Methodolgy

Project Phases and milestones

Phase: Initiation

To select the topic needed for the capstone project and develop a pool of ideas.

Milestones: Create a rough sketch of the design

Develop a pool of ideas

Description

In order to do the capstone project, we began to start discussing it. Our plan was to do a mechanical project using Solidworks designing, machine labs such as lathe and milling because we all were from mechanical background. So we decided to make a simple metal bender. We created a rough sketch and initially planned to use stainless steel as the base metal. To achieve the second milestone we had a group meeting to discuss a pool of ideas.

Phase: Planning

Milestones: Create a scope statement

Develop Gantt chart and budget planning

Create a google site

Description

In this phase we had a group meeting to discuss what are the plannings needed to successfully complete this project. we created an executive summary to get the project approval. Prepared scope statement with signs from professors to complete our first milestone.Gantt chart and budgets are planned to complete the project within time. Changed base metal as Aluminium because stainless steel was expensive as well as difficult to machine.Google site created to update everything we have done online.

Phase: Designing

Milestones: Design in Solidworks

Form bending calculations and formulas

Description

This was the most challenging and important phase of the project any mistakes can cost a lot. Followed each step considering design calculations and providing necessary allowance and clearance to parts. We applied bending equations and knowledge from our ENGR class to make a safe design.

Design (Fig 1 & Fig 2 ) and equations are shown below

A_b=(2π α(R+K_ba t))/360

where A_b = bend allowance; a = bend angle; R= bend radius; t = stock thickness; and K_ba is factor to estimate stretching

if R < 2t, K_ba = 0.33, If R ³ 2t, K_ba = 0.50

Maximum bending force F can be calculated by,

F=(K_bf .TS.wt^2)/D

Where,

· F= Bending force

· K_{bf =} Bending factor

· t = Thickness of plate

· TS= Tensile strength of the material

Phase: Execution

Unfortunately, the execution phase of the project was interrupted by COVID-19,so machining and presentations were canceled.

Individual Contributions.

Amal.

My contribution to this project was preparing documents like Gantt chart, budget planning, EVA analysis and preparing engineering calculations needed for the project. Whenever I am preparing the documents new doubts popup and used old project references to clear out.

Feedback from our capstone professor was really helpful in making these documents. Bending equations from our ENGR class applied to the capstone project to find out physical forces on the machine.

Britto.

In this project I worked on creating google site and risk assessment. In every project it is necessary to find what are the risks that would be occurred and precautions needed to be taken. So that as a team we discussed with tech advisor to avoid machining risks by using PPE while operation.

When creating a website I had doubts but followed google steps and comments to clear it. seperately created a mail id for our capstone and linked group members mail id to anyone in the group can edit.

Sachu.

In this project, I had completed all work related to design. Solidworks design software was used to create our proposed plan. any mistakes in the design would affect our machining so extra care and time had taken while designing.

Furthermore added hole clearance and tolerances to make design safe and reliable. Suggetions from team members included in part files and assembly.