itu digunakan untuk membentuk model contoh sulung cepat dengan

stereolitografi (SLA 3500) oleh 3D System dan 3D Printer Z402 oleh Z-corp.

Kedua-dua cara ini dinilai dari segi kos, kecepatan proses, kemesraan kepada

IV

ialah bagi memudahkan komunikasi produk dengan pelanggan-pelanggan.

Kedua-dua kaedah telah digunakan bagi tujuan mempelajari pelbagai kaedah

contoh sulung cepat menggunakan pelbagai pendekatan dan menentukan

kaedah-kaedah terbaik dalam sebutan mutu, kos dan kecepatan pemprosesan.

Komunikasi reka bentuk menggunakan contoh sulung cepat adalah salah satu

unsur penting dalam kaedah kejuruteraan setemu. Sistem kotak injak ini direka

bentuk dengan bertujuan memenuhi objektif akhir iaitu, pengurangan berat

dengan menggunakan proses pengacuan suntikan.

v

ACKNOWLEDGEMENTS

I would like to express my gratitude to the chairman of the supervisory

committee Associate Professor Ir. Dr. Mohd Sapuan Salit for his advice and

guidance throughout the duration of this research. I would also like to thank all

lecturers and laboratory and administrative staff of Department of Mechanical

and Manufacturing Engineering, Universiti Putra Malaysia especially Associate

Professor Dr. Shamsuddin Sulaiman and Associate Professor Dr Megat

Mohamad Hamdan Megat Ahmad who both acted as supervisory committee

members.

I would also like to express thanks to Mr Harun @ Eyong Jantrik from

Institute of Multimedia and Software Development, Universiti Putra Malaysia

in assisting me in the stereolithography process and staff from Rapid

Technology Solutions Sdn. Bhd., which is situated in Technology Park

Malaysia in providing the 3D printing service. I would like also to thank

Ministry of Science, Technology and Environment, Malaysia for providing the

fund for this project under the vot number 54068.

Further appreciation is extended to my parents Mr Lee Kok Siang and

Madam Tan Chen Kim who have supported me with their encouragement and

financially.

Vi

I certify that an Examination Committee met on 5th November 2003 to conduct the final examination of Lee Ho Boon on his Master of Science thesis entitled "Comparison of Cost, Surface Roughness and Time Using Stereo Lithography and 3D Printer for the Design of Composite Pedal" in accordance with Universiti Pertanian Malaysia (Higher Degree) Act 1980 and Universiti Pertanian Malaysia (Higher Degree) Regulations 1981. The Committee recommends that the candidate be awarded the relevant degree. Members of the Examination Committee are as follows:

Ir. Barkawi Sahari, Ph.D. Professor Faculty of Engineering Universiti Putra Malaysia (Chairman)

Ir. Mohd. Sapuan Salit, Ph.D. Associate Professor

Faculty of Engineering Universiti Putra Malaysia (Member)

Megat Mohamad Hamdan Megat Ahmad, Ph.D. Associate Professor Faculty of Engineering Universiti Putra Malaysia (Member)

Shams uddin Sulaiman, Ph.D. Associate Professor Faculty of Engineering Universiti Putra Malaysia (Member)

ProfessorlDepu Dean School of Graduate Studies Universiti Putra Malaysia

Date: 1 1 FEB 1004

vii

This thesis submitted to the Senate of Universiti Putra Malaysia has been accepted as fulfilment of the requirements for the degree of Master of Science. The members of the Supervisory Committee are as follows:

Ir. Mohd. Sapuan Sa lit, Ph.D. Associate Professor Faculty of Engineering Universiti Putra Malaysia (Chairman)

Megat Mohamad Hamdan Megat Ahmad, Ph.D. Associate Professor Faculty of Engineering Universiti Putra Malaysia (Member)

Shams uddin Sulaiman, Ph.D. Associate Professor Faculty of Engineering Universiti Putra Malaysia (Member)

k2 .. t-" J

AINI IDERIS, Ph.D. ProfessorlDean School of Graduate Studies Universiti Putra Malaysia

Date: 2 5 FEB 2004

viii

DECLARATION

I hereby declare that the thesis is based on my original work except for quotations and citations which have been duly acknowledged. I also declare that it has not been previously or concurrently submitted for any other degree at UPM or other institutions.

LEE HO BOON

Date: 29-12-2003

IX

TABLE OF CONTENTS

ABSTRACT ABSTRAK ACKNOWLEDGEMENTS APPROVAL DEC LARA nON LIST OF TABLES LIST OF FIGURES LIST OF PLATES LIST OF ABBREVIA nONS

CHAPTER

1

2

INTRODUCTION

1.1 Background

1.2 Statement of problem

1.3 Objectives of the research 1.4 Scope of the research

1.5 Structure of the thesis

LITERATURE REVIEW

2.1 Introduction 2.2 Polymeric-Based composite 2.3 Automotive pedal box system 2.4 Application of polymeric-Based composite in

automotive industries 2.5 Review of current application of polymeric-based

composite in automotive pedal box system 2.6 Rapid prototyping 2.7 Recent development in rapid prototyping 2.8 Injection moulding

2.8.1 The injection moulding machine 2.8.2 The injection mould

II IV VI VII IX XII Xlll xv xvi

2.9 Recent developments in plastic injection mould design 2.10 Summary of literature review

3 METHODOLOGY 3.1 Structure of the research

Page

1 2 3 4 7

8 8 9

10

11 19 24 25 26 29 30 32

34 3.2 Closed form and non numerical data analysis of non metal

pedal box system 35 3.3 Data collection process with coordinate measuring

machine 36 3.3.1 MISTRAL motorized measuring machine 39

X

3.4 3.5

3.6

3.7

Modelling the pedal system with Unigraphics The rapid prototyping process with SLA machine 3.5.1 The SLA 3500 machine 3.5.2 The transfer from CAD to RP model The rapid prototyping process with the 3D Printer 3.6.1 The printing process Direct comparison of the rapid prototyping model with the existing metal pedal box system

40 41 42 42 45 46

47

4 RESULTS AND DISCUSSIONS

5

4.1 Closed form and non- numerical data analysis of non metal pedal box system 48 4.1.1 Pedal design cross-section calculation 48

4.1.1.1 Bending stiffness 49 4.1.1.2 Torsion strength 51 4.1.1.3 Weight calculation 52

4.1.2 Calculation of the yield stress for the pedal design 54 4.1.3 Functional capability calculation 58

4.2 The result from the modelling of the pedal component with Unigraphics 60

4.3 The result of the rapid prototyping process with the SLA system 66

4.4 The result of the rapid prototyping process with 3D Printer Z402 73

4.5 Comparison of SLA and 3D printing processes 77 4.6 Comparison of the Non Metal Pedal Box with the

Original Steel Pedal Box System 81 4.7 Discussion on the composite pedal design 85

CONCLUSIONS AND RECOMMENDATIONS 5.1 Conclusions 5.2 Recommendations

87 89

REFERENCES 90

BIODATA OF THE AUTHOR 94

Xl

LIST OF TABLES

Table Page

4.1 The M section is ranked the 4th in the bending stiffiless calculation 50

4.2 The M section is ranked the 1 st in the torsion strength calculation 51

4.3 The M section is ranked the 5th in the weight calculation 52

4.4 Maximum load of the different pedals 54

4.5 Maximum bending moment of the different pedals 55

4.6 Volume of each part calculated by Unigraphics based on the model 65

4.7 Weight comparison of composite and steel pedals 66

4.8 Comparison between the two rapid prototyping systems 80

xu

LIST OF FIGURES

Figure

1.1 Concurrent engineering approach of pedal box design

2.1 Brake pedal housing from Solvay Automotive Ltd. UK. [Bradbury (18)]

2.2 Accelerator pedal by AlliedSignal Plastics for Ford (22)

2.3 AB Elektronik accelerator pedal module (30)

2.4 Stereo lithography model and metal casting model (32)

2.5 Example of stereolithography model (32)

2.6 A typical injection moulding machine component (35)

2.7 Injection moulding machine-operating sequence (35)

2.8 Typical example of a plastic injection mould block (38)

3.1 Flowchart of the methodology

4.1 Cross section shape suggested in this study

4.2 The M cross section with four areas. (All dimensions are in millimetres)

4.3 The approximate dimensions of the newly design pedal in millimeters

4.4 The M cross section with the increase in size (All dimension in mm)

4.5 The M cross section with the increase of ribbing thickness

4.6 The graphical result of the finite element analysis of the brake pedal

4.7 The graphical image of the accelerator pedal in

Page

6

15

17

19

21

21

28

28

30

35

48

49

55

56

57

60

Unigraphics 61

4.8 The graphical image of the brake pedal in Unigraphics 62

xiii

4.9 The graphical image of the clutch pedal in Unigraphics 63

4.10 The graphical image of the mounting bracket in Unigraphics 64

4.11 The graphical image of accelerator pedal with the support structure 67

4.12 The graphical image of brake pedal with support structure 68

4.13 The graphical image of clutch pedal with support structure 69

4.14 The graphical image of mounting bracket with the support structure 70

4.15 The first built process consists of the whole brake pedal and half of the accelerator pedal 73

4.16 The second built process 74

4.17 The graphical image of the assembly of the pedal box system in Unigraphics 80

XIV

LIST OF PLATES

Plate Page

3.1 The front view of the existing steel pedal box system 37

3.2 The bottom view of the existing steel pedal box system 38

3.3 The mounting bracket inside the peA undergoing post-processmg 45

4.1 The accelerator pedal SLA model in its fmal form 71

4.2 The brake pedal SLA model in its final form 71

4.3 The clutch pedal SLA model in its final form 72

4.4 The mounting bracket SLA model in its fmal form 72

4.5 The whole assembly SLA model in its final form 73

4.6 The completed accelerator pedal 3D Printer model 75

4.7 The completed brake pedal 3D Printer model 75

4.8 The completed clutch pedal 3D Printer model 76

4.9 The completed mounting bracket 3D Printer model 76

4.10 The completed assembly pedal system 3D Printer model 77

4.11 The comparison of the existing metal pedal box systems on the left with the SLA rapid prototyping model on the right 82

xv

LIST OF ABBREVATIONS

2D Two-dimensional

3D Three-dimensional

ABS - Acry lonitrile-butadiene-styrene

C Section with C shape

CAD - Computer aided design

CAE - Computer aided engineering

ClM - Computer-integrated manufacture

CMM - Coordinate measuring machine

CNC - Computer numerical control

CO2 Carbon dioxide

E Elastic modulus

FEA - Finite element analysis

I Second moment of area

I Section with I shape

IPC Intelligent process control

KBS - Knowledge based system

KEE - Knowledge Engineering Environment

LOM - Laminated object manufacturing

M Section with M shape

M Bending moment

NC Numerical control

NVH - Noise, Vibration and Harshness

p Load in Newton

XVi

PA Polyamide

PBT - Polybutylene terephthalate

PC Polycarbonate

PCB - Printed circuit board

PDS Product design specifications

PEl Pol yetherimide

PP Polypropylene

PPS Polyphenylene sulfide

RP Rapid prototyping

Rz Mean roughness depth

SGC - Solid ground curing

SLiSLA- Stereo lithography

SLS Selective laser sintering

SOl Standard Operator Interface

STL Standard triangle language

U Section with U shape

Z-corp - Z Corporation

eM Torsion strength

(J' Yield stress

() Deflection

y Centre of geometry

Z Y/I

XVll

CHAPTER 1

INTRODUCTION

1.1 Background

Business worlds nowadays often experience rapid change especially in the

market place. Consumers were expecting more value added feature from the

products they buy with the trend of cheaper prices. These have driven

industrialists to search for more advanced methodologies and technologies to

satisfy consumer demands. One of the potential areas is weight saving through the

use of polymeric based composite to substitute metal component. By using

composite as material the product can achieve lower weight. And this has been

demonstrated for quite some time especially in automotive industries. The major

weights saving examples so far are sheet body panel, body frames and even

chassis. The advantages of polymeric-based composite are innumerable. It has

high strength, high stiffness, and aesthetically pleasing, corrosion resistance and

light weight due to low density. It also provided manufacturer flexibility in design.

The manufacturing cost is also lower due to the ability of moulding several parts

in one process thus shortens manufacturing lead-time and also reduces assembly

time with part reduction. Injection moulding is a very good example. It is essential

that more development and study on replacing more components in automobile to

light weight composite to be carried out.

1

1.2 Statement of Problem

There are over 286 million cars in the world and about 10% is replaced or

scraped every year. This means that 28.6 million vehicles need to be scraped each

year. The components of the vehicle were usually recycled but not 100 percent of

the vehicles can be recycled easily.

Vehicle needs fuel every time in operation. The limited petroleum

reserves have urged manufacturer of vehicle to come up with more and more fuel­

efficient vehicle. One of the tactics they currently interested in is to 'slim' down

the vehicle or to reduce the weight of the vehicle. It is common sense that lighter

weight vehicle always consume lesser fuel.

In order to have a lighter weight and easier recyclable vehicle, the

manufacturer found their answer in composite material especially fibre reinforced

polymeric composite material.

A lot of work has been carried out in the past on the application of

polymeric composite material in automotive industries. Composite has been used

for some components such as bumper, tailgate, and door panel, just to name a few.

A number of applications of pedal box system using composite material were also

found. But currently there is no example that deals with the design of the whole

pedal box system. The manufacturer only design parts of the pedal box system and

especially there is no work has been carried out on the development of composite

2

brake pedal. In addition there is no work carried out on the use of rapid

prototyping for composite pedal box system Therefore, there is a need to carry out

design of the whole pedal box system from polymeric-based composite material

and to develop rapid prototyping models using methods like SLA and 3D Printer.

1.3 Objectives of the Research

The main objectives of this research are:

i) to carry out a process of redesigning a pedal box system with a

specific model of car. The vehicle selected is Proton Wira 1.5 litre

manual transmission configuration. The pedal box must be able to

be fitted in to a real vehicle. The performance is equal to its steel

counterpart with the additional advantage of weight saving.

ii) to develop rapid prototyping models of the redesigned pedal

system using stereolithography and 3D printing methods to

facilitate design communication which is the essence of concurrent

engineering.

iii) to compare both rapid prototyping methods in terms of cost,

surface finishing and speed of the processes, in order to determine

the optimum method of rapid prototyping process for a non metal

automotive pedal box system.

3

1.4 Scope of the Research

The research focuses on the manufacturing process of the pedal box

system. Previous work have already included the material selection using

knowledge-based system (KBS) (I), concept design with product design

specifications (PDS) ( 1 ), detail design process by 3D CAD ( 1 ) and finite element

analysis (FEA) ( 1 ), and cost estimation using KBS ( 1 ).

By using the available data and information from previous work, this

research work on the redesigning the models based on Proton Wira 1.5 model and

on the development of the rapid prototyping models for pedal box system is

presented. The redesigning process is carried out using conventional calculations

such as torsion strength, bending stiffness and yield stress. It is to decide on the

best cross section of pedal lever. Comparison between the design from non metal

pedal box system and steel pedal box system is carried out. Basically, the size and

location of both designs do not differ but the main difference is on some of the

design features such as incorporation of ribbing, part integrations and others. Two

different methods of rapid prototyping are used in this research and the models

developed are compared. The criteria for comparison includes user friendliness,

cost, time and other issues in both rapid prototyping methods. Two different rapid

prototyping methods used were the Stereolithography and the 3D Printer. The

former is a liquid based laser cure system and the latter is a powder-based system.

Both of the systems are based on the Stereo lithography (SLA) technique. This

technique is always referred to as building a solid model by tracing a profile of a

4

previously sliced digital model and stacking them layer by layer in their proper

position to form the final solid modeL The selection of the optimum method is

essential to facilitate the design communication, which is the essence of

concurrent engineering. It is shown in Figure 1 . 1 .

5

DESIGN CALCULATIONS DESIGN FEATURES COORDINA1E V) ON TORSION STRENGTH, DETERMINA nON: MEASURING

�� BENDING STIFFNESS 4-t PART INTE GRATION, ..... SYSTEM. AND YIELD STRESS. RIBBING STR U C� .....

O�

h DESIGN STA GE

U CAD MODELLING. COMPARISON OF NON 2DDRAWING. ftAETAL PEDAL BOX 3D SOUD MODEL SYS1EM AND ftAET ALLIC WEIGHT CALCULATION PEDAL BOX SYS1EM

�i 1 -QIGN ::>-3DPRrnTER .....

SLAMODEL COMMUNICATION

O m STAGE. MODEL

I� I RAPID PROTOTYPlNG <z

U COMP AlUSON AND

SELECTION

� PROTOTYPE �A� MANUFA=mG

STAGE INSTRUCTION

<

I PEDAL BOX SYSTEM I

Figure 1.1: Concurrent engineering approach of pedal box design

6

1.5 Structure of the Thesis

The objectives and scope of the research are presented in chapter I.A

literature review is presented in Chapter 2. Literature review begins with some

general background of polymeric-based composite and automotive pedal box

system, and it is followed by the review of current development in the applications

of polymeric-based composite in various parts of automobile especially the pedal

box system.

It also includes some review on rapid prototyping and injection moulding

technologies with particular emphasis on plastic injection moulding of

thermoplastic materials.

In Chapter 3 the methodology a closed form non-numerical data analysis

of the designed pedal box system is presented. Application and procedure to

produce the rapid prototyping with the Stereolithography and 3D printer are

explained in detail. This includes collecting the data and dimensions of the

existing steel pedal system with the use of coordinate measuring machine and

modelling the new design of the pedal box system by using Unigraphics package

the results from the modelling were used to carry out the development of rapid

prototyping models. Two different rapid prototyping methods were used namely

the SLA 3500 by 3D System and the 3D Printer by Z-corp. The results, discussion

and comparisons of both models are made in Chapter 4. Finally conclusions and

recommendations are presented in Chapter 5.

7