FACULTY OF MECHANICAL ENGINEERING

UNIVERSITI TEKNOLOGI MARA (UiTM), SHAH ALAM

BACHELOR OF ENGINEERING (HONS) MECHANICAL (EM220)

EMD5M9A

MANUFACTURING PROCESSES
MEM 560

INDIVIDUAL ASSIGNMENT
PRODUCT : PORTABLE VACUUM CLEANER

PREPARED FOR :
(IR. DR.) WAN EMRI WAN ABDUL RAHAMAN

PREPARED BY:
Name : NURUL AMIRA BINTI CHE AZIZAN
Student ID : 2019725287
Group : EMD5M9A

SUBMISSION DATE:
1st JULY 2020
 FACULTY OF MECHANICAL ENGINEERING,
UNIVERSITI TEKNOLOGI MARA (UiTM)
INDIVIDUAL ASSIGNMENT

Program : Bachelor of Engineering (Hons) Mechanical (EM220)

Course : Manufacturing Processes

Course Code : MEM560

Lecturer’s Name : (IR. DR.) WAN EMRI WAN ABDUL RAHAMAN

Group : EMD5M9A

Student’s Name : NURUL AMIRA BINTI CHE AZIZAN

General Guidelines:

Scale 1 2 3 4 5
Level Very poor Poor Acceptable Good Excellent

Level Marks
Criteria Scale
Achieved Obtained
Qualifying requirements:
Cover - Acceptable? * Yes / No
References - Acceptable? * Yes / No
Turn-it-in Report - Acceptable? * Yes / No
Demonstrates understanding / knowledge of discussed
2
area.
CO3 Writes and observes with good comprehension. 1
Communicates clearly in a well-organized manner. 1
Total Marks (20%)
 TABLE CONTENT

No Content Pages

1 1.0 Introduction to product 1-2

2 2.0 Objective 2

3 3.0 Findings 3

3.1 Materials

3.2 Manufacturing process 4-7

3.3 Material joining process 8 - 10

3.4 Material defects 10 - 12

4 4.0 Recommendation 12 - 13

5 5.0 References 13
1.0 INTRODUCTION TO PRODUCT

Vacuum cleaner can be simply known as vacuum. Vacuum is a mechanical device that uses of
suction in order to remove dust or debris from the floors, draperies, upholstery, and other surfaces. It
is generally electrically driven and some of it battery powered. There are many types of vacuum
cleaner. Different types of vacuum cleaner can used for different functions.

Table 1.0: Type of vacuums

No Types Explanations

1 Upright vacuum
Upright vacuum cleaner is suitable for large, carpeted areas of the
house. This type of vacuum is generally electrically driven. It used
motor-driven beater brush that loosens and removes dirt through
suction. Mostly, upright vacuums come with on-board attachments for
versatile use. Some are bag-less design while others have bags to
capture or collect dust and debris. This type of vacuum have features
that include height adjustments for easy transition from dense carpet
cleaning to hardwood floors with the flip of a switch. Upright vacuums
tend to be the best use for hardwood floors and carpet.

2 Hand-held vacuum
Hand-held vacuums are portable and cordless make it ideal for
cleaning small areas. This vacuums are typically battery powered that
make it portable and handy for cleaning. These are perfect for
cleaning up after pets, children and also for vehicles such as cars.
Hand-held vacuums are lightweight, quiet and easy to use.

3 Sweeper or stick Stick or sweeper vacuum is combination or middle ground between

vacuum hand-held and upright vacuum. This type of vacuum quite light in
weight and battery powered. This vacuum offered convenience of
hand-held but feature upright construction of a traditional vacuum.
Most of this type of vacuum have dirt cup or container as the opposed
to bags to collect debris.

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4 Robotic vacuum Robotic vacuums represent the latest invention in vacuum technology.
This type of vacuums can be simply set up including the sensor
boundaries and the settings. Robotic vacuums are cordless and
compact. Usually to vacuum the carpet or floor we have to move the
vacuum but these kind of vacuums can move by itself and clean with
precision while saving your time. Robotic vacuums not as powerful or
versatile as traditional vacuums, but the constant cleaning action offers
ease and convenience to the users.

2.0 OBJECTIVE OF THE INDIVIDUAL ASSIGNMENT

1. To get real knowledge involving the industry.

2. To get the relation or the difference between theoretical and practical knowledge.
3. To expose the students to the real working situation.
4. To enhance the current skill and knowledge from what students have learned.
5. To expose student to many manufacturing process that have been used now a day.
6. To expose student to many precaution that involving manufacturing process such as type of
defects and way to reduce or to prevent it.

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3.0 FINDINGS
3.1 MATERIALS

Figure 1: Portable vacuum parts

Table 2: Materials and properties of vacuum parts

No Part Material Properties
1 Dust cup  Excellent impact, chemical
and abrasion resistance
2 Handle  Superior stiffness and strength
 Easily machined and
3 Filter holder thermoformed
 Easy to paint and glue
4 Main body Acrylonitrile butadiene styrene  Good dimensional stability
 Excellent electrical properties
5 Power switch button

6 Suction nozzles

7 Dust storehouse button

8 HEPA filter Borosilicate glass fibers or  Very good filtration
plastic fibers ( polypropylene)

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 3.2 MANUFACTURING PROCESS

All things will undergoes manufacturing process including portable vacuum which process or steps
that will go through by the raw materials that will be transformed into a final product. Including
portable vacuum, each parts of the vacuum initially a raw material that facing different type of
manufacturing process to develop each of the parts.
Almost all type of materials can undergoes manufacturing process including metal, plastic, wood,
food and many more. Manufacturing process is a complex activity involving variety of resources and
activities such as product design, machinery and tooling, process and planning, production control
and many more. Hence, below is the type of forming process of the vacuum parts.

Table 3: Process that undergoes by certain body part of portable vacuum

Parts Process Explanation

Suction nozzle Extrusion process

 Extrusion process is a metal forming

process which forcing the raw material to flow
through a die to reduce its cross section or convert
it into desire shape. This process is usually or
extensively used in pipes and steel rods
manufacturing. This process is similar to drawing
process but the drawing process uses tensile stress
to extend the metal work piece.
 Common raw materials that used are thermoplastic
pallets, granules or powder. This raw materials
will feed into the hopper and will be heated using
heaters that helps to melt the materials. Then the
materials is compressed and blend using rotating
screw.

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  After that, the molten material flow through the
breaker plate and then through the die. The
extruded material will follow the shape of the die.
Dust cup
Injection moulding

Main body

 Injection molding is a method to obtain molded

products by injecting plastic materials molten by
heat into a mold, and then cooling and solidifying
Handle them. This process is suitable for the mass
production of products with complicated shapes,
and takes a large part in the area of plastic
processing.
 Injection molding machine is divided into 2 units
which are clamping unit and an injection unit. At
clamping section, there are two type of clamping
unit that usually used which are toggle-type and
straight-hydraulic type. The clamp mold opened
and closed using hydraulic cylinder.
 At the injection unit, the material molted by heat
and then to inject molten plastic into mold. After
the required amount of molten plastic is
accumulated, injection process is started. While
molten plastic is flowing in a mold, the machine
controls the moving speed of the screw, or
injection speed. On the other hand, it controls well
pressure after molten plastic fills out cavities.
 The position of change from speed control to
pressure control is set at the point where either
screw position or injection pressure reaches a

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 certain fixed value.

Power switch button

Compression
molding

 An old and widely used for thermosetting plastics.

Moulding compound available in several forms
such as powders or pellets. By using this method,
the amount of charge must be precisely controlled
to obtain repeatable consistency in the molded
product.
 The step of this method including to place or
loaded the powders that known as charge into the
mold cavity at the lower mold half.
 Then, the upper mold half will punch the lower
mold half. The punched material will follow the
shape of the mold cavity. Next, the molded part
will be ejected and removed.

Advantages of manufacturing process;

Extrusion moulding
 Continuous process can produce lengths of up to 60 feet
 Consistent cross-section results in the production of complex shapes
 High production volumes
 Low cost per pound of materials used
 Good for producing tube-shaped products such as pipes and hoses
Injection moulding

 High production rates and shorter production cycles (results in lower per unit cost)
 Allows for close tolerances in small intricate parts
 Requires little post-production work because parts have a finished look upon ejection
 Full automation is possible, which leads to reduced production costs

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Compression molding

 Lower cost Tooling

The tooling has less infrastructure requirements than tools designed for other moulding methods.
There is little else needed in the way of additional features, other than the particular features of
the cavity itself that will produce the moulded parts, which clearly have to replicate the detail
required of the product. Tools can be made of aluminium or lower cost grades of steel which can
reduce costs, although any tool must be capable of withstanding the considerable moulding
pressures required.
 Good for small production runs
The lower capital cost of manufacturing a mould tool, setting up a press and beginning to run
production parts means that Compression moulding is the most cost effective method of making
smaller runs of parts. There is of course a breakeven point at which the higher capital cost of an
injection mould tool becomes viable due to the lower cost of the parts that it makes. Correct
assessment of the cost / benefit point is a key consideration when developing the best production
solution for a new product.
 No gates, sprues or runners
This form of moulding does not use gates, sprues or runners which are tooling features that
materials have to pass through in other methods of production before entering the mould cavity.
These can consume extra material and therefore cost and can also detract from the cosmetic
requirements of a part.
 Good for large parts
This form of moulding is best suited to producing large parts that require a significant bulk of
material to manufacture. Given that the material is directly loaded into the mould cavity, there is
no limitation on the weight of part that can be made, other than the size of press and tonnage
required, whereas Injection moulding presses are limited in the weight of part they can produce
by the volume of the injection barrel that fills the mould
 Little waste is lost during the molding process.

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 3.3 MATERIAL JOINING PROCESS

Joining processes are typically divided into three categories: mechanical joining, welding, and
adhesive bonding. Mechanical joining is a process for joining parts through clamping or fastening
using screws, bolts or rivets. Advantages of mechanical joining include versatility, ease of use, and
the option to dismantle the product in cases where regular maintenance requires it. The ability to join
dissimilar materials is another benefit. A drawback of using mechanical joining is the lack of a
continuous connection between parts, because the joint is achieved through discrete points. Also,
holes created for joining are vulnerable to fractures and corrosion.

Table 4: Type of joining used by portable vacuum

Joining types Example Explanation

Screw
1. TPLAST30 ROUND SHANK
THREAD FORMING SCREWS

 Coarse, sharply angled threads with

round shank are used in plastics
such as polypropylene,
polycarbonate, acetal, polystyrene,
and ABS to provide maximum
holding strength with minimal
stress. These high performance
plastic screws are compatible with
PT and Delta PT type screws.

 These screws are best suited for soft

plastics with thin bosses. Thread
profile is 30º with expanded thread
pitch.

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 2. TPLAST60 TAPPING THREAD
ROUND SHANK TYPE B
SCREWS

 Round shank, coarse spiral threads,

and blunt tip facilitate use in
plastics such as polypropylene and
non ferrous castings. These plastic
screws have reduced tip for easy
entry.

 Also called thread forming screws,

these are commonly used in both
soft and hard plastics. Thread
profile is 60º with medium thread
pitch. They are generally used with
plastics having a modulus smaller
than 3000 MPa.

Snap joint

 A snap-fit is an assembly method used

to attach flexible parts, usually plastic,
to form the final product by pushing
the parts' interlocking components
together.

Soldering  Soldering is a process in which two or

more items are joined together by

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 melting and putting a filler
metal (solder) usually alloys of tin
(Tn) and lead (Pb) into the joint. The
filler metal having a lower melting
point which below 450°C (800°F)
 After the filler metal cools, the
resulting joint are not as strong as the
base metal but have adequate strength,
electrical conductivity and
water-tightness for many uses.

3.4 MATERIAL DEFECTS

Defects in manufacturing can gives many problems that will be facing by the consumer and can lead
to injuries. A well-designed product can still harm consumers. Defects in manufacturing occur when
a product is improperly manufactured and departs from its intended design. A defect in
manufacturing is one that the manufacturer did not intend. Below is type of defects that may be
facing in manufacturing process.

Table 5: Defects in injection moulding process

Defects Explanations
Flash  The occurrence of molten material seeping
out of the mold cavity and solidifying. Once
the part is ejected, a thin layer of material
will have formed attached to the part along
the parting line.
 Causes:
i. Injection pressure too high
ii. Clamp force too low
iii. Parting line mismatch or mold damage
 Prevention:
i. Use a press with higher clamp force.

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 ii. Clean mold surfaces and behind slides and
inspect cavity for any obstruction to proper
clamping. Also check for a clamp
misalignment, tool damage, uneven tiebar
stretch, or improper machine leveling. Use
pressure-sensitive paper to check pressure on
parting line in flash area and non flash area
while the tool is in the press.
Bubbles  Trapped gas, which includes air, moisture
vapor, volatiles from the resin, or
decomposition gases from the polymer or
additives.
 Causes:
i. Injection temperature too high
ii. Too much moisture in material
iii. Non-uniform cooling rate
 Prevention:
i. Increase backpressure or make the melt
tempereture low.
ii. Increase the intensity of the drying
process
iii. Decrease the speed of the screw or the
injection pressure
iv. Make the air vent larger to improve the
exhaust effect
v. Decrease the size of gate or change the
shape of gate
Sink marks  When molten material is injected into a
mold, voids can occur if certain sections
solidify first, caused by a low injection
pressure or non-uniform wall thickness. The
remaining material will fill these voids as it
continues to cool and shrink. This shrinkage

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 causes marks on the part where the material
sunk into the void.
 Causes:
i. Injection pressure too low
ii. Non-uniform cooling rate
 Prevention:
i. Increase the hold time in which the part is
under injection pressure.
ii. Increase the injection pressure to force more
material into the mold and reduce shrinkage.
iii. Modify the geometry to place the features
causing sink marks in areas where they have
less impact on the design.
iv. Reduce the injection temperature of the
material and the mold.

4.0 RECOMMENDATION

Nowadays, there are many different types of technology produced by the manufacturer. The

capabilities of a technology are measured by consumers through their satisfaction with the

technology. Therefore, the manufactured goods must satisfy the consumer. If the product does not

meet the consumer's demand, the desire to the technology will decrease and the manufacturer will

likely suffer high losses. To always be able to satisfy the consumer, the manufacturer must always

create something that will satisfy them over time such as creating something that can ease consumer

life and day such as saving time, money, space and energy.

Portable vacuum is one of technology that created by the manufacturer to help people to

cleaning their house. Even though the portable vacuum meet the customer’s demand but there are

few things that can be done to improve the portable vacuum. Based on the previous brand which is

RUNDONG (R-6053) Portable Vacuum Cleaner, this vacuum have many advantages which using

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HEPA filter, for dry and wet use, light in weight and also easy to handle but the capacity of the

battery is not good enough. The battery only can withstand for a hour but consume more hours to

fully recharge it.

Lastly, the manufacturer of this company must also improvise their product in term of the

suction power. Even though this model has it own advantages but during the cleaning process, the

suction power of this model become decrease and losing it power to collect the dust when the filter

has many dust on it, so the manufacturer must improvise their product by increase the suction power

of their model. Hence, the manufacturer must improve the weakness of their product to make

consumers become more satisfy with their product.

5.0 REFERENCES
1. “Vacuum Cleaner” Retrieved from: https://en.wikipedia.org/wiki/Vacuum_cleaner ( Access: 10
June 2020)
2. “Extrusion Process” Retrieved from:
https://paulmurphyplastics.com/2019/09/25/extrusion-process-working-types-application-advant
ages-and-disadvantages/#:~:text=Extrusion%20is%20a%20metal%20forming,piece%20is%20c
ompressive%20in%20nature. ( Access: 10 June 2020)
3. “Injection Moulding” Retrieved from:
https://www.polyplastics.com/en/support/mold/outline/#:~:text=Injection%20molding%20is%20
a%20method,the%20area%20of%20plastic%20processing. ( Access: 26 June 2020)
4. “Compression Moulding” Retrieved from: https://en.wikipedia.org/wiki/Compression_molding
( Access: 18 June 2020)
5. “Screw For Plastic” Retrieved from: http://www.eisennet.com/f/Screws-For-Plastic.html
( Access: 19 June 2020)
6. “Snap-fit” Retrieved from: https://en.wikipedia.org/wiki/Snap-fit ( Access: 24 June 2020)
7. “Electronics Primer: How to Solder Electronic Components” Retrieved from:
https://www.sciencebuddies.org/science-fair-projects/references/how-to-solder#:~:text=Solderin
g%20is%20a%20process%20in,permanent%20connection%20between%20electronic%20comp
onents. ( Access: 24 June 2020)
8. “Injection Moulding” Retrieved from: https://www.custompartnet.com/wu/InjectionMolding
( Access: 25 June 2020)

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