Final Report

ACKNOWLEDGEMENT

On the very outset of the report, I would like to extend my sincere and heartfelt obligation towards all the personage who have helped me in this project work. Without their active guidance, help, cooperation, and encouragement, I would not have made headway in the project.

We wish to express my sincere gratitude to Mr. Martin Volkening for supplying us with an opportunity to do our project work at Fanshawe College.

We sincerely thank Mr. Bruce Steers for his design guidance and encouragement in carrying out his project. We also wish to express my gratitude to my colleagues and technical advisors of Fanshawe College who helped me during my project work.

Lastly, we also thank our team member itself for their consent, efforts, and precious time in this project work.

Parin Patel (0901910)
Darshil Patel (0900801)
Akash Patel (0901064)

Introduction

In the following report we would like to describe a detail about a Yoke type Pipe Vice as our capstone project. It has 65 to 70% machining which is helpful to enhance our mechanical and machining knowledge as well. Pipe vise has been made by milling, drilling, threading consequently. For making a pipe vice we need to face two metal plates with some amount of tolerance. Pipe should behold by one fix jaw and one movable jaw. Movable jaw is moved by one threaded rod. Four supporting beams are used to hold two metal plates vertically. It is a portable plumbing tool. According to our research, the main application of pipe vise is to hold different shapes of pipes and tubing. The main characteristic of this machine is to hold a fixed range of pipes. The project also connects with different accessories and supporting components. Pipe vice stand and system increasing holding capacity and strength in mechanical industries. It can hold fix range of diameter cylinders at a single time. The system includes a pipe holding mechanism supported on a base of stand. The project has a movable jaw which helps to increase and decrease holding diameter of pipe. There are two types of pipe vice such as Chain and Yoke. The main problem of Yoke Pipe Vice is that it can hold round and cylindrical geometry instead of other shapes.

MATERIAL SELECTION

Material selection is part of designing process. For every project material selection comes at a first position because, proper material selection minimizes the cost and time. There are five different categories that designer must focus on it such as functionality, processability and machinability, economical, reliability and strength. According to professor guidance we choose 6061-T6511ASTMB221234267 (cold roll steel) because it has ahigh strength, stiffness and good mechanical properties. Moreover, we selected a specific fastener which helps to clamp two or more objects together such as movable jaw with the top plate. Basically, it is called as a no permanent joint because, friction ratio is high at this location.

Methodology

There are three types of the following phase in Project Methodology.

1. Planning Phase

2. Execution Phase

3. Closing Phase

Planning Phase: This is the first phase which helps to initiate a project. In this phase our team makes all the brief plan of our project. It includes budget estimation, basic structure of the design, risk estimation and sequence of manufacturing process. Also, in this phase our team distribute project work into team members. Also, in this team ask for lab permission and material selection as well.

Milestone: Takes more time to grant project permission and confuse about our basic design structure. We take help from faculty and internet source to design an exact design on a time.

2. Execution Phase: This is the most important phase in every project. In this team member convert drawing into an actual prototype. Also, team members need to construct a perfect design with geometric specifications. All the basic documents such as risk identification, risk mitigation, Gantt chart, team members can identify design calculation and bill of material. Machining is included in this phase but due to the COVID-19 pandemic we can not do convert design into an actual prototype.

Milestone: COVID-19 is a major issue while executing the machining process and team members forgot some minor issues while calculating the budget.

3. Closing phase: This is the final phase of the pipe vice project. In this team submit a final project report to the examiner. Documents have final design, service manual and customer service policy. Also, show an actual work of pipe vice.

Manufacturing Process: The manufacturing process defined as converting raw material into a finished product. According to our design we must do lots of machining such as to cut a moving jaw, to drill a hole on base and top plate, to make a thread on a galvanized bolt.

i. Cutting: We plan to cut the raw metal plate into the required dimensions. Also reduce a length of square and rounded bar to calculate dimensions. So that for cutting decide to use a band saw machine in the machining shop.

ii. Drilling: We intend to use a drilling machine to make a circular hole in a solid material. According to our design we are using some fasteners to fix some parts in assembly. Before applying a drilling operation, we plan to use a spot drill which helps to guide actual drilling the final holes.

iii. Threading: For this operation, we decide to use a lathe machine with the help of taps and dies. We fix hand tapping as our main threading method for this project. We plan to make a thread on a galvanize bolt with a specification of 3/8”-16-5”.

iv. Milling: Milling is the most important process through which machinist some mechanical operation. In that, face mill and end mill are the most important tool to remove material from raw materials. For milling machinist set a block at 45 degrees and hold a block at the same angle. We decide to use VMC to face a material and make a groove on the bottom jaw. We estimate cutter diameter as 0.5’’ and 700 rpm for performing milling operations. V grove on a moving jaw and fixed jaw can be cut on a milling machine.

v. Grooving and finishing: Groove is a long slot built in a metal to fix some other mating part. We built it on our hex head screw on the circumference of the bolt. We perform this operation on a lathe machine. We plan to do the last process called finishing in which our team will remove excess material and sharp edges by using sandpaper.

Individual Content:

Parin Patel

Progress: At an initial stage I was not able to make a drawing file as well as risk-budget estimation. But by taking this project I can perform a solid work’s design and risk- budget calculation.

Work Completed: Mainly I focus on project phase I. in which I must set up a drafting standard, risk Identification and mitigation, prepare a design file and estimation of budget. In this I made project part files in solid works and found a risk about a pipe vice manufacturing. I used Microsoft Excel to calculate the approximated budget of our project. In this I choose red, yellow, and green colour according to the risk strength starts from high to low. I decide basic tolerance, dimensioning style, and prototype specification such as height, width, and length.

Work to be Completed: I will do proofreading of the project report and final checking of part files. Also, I will check project cost lies in an estimated budget amount and finish the risk detail.

Darshil Patel

Progress: I have never got an experience of creating the google site and BOM, so this project helped me to practice and learn more about it.

Work Completed: At first, we saw a lot of projects as references from the college website, and then we decided to make a Pipe vice. Also, I decided to make an application and we got approval from the project advisor. After that, my team-leader made a risk-budget estimation and I started working on Gantt- Chart, depending on the chart we divided our work as per our skills. I made calculations of BOM. I got the part files from the leader and I made an assembly in Solid works. Then I made drawing sheets of each part and assembly. In the end, I made a title block in each drawing sheet.

Work to be completed: I will update the Google site, work on EVA. Also, I will help other team members in the final presentation and report.

Akash Patel

Progress: As of now I have learnt and applied on this project many things such as doing individually rough sketching of the pipe vice, preparing a blueprint of it and checking its strength. I mean for me it’s a great achievement on this project till now.

Work Completed: In the project my main role is to provide my fellow partners a start by providing the scope statement, rough sketch and in the end checking its strength which has been successfully done. Making the scope statement was not much hard as I have my partners and other resources which helped me a lot to gather the information about it and proceed to roughing the sketch, yes in these It took me a lot of time to get an exact idea from YouTube videos of pipe manufacturing process and to make a final blueprint from it with help of AutoCAD and solid works.

Work to be Completed: Almost everything has been done from my side just some final checks and balances are left which will done in couple of days. Finally, in the end I will provide my remaining time to help my partners to get ready for final presentation.

Project Management

Project Schedule: It is the tool that communicates what we need to perform at a specific time. As our project requirements my team plan 4^thFebruary for making a Gantt chart. According to our schedule team initiate to preparing a Gantt chart on a planned date. So, the variance amount of the Gantt chart schedule is 0. Our team task is running behind our project plan because of the COVID-19 so, we are not covering our machining phase. Hence, we are not able to make an actual prototype of Pipe Vice till the final date.

Project SPI value is 0.25 which is less than 1. It means less work has been completed than planned work. Hence, our team running behind the schedule.

Project Costs: According to the table earned value and actual cost are the same as $887.40. By applying the CPI formula, we get one as our CPI value. It means the final product budget meets the estimated cost of the whole project so, the variance amount of project cost is null.

As shown in the below chart EVA Analysis depicts a clear picture of the project completion date, final cost and variance in schedule and budget as project proceeds. From 29^th Feb to 11^th April CPI Value reamain same. However, SPI value lies in a range between approx. 0.25 to 0.34. Upper limits and lower limits are 1.1 and 0.9, respectively.

RECOMMENDATIONS

The functionality of Pipe Vice is almost 90% hence, it is recommended considering the pipe vice for mechanical purpose. Our design is completely successful to manufacture so, our team recommends any manufacturing industry or machining industry to use our design because it was approved by our professor.

LESSON LEARNED

It was an amazing experience for our team to learn a Pipe Vice as our capstone project. This experience is meaningful to our team because we did all the tasks instead of machining within a specific period. While performing all three-phase we face lots of new challenges in a way but, ultimately, we got some solution and lots of project management skills by the guidance of our professors.

Individual Content

1. Parin Patel:

Technical Section

From this project I learned how to pay detail a tension and designing function of solid works and machining because, it has in my further career. Also, I learned some concepts of machining. I got an understanding of different parameters of drilling, milling, threading, cutting. I learned how to read drill charts and fine-coarse thread specification by using an internet source. Also, I visited https://www.mcmaster.com/ website for getting basic knowledge of part details and material property. Also, I got a detailed knowledge of geometric tolerance and bill of material.

2. Akash Patel:

Technical Section

The most important thing in the project and for my future career I have learnt a great team bonding while working together which showed to me that how to tackle our complex technical problem and specially, we just took an idea from websites but found a solution on our own and it was unique. The role and responsibilities we played together, the knowledge and skills we shared with each other. In the terms of skills and knowledge I have gain it more by visiting numerous amounts of company’s websites and getting some extent of ideas and giving it a final shape what I want in the end.

3. Darshil Patel:

This project learned me how to make firm decisions. Also, I got a chance to learn a lot about Solidworks. I saw videos for the reference to my part assemblies so that I can know how to manage my work properly. I have got an understanding to divide work as I worked on Gantt-chart. While creating a google site, I learned how to manage a business-related website which will help me further in my future. Moreover, I started making good decisions right away which is a healthy habit for the future.

Schedule Section

Apart from the technical lesson we learned to maintain a project schedule within a timeframe. We divided all tasks in individual team members so, we finished our project within a schedule. From this we understand a concept of team management and Schedule Performance Index which defines that we are ahead or behind schedule. Also, we learned how to manage time in every type of situation such as during quarantine.

Budget Section

I learned to manage a budget for a specific project by performing this capstone project. I did the budget estimation through which I got a basic idea of the Gantt chart which helps to maintain schedule consequently. I allocated some amount to specific task according to its requirement. Pipe Vice project total budget was $1809.60. A value of the calculated amount of CPI is 1 because, earned value and actual value are equal.

Conclusion

Pipe Vice is an interesting project for our team through which we learned technical, schedule and cost estimation concepts. Our total budget for the project is around 1800 dollars. Due to the COVID-19 we left our machining phase. However, the design of the pipe vice was considerably done by our team. Almost 70% of work has been done in a specific time but, due to the pandemic machining phase was not done by our team. Finally, we recommend our project as a successful capstone work. Designing, documentation and proofreading are completed by our team members. Our project SPI value 0.25 and CPI value is 1 which is much enough to clarify that our project is successful. If you have any doubt or confusion about Pipe Vice made by DPA group, please feel free to ask, you can contact us via Email or Phone number.

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