FALCUTY OF MECHANICAL

BMCU 3013 INTEGRATED DESIGN PROJECT

ENGINEERING ANALYSIS REPORT

GROUP NUMBER: 8

NO GROUP MEMBERS MATRIC NO

1 MUHAMMAD NAILI FITRI BIN MAMAT ASRI B041910207
2 MOHAMED SYAHMI BIN SAUPI B041910208
3 MUHAMMAD ASYAFIQ BIN ABDULLAH B041910214
4 MUHAMMAD SYAMIL MUNIR BIN AHMAD B041910221
BUKHARI

LECTURER’S NAME: DR. SHAFIZAL BIN MAT

1.0 INTRODUCTION

Engineering analysis is important for any product. When a design proposal is ready to be tested,
testing the mechanical and structural characteristics is very important. This analysis including
safety analysis, as many of these characteristics will determine how safety the design will be
under specific conditions. In this report also includes with the detail of the project management
and cost analysis for our product. All the analysis is needed to perform a complete product with
the desire specifications that meet customer requirement.

2.0 ENGINEERING ANALYSIS

2.0.1 Material Properties

Material properties are the physical and mechanical characteristics of a product that influence
its functionality and manufacturability. This would mean that a product's material
properties would specifically define the capabilities of the products in all aspects. Our product
material properties are shown below.

Material Mild Steel

Dimension 1 inch x 1 inch

Thickness 1.6 mm
Yield Strength 440 MPa

Table 1.0: Material Properties

Material properties for our actual product, we have decided to use mild steel. We have chosen
to use 1 inch x 1 inch hollow mild steel with 1.6 mm thickness. This mild steel is the most
important material of our product because this material has been used the main frame of our
product. So, the main frame must be strong to accommodate the load.
2.0.2 Finite Element Analysis
2.0.2.1 Total Deformation

Figure 2.1: Total Deformation of The Product

Total Deformation
Time (s) Minimum (mm) Maximum (mm) Average (mm)
1.0 0 4.9012e-002 1.7e-002

Table 2.1: Total Deformation

Total deformation is the transformation of a body when load is applied. We determine the total
deformation because we want to test our project whether the product is rupture or not when the
load is applied. Figure 6.1 shows the total deformation for our product which is the maximum
is 4.9013e-002 mm. This total deformation was analysed with load at 156.96 N and will get an
average at 1.7e-002. At this maximum value, this product cannot be rupture and it can be used
safely.
2.0.2.2 Equivalent Stress Von Mises

Figure 2.2: Equivalent Stress of The Product

Equivalent Stress
Time (s) Minimum (MPa) Maximum (MPa) Average (MPa)
1.0 0 4.9012e-002 1.7e-002

Table 2.2: Equivalent Stress

Von Mises is a theoretical measure of stress used to estimate yield failure criteria in ductile
materials and is also popular in fatigue strength calculations. For our simulation, we have
applied 156.96 N load. After the load is applied, we can see that the maximum value of the
equivalent stress von mises is 4.9012e-002. Based on our observation, we can confirm the
material that have been chosen can sustain the amount of load applied.
2.0.2.3 Equivalent Elastic Strain Von Mises

Figure 2.3: Equivalent Elastic Strain of The Product

Equivalent Elastic Strain

Time (s) Minimum (mm/mm) Maximum (mm/mm) Average (mm/mm)

1.0 0 2.7123e-005 8.4878e-005

Table 2.3: Equivalent Elastic Strain

The equivalent elastic strain is defined as the limit for the values of strain up to which the
object will rebound and come back to the original shape upon the removal of the load. For
our simulations, the maximum value that have been gained is 2.7123e-005. As the Figure 2.3
shown, our frame does not change into red colour which means the equivalent elastic strain
value is suitable for the material of our product.
2.0.2.4 Safety Factor

Figure 2.0: Safety factor of the product

Table 2.0: Safety Factor Data

Safety is the most important part for all products. The ratio of a structure's absolute strength is
to actual applied load and measure of the reliability of a particular design . Next, we analysed
the safety factor at the frame where the load is applied. The result is shown in the Table 1.0. It
shows the safety factor for our product which the minimum is 4.2245 and the maximum is 15.
This product was applied with load at 156.96 N because our main component is knapsack
sprayer that have 16 litre maximum capacity which means 16 kg. Based on the Figure 1.0, we
found that there are two area affected due to the load applied. This is because when we applied
the load, the frame will hold the knapsack sprayer at the same time fron t tire frame also affected
due to the load. Last but not least, we know that the value of safety factor by using the
simulation is more than one so, our project has a good safety and safe to use.
2.0.3 Theoretical Calculation

FORCE
Force = 16kg x 9.81
= 156.96 N
LENGTH
Length = 0.6868 m
MAGNITUDE
Magnitude = Force x Length
M = 156.96 x 0.6868
= 107.8 Nm

c = d/2
c = 0.0254/2
c = 0.0127

STRESS
𝑀𝑐
𝑆𝑡𝑟𝑒𝑠𝑠, 𝜎 =
𝐼
(107.8)(0.0127)
𝑆𝑡𝑟𝑒𝑠𝑠, 𝜎 =
(1.4445ˉ8 )
Stress, 𝜎 = 94.7774 MPa
 MOMENT OF INERTIA
I = Outer inertia - Inner inertia
I (Outer inertia) = a4/12
= (0.0254)4/12
= 3.4686 -8
I (Inner inertia) = a4/12
= (0.0222)4/12
= 2.0241 -8
I = Outer inertia - Inner inertia
I (Outer inertia) = a4/12
= (0.0254)4/12
= 3.4686 -8
I (Inner inertia) = a4/12
= (0.0222)4/12
= 2.0241 -8
I = 3.4686 -8 - 2.0241-8
I = 1.4445 -8

FACTOR OF SAFETY
Strength of material mild steel = 440 MPa
𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ
𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑠𝑎𝑓𝑒𝑡𝑦 , 𝐹𝑆 =
𝑆𝑡𝑟𝑒𝑠𝑠
440 𝑀𝑃𝑎
𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑠𝑎𝑓𝑒𝑡𝑦 , 𝐹𝑆 =
94.7774 𝑀𝑃𝑎
Factor of safety, FS = 4.642
𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ
For the theoretical calculation to find factor of safety, we use 𝐹𝑆 = formula. Firstly,
𝑆𝑡𝑟𝑒𝑠𝑠

by using this formula we need to find the value of stress and strength. To find the stress, we
𝑀𝑐
used the 𝜎 = formula that obtain the value of Magnitude, M equal to 107.8 Nm, Distance
𝐼

of cross section, c equal to 0.0127 m and Moment of Inertia, I equal to 1.4445 -8. Moreover, the
value of the strength for our material is 440 MPa. After we obtained all the information, we
𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ
calculate it into the 𝐹𝑆 = formula. The result that we gain is 4.642.
𝑆𝑡𝑟𝑒𝑠𝑠
2.0.4 Discussion

Based on the result that already obtained by simulation and calculation, we point out some
difference that we can compare in term of Factor of Safety (F0S). For the simulation, we are
using ANSYS software to calculate it. We applied the load to the cast steel material that have
344 MPa yield strength to the frame. We choose cast steel as the material in the software
because there is no actual material that we used for fabricating which is mild steel that have
yield strength 440 MPa. If you can see the result that we got, the value in ANSYS software is
4.2245. However, for the theoretical calculation, we use mild steel as the material reference to
calculate the safety factor because we use it in the actual process to fabricate our product. The
result that we get is 4.642 so, there is slightly different between simulation and calculation
because the difference of yield strength. Last but not least, after the simulation and calculation
we can conclude that our product is safely to use.

3.0 PROJECT MANAGEMENT

3.0.1 Scope of Work
Scope of work (SOW) defines the activities that must be completed and serves as a measuring
instrument to ensure that the design criteria is met. SOW brings all of the tasks together in
terms of the target to be met in the timeframe allotted when achieving the desired result. SOW
shall include the project target as well as the project goals that will help achieve the goal when
adhering to a standard template. The practices that help the works are accompanied by a
constraint that defines the design's limits or characterizes the design or technique. The template
of the Scope of Work (SOW) is shown below.

Project goals:
To complete the fabrication of “The Effortless Plant Sprayer”
Objective:
• Fabricate all part that involve with this project.
• Do engineering analysis and report writing about the product.
Works:

• Find and buy the selection material to fabricate.

• Calculate the cost that we paid.
• Start fabricating part by part based on drawing that we are planning.
• Cutting, welding, drilling, grinding, and polishing process have been used to complete
the fabrication of the product.
• Find safety factor of the product by using Finite Element Analysis Method.

Limitation:

• To setting knapsack pump with connector pump during installation.

• The movement of the product can only move forward and backward.
• The nozzle only can spray 4 at one time.
• Knapsack sprayer capacity only 16 liters.
• Material selection to use.
Deliverables:

• Perform engineering analysis.

• Project management presentation.
• Project fabrication.
• Prototype pretesting.
• Prototype presentation.
• Technical report.
Milestones

• Engineering analysis has been started.

• Start project to fabricate the product.
• Perform prototype testing
• Ready for presentation and competition.
• Submit technical report and engineering drawing.
Assumption

• The prototype is assumed to be made with safety factor more than 1

 Figure 3.0: Gantt Chart

Refer to Figure 8.4.2, the Gantt Chart is our planning task for this semester so that we can
finished fabricated the project within expected time. This Gantt Chart also represent our
milestone in this project. Total timeframe that given to us is 14 weeks to finish fabricating our
product. The activities that involve in this timeframe is including the fabrication, analysis and
the final report. It is important to have initial planning so that we can be physically and mentally
prepared to face any challenges this semester.
 3.0.3 Work Breakdown Structure

The Effortless Plant Sprayer

Paperwork Product Fabrication Engineering

Drawing

Metal
Cutting Component
Proposal
Drawing

Welding
Assembly
Technical Report Drawing
Drilling

Detail Drawing
Grinding

Assembly
Product

Product
Testing

Figure 3.1: Work Breakdown Structure

Work Breakdown Structure (WBS) is a deliverable project into smaller part or activity in order
to organise the team members into more manageable work. It presents the hierarchical structure
of activities to support the set goal as shown in Figure… The project goal is first established and
the key activities that have the support values to the goal are determined. Work Breakdown is
very significant to ensure each team member performs on the same path. Fo r our product, we
separated the activities into three section which is paperwork, product fabrication and
engineering drawing. All the activities have been listed with some fractional activities to fulfil
the main activities.
3.0.4 Operation Breakdown Structure (OBS)

PROJECT MANAGER:
DR. SHAFIZAL BIN MAT

GROUP LEADER: GROUP MEMBER: GROUP MEMBER:

MUHAMMAD GROUP MEMBER :
MUHAMMAD MUHAMMAD
NAILI FITRI BIN SYAMIL MUNIR MOHAMED
ASYAFIQ BIN SYAHMI BIN SAUPI
MAMAT ASRI BIN AHMAD
ABDULLAH BUKHARI (B041910208)
(B041910207) (B041910214)
(B041910221)

- Fabricate the - Fabricate the project - Fabricate the project - Fabricate the
project project
- Ensure that the -Ensure that the
-Make the list of task project is perfect and project proceeds -Do more research
and distribute to very professionally within the specific about the project that
group members done by following the time frame under the will build and meet
specific design established budget. all the specific
requirements of the
project.

Figure 3.2: Operation Breakdown Structure

Operation Breakdown (OBS) is a structured approach that involves structuring and integrating
team members in order to divide activities and achieve previously established goals. OBS
defines the role and responsibilities of each team member for smooth and clear project
management. In this section, the overall organisational chart is set up with each functional
work. A team leader with quality and responsibility for guiding, instructing, and controlling
the team to achieve the team goal should be part of the organisational structure. In order to
support the group work, the team member shows some effort in committing and getting
involved in the works that are related to the goal of the group project. The structure of an
organisational chart can be shown in figure
4.0 FINANCE ANALYSIS
4.0.1 Material Cost

Component Quantity/Size Operation Cost (RM)

Hollow Bar Mild Steel 6 meters 38
Zinc 1 unit 28
Front Tire 1 unit 47
Bolt and Nut 7 units 3.50
Rear Tire 2 units 72
Shaft (150 mm, length) 1 unit 15
Shaft Joint 1 unit 20
Rear Tire Shaft 1 unit 18
Sprocket and Chain 3 unit 25
Knapsack 1 unit 41.50
Bearing 5 unit 15
Connector Pump 1 unit 10
Gear Pump 1 unit 5
Nozzle 4 unit 12
Nozzle Hose 1 unit 20
Angle Steel 6 meters 45
TOTAL 415
Table 4.1: Material Cost

For the material cost, the cost for each component has been decided. The material cost is
needed to set the budget for the product. This cost is based on the actual material that we have
already bought with the actual price. The cost for knapsack sprayer is RM 41.50 per unit and
RM 25 for sprocket and chain. There are three tires needed in this project and it cost RM
119. The cost for hollow mild steel is RM 38 and it required mild steel angle that cost RM 45.
Next, the cost for a unit ball bearing is RM 15 and it needed five units for these components.
The cost for nozzle and nozzle hose is RM 35. Next, the total cost for 3 units shafts that cost
RM 53. Furthermore, the price for zinc is RM 28 per unit. This zinc we want to use the
cover for the knapsack sprayer. The last components are bolt and nut that cost RM3.50. All
the components can be purchase at the online shop or hardware shop. The cost for the certain
components is expensive if it be purchase at the hardware compare to the cost online shop.
The project is lower than benchmarking. The total estimation cost is RM 415.
4.0.2 Manufacturing Cost

Manufacturing Process Labour Cost (RM)

Welding 50
Grinding 30
Drilling 5
Polishing 15
TOTAL 100
Table 4.2: Manufacturing Cost

After we listed the material cost, we continue to identify the manufacturing cost for every
component. This manufacturing cost is the cost for every process that involve d in our project.
This manufacturing cost also obtained by observing the actual labour cost that involved to
produce this product. The process that been used to create this product is welding, grinding,
drilling and polishing. After we gathered all the cost and process that involved, we finalized
the total of the manufacturing cost is RM 100.

4.0.3 Cost Development

Type of Cost Value (RM)

Material Cost 415

Manufacturing Cost 100
Product Price 650

Table 4.3: Manufacturing Cost

Product Price – (Material Cost + Manufacturing Cost) = Profit

RM 650 – RM515 = RM 135

Percentage of Profit Per Unit = (Profit / Product Price) X 100%

(RM 135 / RM 650) X 100% = 20.77%
As we know, profit is one of the most important point in the production of a product. A good
definition of profit is the reward or return for taking risks & making investments. After that we
calculated the costs that is including the material cost and labour cost. Then, we discussed
among the team members to determine the product price. We determined the product price by
observing the manufacturing cost and at the same time we studied the market price of the
product that have a little bit similarity with our product. After that, we finalized the product
price which is RM650. As the result, the profit is RM 135 by subtract the product price with
material and manufacturing cost. Besides that, we also determined the percentage profit that
we gain if we sell our product per unit. Based on the profit that we obtained, we think the
product price is reasonable and affordable.

5.0 CONCLUSION
From this analysis, we can conclude that by making this analysis is important to choose the
best material and components that meet our customer requirement. The engineering analysis
also important to meet the best safety factor to make sure the product is safely to use. Besides
that, the management and the teamwork among the team members are important to achieve the
objective of this project in each time. We also know how to handle the time management and
design process to produce a better design for our project. Lastly, by doing all the analysis and
process we have successfully identified the result to make the improvement for our project. So,
our project will become more efficient to be commercial.