IDP Report - Jig and Fixture With Adjustable Angle

BMFU 3223 | 2020 | Doc No.
R-011 | Examiner
FAKULTI KEJURUTERAAN PEMBUATAN

INTEGRATED DESIGN PROJECT (BMFU 3223)
REPORT EVALUATION FORM FOR EXAMINER
PROJECT TITLE: JIG AND FIXTURE WITH ADJUSTABLE ANGLE
SUPERVISOR: EN. NOR AKRAMIN BIN MOHAMAD
No Student Name Matric no.
1. EUNICE NG XIN HUI B051820035

2. SITI ZUBAIZAH BT AHMAD B051820066
3. MAHMUD NABIL B MOHAMAD HASANNUDDIN B051820054
4. MOHAMAD ASHRAFIEL PUTRA B JAAFAR B051820055
5. NURUL AINA HAZIERA BT NAZARUDIN B051820079
PLEASE CIRCLE THE SCORE FOR EACH EVALUTION CRITERIA

Comments
Problem/Scenario Clarification (LO1) (WP1) SCORE WEIGHTAGE
/Remarks
To solve the problem require in depth understanding of engineering knowledge.
This problem is infrequently encountered where there is no immediate solution in
the market. 5
Problem/issue has been very clearly explained and can be solved.
Market and customer has been clearly identified.
To solve the problem requires good depth understanding of engineering
knowledge.
The problem is somewhat infrequent encountered where there is no immediate
4
solution in the market.
Problem/issue has been well explained and can be possibly solved.
Market and customer quite clearly identified
Meet the requirements of the understanding depth for engineering knowledge.
The problem is frequently encountered where there is a possible solution
available in the market. 4
3
The problem/issue is given, but could be better written.
Market and customer has been possibly identified.
To solve the problem requires moderate depth understanding of engineering

knowledge.
The problem provided is not a real issue. 2
There is a product available in the market that can solve the stated problem.
Not a clear problem/issue to be solved.
Minimum depth of engineering knowledge is required to solve the problem
The problem provided is not an issue.
1
Plenty of product is available in the market can solve the stated problem.
Not a clear problem/issue to be solved.
Absent of Problem scenario. 0
Objectives & Scopes (LO1)
BMFU 3223 | 2020 | Doc No. R-011 | Examiner
Excellent – Objectives and scopes are very clear and informative. 5

Good - Objectives and scopes are clear. 4
Satisfactory- Meet the requirements for objectives 3
1
Poor – Objectives are poorly written. 2
Very poor- Objectives are not relevant. 1
Absent of objectives and scopes. 0
Product Description (LO1) (EA2)
Students have shown high creativity/innovation for the proposed product.
Excellent ideas have been provided. 5
Very clear and detail functionality of the proposed product.
Students have shown creativity/innovation for the proposed product.
Good ideas have been provided. 4
Clear and detail functionality of the proposed product.
Students have meet the creativity/innovation for the proposed product.
Moderate ideas have been provided. 3
The product description is given, but could be better written. 2
Students have meet below average creativity/innovation requirements for the
proposed product.
2
Ideas provided are below average.
The product description is given, but lost some information.
Poor creativity/innovation for the proposed product.
Poor ideas have been provided. 1
Poor Product description.
Absent of product description. 0
Product Analysis (LO3) (WP3)
Students have performed outstanding all FIVE given engineering design analysis
5
(stress/material/ergonomics/optimization/costing)
Students have performed a good given engineering design analysis
(stress/material/ergonomics/optimization/costing) OR only done FOUR design 4
analysis
Students have meet the requirements for engineering design analysis OR
analyses only THREE design analysis 3 4
(stress/material/ergonomics/optimization/costing)
Students poorly performed the engineering design analysis OR only TWO design
2
analysis (stress/material/ergonomics/optimization/costing)
Students very poorly performed the engineering design analysis OR only ONE
1
design analysis (stress/material/ergonomics/optimization/costing)
Absent of product analysis. 0
Process Planning and description (LO5)(EA1)
Involve at least FIVE manufacturing processes to fabricate the product.
Students have provided details of manufacturing process flow. 5
In depth details of complete Gantt Chart.
Involve FOUR manufacturing processes to fabricate the product OR
Students have provided details of manufacturing process flow OR 4
In depth details of complete Gantt Chart.
Involve THREE manufacturing processes to fabricate the product OR
Students have provided the list of manufacturing process flow OR 3
4
Complete Gantt Chart is shown, but no explanation.
Involve TWO manufacturing processes to fabricate the product OR
Students have provided the list of manufacturing process flow. 2
Complete Gantt Chart is shown, but no explanation.
Only ONE manufacturing process to fabricate the product OR
Missing some of the details/list of manufacturing process flow. 1
Only simple Gantt Chart has been provided.
Absent of process planning and description. 0
Cost Analysis (LO5) (WP3)
Students correctly calculate:

Variable and fixed cost of the product.
5
Prototype and manufacturing costs.
The cost benefit analysis/return of investment.
The costing formula/technique is correct but there is 1-2 mistake in the
identification of the cost elements/assumption. 4
1-2 cost type not included
Students meet the minimum requirements in costing.
The technique used is correct but more than 2 mistakes found in the identification 3 4
of the cost elements/assumption.
Students have consider some of the costing elements, but approach is wrong. 2
Some costing calculation are shown but cannot be understand.
1
WRONG calculation.
Absent of cost analysis.
0
Sustainability/Environment/ Safety Consideration (LO3) (WP2)

Students have considered three elements of sustainability that are economy,
society and environment in their project. 5
Detail explanation has been provided for each element.
Students have considered three elements of sustainability that are economy,
society and environment in their project. 4
BUT simple explanation has been given for each element.
Students only consider any two elements of the sustainability. 4
3
Moderate details have been provided on the selected elements.
Students only consider any two elements of the sustainability.
2
BUT simple explanation has been given for each element.
Students only consider one element of sustainability.
1
Poor details have been provided on the selected elements.
Absent of sustainability/environment/safety consideration. 0
Conclusion (LO1)
Clear and complete summary of all THREE the project objectives.
5
Clear and realistic recommendations and limitations.
Complete summary of all THREE the project objectives but not clear in detail. 4
Meet TWO project objectives. Acceptable recommendations and limitations. 3
Meet TWO project objectives. Not clear and realistic recommendations and 1
2
limitations.
Meet ONE project objective. Limited summarization of the project achievements.
1
No recommendations and limitations.
Absent of conclusion 0
Drawings (LO2) (WP2)
Excellent – Detail drawing with top, side and front view complete with dimension.
5
Exploded, details, assembly view and BOM.
Missing ONE of the above drawing requirements. 4
Missing TWO of the above drawing requirements. 3 2
Missing THREE of the above drawing requirements. 2
Missing more than FOUR of the above drawing requirements. 1
Absent of drawings 0
Engineering and IT tools (LO2)(EA1)
Students intensively applied computer aided engineering tools/simulation
5
software. 2
Students applied computer aided engineering tools/simulation software. 4
Students MEET THE REQUIREMENTS in applying computer aided engineering

3
tools/simulation software.
Students minimally applied computer aided engineering tools/simulation
2
software.
Students very minimum applied computer aided engineering tools/simulation
1
software.
Overall Comments:
__________________________________________________________________________________
__________________________________________________________________________________
Evaluate by:
Signature :
Name : ________________________________
Date : ________________________________
FACULTY OF
MANUFACTURING ENGINEEERING
BMFU 3223- INTEGRATED DESIGN PROJECT
SEMESTER/ YEAR: I / 2020/2021
GROUP 8 IDP FINAL REPORT- JIG AND FIXTURE WITH ADJUSTABLE

ANGLE
NAME MATRIX # SECTION
EUNICE NG XIN HUI B051820035 4
SITI ZUBAIZAH BT AHMAD B051820066 4
MAHMUD NABIL B MOHAMAD B051820054 4

HASANNUDDIN
MOHAMAD ASHRAFIEL PUTRA B B051820055 4
JAAFAR
NURUL AINA HAZIERA BT B051820079 4
NAZARUDIN
GROUP SUPERVISOR: EN. NOR AKRAMIN BIN MOHAMAD

ACKNOWLEDGEMENT
The project is like a bridge between theoretical and practical work. That the reason why
we need to participate in this project. First of all, we would like to thank the Almighty God that
guided us to work the right path of life. Without his grace, this report cannot be done. We also
want to express our special gratitude to our supervisor Nor Akramin Bin Mohamad for his
guidance, comments and suggestions along this semester on the product and report. We also
would like to thank Dr Mohamad Kamil Bin Sued to guide us the way to complete the IDP
report. We want to thanks to our parents who mentally, physically and financially support us
for the whole semester. Without them, it will be hard for us to finish the report on time. Lastly,
we would like to thanks to the respondents for the willingness to spend their time with us to
fill the questions for the survey of this project.
i
ABSTRACT
Integrated Design Project (IDP) is an important subject of higher education degrees

which helps to consolidate students' learning by providing an opportunity for applying a broad
range of knowledge to a real-life problem while developing other useful skills. Students work
near to their assigned supervisors who guide them on a learning path during their project work.
This is the continuation subject from last semester Product Design and Manufacturing (PDM)
subject, thus students have to produce a soft prototype product using CAD software. The first
part of this report contains the introduction of the jig and fixture with adjustable angle which
includes the background, aim, scope, problem statement and objective. The design was chosen
(design F) is drawn in 3D at the SolidWorks software to give the full detail of the product.
After the design is chosen, the team have carried out the material and process selection of the
design F by suing CES Edupack software. The result material analysis for two main product
which is jaw and adjustable angle plate is attached in this report. The material for the jaw piece
is cast iron and adjustable angle plate is low alloy steel. The process needed to manufacture
design F is listed out with details. DMFA is also carried out as it is important in product design.
It can minimize the cost and time consuming during the assembly process. After the DMFA,
the cost and time for assembly of design F are RN0.54 and 54.57s respectively. Besides, in this
report, design for environment (DfE) and its tools such as life cycle thinking, eco-design web,
eco- indicator and sustainability report is used to analyze the jig and fixture with adjustable
angle. Life cycle thinking is a systematic framework which evaluates how a consuming product
brings impacts on the environment through the entire product life cycle. The product life cycle
of the material and product and the eco-design web is sketched based on the 5 different types
of material which is as cast iron, mild steel, carbon steel, high tensile steel and die steel. From
the eco indicator, it shows that the total indicator for design F is 23693.92. From the
sustainability report, it mentioned that for design F, there is 22% material able to recycle, 6.1%
material is incinerated, and 72% material ends up in the landfill. Next, a study in mechanical
analysis is being made. The study on the mechanical engineering analysis using SolidWorks
ii
simulation shows the stress, strain and factor of safety of the material. The result for the jaw,
adjustable angle plate and handle is attached in this report. The jaw has lower value of stress
(maximum 5.67e+06 N/m2, minimum 4041e+01N/m2), strain (maximum 5.677e-05 N/m2,
minimum 4.11e-10 N/m2), and higher value of factor of safety (maximum 1.130e+07,
minimum 9.233e+01). Besides, the adjustable angle plate has lower value of stress (maximum
5.347e+04 N/m2, minimum 6.333e+01 N/m2), strain (maximum 1.796e-07 N/m2, minimum
4.731e-12 N/m2), and higher value of factor of safety (maximum 9.719e+08, minimum
1.16e+04).The handle has lower value of stress (maximum 1.015e+05 N/m2, minimum 2.117e-
06 N/m2), strain (maximum 4.782e-07 N/m2, minimum 1.309e-17 N/m2), and higher value
of factor of safety (maximum 2.931e+14 , minimum 6.113e-03). The cost analysis is taking
part to determine the estimated price of the jig and fixture with adjustable angle and the profit
gain. After the analysis, it found that the product selling price is RM660.30 with a profit of
30%. Although the price of the jig and fixture with adjustable angle is slightly higher compare
to the current product but it consists of more features and more environmentally friendly. The
study of human analysis or ergonomic is analyzed based on the tool in Catia Software which
the jig and fixture with adjustable angle plate get the score of 3 for the RULA analysis. For
push-pull analysis, 331.89N force is required to push and 269.547N for is required to pull
during the usage of the jig and fixture with adjustable angle plate. Lastly, a product comparison
between the two concepts is carried out based on the analysis taken part. The team has chosen
the design product which obtains second place (design D) in the screening and scoring step to
perform the comparison. The comparison is carried out based on the analysis such as features,
material selection, DMFA, product sustainability analysis, mechanical analysis, cost analysis
and ergonomic analysis. After the comparison, the team has chosen design F as the final
product although the design F is slightly less ergonomic and the better material for angle plate
compare to the design D, design F which have more advantages is better. Design F has more
features which cause high accuracy and production rate, less assembly cost and time, more
sustainable and high mechanical properties.
iii
TABLE OF CONTENT
ACKNOWLEDGEMENT .......................................................................................................... i
ABSTRACT...............................................................................................................................ii
TABLE OF CONTENT ............................................................................................................ iv
LIST OF FIGURES .................................................................................................................. ix
LIST OF TABLES ...................................................................................................................xii
CHAPTER 1 INTRODUCTION ............................................................................................... 1
1.0 Overview ..................................................................................................................... 1
1.1 Background ................................................................................................................. 1
1.2 Aim .............................................................................................................................. 2
1.3 Scope ........................................................................................................................... 3
1.4 Problem Statement ...................................................................................................... 4
1.5 Objectives .................................................................................................................... 5
1.6 Report Explanation ...................................................................................................... 5
CHAPTER 2 PRODUCT DESCRIPTION-DESIGN F ............................................................ 7
2.0 Overview ..................................................................................................................... 7
2.1 Jig and Fixture with Adjustable Angle- Working Mechanism ................................... 7
2.2 Part Description ........................................................................................................... 9
2.3 Exploded View Jig and Fixture with Adjustable Angle............................................ 19
2.4 3D CAD for Jig and Fixture with Adjustable Angle ................................................. 20
2.5 2D CAD for Jig and Fixture with Adjustable Angle................................................. 21
2.6 Parts Limitations ....................................................................................................... 22
CHAPTER 3 PRODUCT ANALYSIS-DESIGN D ................................................................ 24
3.0 Overview ................................................................................................................... 24
3.1 Material Selection ..................................................................................................... 24
3.1.1 Material Selection Process ................................................................................. 24
3.1.1.1 Material Selection Jaw Piece ...................................................................... 25
3.1.1.2 Material selection Adjustable Angle Plate ................................................. 28
3.2 DMFA ....................................................................................................................... 31
3.3 Product Sustainability Analysis ................................................................................ 33
3.3.1 Product Life Cycle ............................................................................................. 33
3.3.2 Eco Design Web ................................................................................................ 35
3.3.3 Eco Indicator ...................................................................................................... 41
3.3.3.1 Process Tree ................................................................................................ 41
3.3.3.2 Eco Indicator Table .................................................................................... 42
iv
3.3.4 Sustainability Report.......................................................................................... 43
3.4 Mechanical Analysis ................................................................................................. 49
3.4.1 Static and Strength of Material....................................................................... 49
3.4.1.1 FBD for Jig and Fixture with Adjustable Angle (During Machining
Process) 49
3.4.1.1.1 Calculation Structural Analysis (Compression Force) ............................ 50
3.4.1.1.2 Calculation of Stress ................................................................................ 51
3.4.1.1.3 Calculation Normal Stress and Shear Stress............................................ 51
3.4.1.2 FBD During Machining Process on Angle Plate-Design F ........................ 52
3.4.1.2.1 Calculation Structural Analysis ............................................................... 52
3.4.1.2.2 Calculation of Stress ................................................................................ 52
3.4.1.2.3 Calculation Normal Stress and Shear Stress............................................ 53
3.4.1.3 Calculation Factor of Safety ....................................................................... 54
3.4.2 Simulation Analysis ....................................................................................... 54
3.4.2.1 Part 1 (Jaws) ............................................................................................... 54
3.4.2.1.1 Study Result ......................................................................................... 57
3.4.2.2 Part 2 (Adjustable Angle Plate) .................................................................. 60
3.4.2.2.1 Study Result ......................................................................................... 61
3.4.2.3 Part 3 (Handle)............................................................................................ 64
3.4.2.3.1 Study Result ......................................................................................... 65
3.4.3 Heat Flow Analysis ........................................................................................ 68
3.5 Cost Analysis............................................................................................................. 68
3.5.1 Bill of Material (BOM) .................................................................................. 68
3.5.1.1 Estimation Cost........................................................................................... 69
3.5.1.1.1 Material Cost ........................................................................................... 69
3.5.1.1.2 Labor Cost ............................................................................................... 69
3.5.1.1.3 Fixed Cost (Overhead Manufacturing Cost) ........................................... 70
3.5.1.1.4 Total Manufacturing Cost ........................................................................ 70
3.5.1.1.5 Break-Even Point Analysis ...................................................................... 71
3.5.1.1.6 Return of Investment (ROI) ..................................................................... 71
3.6 Ergonomic Analysis .................................................................................................. 72
CHAPTER 4 PRODUCT ENHANCEMENT- DESIGN D .................................................... 77
4.0 Overview ................................................................................................................... 77
4.1 Design Drawing......................................................................................................... 77
4.1.1 Part Description ................................................................................................. 77
4.1.2 Exploded View for Design D ............................................................................. 78
4.1.3 3D CAD for Design D ....................................................................................... 79
v
4.1.4 2D CAD for Design D ....................................................................................... 80
4.2 Material Selection and Analysis................................................................................ 81
4.2.1 Material Selection Jaw Piece- Design D ............................................................ 81
4.2.2 Material Selection Adjustable Angle Plate- Design D ...................................... 85
4.3 DMFA ....................................................................................................................... 87
4.4 Product Sustainability Analysis ................................................................................ 89
4.4.1 Product Life Cycle ............................................................................................. 89
4.4.2 Eco-Design Web ................................................................................................ 90
4.4.3 Eco Indicator ...................................................................................................... 96
4.4.4 Sustainability Report.......................................................................................... 98
4.5 Mechanical Analysis ............................................................................................... 105
4.5.1 Static and Strength of Material-Design D ........................................................ 105
4.5.1.1 FBD During Machining Process on Workpiece-Design D ...................... 105
4.5.1.1.1 Calculation Structural Analysis (Compression Force) .......................... 106
4.5.1.1.2 Calculation of Stress .............................................................................. 107
4.5.1.1.3 Calculation Normal Stress and Shear Stress.......................................... 107
4.5.1.2 FBD During Machining Process on Angle Plate-Design D ..................... 108
4.5.1.2.1 Calculation Structural Analysis ............................................................. 108
4.5.1.2.2 Calculation of Stress .............................................................................. 109
4.5.1.2.3 Calculation Normal Stress and Shear Stress.......................................... 110
5.5.1.3 Calculation Factor of Safety .................................................................... 111
4.5.2 Simulation Analysis ......................................................................................... 111
4.5.2.1 Jaw Piece .................................................................................................. 111
4.5.2.1.1 Study Result ....................................................................................... 113
4.5.2.2 Adjustable Angle Plate ............................................................................. 116
4.5.2.2.1 Study Result........................................................................................... 119
4.5.2.3 Handle ....................................................................................................... 121
4.5.2.3.1 Study Result........................................................................................... 123
4.5.3 Heat Flow Analysis .......................................................................................... 125
4.6 Cost Analysis........................................................................................................... 125
4.6.1 Bill of Material (BOM) .................................................................................... 125
4.6.2 Estimation Cost ................................................................................................ 126
4.6.2.1 Material Cost ............................................................................................ 126
4.6.2.2 Labour Cost .............................................................................................. 126
4.6.2.3 Fixed Cost (Overhead Manufacturing Cost) ............................................ 126
4.6.2.4 Total Manufacturing Cost ......................................................................... 127
4.6.2.5 Break-Even Analysis ................................................................................ 127
vi
4.6.2.6 Return of Investment (ROI) ...................................................................... 128
4.7 Human Factor Engineering Analysis ...................................................................... 129
4.8 Comparison Between Design F and Design D ........................................................ 135
CHAPTER 5 PROCESS PLANNING................................................................................... 141
5.0 Overview ................................................................................................................. 141
5.1 Process Selection ..................................................................................................... 141
5.1.1 Machining Process ........................................................................................... 141
5.1.2 Welding ............................................................................................................ 142
5.1.3 Non-Conventional Manufacturing Processes .................................................. 143
5.1.3.1 Laser Cut................................................................................................... 143
5.2 Manufacturing Process Involved in Parts................................................................ 144
5.3 Gantt Chart for Manufacturing Process .................................................................. 149
CHAPTER 6 CONCLUSION................................................................................................ 152
6.1 Suggestion .............................................................................................................. 153
REFERENCES ...................................................................................................................... 155
Appendix ................................................................................................................................ 156
Appendix A- 2D drawing for components......................................................................... 156
A1- Main Base - Design F ............................................................................................. 156
A2- Middle Base - Design F .......................................................................................... 157
A3- Rotating Base - Design F ........................................................................................ 158
A4- Middle Fixture - Design F ...................................................................................... 159
A5- Fixture Base - Design F .......................................................................................... 160
A6- Bolt - Design F........................................................................................................ 161
A7- Hinge - Design F&D ............................................................................................... 162
A8- Hinge Rod - Design F&D ....................................................................................... 163
A9- Sliding Jaw - Design F&D ...................................................................................... 164
A10- Jig - Design F&D .................................................................................................. 165
A11- Screw- Design F&D ............................................................................................. 166
A12- Handle - Design F&D ........................................................................................... 167
A13- Handle Cap - Design F&D ................................................................................... 168
A14- Jaw Piece- Design F&D........................................................................................ 169
A15- Fixture- Design F&D ............................................................................................ 170
A16- Thread Forming Block- Design F&D ................................................................... 171
A17- Screw Thread Forming - Design F&D ................................................................. 172
A18- Cylindrical Metal- Design F ................................................................................. 173
A19- Adjustable Angle Plate- Design F ........................................................................ 174
A19- Adjustable Angle Plate- Design D ........................................................................ 175
vii
A20- Cylindrical Metal- Design D ................................................................................ 176
A21- Nut- Design D ....................................................................................................... 177
A22- Fixture base- Design D ......................................................................................... 178
Appendix B- PDM report................................................................................................... 179
Appendix C- Product Pamphlet ......................................................................................... 180
viii
LIST OF FIGURES
Figure 1.1: Jig and fixture in 2D design .................................................................................... 2

Figure 1.2: Box jig with unequal legs ........................................................................................ 5
Figure 1.3: Product Enhancement Instruction ........................................................................... 6
Figure 2.1: Hand Sketch of Jig and Fixture with Adjustable Angle .......................................... 7
Figure 2.2: Jig and Fixture with Adjustable Angle .................................................................... 8
Figure 2.3: Main base ................................................................................................................ 9
Figure 2.4: Middle base ............................................................................................................. 9
Figure 2.5: Rotating base ......................................................................................................... 10
Figure 2.6: Middle fixture ........................................................................................................ 10
Figure 2.7: Fixture base ........................................................................................................... 11
Figure 2.8: Hinge ..................................................................................................................... 11
Figure 2.9: Hinge rod ............................................................................................................... 12
Figure 2.10: Sliding jaws ......................................................................................................... 12
Figure 2.11: Jig ........................................................................................................................ 13
Figure 2.12: Handle ................................................................................................................. 13
Figure 2.13: Handle cap ........................................................................................................... 14
Figure 2.14: Jaw piece ............................................................................................................. 14
Figure 2.15: Fixture ................................................................................................................. 15
Figure 2.16: Thread forming block .......................................................................................... 15
Figure 2.17: Screw thread forming rolls .................................................................................. 16
Figure 2.18: Bolt and nuts ........................................................................................................ 16
Figure 2.19: Cylindrical metal ................................................................................................. 17
Figure 2.20: Adjustable angle plate ......................................................................................... 17
Figure 2.21: Screw ................................................................................................................... 18
Figure 2.22: Exploded view jig and fixture with adjustable angle .......................................... 19
Figure 2.23: 3D view of jig and fixture with adjustable angle-design F ................................. 20
Figure 2.24: 2D CAD for jig and fixture with adjustable angle-design F ............................... 21
Figure 3.1: Jaw piece (Material Selection) .............................................................................. 24
Figure 3.2: Adjustable angle plate (Material Selection) .......................................................... 25
Figure 3.3: Potential material chosen for the jaw piece ........................................................... 27
ix
Figure 3.4: Potential material chosen for the adjustable angle plate ....................................... 30
Figure 3.5: Decision matrix of design efficiency based on Boothroyd & Dewhurst method .. 33
Figure 3.6: Life cycle thinking of jig and fixture with adjustable angle.................................. 34
Figure 3.7: Eco design web for mild steel ............................................................................... 35
Figure 3.8: Eco design web for carbon steel ............................................................................ 37
Figure 3.9: Eco design web for die steel .................................................................................. 38
Figure 3.10: Eco design web for high tensile steel .................................................................. 39
Figure 3.11: Eco design web for cast iron ............................................................................... 40
Figure 3.12: Process tree for jig and fixture with adjustable angle ......................................... 41
Figure 3.13: Jig and fixture with adjustable angle ................................................................... 49
Figure 3.14: FBD during the machining process ..................................................................... 50
Figure 3.15: FBD during the machining process on angle plate- Design D ............................ 52
Figure 3.16: Example of contact area for design F .................................................................. 53
Figure 3.17: Different working view of the operator ............................................................... 73
Figure 3.18: Isometric view before improvement.................................................................... 73
Figure 3.19: Isometric view after improvement ...................................................................... 74
Figure 3.20: Left view after improvement ............................................................................... 74
Figure 3.21: Push-pull analysis ................................................................................................ 75
Figure 4.2: Exploded view for design D .................................................................................. 78
Figure 4.3: 3D CAD for jig and fixture with adjustable angle-design D ................................. 79
Figure 4.4: 2D CAD for jig and fixture with adjustable angle-design D ................................. 80
Figure 4.5: Jaw piece (material selection)- design D ............................................................... 81
Figure 4.6: Adjustable angle plate (material selection)- design D........................................... 81
Figure 4.7: Potential material chosen for the jaw piece- design D .......................................... 84
Figure 4.8: Potential material chosen for the adjustable angle plate-design D ........................ 86
Figure 4.9: Product Life Cycle- Design D ............................................................................... 90
Figure 4.10: Eco-design web for mild steel ............................................................................. 91
Figure 4.11: Eco-design web for carbon steel ......................................................................... 92
Figure 4.12: Eco-design web for die steel ............................................................................... 93
Figure 4.13: Eco-design web for high tensile steel .................................................................. 94
Figure 4.14: Eco-design for cast iron ....................................................................................... 95
Figure 4.15: Eco-design for stainless steel .............................................................................. 96
Figure 4.16: Jig and fixture with adjustable angle- Design D ............................................... 105
Figure 4.17: FBD during the machining process on the workpiece- Design D ..................... 106
x
Figure 4.18: FBD during the machining process on angle plate- Design D .......................... 108
Figure 4.19: Example of contact area for design D ............................................................... 109
Figure 4.20: Calculation of rectangular contact area for design D ........................................ 110
Figure 4.21: Result for rectangular contact area for design D ............................................... 110
Figure 4.22: Different working view of the human operator- design D ................................ 130
Figure 4.23: Result of RULA analysis on old posture- design D .......................................... 130
Figure 4.24: Result of RULA analysis in new posture from the isometric view- design D .. 131
Figure 4.25: Result of RULA analysis in new posture from the left view- design D ............ 132
Figure 4.26: Result of RULA analysis for new posture- design D ........................................ 133
Figure 4.27: Push and pull analysis- design D ....................................................................... 134
Figure 5.1: Welding process .................................................................................................. 142
Figure 5.2: Laser cut .............................................................................................................. 144
Figure 5.3: Gantt Chart for Manufacturing Process of Jig and Fixture with Adjustable Angle
................................................................................................................................................ 149
xi
LIST OF TABLES
Table 3.1: Design of requirement for jaw piece ...................................................................... 25

Table 3.2: Comments on the materials for jaw piece............................................................... 27
Table 3.3: Design of requirement for adjustable angle plate ................................................... 28
Table 3.4: Comments on potential materials for adjustable angle plate .................................. 30
Table 3.5: Components with their respective assembly time .................................................. 31
Table 3.6: Eco indicator table for jig and fixture with adjustable angle .................................. 42
Table 3.7: Details for simulation ............................................................................................. 49
Table 3.8: Quantity and material used for jig and fixture with adjustable angle ..................... 68
Table 3.9: Material cost for jig and fixture with adjustable angle ........................................... 69
Table 3.10: Fixed cost for manufacturing jig and fixture with adjustable angle ..................... 70
Table 3.11: Costs for Jig and fixture with adjustable angle ..................................................... 71
Table 4.1: Design of requirement for jaw piece- design D ...................................................... 81
Table 4.2: Comments on the materials for jaw piece-design D ............................................... 84
Table 4.3: Design of requirement for adjustable angle plate- design D .................................. 85
Table 4.4: Comments on potential materials for adjustable angle plate- design D ................. 87
Table 4.5: Components with their respective assembly time for Design D............................. 87
Table 4.6: Eco indicator table for design D ............................................................................. 97
Table 4.7: Details for simulation-Design D ........................................................................... 105
Table 4.8: Quantity and material used for design D ............................................................. 125
Table 4.9: Material cost for design D .................................................................................... 126
Table 4.10: Fixed cost for manufacturing design D .............................................................. 126
Table 4.11: Costs for Jig and fixture with adjustable angle ................................................... 127
Table 4.12: Comparison between Design F and Design D .................................................... 135
Table 5.1: Manufacturing process involved in manufacture jig and fixture with adjustable angle
................................................................................................................................................ 144
Table 5.2: Manufacturing Process of Jig and Fixture with Adjustable Angle ....................... 150
xii
CHAPTER 1
INTRODUCTION
1.0 Overview
The purpose of this chapter is to explain briefly about the project of the jig and fixture
with adjustable angle. This chapter will describe the project background, aim, scope, problem
statement and objective. The fundamental of jig and fixture and the design of jig and fixture
will be discussed in the background of the study.
1.1 Background
The drilling process is a cutting process by using a drill bit to drill a hole in a workpiece.
The drilling process is classified into different types which is spot drilling, centre drilling, deep
hole drilling, gun drilling, micro-drilling, vibration drilling and others. The workpiece material
is metal, wood and others. During the cutting process, no matter which drilling process or
material for workpiece is selected, jig and fixture are always used to guide the path of the
machining tool in a precise way to prevent the wrong way of machining the product. Besides,
it also used to fix the product on the machining table in a stable way for a better machining
environment. Figure 1.1 shows the design of the jig and fixture nowadays in the industry such
as the machining industry, spare part manufacturing industry etc.
1
Figure 1.1: Jig and fixture in 2D design
The jig is a type of custom-made tool used for the location and motion of another tool
[1]
. They observed that the primary purpose of a jig is to provide repeatability, accuracy, and
interchangeability in the manufacturing of products. Although the most common jigs are the
drilling and boring jigs, they are all identical except for the shape, type, and the position of the
bushings for drilling or boring.
The main purpose of a fixture is to locate and, in some cases, hold a workpiece during
either a machining operation or some other industrial processes. Kaija has pointed out that what
makes fixtures unique is that they are all manufactured to fit a particular shape or part [2].
The basic purpose of the jig and fixture of developing and using suitable jigs and
fixtures for batch production in machine shops are eliminating marking, punching, positioning,
alignments etc [3]. Next, jig and fixture able to easy, quick and consistently accurate locating,
supporting and clamping the blank in the alignment of the cutting tool. Furthermore, jig and
fixture acted as guide to the cutting tool like drill, reamer etc. After that, an increase in
productivity and maintain product quality consistently. Besides, jig and fixture can reduce the
operator's labour and skill requirement, measurement and its cost. Besides, it can enhance the
technological capacity of the machine tools. Other than that, it can reduce the overall machining
cost and increases in interchangeability.
1.2 Aim
An idea is proposed which is the design and fabricate a jig and fixture with the ability
to perform different angles drilling function with high accuracy. It is also able to hold and fix
the workpiece in a static position without shaking due to the machining process.
2
1.3 Scope
Manufacturing duplicate parts accurately can be done by the production-work holding

devices such as jigs and fixtures. Hold, support and placed on the workpieces or parts that will
be machined are the ultimate purpose of jig and fixture. In this particular project, the design of
jig and fixture will be focusing on drilling machining and operation. The new design of the jig
and fixture with adjustable angle is made for the workpiece which is not only increasing the
effectiveness of the drilling process but also helps to increase the numbers of tool and accuracy.
Through these whole process from developing ideas until the prototype is created, drilling
machine has been chosen as the main focus and root of the problem. Thus, the new design of
the jig and fixture with adjustable angle is restricted and limited to be used only on the drilling
machine and thus might not be useful and efficient for other machines. However, the new
design of the jig and fixture with adjustable angle is suitable for all kind of workpiece. This is
because the problem arises due to there is a lack of jig and fixture available in the market for
drilling angle holes with high accuracy and efficiency. Besides, the jig and fixture with
adjustable angle designed only allowed the user to adjust the jig and fixture in a certain angle,
which is 15, 30, 45 and 60 degrees. To manufacture a jig and fixture with adjustable angle, the
group has decided to use the machine available in the laboratory such as bandsaw steel machine,
milling machine, laser 7 cutting machine, lathe machine and also drilling machine. But due to
the COVID-19 issue, the group has no choice to produce a real product, thus SOLIDWORK is
used to produce a soft prototype. The dimension is first decided using manual handwriting and
calculation and is drawn using the SolidWorks software. The detail drawing, 3D drawing, and
exploded drawing is performed using SolidWorks software too. To ensure that the product
produce has the best material properties, the material selection strategy is performed using the
CES software. Besides, the team has surveyed through the online webpage to find suitable
material for the part. After that, the process selection strategy is carried out to identify the most
suitable manufacturing process in making the jig and fixture with adjustable angle. Furthermore,
the cost analysis is carried out to calculate the total cost for one product. Besides, mechanical
analysis is carried out to calculate the forces, stress and others around the jig and fixture with
adjustable angle to know what exactly the product can withstand how much forces or how
much force can be exerted on the jig and fixture with adjustable angle. On the other hand,
sustainability, environment and safety analysis will be investigated using life cycle thinking
cycle, eco-design web, eco indicator and sustainability report generated from SolidWorks. The
last analysis conducted by the team is the ergonomic analysis performed by the Catia software.
3
Besides, by using the screening and scoring concept, the team has chosen another design
from last semester PDM which is design D as it lays at the second position of screening and
scoring concept. By comparing both designs, the team able to choose a better design in term of
material, cost, mechanical strength, environmentally friendly and more ergonomic.
1.4 Problem Statement
The problem occurs during the drilling process which the jig and fixture in the current
market only able to produce vertical holes but unable to perform angle holes. Thus, to produce
a single angle hole, the user is needed to use extra tools. This situation increases the time
consuming to produce a product and when the time consumes to produce a product increase,
the production rate will decrease, the cost consume will increase thus the profit will decrease.
The time consumes will increase if the traditional jig fixture is used to produce multiple holes
with different angle because the user needs to use other tools such as box jig. Box jig is a type
of jig and fixture which is only use for angular drilling. It is designed by providing the jig with
the legs of unequal length and tilt the jig to the desired angle. Box jig is used when the
workpiece is required to have one or more same angle holes with the axis of the work. Thus, if
the user would like to produce angle holes, the user needs to come out with unequal legs first.
Figure 1.2 shows the jig box which the angle holes can be drilled on the workpiece with the
twist drill in a vertical position.
Other than that, the accuracy of the angle holes might exceed the tolerance if using the
traditional jig and fixture. This is because box jig is put on top of the unequal legs and this will
cause the jig unable to hold and fix the workpiece in a static position. Vibration may occur
during the drilling process and it will cause the measurement of the workpiece not accurate.
Sometimes, due to the wear and tear of the unequal legs, the angles provided by the unequal
legs are not so accurate and it may differ from the angle required. Thus, the angle holes produce
may be different from the angle required.
Therefore, the use of jig and fixture is very important for the industry and there is a
need to enhance the better design of the jig and fixture to improve the quality and the
productivity in a manufacturing company.
4
Figure 1.2: Box jig with unequal legs
By using another word, redesign the traditional jig and fixture to jig and fixture with
adjustable angle can solve the problem faced. The new design of jig and fixture can produce
angle hole by adjusting the angle. It is also able to decrease the number of tools to produce
angle holes. User can use the jig and fixture with adjustable angle rather than box jig and
unequal legs. Besides that, the new design of jig and fixture can increase the accuracy of the
angle holes by hold and fix the workpiece in the static position.
1.5 Objectives
i. To solve the difficulties faced by the user by designing a jig and fixture can drill angle holes.
ii. To design a jig and fixture which can reduce the number of tools to perform drilling angle
holes.
iii. To design a jig and fixture which able to hold workpiece tightly.
iv. To invent a jig and fixture to increase the accuracy and the production rate.
v. To fabricate the best and suitable design by comparing the analysis from both design which
the design comes from the first and second place of screening and scoring concept during last
semester.
1.6 Report Explanation
5
This report is the extension of the PDM report. During the briefing of IDP, the
coordinator of the IDP has explained that the batch are required to carry out the product
enhancement which the batch must choose the option on Figure 1.3. Thus, after discussion
among group member and supervisor, the team have come out the decision to carry out the
option 1 which is choose another concept and do the whole analysis. For this option, the team
is required to choose the concept design from the screening and scoring concept in the PDM
report which attached on the Appendix B. The team has chosen design D which occupied the
second place of the screening and scoring concept and compare its analysis with the design F
(design F occupied the first place of screening and scoring concept and the analysis has been
carried out during last semester- PDM). After comparing the both designs, the team has found
that design F is better compare to design D (the analysis of the design D will be included in the
page 77- Chapter 4- Product enhancement). Thus, in the chapter 2,3, and 5 will explain about
the design F. The comparison of the design F and design D is also included in the chapter 4.
Figure 1.3: Product Enhancement Instruction
6
CHAPTER 2
PRODUCT DESCRIPTION-DESIGN F
2.0 Overview
This section will include the details explanation of working mechanism, the part
description, the drawing of the product and also the part limitations of the product for design
F.
2.1 Jig and Fixture with Adjustable Angle- Working Mechanism
Figure 2.1: Hand Sketch of Jig and Fixture with Adjustable Angle
7
Figure 2.2: Jig and Fixture with Adjustable Angle
Jig and fixture are work holding and supporting devices used in the large-scale
manufacturing process. It used to locate securely and quick positioning of workpiece and tool.
Jigs and fixture help to maintain the correct relationship between the cutting tool and workpiece,
and they simplify the process of locating during machining. They ensure that every part
machined within specified limits and tolerance. It helps the concept of interchangeability in the
manufacturing process. Figure 2.1 and Figure 2.2 shows the hand sketch and soft prototype of
the product. The final design of the jig and fixture with adjustable angle which consists of the
many parts including base, fixture, sliding jaw, handle and others. In this project, the rotating
base acts as the main part of the movement. It can rotate for 360- degree movement in the XY
plane. The base, middle base, rotating base were attached to each other. Then, the jig and fixture
were placed on the very top with whole rotation movement of 360 degrees. Besides, it able to
produce angle holes by the help of the angle plate. The user may hold the middle base and
rotate the who product which this function enlarges the working envelop of the drilling process
compare to the traditional product. For the adjustable angle plate, it is placed at both sides of
the fixture and it is used to adjust the angle in 15, 30, 45 and 60 degrees. Holes are machined
into the angle plate surface to enable the secure attachment to the fixture. The hole is made
according to the specified angle so that the drilling process would be easier and there is no need
to adjust the angle manually. The user is required to insert the cylindrical metal inside the hole
so that the jig and fixture able to fix at the required angle.
8
2.2 Part Description
This part will discuss the function of each component in the jig and fixture with adjustable
angle. The technical drawing of the parts will be included in Appendix A (pg 156).
a) Main Base
Figure 2.3: Main base
Figure 2.3 is the main base made by cast iron and its function is to support a huge load
that coming from top to the bottom is released during the drilling process. Besides, it also
supports the overall weight of this product included the workpiece during the process. It is also
designed to distribute the weight over a greater area and provide increased stability.
b) Middle base
Figure 2.4: Middle base
Figure 2.4 is the middle base that placed between the main base and rotated base. Its
function is to enable the smoothness during the rotary movement of the fixture. It also works
to reduce the friction force between the main base and rotated base.
9
c) Rotating base
Figure 2.5: Rotating base
Figure 2.5 is the rotating base which is placed upper part that supports and holds
components for the entire upper part. Its function is to rotate the base so that the drilling process
can be done at 360 degrees in horizontally.
d) Middle fixture
Figure 2.6: Middle fixture
Figure 2.6 shows the middle fixture. The middle fixture is located between the fixture
base and the rotating base. Its function is to decrease the friction between the fixture base and
rotating base during the rotational motion.
10
e) Fixture base
Figure 2.7: Fixture base
Figure 2.7 is a fixture base that placed under the fixture. Its function is to support the
load of the fixture and the workpiece that placed inside the fixture. The two holes at the fixture
base are used to fix the position of the adjustable angle plate.
f) Hinge
Figure 2.8: Hinge
Figure 2.8 is a hinge that made by carbon steel and its function is to connect the fixture
base and the fixture which hinges allows the fixture adjustable. Fixture and fixture base can
rotate relative to each other about a fixed axis of rotation thus a hinge has one degree of freedom.
Besides, hinge makes works easier if want to produce angle holes.
11
g) Hinge Rod
Figure 2.9: Hinge rod
Figure 2.9 above shows the hinge rod which made by carbon steel. Its function is to
connect the two pieces of hinges and allow the angular movement between the hinges. The
angular movement of the hinge allows the producing of angular holes.
h) Sliding jaw
Figure 2.10: Sliding jaws
Figure 2.10 is a sliding jaw that placed on the fixture. Its function is to apply force to
the workpiece so that during the drilling process, the vibration occurs will not affect the
position product or workpiece until the drilling machining is done. It is important so that the
dimensions produce in within the tolerance given.
12
i) Jig
Figure 2.11: Jig
Figure 2.11 is a jig that works as a holding device which holds, supports and locates the
workpiece. It also guides the cutting tool for a particular drilling process. Besides, the jig is
commonly used to fit with hardened steel to guide others cutting tool. Another function of the
jig is to provide repeatability, accuracy and interchangeability in the manufacturing industry in
producing a product.
j) Handle
Figure 2.12: Handle
Figure 2.12 showed the handle is placed together with screw thread forming rolls. Its
function is to let users move and rotate the screw thread to tighten the workpiece easily.
13
k) Handle Cap
Figure 2.13: Handle cap
Figure 2.13 shows the handle cap which is made by cast iron. The function of the handle
cap is to tighten the handle prevent the handle from coming out from the screw thread forming
rolls.
l) Jaw Piece
Figure 2.14: Jaw piece
Figure 2.14 shows the jaw piece made by the cast iron. It is an important part of the jig
and fixture as it will directly contact the workpiece. The function of the jaw pieces to clamp
the workpiece tightly and at the same time protects the workpiece from damage dented. When
the workpiece is clamped tightly, the accuracy of the workpiece is increased.
14
m) Fixture
Figure 2.15: Fixture
Figure 2.15 is a fixture. This component act as a holding device that holds, supports
and locates the workpiece to do a drilling process but not to guide the cutting as the jig does. It
is work as a reference surface. The special part of the fixture is it can be built to fit a particular
part or shape that want to be machining. The hole in the middle part helps the user to fix the
angle by allowing the cylindrical metal to pass through it.
n) Thread Forming Block
Figure 2.16: Thread forming block
Figure 2.16 shows the thread forming block made by the cast iron. Its function is to fix
the screw threw forming to the sliding jaw by using the screw. By using thread-forming block,
the screw threw forming will not easily come out from the sliding jaw during the tightening
process of the workpiece.
15
o) Screw thread forming rolls
Figure 2.17: Screw thread forming rolls
Figure 2.17 has shown the screw thread forming rolls. It is made by die steels and it is
attached at the hole at the fixture. Its function is to tighten the workpiece that wants to be
machining according to their size by applying force to the sliding jaws.
p) Bolt and nuts
Figure 2.18: Bolt and nuts
Figure 2.18 above shows the bolt and nut which will used to assembly the jig and fixture.
These two partners are kept together by a combination of threads friction. Its function is to lock
the movement between the fixture and adjustable angle plate. Besides, it is used to assembly
the middle base and rotating base by allowing the rotational movement. Hexagonal nuts are
occasionally used in some situations when a maximum amount of torque and grip is needed.
So, if there is high pressure applied during the process, the hexagonal nuts can afford the load
applied.
16
q) Cylindrical Metal
Figure 2.19: Cylindrical metal
Figure 2.19 is a cylindrical metal is made by high tensile steel and it acts as a locking
device in this product. It is attached with an adjustable angle plate. Its function is to prevent
inadvertent operator error in prematurely releasing the lifting mechanism and it also to hold the
mechanism for a certain angle. Besides, it also relates to a safety device release mechanism to
adjust to another angle.
r) Adjustable angle plate
Figure 2.20: Adjustable angle plate
Figure 2.20 is an adjustable angle plate is placed at both sides of the fixture. The angle
plate is made by mild steel and it is used to adjust the angle in 15, 30, 45 and 60 degrees. Holes
are machined into the angle plate surface to enable the secure attachment to the fixture. The
hole is made according to the specified angle so that the drilling process would be easier and
there is no need to adjust the angle manually.
17
s) Screw
Figure 2.21: Screw
Figure 2.21 shows the screw. In the jig and fixture with adjustable angle, the screw is
used to join two components together. The screw joins the fixture base and fixture together
through hinge so that the fixture able to create an angle. Besides the screw is used to join the
sliding jaw and screw thread forming through thread forming block. By rotating movement of
the screw thread forming, the sliding jaw able to have forward and backward motion.
18
2.3 Exploded View Jig and Fixture with Adjustable Angle
Figure 2.22: Exploded view jig and fixture with adjustable angle
19
2.4 3D CAD for Jig and Fixture with Adjustable Angle
Figure 2.23: 3D view of jig and fixture with adjustable angle-design F
20
2.5 2D CAD for Jig and Fixture with Adjustable Angle
Figure 2.24: 2D CAD for jig and fixture with adjustable angle-design F
21
2.6 Parts Limitations
The goal of the jig and fixture with adjustable angle is to meet the customer requirement
and the critical specification. But there is still some limitations or restriction against the parts. By
knowing the parts limitation is important because able to prevent the product from failure and
indirectly this able to increase the useful time of the product. The limitations of the parts will be
elaborate below.
1. Fixture house
Limitation
i. Since the design of the jig and fixture is portable and lightweight, thus the size of the
fixture house has a constraint. This causes the workpiece to have dimension
restriction which the workpiece should not exceed the length of 202mm and width
90mm.
ii. Maintenance is needed as the material used for the fixture house is mild steel. The
lack of alloying elements in mild steel will cause it easy to rust.
2. Adjustable Angle plate

Limitation
i. The adjustable angle plate design is restricted to drill angled holes of 15, 30, 45
and 60 degrees.
ii. The adjustable angle plate may occur failure if the weight of workpiece is too
heavy and this situation will cause the inaccuracy of angle holes produced. For
example, the radius of the hole of the adjustable angle plate is 5mm, if the weight
of the workpiece is too heavy and exceed the compressive strength that can afford
by the angle plate, the radius of the angle plate will become bigger which may
affect the accuracy of the angle holes.
3. Cylindrical metal
Limitation
i. The cylindrical metal may occur failure when the weight of the workpiece is too
heavy. This is because, during the process, the cylindrical rod acts as a locking
device in this product. The weight of the workpiece and jig and fixture will
22
become a force exerted to the cylindrical rod. If the force exerted on the cylindrical
metal is exceeded its limit, the cylindrical metal may occur failure.
4. Rotating Base
Limitation
i. The rotation of the rotating base is not locked. It can move during the machining
process.
ii. Friction caused by the rotation of the rotating base may cause the rotating base to
wear easily.
5. Jaw piece
Limitation
i. The material for the jaw piece is grey cast iron. Thus, if the machining material is
too soft, it may cause dented on the workpiece. To overcome this problem, a soft
cloth can be used to cover the jaw piece before the workpiece is clamped.
23
CHAPTER 3
PRODUCT ANALYSIS-DESIGN D
3.0 Overview
This section will include the product analysis for design D such as the material analysis,
DMFA, product sustainability analysis, mechanical analysis, cost analysis and also ergonomic
analysis.
3.1 Material Selection

3.1.1 Material Selection Process
The material selection process is a vital process in manufacture a product as a wrong

material use may lead to product failure. This process can help engineers to eliminate unsuitable
material and choose one or a few materials which are the most suitable for the part systematically
and rapidly. In this assignment, the student has to choose two important parts and the team has
chosen the jaw piece and the adjustable plate. Figure 3.1 and Figure 3.2 shows the 3D drawing
of the parts. The design of requirement needs to be determined based on the parts chosen and for
this assignment, Ashby chart is used to find the most suitable material. There are 4 strategies to
perform the suitable material which is translation, screening, raking and documentation.
Figure 3.1: Jaw piece (Material Selection)
24
Figure 3.2: Adjustable angle plate (Material Selection)
3.1.1.1 Material Selection Jaw Piece
Table 3.1: Design of requirement for jaw piece

Functions 1) To clamp workpiece tightly by apply force to the workpiece
2) To increase the accuracy of the workpiece by preventing
vibration caused by machinery process
3) To protect the workpiece by preventing damage dented at the
workpiece
Constraint 1) Fatigue strength above 50 MPa
2) Melting temperature above 100 °C
3) Hardness- Vickers more than750 MPa
4) Must have high compressive strength to clamp workpiece tightly
Objective 1) Minimize the material cost
2) Minimize the weight
Free variables 1) Manufacturing process
2) Choice of material
Table 3.1 shows the design requirement of the jaw piece.

The design requirement of a product is very important since it helps the designer to convert design
idea to product features. It also helps the designer to determine the material properties of the
product. In the table, the function of the product is first identified, and it is important because it
helps the designer to have a clearer mind to design and decide the material used. The function of
the jaw pieces to clamp the workpiece tightly and at the same time protects the workpiece from
25
damage dented. When the workpiece is clamped tightly, the accuracy of the workpiece is
increased.
Furthermore, the fatigue strength of the material to produce the jaw piece should more
than 50MPa. This is because when the machinery process is taking part, the vibration occurs
where if the amplitude if the vibration is too high, the failure of the jaw piece will occur. Thus,
the fatigue strength should be higher than the amplitude of vibration as more vibration means
more loading and unloading at a high frequency. Another reason for the material of jaw piece
should have higher fatigue is when there is the vibration energy produced during machinery
process is transferred to the jigs it will cause the jaw piece to break down. Based on the
mechanical loss coefficient, the more the energy absorbed, the easier the jaw piece of cur failure.
On the other hand, the material of the jaw piece should have the mechanical properties
which are high melting temperature which is above 100 °C. The melting point of the material
used is important because it can protect and elongate the lifetime of the jaw piece. During the
machinery process, heat is producing due to the friction between the machining tool and the
workpiece. As most of the workpiece used is metal, thus the heat produced by the friction will
transfer to the jaw piece. Thus, the jaw piece needs to have a high melting point so that the jaw
piece can withstand the heat from the workpiece.
Next, the Vickers hardness of the material should more than 750MPa. This is because
the hardness is always having a direct relationship with the wear resistance. The harder the
material, the higher the wear resistance. The higher wear resistance enables jaw piece to resist
wear due to rubbing or impact from the workpiece. Another reason for the material for jaw piece
should harder is to prevent the jaw piece from indent when clamping a harder material such as
diamond. If the material for the jaw piece is too soft it may cause the harder workpiece to embed
into the jaw and stuck. The compressive strength of material should be maximized so that it
ensures the fixture able to clamp workpiece tightly with high grip force without breaking the jaw
piece.
The objectives of the material selected are also vital criteria for a design requirement.
The material selected should have minimized cost so that the profit gain by the company is
maximized. This is important because the profit gain for this product will help the company to
design another new product which brings benefit to the customers. Other than that, the weight
should be minimized since one of the features of the jig and fixture with adjustable angle designed
is portable, if the density of jaw piece is high, it will affect the overall weight of the jig and fixture
26
with the adjustable angle in which it may cause the user hard to carry the jig and fixture with
adjustable angle.
The free variables are the manufacturing process to produce the material and also the
choice of material selection. In short, the design requirements of jaw piece are important so that
designer can produce a product with a clearer vision on what is the important mechanical
properties should include in the material selected.
After determining the design of the requirement, the Ashby chart is used to determine the
suitable material for the jaw piece. Figure 4.48 shows the potential materials determine by the
Ashby chart.
Figure 3.3: Potential material chosen for the jaw piece
Based on Figure 3.3 above, it clearly shows that the potential material chosen is stainless
steel, aluminium alloy, grey cast iron, wrought magnesium alloy and high carbon steel. The final
material chosen is the grey cast iron which has the second ranking among all. Although the high
carbon steel has the highest material properties such as fatigue strength, hardness-Vickers and the
lowest price it is not the BEST material for jaw piece. This is because, among the candidates, the
cast iron which is the is chosen as the BEST material for manufacture jaw since, among the
candidates, there is only one material which is cast iron have the history of use for manufacture
jaw. Despite it does not have a high material property compare to high carbon steel but the history
of cast iron to manufacture jaw piece allows cast iron to stand out the most suitable material over
the other material. Table 3.2 shows the comments on the material chosen.
Table 3.2: Comments on the materials for jaw piece

Material Comments
27
Stainless steel High cost; High density
Age Hardening Wrought Moderate cost, Low density
Aluminium alloy
Wrought Magnesium Alloy Low density; Low cost; Performance not good as others
Gray Cast Iron Good performance with a minimum cost; Moderate
density; Have a history to manufacture jaw piece
High carbon steel Good performance with low cost; No history to
manufacture jaw piece
3.1.1.2 Material selection Adjustable Angle Plate
Table 3.3: Design of requirement for adjustable angle plate

Functions 1) To increase the accuracy of the angle holes
2) To make the process of drilling angle holes easy.
3) To decrease the number of tools for drilling angle holes.
Constraint 1) Fatigue strength above 40MPa
2) Fracture toughness above 70MPa
3) Compressive Strength more than 900MPa
Objectives 1) Minimize the material cost
3) Maximize the stiffness
Free variables 1) Maximize the stiffness
Table 3.3 above shows the design requirement of the jaw piece. The
function of the adjustable plate is to increase the accuracy of the angle holes and at the same time
decrease the number of tools for drilling angle holes. By using the adjustable plate, the drilling
process of angle holes will become simpler.
Furthermore, the fatigue strength of the material to produce the adjustable plates needs to
more than 60MPa. This is because the adjustable angle plates have to support the load of the jig
and fixture and workpiece during the machinery process. The vibration of the machinery process
and the weight of jig and fixture and workpiece may cause the adjustable angle plates failed to
support the weight. A material with high fatigue strength will prevent the weakening of a material
28
caused by the increasing number of loading which results in the structural damage and the growth
of cracks.
Besides, the fracture toughness should higher than 70MPa to prevent fracture of the
adjustable angle plate. This is because once the fatigue crack has appeared, every single loading
cycle will cause the crack to grow in a small amount. The crack will continue to grow until it
reached a critical point, cause the adjustable angle plate to fracture once the stress intensity factor
of the craw exceeds the fracture toughness. Thus, the material of the adjustable angle plate should
have high fracture toughness.
Next, the compressive strength of the adjustable angle plate should be higher as there is a
cylindrical metal pass through the holes on the adjustable angle plate. The cylindrical metal will
withstand the weight of jig and fixture and workpiece. The cylindrical metal will absorb the
compressive force caused by the weight of the jig and fixture and workpiece and transfer it to the
adjustable plate. Thus, the compressive force of the adjustable angle plate should higher prevent
the loads tending to change the shape of the holes which this indirectly increases the accuracy of
the adjustable angle plate.
On the other hand, the objectives of the material selected are to minimize the cost, weight
and maximize the stiffness of the material. The reason why the cost and weight should be
minimized is the same as the jaw piece. The reason to maximize the stiffness of the material is to
resist the deflection of the adjustable angle plate under the bending force caused by the cylindrical
metal. Maximize the stiffness will increase the accuracy of the drilling holes because each angle
holes have a specified angle If the holes on the adjustable angle plates occur deflection, it will
affect the accuracy of the workpiece.
Lastly, the free variable is the choice of the material selected. In short, the design
requirements of adjustable angle holes are important so that designer can produce a product with
a clearer vision on what is the important mechanical properties should include in the material
selected.
29
Figure 3.4: Potential material chosen for the adjustable angle plate
Based on Figure 3.4 above, it clearly shows that the potential material for the adjustable
angle plate is high carbon steel, low alloy steel, medium carbon steel, stainless steel and titanium
alloys. The final material chosen is the low alloy steel as the low alloy steel has the highest score
among the five materials. It also has a history of manufacture plates. Although the price of low
alloy steel is slightly higher than the medium and high carbon steel, the low alloy steel have a
better material performance in term of fatigue strength, hardness young’s modulus. Thus, the low
alloy steel is chosen as the best material for the adjustable steel plate with its history and
outstanding material performance. Table 3.4 shows comments on potential materials.
Table 3.4: Comments on potential materials for adjustable angle plate

Material Comments
Stainless steel Low Compressive Strength; High cost; Same density as others except
for Titanium alloy
Titanium alloy Low young modulus; High cost; Low Density
Low alloy steel Good performance with a minimum cost; Same density as others
except for Titanium alloy;
Medium carbon steel Lower hardness; Lower fatigue strength; Lowest cost; Same density
as others except for Titanium alloy
High carbon steel Lower Compressive strength; Lower young’s modulus; Lowest Cost;
Same density as others except for Titanium alloy
30
3.2 DMFA
Based on the exploded view of the jig and fixture with adjustable angle which shows in
Figure 2.22, the team have developed the Table 3.5 which is the parts of jig and fixture with
adjustable angle and their respective assembly time.
Table 3.5: Components with their respective assembly time

No
of Theoretica Handling Insertion Assembly Assembly
No Part Name Part l Part Time (s) Time (s) time (s) cost (cent)
1 Main Base 1 1 3.10 2.30 7.13 0.93
2 Middle Base 1 1 2.36 5.00 11.80 1.53
Rotating
3 Base 1 1 3.80 2.36 8.97 1.17
Middle
4 Fixture 1 1 3.77 2.58 9.73 1.26
5 Fixture Base 1 1 3.65 4.60 16.79 2.18
Bolt
(Rotating
6 Base) 2 1 2.00 15.00 30.00 3.90
Hinge
7 (Upper part) 1 1 3.03 2.36 7.15 0.93
Hinge
8 (Lower part) 1 1 3.03 2.36 7.15 0.93
9 Hinge Rod 1 1 2.11 3.00 6.33 0.82
10 Sliding Jaw 1 1 4.30 2.36 10.15 1.32
11 Jig 1 1 3.65 2.58 9.42 1.22
12 Screw 8 1 2.31 60.00 138.60 18.02
13 Handle 1 1 3.00 3.15 9.45 1.23
14 Jaw Piece 2 1 2.30 3.10 7.13 0.93
15 Fixture 1 1 3.90 3.15 12.29 1.60
31
Thread
Forming
16 Block 1 1 2.30 5.87 13.50 1.76
Screw
Thread
17 Forming 1 1 4.23 7.25 30.67 3.99
Bolt (Fixture
18 Base) 4 1 2.00 30.00 60.00 7.80
Cylindrical
19 Metal 1 1 5.30 2.36 12.51 1.63
Adjustable
20 Angle Plate 2 1 2.60 4.25 11.05 1.44
Total 33 20 62.74 163.63 419.80 54.57
𝑁𝑚𝑖𝑛 𝑥 𝑡𝑎
Design efficiency, Ema = 𝑡𝑚𝑎
where:
Nmin = the theoretical part minimum
tma = total assembly time
ta = the theoretical, lowest assembly time
So, the design efficiency for the immobile people carrier is,
Ema = 𝑡𝑚𝑎
where:
Nmin = 20 parts
tma = 419.80
ta = 6.33
(20)𝑥 6.33𝑠
Design efficiency, Ema = x 100% = 30.16%
419.80
According to the decision matrix, the product with design efficiency of 30.16% is in the
decision category of a very good result.
32
Figure 3.5: Decision matrix of design efficiency based on Boothroyd & Dewhurst method
According to Boothroyd and Dewhurst Analysis of Manual Assembly Methods, Figure

3.5 above shows that design efficiency above 20% can be accepted and proceeds with production.
After the team have done the calculation on design efficiency of our product, the team get 27%
of efficiency. Hence, it can proceed to production without needing any redesign on the product.
Other than that, the assumption is made to calculate the assembly cost of the product. The
team have assumed the labour cost to be RM 7.5 per hour or RM0.13 per second to assemble the
product. The assembly cost for the product is 54.57 cents which are around RM 0.54 for each
unit.
3.3 Product Sustainability Analysis

3.3.1 Product Life Cycle
A product life cycle is an important tool which helps manufacturers to consider the
environmental and social impacts during the manufacturing process. It will help whenever they
are involved in analysing a potential design or an actual product. Figure 3.6 shows the life cycle
for the jig and fixture with adjustable angle. It is divided into 5 different types of material which
is as cast iron, mild steel, carbon steel, high tensile steel and die steel. The material that used to
produce the jig and fixture with adjustable angle is mostly metal which can be reused, recycle or
remanufacture so that the environmental impact afterlife will be mitigated.
33
Figure 3.6: Life cycle thinking of jig and fixture with adjustable angle
34
3.3.2 Eco Design Web
This section has shown the eco web design for each material which used to produce every
component of jig and fixture. By using this eco web design, the team can compare how bad and
good of the design areas product, to assess the environmental performances of a current product,
identify the problem areas of the product and outlines the targets for the redesign.
Figure 3.7: Eco design web for mild steel
Figure 3.7 is showed eco-design web for mild steel material. There are two components
used mild steel material which is the body of fixture and jig. Mild steel is economical and cheapest
35
material that often used for jig and fixture material. It also has good material selection because
steel is the most recycled material in the world. The scales showed all the criteria is give a good
impact on the two components. Mild steel is a green product. It is 100% recyclable, as it is not
coated with any toxic material it does not produce toxic run-off. During production, mild steel
uses scrap metal as its primary raw material, with up to 70% of the product coming from recycled
material. Increased efficiency in the process technology has also decreased the amount of energy
required to manufacture stainless steel. Even if mild steel is not recycled and it does find its way
to a landfill or disposal site, it will have no detrimental effect on the soil or groundwater. Mild
steel is the preferred material for green building throughout the world. Its impact on the
environment is minimal when compared to other materials and its life impact reduces
significantly as it used and recycled.
36
Figure 3.8: Eco design web for carbon steel
Figure 3.8 is showed eco-design web for carbon steel. There is one component used
carbon steel material which is the hinge. Carbon steel has higher carbon content so carbon steel
has higher strengthens and hardness. The scaled showed all the criteria give a good impact on the
component.
37
Figure 3.9: Eco design web for die steel
Figure 3.9 showed Eco design web for die steel material. There are two component used
die steel material which is screw threading forming rolls and handle. The material properties of
die steel properties are high hardness, high wear and abrasion resistant properties so suitable used
for this component. The scaled shows all criteria give good impact for this component.
38
Figure 3.10: Eco design web for high tensile steel
Figure 3.10 showed eco-design web for high tensile steel material. This material is only
used for one component which is bolt and nut. Bolt and nut are just joining process for this product
and this material most suitable for the fastener. The scaled showed all criteria give good impact
except the optimal life. it is because the high tensile steel is brittle so cannot be repaired.
39
Figure 3.11: Eco design web for cast iron
Figure 3.11 showed Eco design web for cast iron material. There are seven component
used cast iron material which it can be said that most of the part for jig and fixture with adjustable
angle is made from cast iron. The scaled shows that all criteria give the average impact of the
component. Cast iron is one of the oldest materials in engineering, it is seeing something of a
rebirth of fortunes in the modern world with regards to environmental impact and sustainability.
This is based on the fact that cast iron does not rust in the traditional sense, it oxidises very slowly.
This process gives off iron ashes which are carbon-based on good for the environment. It
promotes green growth on plants and increases planktonic life in in the oceans, thus combating
global warming. Cast iron is also totally recyclable and recycled steel, largely from the
40
automotive and engineering industries, and any house returns meaning that any wastage in the
manufacturing process is put back into the furnace and melted to make new iron.
3.3.3 Eco Indicator

3.3.3.1 Process Tree
Figure 3.12 shows the process tree of the jig and fixture with adjustable angle. By using
the process tree, all the process undertaken through the life cycle is determined and used for the
eco indicator table.
Figure 3.12: Process tree for jig and fixture with adjustable angle
41
3.3.3.2 Eco Indicator Table
Table 3.6 shows the eco indicator of the jig and fixture with adjustable angle.
Table 3.6: Eco indicator table for jig and fixture with adjustable angle
Jig and Fixture with Adjustable Angle
Production
Materials, processing, transport and extra energy
Material or process Amount Indicator Results
Cast iron 12.13 kg 240 2911.2
Mild steel 10.77 kg 86 926.22
Carbon steel 0.43 kg 110 47.3
High tensile steel 0.08 kg 910 72.8
Die steel 0.034 kg 910 30.94
Milling, Turning, Drilling 22.552 kg 800 18041.6
Total 22030.06
Use
Transport, energy and auxiliary materials
Process Amount Indicator Results
Transport (40-tonne truck) 257.84 tkm 15 3867.6
Total 3867.6
Disposal
Disposal processes per type of material
Material Amount Indicator Results
Recycling Ferro metals 23.44 kg -94 -2203.736
Total -2203.736
Grand Total 23693.92
42
The assumption for product life span and average daily used
a) Product life span: Assume that jig and fixture with adjustable angle can use for one year.
b) Average daily use: Assume use 20 hours per day to produce 1000 parts per day.
Assumption for transport
Total weight = 23.44 kg
Assuming distance to be transported = 11000 km
23.44
( ) × 11000 𝑘𝑚 = 257.84 𝑡𝑘𝑚
1000
Based on the table above it can be concluded that the eco indicator is 23693.92 which are
quite high. The main reason for the high eco indicator value is the product produce is using a lot
of metal such as cast iron, mild steel, carbon steel, high tensile steel and die steel. Besides, the
manufacturing process used to produce jig and fixture also has a high number of indicator.
Although the metal used to produce jig and fixture with adjustable angle have a high value of the
eco indicator, there is an advantage that the metal used can be recycled. Thus, by recycling the
metal, the value of the eco indicator will decrease and the environmental impact will also decrease.
3.3.4 Sustainability Report
The sustainability report is generated by using the Solidwork software. The sustainability
report is a vital component for product design as it helps the manufacturer to measure, understand
and communicate the economic, environmental, social and governance performance. It is a report
published by a manufacturer about the economic, environmental and social impact caused by the
product in the daily activities.
43
[company logo here]
[city, state Sustainability Report

[company name here] here] [company url here]
[name] ∙ [title] ∙ ∙ [email address] ∙ (###) ###-####
Model Name: Jig and Fixture

Assembly
Weight: 23444.24 g
Built to last: 1.0 year
Duration of use: 1.0 year
Manufacturing Region
The choice of manufacturing region determines the
energy sources and technologies used in the
modelled material creation and manufacturing steps
of the product’s life cycle.
Use Region
The use region is used to determine the energy
sources consumed during the product’s use phase
(if applicable) and the destination for the product at
its end-of-life. Together with the manufacturing
region, the use region is also used to estimate the
environmental impacts associated with transporting
the product from its manufacturing location to its use
location.
Learn more about Life Cycle Assessment
Sustainability Report
44
Model Name: Jig and Fixture Assembly Weight: 23444.24 g
Duration of 1.0 year
use:
Assembly Process Use
Region: Asia Region: Asia

Energy type: None Energy type: None
Energy amount: 0.00 kWh Energy amount: 0.00 kWh
Built to last: 1.0 year Duration of use: 1.0 year
Transportation End of Life
Truck distance: 1600 km Recycled: 22 %

Train distance: 0.00 km Incinerated: 6.1 %
Ship distance: 0.00 km Landfill: 72 %
Airplane Distance: 0.00 km
Click here for alternative units such as ‘Miles Driven in a Car’
Model Jig and Fixture Assembly Weight: 23444.24 g

Name: Built to last: 1.0 year
use:
Environmental Impact (calculated using CML impact assessment methodology)

Carbon Footprint Total Energy Consumed
Material: 37 kg CO2e Material: 500 MJ
Manufacturing Manufacturing
18 kg CO2e 180 MJ
: :
Use: 0.00 kg CO2e Use: 0.00 MJ
Transportatio Transportation
3.8 kg CO2e 52 MJ
n: :
End of Life: 15 kg CO2e End of Life: 11 MJ
73 kg CO2e 740 MJ
45
Air Acidification Water Eutrophication
Material: 0.106 kg SO2e Material: 0.025 kg PO4e
Manufacturing Manufacturing
0.239 kg SO2e 9.5E-3 kg PO4e
: :
Use: 0.00 kg SO2e Use: 0.00 kg PO4e
Transportatio Transportation
0.019 kg SO2e 3.9E-3 kg PO4e
n: :
End of Life: 6.3E-3 kg SO2e End of Life: 0.022 kg PO4e
0.371 kg SO2e 0.061 kg PO4e
Material Financial
9.50 USD
Impact
Click here for alternative units such as ‘Miles Driven in a Car’
Model Name: Jig and Fixture Assembly Weight: 23444.24 g

use:
Component Environmental Impact
Top Ten Components Contributing Most to the Four Areas of Environmental Impact
46
Component Carbon Water Air Energy
Fiixture 16 0.012 0.093 190
Adjustable angle
8.5 6.4E-3 0.049 99
plate
Middle base 8.5 6.4E-3 0.049 85
Main Base 7.3 5.5E-3 0.042 73
Rotating Base 6.5 4.9E-3 0.037 65
Fixture Base 6.2 5.1E-3 0.014 62
Jig 2.2 1.7E-3 0.013 27
Middle Fixture 2.3 1.7E-3 0.013 23
Screw Thread
1.7 1.4E-3 0.010 21
Forming
sliding jaw 1.7 1.3E-3 9.6E-3 19
47
Based on the report above, it clearly shows that there is no energy amount during the
usage of the jig and fixture with adjustable angle. From the report, it can be concluded that the
jig and fixture with adjustable angle brings a huge impact to the environment at the end of life as
it is only 22% of the material able to recycle. There is 72% of the material used to end up in the
landfill. As all the components used to produce the jig and fixture with adjustable angle is metal,
thus, the carbon footprint, total energy consumed and the water eutrophication during the material
extraction process is very high. Besides, the air acidification during the manufacturing process
of jig and fixture with adjustable angle is quite high compare to others. Furthermore, the report
shows that there is no environmental impact during the useful time of the jig and fixture with
adjustable angle. This is because during the useful time it acts as an assistant to product angle
holes. It does not require any energy to operate it. From the report, it also can be concluded that
the fixture has the highest environmental impact and followed by the adjustable angle plate and
middle base. This is because the size of material used in these three components is larger compare
to the other components and the type of material used for the three components produce larger
48
environmental impact compared to others. On the other hand, bolt for the fixture base has the
least environmental impact due to its small size and material used.
3.4 Mechanical Analysis

3.4.1 Static and Strength of Material
Figure 3.13: Jig and fixture with adjustable angle
Table 3.7: Details for simulation

Force Assumed Machining Force: 12000 N
Clamping Force (Sliding jaw): 1000 N
Clamping Force (Nut): 15455 N
Mass Mass workpiece: 3.5 kg
Area Product: 320 x 342 mm
Workpiece: 90mm (L) x 100 (W) x 60 mm (H)
3.4.1.1 FBD for Jig and Fixture with Adjustable Angle (During Machining Process)
49
Figure 3.14: FBD during the machining process
3.4.1.1.1 Calculation Structural Analysis (Compression Force)
Clamping Force, Fc = 1000 N

Machining Force , Fm = 12000 N
Mass of workpiece = 3.5 kg
Degree for angle hole = 30°
W= mg cos Ɵ
W= 3.5(9.81) cos 30
= 297.35
∑Fy = 0
0 = -Fm – W + Fc sin 30 + (-Fna sin 30) + Fnb sin 30+ 2 f cos 30
0 = -12000 – 297.35 + 1000 sin 30 – Fna sin 30 + Fnb sin 30 + 2f cos 30
119797.35 = 0.5(Fnb- Fna) + 1.732 f
119797.35 = 0.5(Fnb- Fna) + 1.732(-866.03 N – 0.866 (Fna- Fnb)
∑Fx = 0
Fc cos 30 + Fna cos 30 – Fnb cos 30 + 2f sin 30 = 0
1000 cos 30 + 0.866 ( Fna – Fnb) + f = 0
f = -866.03 N – 0.866 ( Fna- Fnb)
f = -866.03 N – 0.866 (- 48518.92 – 48518.92)
= 83168.74 N
50
Normal Force Answer
Fna = -48518.92 N
Fnb = 48518.92 N
↷∑Mx = 0
= Fm xd – Wd + f(d) – f(d)
= 12000 (30 cos 30) – 297.35 + 83168.74 ( 50) - 83168.74 ( 50)
= 3117691.45 Nm
3.4.1.1.2 Calculation of Stress
Stress on the workpiece

Clamping Force
Stress = Area
1000
= 2(90 x 60)mm2
1000
= 0.0108m2
= 92592.59 N/𝑚2
3.4.1.1.3 Calculation Normal Stress and Shear Stress
Normal Stress
P = 48548.92N
Area = 90 x 60 𝑚𝑚2 =0.0054𝑚2
𝑃 48548.92 𝑁
ꝹBC = 𝐴 = = 8990540.74 Pa
0.0054𝑚2
Shear Stress
V = 1000 N
A = 90 x 60 𝑚𝑚2 =0.0054𝑚2
𝑉 1000 𝑁
Ꞇavg = 𝐴 = 0.0054 = 185185.19 Pa
51
3.4.1.2 FBD During Machining Process on Angle Plate-Design F
Figure 3.15: FBD during the machining process on angle plate- Design D
3.4.1.2.1 Calculation Structural Analysis
F= Machining Force (Fm) + Weight for Jig and Fixture+ Weight of Workpiece
= 12000 N + 23.444 (9.81) cos 30+297.35N
= 120496.52 N
∑Fy = - F + FN
0 = -120496.52N + Fn
Fn= 120496.52N
∑Ma =0
= -120199.17 (145.03) + 120199.17 ( 145.03)
=0
Stress on angle plate (Assume contact surface of the cylinder and angle plate is 2πrh=
2(3.142)(10)(10)=628.42mm2 =0.00062842m2
52
Figure 3.16: Example of contact area for design F
Force
Stress = 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑎𝑛𝑔𝑙𝑒 𝑝𝑙𝑎𝑡𝑒 𝑑𝑢𝑟𝑖𝑛𝑔 𝑚𝑎𝑐ℎ𝑖𝑛𝑖𝑛𝑔 𝑝𝑟𝑜𝑐𝑒𝑠𝑠
120496.52
= 2πrh
120496.52
= 0.00062842
= 191745202.3 𝑚2
Normal Stress
P = 120496.52 N
Area = 0.00062842𝑚2
𝑃 120496.52 𝑁
ꝹBC = 𝐴 = 0.0006284𝑚2 = 191751304.9 Pa
Shear Stress
V = 120496.52N
A = 0.00062844m2
53
𝑉 120496.52 𝑁
Ꞇavg = 𝐴 = 0.0006284𝑚2 = 191751304.9 Pa
3.4.1.3 Calculation Factor of Safety
Factor of Safety
i. (Jaws)
Ꞇfail 𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ
F.S = Ꞇallow , F.S.n = 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑆𝑡𝑟𝑒𝑠𝑠
1.52 𝑥 108
Factor of Safety , FoS = 5.676 𝑥 106 𝑃𝑎 = 26.78
ii. (Plate)
7.2382𝑥 108
Factor of Safety, FoS = = 13536.94
5.347 𝑥 104
iii. (Handle)
7.23 𝑥 108
Factor of Safety, FoS = 1.015 𝑥 105 = 7123.15
3.4.2 Simulation Analysis

3.4.2.1 Part 1 (Jaws)
For the first step, the jaw piece is fixed at the base jaws and force is exerted on the
workpiece. The team has chosen to exert force on the workpiece because when machining process,
clamping force will exert to workpiece and effect to the jaws. The assumed clamping force is
1000N.
Simulation Jaws
Date: Thursday, May 28 2020
Designer: Solidwork
Study Name: Simulation
Clamping
Analysis Type: Static
54
Next, the mesh control setting is done. The mesh will be setting to fine because it will get
an accurate result.
55
56
This figure below shows the after mesh control. The geometry of mesh is smaller than
other which means the accuracy and quality are more fine and good after doing mesh control.
The grey cast iron material will apply fine mesh and get an accurate result.
3.4.2.1.1 Study Result
The final result for static, strain, displacement and factor of safety is shown below after
the simulation is run.
57
58
The jaws part used to clamp the workpiece. Material for jaws is grey cast iron. The
maximum value for the stress of this part is 5.67e+06 N/m2 while the minimum value is
4.041e+01 N/m2. The maximum displacement value is 3.1775e-04mm. The strain value 5.677e-
05. Its shows the value is higher than material properties of yield strength. The maximum factor
of safety value is 1.130e+07 and minimum value is 9.233e+01. In short, from the simulation
59
result above, it shows that the jaws are safe for use. Minimal stress and deformation should give
the effect of both a solid and lightweight jaws.
3.4.2.2 Part 2 (Adjustable Angle Plate)
First, the plate is fixed at the fixture base by using bolt and force will exert on the holes.
For this part, the team has chosen a degree of 30 for simulation purpose. Thus, the force will be
exerted at the hole for 30 degrees because when machining process, machining force will exert
to the workpiece. The force exerted on the workpiece is transfer to the adjustable angle plate. The
assumed machining force is 12000N.
Simulation of Adjustable Angle
Plate
Date: Thursday, May 28, 2020
Designer: Solidwork
Study Name: Simulation Force
an accurate result.
60
61
62
The adjustable angle part is used to adjust angle fixture and make workpiece in angle
position. This part used alloy steel. The maximum value for the stress of this part is 5.347e+04
N/m2 while the minimum stress value is 6.333e+01 N/m2. The maximum displacement value is
1.124e-06mm. The maximum strain value is 1.796e-07N/m2 while the minimum strain value is
63
4.731e-12N/m2. The maximum factor of safety value is 9.719e+08. All this result shows that
parts limit to breakage and effect the workpiece. In a nutshell, from the result simulation can see
the plate is safe for use. Minimal stress and deformation should give the effect of both a solid and
lightweight plate.
3.4.2.3 Part 3 (Handle)
Firstly, the handle is fixed at the screw thread forming rod. The force is exerted on both
corners of the rod because when to set up to clamp the workpiece, the human force will exert to
handle and effect to the handle. The assumed human force 1.1 N.
Simulation of Handle
Designer: Solidwork
Study Name: c Simulation Force
Analysis Name: Static
64
an accurate result.
65
66
The handle part used to turn the screw thread forming and move the sliding jaws. Material
for the handle is die steel. The maximum value for the stress of this part is 1.015e+05 N/m 2
while the minimum value is 2.117e-06 N/m2. The human force 1.1 N will exert to the handle.
The maximum displacement value is 4.089e+06 mm. The maximum strain value 4.782e-07 while
67
the minimum strain value is 1.309e-17. Its shows the value is higher than material properties of
tensile strength that make part will fracture. The maximum factor of safety value is 2.931e+14
and the minimum value is 6.113e+03. In conclusion, the result simulation can see the handle
deemed safe for use. Minimal stress and deformation should give the effect of both a solid and
lightweight handle.
3.4.3 Heat Flow Analysis
Heat flow is defined as the transfer of thermal energy from one party to another by having
contact. In this assignment, heat flow analysis will not be carried out since for the team’s product,
it will not experience a lot of heat changes during operation.
3.5 Cost Analysis

3.5.1 Bill of Material (BOM)
Table 3.8 below shows the quantity and material used of jig and fixture with adjustable
angle. The jig and fixture with adjustable angle have 19 components and every part is very
important and each part has its function.
Table 3.8: Quantity and material used for jig and fixture with adjustable angle
Part Number Part Name Quantity Material
1 Main Base 1 Cast Iron
2 Middle Base 1 Cast Iron
3 Middle Fixture 1 Cast Iron
4 Rotating Base 1 Cast Iron
5 Fixture 1 Mild Steel
6 Fixture Base 1 Cast Iron
7 Sliding Jaws 1 Cast Iron and Mild Steel
8 Jaw Piece 1 Cast Iron
9 Hinge 1 Carbon Steels
10 Bolt 6 High Tensile Steel
11 Cylindrical Metal 1 High Tensile Steel
68
12 Adjustable Angle Plate 2 Cast Iron
13 Jig 1 Mild Steels
14 Screw thread forming rolls 1 Die Steels
15 Screw 8 Stainless Steel
16 Handle 1 Die Steels
17 Handle Cap 1 Die Steels
18 Hinge Rod 1 Stainless Steel
19 Thread Forming Block 1 Cast Iron
3.5.1.1 Estimation Cost
Estimation of cost product

Production per unit: 1 unit
3.5.1.1.1 Material Cost
Table 3.9 shows the material cost for jig and fixture with adjustable angle.
Table 3.9: Material cost for jig and fixture with adjustable angle
Material Used Kilograms Used Price/ Total Price for Material
Kilogram Used
Cast iron 12.13kg RM 5.21 /kg RM 63.20
Mild steel 10.77kg RM2.17/kg RM 23.37
Carbon steels 0.43kg RM2.2/kg RM 0.95
High tensile 0.08kg RM3.16/kg RM 0.25
steel
Die steels 0.034kg RM4.34/kg RM 0.15
Total RM87.92
3.5.1.1.2 Labor Cost
69
Labour cost consists of labour wages for producing one product. Minimum wages in
Malaysia for labour is RM 1500.00 for a month. One labour can produce 10 jig and fixture a
month. Thus, the labour cost per unit is RM 150.00.
3.5.1.1.3 Fixed Cost (Overhead Manufacturing Cost)
Fixed cost is the cost that about going business expenses excluded labour cost and material
cost.
Table 3.10: Fixed cost for manufacturing jig and fixture with adjustable angle
Overhead Cost Cost (RM)
Water Bill 150.00
Electrical Bill 500.00
Maintenance Fees 1000.00
Insurances 300.00
Machine Handling Tools 550.00
Assessment Tax 200.00
Total 2700.00
From Table 3.10, it shows that the fixed cost for a month is RM 2700.00. Since the section
above, the team mentioned that labour will produce 10 pieces of product per month. Thus, the
fixed cost per unit for a month is RM 270.00.
3.5.1.1.4 Total Manufacturing Cost
Total Manufacturing Cost per Unit

= Direct Labor Cost + Direct Materials Cost + Manufacturing Overhead Cost
= 150 + 87.82 + 270
= RM 507.92
The selling price per unit will be charged for 30% of total manufacturing cost per unit:
507.92 X (30/100) = 152.38
Therefore, selling price = 507.92 + 152.38
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= RM 660.30
3.5.1.1.5 Break-Even Point Analysis
Break-even point analysis is a tool to determine either the market of the product can cover
all the cost, fixed cost and variable cost that involving in manufacturing costing. The Table
3.11shows the costs for the jig and fixture with adjustable angle.
Table 3.11: Costs for Jig and fixture with adjustable angle
Fixed Cost RM 2700.00
Sales price per unit RM 660.30
Variable costs per unit RM 87.92
Break-Even point (units) = Fixed Costs ÷ (Sales price per unit – Variable costs per unit)
Break-Even point (units) = 2700 ÷ (660.30 -87.92)
= 4.71
Break-Even point (RM) = 4.71 x 660.30
= RM 3114.73
3.5.1.1.6 Return of Investment (ROI)
Return of Investment (ROI) was calculated to measure the performance of company business.
ROI was calculated by Investment Gain / Investment Base.
Year 1 Year 2 Year Year Year Year

3 4 5 6
Total No. of unit produce x 12 months x RM79236
Inflow selling price
(Revenue) =10 units x12 month x RM660.30
=RM79236
Total No. of unit produce x 12 months x RM60950.4
Outflow Cost per unit
=10 units x12 month x RM507.92
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=RM60950.4
Net Cash Total Inflow- Total Outflow RM18285.6
Flow = RM77434.8- RM59565.6
=RM18285.6
ROI (in%)
= Revenue / Cost = ROI
=77434.8/60950.4
= 1.3
The ROI for design D is 1.3 which mean s is that for every RM1 spend, there will be RM1.3 back
in revenue.
3.6 Ergonomic Analysis
In this part, the human operator normally takes some action. This action is usually
exercised on some kind of control which is to move the handle part at the product. It requires the
human operator to rotate the handle in rotation movement to tightening the workpiece. The action
upon one or more of these controls exerts an influence on the machine and on its output, which
in turn changes the display so that the cycle is continuously repeated. In this part, the human
operator is static, so it required the human operator to accomplish the task from a standing
position where this task might be well accomplished more easily rather than sitting position.
The task required for the human operator is the work of some operation that requiring
equipment and tools that should be placed within the achievable area so that they can be seen and
reached quickly and easily.
Human factor analysis is important in design, the human operator will show how to
operate a product. The human operator should have adequate space, as dictated by human body
dimensions or anthropometry. As a human operator, there is a result of working posture will
display from the CATIA software. Based on the display data, the human operator processes the
data and takes action.
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Figure 3.17: Different working view of the operator
From Figure 3.17 it shows the isometric view, upper view, left view, and front view of
the human operator operates the product. Figure 3.17 can be defined as a normal working area
because space is a standing human operator that can reach and use tools, materials and equipment
when his elbows fall naturally by the side of the body.
Figure 3.18: Isometric view before improvement
From the human operator in Figure 3.18, it is shown that the human operator is
experiencing posture discomfort during work. The RULA analysis before the improvement
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shown that the posture level is 4 and yellow in colour. Hence, the height of the worktable from
the base is 0.83m which is too low. This means that investigation and changes are required
immediately to reduce the discomfort of the human operator while handling the machine. The
problem parts are detected around the forearm and muscle.
Figure 3.19: Isometric view after improvement
Figure 3.20: Left view after improvement
Figure 3.19 and Figure 3.20 shows the isometric and left view of the working environment
of the working posture of the human operator. The product itself is operated by manual handling
74
without any robot or machine assistance. These two figures show the improvement in RULA
analysis of the contact between the human operator and the handle part of the product after the
height of the table has changed. After the improvement, the team has changed the height of the
worktable from the base which is 1.1m. It shows that the human operator is in comfort body
posture. From RULA analysis, it shows that the posture level is 3 and yellow in colour. This
indicates that further investigation is needed and changes may be required. Result score shows
that posture is in good condition and further investigation is needed for any changes.
Problematic posture could be detected using RULA assessment in CATIA software. From
the findings, it shows that further improvement needs to be conducted on manual material
handling at the workstation to avoid discomfort or further health complication.
Figure 3.21: Push-pull analysis
Figure 3.21 shows the push-pull analysis in human activity analysis. The whole-body
working posture for push-pull activity has been designed. This analysis is to study the comfort
level of working posture. Through push-pull analysis, this study identified that the maximum
acceptable initial force when the human operator does the pushing activity is 331.899N. While
the maximum acceptable initial for pulling activity is 269.574. According to the results, the
human operators must either use the initial force of 331.899N to push the handle part or use
269.574N to pull the handle part. The initial force is the primary effort needed for the human
operator to do their works.
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Based on Figure 3.21, the time consumption used is 6seconds to clamp and tighten the
workpiece. Based on our product details, the thread length is 250mm which is 2.5 cm but for the
demo purpose, the distance of push or pull the handle part is 2133.6 millimetres (mm) is equally
2.1m since it is the smallest value in push-pull analysis. Other than that, the population sample is
50% because the subjects for this task is one worker among the two workers. Hence the
population sample is half of the overall workers.
For this part, there is no lift analysis in order human operators does not involve in lifting
the product or uplifting the product. Hence, it only shows the analyses of push-pull analysis data.
Contact stress is damage to the tissue of the body caused by contact between soft tissue
and a hard object. Both internal and external are contact stress. As for the internal, it may occur
when muscles, nerves, tendon, or soft tissue rub, or press, against bone or tendons that may cause
the tissue to bruise. As for the external contact stress, it may cause by a part of the body has to
contact with a hard surface such as a desk. Tissue damage also may occur if a single event or due
to repeated exposure to the stressor over time. Long exposure to contact stress can lead to the
development of musculoskeletal disorders (MSDs). Hence, the workstation should be designed
to limit or prevent exposure to contact stress.
In conclusion, it is important to apply ergonomics standards to keep a healthy life.
Ergonomic is a relatively new field of study and it is acquiring relevance worldwide. In our daily
life, most of the company are applying ergonomic policies because it important for their worker's
posture and habit while working so it will reduce the fatigue and improve the work conditions for
the workers. Problematic posture could be detected using RULA assessment in CATIA software.
From the findings, it shows that further improvement needs to be conducted on manual material
handling at the workstation to avoid discomfort or further health complication.
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CHAPTER 4
PRODUCT ENHANCEMENT- DESIGN D
4.0 Overview
This chapter will include the technical drawing for the design D and the engineering
analysis. Besides, the comparison between design F and design D based on engineering analysis
will also include in this chapter.
4.1 Design Drawing

4.1.1 Part Description
There are some of the parts for design D is same with the design F such as hinges, hinge
rod, sliding jaw, jig, handle, handle cap, jaw piece, fixture, thread forming block, and screw thread
forming rolls (Refer to page 9 for the detail part description). The concept of design D does not
consist of the main base, middle base, rotating base, middle fixture and bolt. The design of the
angle plate for design D is different compare to design F. Besides, the design for the cylindrical
metal, nuts and fixture base is different from the design F. The technical drawing for the
adjustable angle plate, cylindrical metal, nut and fixture base will be included in page 175,176,
177 and 178.
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4.1.2 Exploded View for Design D
Figure 4.1: Exploded view for design D
78
4.1.3 3D CAD for Design D
Figure 4.2: 3D CAD for jig and fixture with adjustable angle-design D
79
4.1.4 2D CAD for Design D
Figure 4.3: 2D CAD for jig and fixture with adjustable angle-design D
80
4.2 Material Selection and Analysis
The material selection process is a vital process in manufacture a product as a wrong

material use may lead to product failure. This process can help engineers to eliminate
unsuitable material and choose one or a few materials which are the most suitable for the part
systematically and rapidly. In this assignment, the student has to choose two important parts
and the team has chosen the jaw piece and the adjustable plate. Figure 4.4 and Figure 4.5 shows
the 3D drawing of the parts. The design of requirement needs to be determined based on the
parts chosen and for this assignment, Ashby chart is used to find the most suitable material.
There are 4 strategies to perform the suitable material which is translation, screening, raking
and documentation.
Figure 4.4: Jaw piece (material selection)- design D
Figure 4.5: Adjustable angle plate (material selection)- design D
4.2.1 Material Selection Jaw Piece- Design D
Table 4.1: Design of requirement for jaw piece- design D

Functions 4) To clamp workpiece tightly by apply force to the workpiece
5) To increase the accuracy of the workpiece by preventing
vibration caused by machinery process
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6) To protect the workpiece by preventing damage dented at the
workpiece
Constraint 5) Fatigue strength above 50 MPa
6) Melting temperature above 100 °C
7) Hardness- Vickers more than750 MPa
8) Must have high compressive strength to clamp workpiece
tightly
Free variables 3) Manufacturing process
4) Choice of material
Table 4.1 shows the design requirement of the jaw piece. The design requirement of a
product is very important since it helps the designer to convert design idea to product features.
It also helps the designer to determine the material properties of the product. In the table, the
function of the product is first identified, and it is important because it helps the designer to
have a clearer mind to design and decide the material used. The function of the jaw pieces to
clamp the workpiece tightly and at the same time protects the workpiece from damage dented.
When the workpiece is clamped tightly, the accuracy of the workpiece is increased.
Furthermore, the fatigue strength of the material to produce the jaw piece should more
than 50MPa. This is because when the machinery process is taking part, the vibration occurs
where if the amplitude if the vibration is too high, the failure of the jaw piece will occur. Thus,
the fatigue strength should be higher than the amplitude of vibration as more vibration means
more loading and unloading at a high frequency. Another reason for the material of jaw piece
should have higher fatigue is when there is the vibration energy produced during machinery
process is transferred to the jigs it will cause the jaw piece to break down. Based on the
mechanical loss coefficient, the more the energy absorbed, the easier the jaw piece of cur failure.
On the other hand, the material of the jaw piece should have the mechanical properties
which are high melting temperature which is above 100 °C. The melting point of the material
used is important because it can protect and elongate the lifetime of the jaw piece. During the
machinery process, heat is producing due to the friction between the machining tool and the
workpiece. As most of the workpiece used is metal, thus the heat produced by the friction will
82
transfer to the jaw piece. Thus, the jaw piece needs to have a high melting point so that the jaw
piece can withstand the heat from the workpiece.
Next, the Vickers hardness of the material should more than 750MPa. This is because
the hardness is always having a direct relationship with the wear resistance. The harder the
material, the higher the wear resistance. The higher wear resistance enables jaw piece to resist
wear due to rubbing or impact from the workpiece. Another reason for the material for jaw
piece should harder is to prevent the jaw piece from indent when clamping a harder material
such as diamond. If the material for the jaw piece is too soft it may cause the harder workpiece
to embed into the jaw and stuck. The compressive strength of material should be maximized
so that it ensures the fixture able to clamp workpiece tightly with high grip force without
breaking the jaw piece.
The objectives of the material selected are also vital criteria for a design requirement.
The material selected should have minimized cost so that the profit gain by the company is
maximized. This is important because the profit gain for this product will help the company to
design another new product which brings benefit to the customers. Other than that, the weight
should be minimized since one of the features of the jig and fixture with adjustable angle
designed is portable, if the density of jaw piece is high, it will affect the overall weight of the
jig and fixture with the adjustable angle in which it may cause the user hard to carry the jig and
fixture with adjustable angle.
The free variables are the manufacturing process to produce the material and also the
choice of material selection. In short, the design requirements of jaw piece are important so
that designer can produce a product with a clearer vision on what is the important mechanical
properties should include in the material selected.
After determining the design of the requirement, the Ashby chart is used to determine
the suitable material for the jaw piece. Figure 4.48 shows the potential materials determine by
the Ashby chart.
83
Figure 4.6: Potential material chosen for the jaw piece- design D
Based on Figure 4.6 above, it clearly shows that the potential material chosen is
stainless steel, aluminum alloy, grey cast iron, wrought magnesium alloy and high carbon steel.
The final material chosen is the grey cast iron which has the second ranking among all.
Although the high carbon steel has the highest material properties such as fatigue strength,
hardness-Vickers and the lowest price it is not the BEST material for jaw piece. This is because,
among the candidates, the cast iron which is the is chosen as the BEST material for manufacture
jaw since, among the candidates, there is only one material which is cast iron have the history
of use for manufacture jaw. Despite it does not have a high material property compare to high
carbon steel but the history of cast iron to manufacture jaw piece allows cast iron to stand out
the most suitable material over the other material. Table 4.2 shows the comments on the
material chosen.
Table 4.2: Comments on the materials for jaw piece-design D

Material Comments
Stainless steel High cost; High density
Age Hardening Wrought Moderate cost, Low density
Aluminum alloy
Wrought Magnesium Alloy Low density; Low cost; Performance not good as
others
Gray Cast Iron Good performance with a minimum cost; Moderate
density; Have a history to manufacture jaw piece
High carbon steel Good performance with low cost; No history to
manufacture jaw piece
84
4.2.2 Material Selection Adjustable Angle Plate- Design D
Table 4.3: Design of requirement for adjustable angle plate- design D

Functions 1) To have a variety of angle holes.
2) To make the drilling process of angle holes easy.
3) To decrease the number of tools for drilling angle holes.
Constraint 1) Fatigue strength above 40Mpa
2) Fracture toughness above 70Mpa
3) Compressive strength more than 900Mpa
3) Maximize the stiffness
Free variables 1) Maximize the stiffness
Table 4.3 above shows the design requirement of the adjustable angle plate. The
function of the adjustable angle plate is to make a variety of angle holes and at the same time
is to decrease the number of tools for drilling angle holes. By using the adjustable angle plate,
the drilling process to perform angle holes will become simpler.
Other than that, the fatigue strength of the material to produce the adjustable angle
plates need to more than 60Mpa. It is because the adjustable angle plates have to support the
load of the jig and fixture and workpiece during the machinery process. Although, the vibration
of the machinery process and the weight of jig and fixture and workpiece may cause the
adjustable an angle plates failed to support the weight. A material with high fatigue strength
will prevent the weakening of a material caused by the increasing number of loading which
results in the structural damage and the growth of cracks.
Besides, to avoid fracturing of the adjustable angle plate, the fracture toughness should
be greater than 70Mpa. This is because each single loading period would cause the crack to
increase in a small amount until the fatigue crack has appeared. The crack will continue to
expand until a critical point is reached. If the stress strength factor of the craw exceeds the
fracture toughness has been set, the adjustable angle plate triggers facture. Therefore, the
material of the adjustable angle plate should have high fracture toughness.
85
Next, the compressive strength of the adjustable angle plate should be higher as there
is a cylindrical metal pass through the holes on the adjustable angle plate. The weight of the jig
and fixture and workpiece will be withstood by the cylindrical metal. The cylindrical metal will
absorb the compressive force caused by the weight of the jig and fixture and workpiece, then
it will transfer to the adjustable angle plate. Thus, the compressive force of the adjustable angle
plate should higher to prevent the loads tending to change the angle of holes which this
indirectly increases the accuracy of the adjustable angle plate.
On the other hand, the objective of the selected material is to reduce the cost, weight
and maximize the rigidity of the material. The explanation of why the price and weight should
be reduced is the same as the piece of the jaw. One of the reasons that required to maximize
the stiffness of the material is to resist the deflection of the adjustable angle plate under the
bending force caused by the cylindrical metal. The accuracy of the drilling holes will be
improved by placing a protractor on the product so that various type of angle can be performed
while drilling the angle holes. If deflection occurs on the adjustable angle plates, it will impact
the work piece’s angle holes accuracy.
Lastly, the free variable is the preference of the chosen content. In short, the design
specifications of the adjustable angle holes are critical so that the manufacturer can create a
product with a clearer vision of what the material chosen should provide in the significant
mechanical propertied.
Figure 4.7: Potential material chosen for the adjustable angle plate-design D
86
Based on Figure 4.7 above, it has been stated that the potential material chosen for the
adjustable angle plate is cast iron, stainless steel, low alloy steel, medium carbon steel and high
carbon steel. Cast iron got the high score for the final material that has been chosen for
adjustable angle plates. Although the price among the five potential material is quite same, cast
iron also has a better material performance in term of fatigue strength, hardness young’s
modulus, easy to machine and have a higher level of vibration damping than steel. Hence, cast
iron is chosen as the best material for the adjustable angle plate with its history and outstanding
performance. Table 4.4 shows the comments on potential materials.
Table 4.4: Comments on potential materials for adjustable angle plate- design D
Material Comments
Stainless steel Low Compressive Strength; High cost; Same density as other
material except for Cast iron
Low alloy steel Good performance with a minimum cost; Same density as other
material except for Cast Iron
Medium carbon steel Lower hardness; Lower fatigue strength, Lowest cost; Same
density as others except for Cast iron
High carbon steel Lower Compressive strength; Lower young’s modulus; Lowest
cost; Same density as others except for Cast iron
Cast iron Good performance with a minimum cost; Moderate density;
Have a history involved in machine tool chassis
4.3 DMFA
Based on the exploded view of the jig and fixture with adjustable angle which shows in
Figure 4.1, the team have developed the Table 4.5 which is the parts of jig and fixture with
adjustable angle and their respective assembly time.
Table 4.5: Components with their respective assembly time for Design D
No
of Theoretical Handling Insertion Assembly Assembly
No Part Name Part Part Time (s) Time (s) time (s) cost (cent)
87
1 Fixture Base 1 1 3.65 4.60 16.79 2.18
2 Nut 2 1 2.00 15.00 30.00 3.90
Hinge
3 (Upper part) 1 1 3.03 2.36 7.15 0.93
Hinge
4 (Lower part) 1 1 3.03 2.36 7.15 0.93
5 Hinge Rod 1 1 2.11 3.00 6.33 0.82
6 Sliding Jaw 1 1 4.30 2.36 10.15 1.32
7 Jig 1 1 3.65 2.58 9.42 1.22
8 Screw 12 1 2.31 60.00 250.95 18.02
9 Handle 1 1 3.00 3.15 9.45 1.23
10 Jaw Piece 2 1 2.30 3.10 7.13 0.93
11 Fixture 1 1 3.90 3.15 12.29 1.60
Thread
Forming
12 Block 1 1 2.30 5.87 13.50 1.76
Screw
Thread
13 Forming 1 1 4.23 7.25 30.67 3.99
Cylindrical
14 Metal 1 1 5.30 2.36 12.51 1.63
Adjustable
15 Angle Plate 2 1 2.60 4.25 11.05 1.44
16 Handle Cap 1 1 2.30 2.10 7.00 0.91
17 Total 30 16 50.01 123.49 441.54 57.4
Design efficiency, Ema = 𝑡𝑚𝑎
where:
Nmin = the theoretical part minimum
tma = total assembly time
ta = the theoretical, lowest assembly time
So, the design efficiency for the immobile people carrier is,
88
Ema = 𝑡𝑚𝑎
where:
Nmin = 16 parts
tma = 441.54
ta = 6.33
(16)𝑥 6.33𝑠
Design efficiency, Ema = x 100% = 22.94%
441.54
According to the decision matrix in Figure 3.5, the product with design efficiency of
22.94% is in the decision category of a very good result. Figure 3.5 above shows that design
efficiency above 20% can be accepted and proceeds with production. After the team have done
the calculation on design efficiency of our product, the team get 27% of efficiency. Hence, it
can proceed to production without needing any redesign on the product.
Other than that, the assumption is made to calculate the assembly cost of the product.
The team have assumed the labor cost to be RM 7.5 per hour or RM0.13 per second to assemble
the product. The assembly cost for the product is 57.4 cents which are around RM 0.57 for each
unit.
4.4 Product Sustainability Analysis

4.4.1 Product Life Cycle
Figure 4.8 shows the life cycle for the Design D. It is divided into 6 different types of
material which are stainless steel, cast iron, mild steel, carbon steel, high tensile steel and die
steel. The material that used to produce the jig and fixture with adjustable angle is mostly metal
which can be reused, recycle or remanufacture so that the environmental impact afterlife will
be mitigated.
89
Figure 4.8: Product Life Cycle- Design D
4.4.2 Eco-Design Web
Eco-design web is a qualitative method which uses to analyze a product design or

existing product. Besides, it is also used during product analysis to identify the problem from
design ideas and help to improve ideas product. Furthermore, it can be used to indicate problem
areas of the product that can be redesigned to improve its environmental sustainability. In short,
the eco-design web is useful when assessing an existing product for redesign or design idea
and it helps to improve idea and products.
90
Eco web design for each material which used to produce every component of jig and
fixture. By using this eco web design, the team can compare how bad and good of the design
areas product, to assess the environmental performances of a current product, identify the
problem areas of the product and outlines the targets for the redesign.
Figure 4.9: Eco-design web for mild steel
Figure 4.9 showed eco-design web for mild steel material. There are three components
used mild steel material which is the body of fixture, sliding jaws and jig. Mild steel is
economical and cheapest material that often used for jig and fixture material. It also has good
material selection because steel is the most recycled material in the world. The scales showed
91
all the criteria is give a good impact on the two components. Mild steel is a green product. It is
100% recyclable, as it is not coated with any toxic material it does not produce toxic run-off.
During production, mild steel uses scrap metal as its primary raw material, with up to 70% of
the product coming from recycled material. Increased efficiency in the process technology has
also decreased the amount of energy required to manufacture stainless steel. Even if mild steel
is not recycled and it does find its way to a landfill or disposal site, it will have no detrimental
effect on the soil or groundwater. Mild steel is the preferred material for green building
throughout the world. Its impact on the environment is minimal when compared to other
materials and its life impact reduces significantly as it used and recycled.
Figure 4.10: Eco-design web for carbon steel
92
Figure 4.10 showed eco-design web for carbon steel. There is one component used
carbon steel material which is the hinge and hinge rod. Carbon steel has higher carbon content
so carbon steel has higher strengthened and hardness. The scaled showed all the criteria give a
good impact on the component.
Figure 4.11: Eco-design web for die steel
Figure 4.11 showed Eco design web for die steel material. There are three components
used die steel material which is screw threading forming rolls, handle cap and handle. The
material properties of die steel properties are high hardness, high wear and abrasion resistant
93
properties so suitable used for this component. The scaled shows all criteria give good impact
for this component.
Figure 4.12: Eco-design web for high tensile steel
Figure 4.12 showed eco-design web for high tensile steel material. This material is only
used for one component which is cylindrical metal. Cylindrical metal is just joining process for
this product and this material most suitable for the fastener and joint part because high tensile
steel material was hardest. The scaled showed all criteria give good impact except the optimal
life. it is because the high tensile steel is brittle so cannot be repaired.
94
Figure 4.13: Eco-design for cast iron
Figure 4.13showed Eco design web for cast iron material. There are seven component
used cast iron material which it can be said that most of the part for jig and fixture with
adjustable angle is made from cast iron. The component that used cast iron material is fixture
base, angle plate, jaw piece and thread forming block The scaled shows that all criteria give
the average impact of the component. Cast iron is one of the oldest materials in engineering, it
is seeing something of a rebirth of fortunes in the modern world with regards to environmental
impact and sustainability. This is based on the fact that cast iron does not rust in the traditional
sense, it oxidises very slowly. This process gives off iron ashes which are carbon-based on
good for the environment. It promotes green growth on plants and increases planktonic life in
in the oceans, thus combating global warming. Cast iron is also totally recyclable and recycled
steel, largely from the automotive and engineering industries, and any house returns meaning
that any wastage in the manufacturing process is put back into the furnace and melted to make
new iron.
95
Figure 4.14: Eco-design for stainless steel
Figure 4.14 shows the Eco design web for stainless steel. The component used material
stainless steel is nut and screw. Stainless steel suitable for nut function because of high strength
and durability. Stainless steel is a green material that can recyclable. Stainless steel has good
mechanical properties at low and high temperatures.
4.4.3 Eco Indicator
Table 4.6 shows the eco indicator of design D.
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Table 4.6: Eco indicator table for design D
Jig and Fixture with Adjustable Angle
Production
Materials, processing, transport and extra energy
Material or process Amount Indicator Results
Cast iron 8.307 kg 240 1993.68
Mild steel 11.32 kg 86 973.52
Carbon steel 0.295 kg 110 32.45
High tensile steel 0.092 kg 910 83.72
Die steel 0.408 kg 910 371.28
Stainless steel 0.885 kg 86 76.11
Milling, Turning, Drilling 20.127 kg 800 16101.6
Total 19632.36
Use
Transport, energy and auxiliary materials
Process Amount Indicator Results
Transport (40-tonne truck) 234.377 tkm 15 3515.655
Total 3515.655
Disposal
Disposal processes per type of material
Material Amount Indicator Results
Recycling Ferro metals 21.307 kg -94 -2002.858
Total -2002.858
Grand Total 21145.157
The assumption for product life span and average daily used
a) Product life span: Assume that jig and fixture with adjustable angle can use for one year.
b) Average daily use: Assume use 20 hours per day to produce 1000 parts per day.
Assumption for transport
Total weight = 21.307 kg
Assuming distance to be transported = 11000 km
(21.307
1000
) × 11000 𝑘𝑚 = 234.377 𝑡𝑘𝑚
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4.4.4 Sustainability Report
Sustainability
Report
Model Name: Assem1
Weight: 15111.53 g
Manufacturing Region
The choice of manufacturing region determines
the energy sources and technologies used in the
modeled material creation and manufacturing
steps of the product’s life cycle.
Use Region
The use region is used to determine the energy
sources consumed during the product’s use
phase (if applicable) and the destination for the
product at its end-of-life. Together with the
manufacturing region, the use region is also used
to estimate the environmental impacts
associated with transporting the product from its
manufacturing location to its use location.
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Model Name: Assem1 Weight: 15111.53 g
Assembly Process Use
Region: Asia Region: Asia

Energy type: None Energy type: None
Energy amount: 0.00 kWh Energy amount: 0.00 kWh
Built to last: 1.0 year Duration of use: 1.0 year
Transportation End of Life
Truck distance: 1600 km Recycled: 21 %

Train distance: 0.00 km Incinerated: 5.7 %
Ship distance: 0.00 km Landfill: 73 %
Airplane Distance: 0.00 km
99

Environmental Impact (calculated using CML impact assessment methodology)

Carbon Footprint
Total Energy Consumed
Materi 22 kg
Materi
al: CO2e 300 MJ
al:
Manuf
12 kg Manuf
acturin
CO2e acturin 120 MJ
g:
g:
0.00 kg
Use: Use: 0.00 MJ
CO2e
Trans
Transp
2.4 kg portati 33 MJ
ortatio
CO2e on:
n:
End of
End of 8.9 kg 6.4 MJ
Life:
Life: CO2e
460 MJ
46 kg CO2e
Water Eutrophication
Air Acidification 0.015 kg
Material:
PO4e
Material: 0.064 kg SO2e
Manufact 6.4E-3 kg
Manufacturi
0.163 kg SO2e uring: PO4e
ng:
0.00 kg
Use: 0.00 kg SO2e Use:
PO4e
Transportati
0.012 kg SO2e Transport 2.5E-3 kg
on:
ation: PO4e
End of Life: 3.8E-3 kg SO2e
End of 0.014 kg
0.243 kg SO2e Life: PO4e
0.037 kg PO4e
100
Material Financial Impact 6.10 USD
101

use:
Component Environmental Impact

Top Ten Components Contributing Most to the Four Areas of Environmental Impact
102
Component Carbon Water Air Energy
Fixture Base
20 0.015 0.112 200
(Design 2)
Fixture 16 0.012 0.093 190
Jig 2.2 1.7E-3 0.013 27
Screw Thread
1.7 1.4E-3 0.010 21
Forming
sliding jaw 1.7 1.3E-3 9.6E-3 19
Angle plate
2.0 ( Design 1.1 6.3E-4 4.9E-3 14
2)
hinge (upper
0.874 4.7E-4 7.5E-3 9.9
part)
hinge6(lower
0.495 2.7E-4 2.8E-3 5.8
part)
Cylinder
0.381 3.1E-4 1.7E-3 4.9
(Design2)
jaws 0.211 1.6E-4 1.2E-3 2.1
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Based on the report above, it clearly shows that there is no energy amount during the
usage of the Design D. From the report, it can be concluded that the design D brings a huge
impact to the environment at the end of life as it is only 21% of the material able to recycle.
There is 73% of the material used to end up in the landfill. As all the components used to
produce the design D is metal, thus, the carbon footprint, total energy consumed and the water
eutrophication during the material extraction process is very high. Besides, the air acidification
during the manufacturing process of design D is quite high compare to others. Furthermore,
the report shows that there is no environmental impact during the useful time of the jig and
fixture with adjustable angle. This is because during the useful time it acts as an assistant to
product angle holes. It does not require any energy to operate it. From the report, it also can be
concluded that the fixture base has the highest environmental impact and followed by the
fixture base and jig. This is because the size of material used in these three components is larger
compare to the other components and the type of material used for the three components
produce larger environmental impact compared to others. On the other hand, jaws have the
least environmental impact due to its small size and material used.
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4.5 Mechanical Analysis
4.5.1 Static and Strength of Material-Design D
Figure 4.15: Jig and fixture with adjustable angle- Design D
Table 4.7: Details for simulation-Design D

Force Assumed Machining Force: 12000 N
Clamping Force (Sliding jaw): 1000 N
Clamping Force (Nut): 15455 N
Mass Mass workpiece: 3.5 kg
Area Product: 320 x 342 mm
Workpiece: 90mm (L) x 100 (W) x 60 mm (H)
4.5.1.1 FBD During Machining Process on Workpiece-Design D
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Figure 4.16: FBD during the machining process on the workpiece- Design D
4.5.1.1.1 Calculation Structural Analysis (Compression Force)

Machining Force, Fm = 12000 N
Mass of workpiece = 3.5 kg
W= mg cos Ɵ
W= 3.5(9.81) cos 30
= 297.35N
∑Fy = 0
0 = -Fm – W + Fc sin 30 + (-Fna sin 30) + Fnb sin 30+ 2 f cos 30
0 = -12000 – 297.35 + 1000 sin 30 – Fna sin 30 + Fnb sin 30 + 2f cos 30
119797.35 = 0.5(Fnb- Fna) + 1.732 f
119797.35 = 0.5(Fnb- Fna) + 1.732(-866.03 N – 0.866 (Fna- Fnb)
∑Fx = 0
Fc cos 30 + Fna cos 30 – Fnb cos 30 + 2f sin 30 = 0
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1000 cos 30 + 0.866 ( Fna – Fnb) + f = 0
f = -866.03 N – 0.866 ( Fna- Fnb)
f = -866.03 N – 0.866 (- 48518.92 – 48518.92)
= 83168.74 N
Normal Force Answer
Fna = -48518.92 N
Fnb = 48518.92 N
↷∑Mx = 0
= Fm xd – Wd + f(d) – f(d)
= 12000 (30 cos 30) – 297.35 + 83168.74 ( 50) - 83168.74 ( 50)
= 3117691.45 Nm
Stress on the workpiece

Clamping Force
Stress = Area
1000
= 2(90 x 60)mm2
1000
= 0.0108m2
= 92592.59 N/𝑚2
Normal Stress
P = 48548.92N
Area = 90 x 60 𝑚𝑚2 =0.0054𝑚2
𝑃 48548.92 𝑁
ꝹBC = 𝐴 = = 8990540.74 Pa
0.0054𝑚2
Shear Stress
V = 1000 N
A = 90 x 60 𝑚𝑚2 =0.0054𝑚2
𝑉 1000 𝑁
Ꞇavg = 𝐴 = 0.0054 = 185185.19 Pa
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4.5.1.2 FBD During Machining Process on Angle Plate-Design D
Figure 4.17: FBD during the machining process on angle plate- Design D
4.5.1.2.1 Calculation Structural Analysis

Machining Force, Fm = 12000 N
Mass = 3.5 kg
∑Fx = 0
- 𝐹𝑛 cos 30 + f sin 30 = 0
−(240316.231 + 1.732f) cos 30 +f0.5 = 0
−208119.96 + 1.5f + 0.5f = 0
2𝑓 = 208191.07
f = 104059.98
∑Fz = 0
− 𝐹𝑚 - 𝐹𝑛 sin 30 - f cos 30 = 0
𝐹𝑚 = 𝑚𝑎𝑐ℎ𝑖𝑛𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒 + 𝑤𝑒𝑖𝑔ℎ𝑡 𝑓𝑜𝑟 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 + 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑤𝑜𝑟𝑘𝑝𝑖𝑒𝑐𝑒
= 120000 + 15.11 (9.81) cos 30 + 3.5(9.81) cos 30
= 120158.11 N
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0.5𝐹𝑛 + 0.866f = 120158.11
120199.17−0.866𝑓
𝐹𝑛 =
0.5
= 24016.23 – 1.732f
=-156215.66N
∑Fy = 0
Fy = Fc
= 15455 N
Stress on angle plate (Assume contact surface of the cylinder and angle plate is 10mm x
3.917mm)
Figure 4.18: Example of contact area for design D
109
Figure 4.19: Calculation of rectangular contact area for design D
Figure 4.20: Result for rectangular contact area for design D
Force
Stress = 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑎𝑛𝑔𝑙𝑒 𝑝𝑙𝑎𝑡𝑒 𝑑𝑢𝑟𝑖𝑛𝑔 𝑚𝑎𝑐ℎ𝑖𝑛𝑖𝑛𝑔 𝑝𝑟𝑜𝑐𝑒𝑠𝑠
120158.11
= 2(10x3.917)mm2
120158.11
= 0.00007834
= 1533802783 N/𝑚2
Normal Stress
P = 156215.66 N
Area = 0.00007834𝑚2
𝑃 156215.66 𝑁
ꝹBC = 𝐴 = 0.00007834𝑚2 = 1994072760 Pa
Shear Stress
V = 120158.11 N
A = 2(10x3.917)mm2 = 0.00007834m2
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𝑉 120158.11 𝑁
Ꞇavg = 𝐴 = = 1533802783 Pa
0.00007834
5.5.1.3 Calculation Factor of Safety
Ꞇfail 𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ

Factor of Safety = Ꞇallow , F.S.n = 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑆𝑡𝑟𝑒𝑠𝑠
i. (Jaws)
1.52 𝑥 108
Factor of Safety , FoS = 5.676 𝑥 106 𝑃𝑎 = 26.78
ii. (Plate)
1.5165 𝑥 108
1.41 𝑥 1010
iii. (Handle)
7.23 𝑥 108
1.015 𝑥 105
4.5.2 Simulation Analysis

4.5.2.1 Jaw Piece
For the first step, the jaw piece is fixed at the base jaws and force is exerted on the
workpiece. The team has chosen to exert force on the workpiece because when machining
process, clamping force will exert to workpiece and effect to the jaws. The assumed clamping
force is 1000N. The material chosen for jaws is grey cast iron.
Simulation Jaws
Date: Thursday, May 28 2020
Designer: Solidwork
Study Name: Simulation Clamping
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Next, the mesh control setting is done. The mesh will be setting to fine because it will
get an accurate result.
This figure below shows the after mesh control. The geometry of mesh is smaller than
other which means the accuracy and quality are more fine and good after doing mesh control.
The grey cast iron material will apply fine mesh and get an accurate result.
112
113
114
The jaws part used to clamp the workpiece. Material for jaws is grey cast iron. The
maximum value for the stress of this part is 5.67e+06 N/m2 while the minimum value is
4.041e+01 N/m2. The maximum displacement value is 3.1775e-04mm. The strain value
5.677e-05. Its shows the value is higher than material properties of yield strength. The
maximum factor of safety value is 1.130e+07 and minimum value is 9.233e+01. In short, from
the simulation result above, it shows that the jaws are safe for use. Minimal stress and
deformation should give the effect of both a solid and lightweight jaws.
115
4.5.2.2 Adjustable Angle Plate
Firstly, the plate is fixed at the fixture base by using cylinder and nuts then the force
will exert along on the slot. For this part, the team has chosen the area angle that force exerts
for simulation purpose. Thus, the force will be exerted at the slot for degrees angle because
when machining process, machining force will exert to the workpiece. The force exerted on
the workpiece is transfer to the adjustable angle plate. The assumed machining force is 12000N.
The second force is the force from tightening nuts when the fixture has fixed at certain angle
slot needs tightening force exerted 15455N. the material chosen for this plate angle is grey cast
iron.
Simulation of Plate Angle

Designer: Solidwork
Study Name: Simulation Force Analysis
Type: Static
116
117
118
119
The adjustable angle part is used to adjust angle fixture and make workpiece in angle
position. This part used alloy steel. The maximum value for the stress of this part is 1.414e+10
N/m2 while the minimum stress value is 9.338e+05 N/m2. The maximum displacement value
is 1.124e-06mm. The maximum strain value is 1.31e-01N/m2 while the minimum strain value
is 2.23e-5 N/m2. The maximum factor of safety value is 2.278e+02. All this result shows that
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parts limit to breakage and effect the workpiece. In a nutshell, from the result simulation can
see the plate is safe for use. Minimal stress and deformation should give the effect of both a
solid and lightweight plate.
4.5.2.3 Handle
Firstly, the handle is fixed at the screw thread forming rod. The force is exerted on both
corners of the rod because when to set up to clamp the workpiece, the human force will exert
to handle and effect to the handle. The assumed human force 1.1 N. The material chosen for
the handle is alloy steel.
Simulation of Handle

Designer: Solidwork
Study Name: c Simulation Force
Analysis Name: Static
121
Next, the mesh control setting is done. The mesh will be setting to fine because it will
get an accurate result.
122
123
The handle part used to turn the screw thread forming and move the sliding jaws.
Material for the handle is die steel. The maximum value for the stress of this part is 1.015e+05
N/m 2 while the minimum value is 2.117e-06 N/m2. The human force 1.1 N will exert to the
handle. The maximum displacement value is 4.089e+06 mm. The maximum strain value
4.782e-07 while the minimum strain value is 1.309e-17. Its shows the value is higher than
material properties of tensile strength that make part will fracture. The maximum factor of
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safety value is 2.931e+14 and the minimum value is 6.113e+03. In conclusion, the result
simulation can see the handle deemed safe for use. Minimal stress and deformation should give
the effect of both a solid and lightweight handle.
4.5.3 Heat Flow Analysis
Heat flow is defined as the transfer of thermal energy from one party to another by
having contact. In this assignment, heat flow analysis will not be carried out since for the team’s
product, it will not experience a lot of heat changes during operation
4.6 Cost Analysis

4.6.1 Bill of Material (BOM)
Table 4.8 below shows the quantity and material used of design D. The jig and fixture
with adjustable angle have 15 components and every part is very important and each part has
its function.
Table 4.8: Quantity and material used for design D
Part Number Part Name Quantity Material
1 Fixture base 1 Cast Iron
2 Fixture 1 Mild Steel
3 Angle Plate 2 Cast Iron
4 Sliding Jaws 1 Mild Steel
5 Jaw Piece 2 Cast Iron
6 Hinge 2 Carbon Steel
7 Hinge Rod 1 Carbon Steel
8 Cylindrical Metal 1 High Tensile Steel
9 Nut 2 Stainless steel
10 Jig 1 Mild Steels
11 Screw thread forming rolls 1 Die Steels
12 Screw 12 Stainless Steel
13 Handle 1 Die Steels
14 Handle Cap 1 Die Steels
15 Thread Forming Block 1 Cast Iron
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4.6.2 Estimation Cost
4.6.2.1 Material Cost
Table 4.9 shows the material cost for design D.
Table 4.9: Material cost for design D

Material Used Kilograms Used Price/ Kilogram Total Price for Material
Used
Cast iron 8.307 kg RM 5.21 /kg RM 43.28
Mild steel 11.32 kg RM 2.17/kg RM 24.56
Carbon steels 0.295 kg RM 2.2/kg RM 0.65
Stainless steel 0.885 kg RM 3.63/kg BM 3.21
High tensile steel 0.092 kg RM 3.16/kg RM 2.91
Die steels 0.408 kg RM 4.34/kg RM 1.77
Total RM 76.38
4.6.2.2 Labour Cost
Labour cost consists of labour wages for producing one product. Minimum wages in
Malaysia for labour is RM 1500.00 for a month. One labour can produce 10 jig and fixture a
month. Thus, the labour cost per unit is RM 150.00.
4.6.2.3 Fixed Cost (Overhead Manufacturing Cost)
Fixed cost is the cost that about going business expenses excluded labour cost and
material cost.
Table 4.10: Fixed cost for manufacturing design D
Overhead Cost Cost (RM)
Water Bill 150.00
Electrical Bill 500.00
Maintenance Fees 1000.00
Insurances 300.00
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Machine Handling Tools 550.00
Assessment Tax 200.00
Total 2700.00
From Table 4.10, it shows that the fixed cost for a month is RM 2700.00.
Since the section above, the team mentioned that labor will produce 10 pieces of
product per month. Thus, the fixed cost per unit for a month is RM 270.00.
4.6.2.4 Total Manufacturing Cost
Total Manufacturing Cost per Unit

= Direct Labor Cost + Direct Materials Cost + Manufacturing Overhead Cost
= 150 + 76.38 + 270 = RM 496.38
The selling price per unit will be charged for 30% of total manufacturing cost per unit:
496.38 x (30/100) = 148.91
Therefore, selling price = 496.38 + 148.91
= RM 645.29
4.6.2.5 Break-Even Analysis
Break-even point analysis is a tool to determine either the market of the product can
cover all the cost, fixed cost and variable cost that involving in manufacturing costing. The
Table shows the costs for the jig and fixture with adjustable angle.
Table 4.11: Costs for Jig and fixture with adjustable angle
Fixed Cost RM 2700.00
Sales price per unit RM 645.29
Variable costs per unit RM 76.38
Break-Even point (units) = Fixed Costs ÷ (Sales price per unit – Variable costs per unit)
Break-Even point (units) = 2700 ÷ (645.29 – 76.38)
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= 4.75
Break-Even point (RM) = 4.75 x 645.29
= RM 3065.13
4.6.2.6 Return of Investment (ROI)
Return of Investment (ROI) was calculated to measure the performance of company business.
ROI was calculated by Investment Gain / Investment Base.
Year 1 Year 2 Year Year Year Year

3 4 5 6
Inflow selling price
(Revenue) =10 units x12 month x RM645.29
=RM77434.8
Outflow Cost per unit
=10 units x12 month x RM496.38
=RM59565.6
Net Cash Total Inflow- Total Outflow RM17869.2
Flow = RM77434.8- RM59565.6
=RM17869.2
ROI (in%)
= Revenue / Cost = ROI
=77434.8/59565.6
= 1.3
The ROI for design D is 1.3 which mean s is that for every RM1 spend, there will be RM1.3
back in revenue.
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4.7 Human Factor Engineering Analysis
Ergonomic plays an important role in the industry to improve the safety and health of
the human body. It is related to the worker in the workplace. The ergonomic goal is to merge
machine and man to increase the efficiency of the worker, minimize risk, stress and fatigue at
the workplace. Ergonomics concerns are often connected to the workplace, and workplaces
that have ergonomics problem will affect humans, for example through muscle pain and even
worse such as an accident will occur in the workplace. The most common forms of ergonomic
accidents and illness are musculoskeletal disorders (MSDs). MSDs are injuries to the human
body that affect the spinal tendons, muscles, ligaments, and nerves in particular. It is a big issue
in ergonomics that can cause permanent disability. Planning how the job is conducted may
affect the human body when working and needs to be done properly to prevent harm to the
human being at work. RULA analysis is one of the methods that allow the assessment of loads
incurred by the muscle-skeletal system due to work posture, use of muscle that exerted force
and can quantify sensitivity to risk factors associated with work-related upper limb disorder.
In this ergonomic analysis part, some changes made on the product itself. The human
operator normally takes some action and this kind of action usually exercised on some kind of
control which is to move the handle part of the product intermittently. This kind of action
requires the human operator to rotate the handle in rotation movement to tightening the
workpiece. The action upon one or more of these controls exerts an influence on the machine
and on its output, which in turn changes the display so that the cycles is continuously repeated.
Based on the real situation in the industry, the human operator is static in his position, so it is
required the human operator to accomplish the task from a standing position where it might be
well accomplished more easily than sitting position. Other than that, based on ergonomic
analysis standing position is preferred over seating when the working area is too large to be
comfortably reached.
The task required for the human operator is the work of some operation that requiring
equipment and tools that should be placed within the achievable area so that they can be seen
and reached quickly and easily.
Human factor analysis is important in design. It is stated that the human operator will
show how to operate a product. The human operator should have adequate space, as dictated
by human body dimensions or anthropometry. As a human operator, there is a result of standing
working posture that the team get from the CATIA software. Based on the display data, the
human operator processes the data and takes action.
129
Figure 4.21: Different working view of the human operator- design D
Based on Figure 4.21, the CATIA software shows the isometric view, upper view, and
front view of the human operator to operate the product. Other than that, as space is a standing
human operator who can reach and use instruments materials and equipment when his elbows
fall naturally on the side of the body based on the Figure 4.21 that can be described as a normal
working area.
Figure 4.22: Result of RULA analysis on old posture- design D
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Based on Figure 4.21, it has shown the human operator is experiencing posture of
discomfort during work progress. The RULA analysis for the old posture shows that the posture
level or the score is 5 and orange in colour. Besides, the height of the worktable from the base
is 0.73m which is too low. This means that the investigation and changes are required
immediately to reduce the discomfort of the human operator while operating the drilling
machine. The problem parts that are detected from the human operator are forearm, wrist, neck,
trunk, and leg.
According to the current posture, the human operator not only feel uncomfortable
during the drilling process but it also resulted in a bad drill because of the human operator
cannot maintain the same posture during the drilling. Figure 4.21 show that several human
body parts have a high score with a score of 6 at the neck, trunk and leg. It is showing the
orange colour indicating high risk and required changes immediately. The posture set to be
intermittent with a final score of 5.
Figure 4.23: Result of RULA analysis in new posture from the isometric view- design D
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Figure 4.24: Result of RULA analysis in new posture from the left view- design D
Figure 4.23 and Figure 4.24 shows the new posture of the human operator during the
drilling activity from two views which is the isometric and left view. These two figures show
the improvement in RULA analysis of the contact between the human operator and the handle
part of the product after the height of the table has changed. After the improvement was made,
the team changed the height of the worktable from the base which is 1.1m. It shows that the
human operator is in comfort body posture. The student can use a floor mat while performing
the drilling activity to reduce the discomfort if it takes too long. The majority of the load of the
body is transferred to the arms where both arms are supported by the handle of the product
while tightening the workpiece.
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Figure 4.25: Result of RULA analysis for new posture- design D
The result of RULA analysis for the new posture in Figure 4.25 shows an improvement
compared to the current posture using the existing design. Most parts of the human operator
have a lower score between 0 and 2. Besides, the colour shown is green, indicating that the
posture is at a lower risk. For this analysis, the posture of the human operator was set to be
intermittent with the arm supported. The final score is 2 and the posture can be considered as
acceptable. This result has also shown that the human operator does not have any ergonomic
problems while performing the drilling activity. It can be confidently assumed that the changes
in the worktable height are successful in eliminating the risk of ergonomics experienced by the
human operator.
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Figure 4.26: Push and pull analysis- design D
Figure 4.26 shows the push and pull analysis in human activity analysis. The whole-
body working posture or push and pull activity has been designed. This analysis is to study the
comfort level of working posture. Through the push and pull analysis, this study identified that
the maximum acceptable initial for pushing activity is 328.55N. While the maximum
acceptable initial for pulling activity is 257.51N. According to the results, the human operators
must either use the initial force of 328.55N to push the handle part or use 257.1N to pull the
handle part. The initial force is the primary effort needed for the human operator to do their
work.
Based on Figure 4.26, the time consumption used is 6 seconds to clamp and tighten the
workpiece. Based on our product details, the thread length is 251mm which is 2.51 cm but for
the demo purpose, the distance of push and pull of the handle part is 2133.6 millimetres (mm)
which is equal to 2.1m since it is the smallest value in push-pull analysis. Other than that, the
population sample is 50% because the subjects for this task is one worker among the two
workers. Hence the population sample is half of the overall workers.
As for this part, there is no lift analysis in order human operators does not involve in
lifting the product or uplifting the product. Hence, it only shows the analysis of push-pull data.
Touch stress is damage to body tissue caused by contact between soft tissue and a hard
object as for both internal and external. For the internal, it may occur when muscles, nerves,
tendons, or soft tissues rub or push against bones or tendons that may cause the tissue to bruise.
As for the external part, it may cause by a part of the body has to contact with a hard surface
134
such as the worktable. Tissue damage also may occur if a single event or due to repeated
exposure to the stressor over time. Long exposure to contact stress can lead to the development
of musculoskeletal disorders (MSDs). Hence, the workstation should be designed to limit or
prevent exposure to contact stress.
It can be concluded that it is important to examine the human body’s posture using an
ergonomic analysis to prevent any injuries and disease. This refers not only to the worker at
the workplace but also to the student doing a workshop assignment. Based on the results of the
RULA study, it has been shown that the proposed design provides a better outcome where the
final score has been reduced from 6 to 2 while the colour has changed from orange to green.
Additionally, the proposed design improved the student’s posture, reducing muscle pain and
fatigue. It can also be inferred that the proposed design using an ergonomic solution eliminates
fatigue and musculoskeletal disorders (MSDs). In short, it is also critical that the student can
perform drilling activities with comfort and safety and thus produce a better drilling result.
4.8 Comparison Between Design F and Design D
After having the engineering analysis for both designs, Table 4.12 shows the
comparison between both designs.
Table 4.12: Comparison between Design F and Design D

Design F Design D
Features i. Able to produce angle holes i. Able to produce angle
with 15, 30, 45 and 60 holes with 0 to 89 degrees.
degrees. ii. Need additional tools to
i. No need additional tools to perform drilling process
perform angle holes. such as protractor to
ii. Consists of 20 parts and determine the degree
able to rotate 360 degrees Celsius and nut to fi the
horizontally. position of fixture and
iii. Able to hold workpiece workpiece.
tightly. iii. Consists of 15 parts but
iv. High accuracy (no need to unable to rotate 360
measure using a protractor) degrees horizontally.
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and production rate (no iv. Able to hold the workpiece
additional tools needed). with lesser weight tightly.
v. Lower accuracy (need to
based on the protractor)
and production rate (need
to measure the angles to
drill using additional tools).
Material Jaw piece Jaw piece
selection and i. Cast iron. i. Cast iron.
analysis Adjustable angle plate Adjustable angle plate
i. Low alloy steel. i. Cast iron.
DMFA Assembly time Assembly time

i. 419.80 s i. 441.54 s
Assembly cost per unit Assembly cost per unit
i. RM0.54 i. RM0.57
Product Product Life Cycle, Eco Design Product Life Cycle, Eco Design
sustainability Web Web
analysis i. consist of 5 different metal i. consist of 6 different metal
which is cast iron, mild which is stainless steel, cast
steel, carbon steel, high iron, mild steel, carbon
tensile steel and die steel. steel, high tensile steel and
Eco Indicator die steel.
i. Production- 22030.06 Eco Indicator
ii. Transportation-3867.6 i. Production- 19632.36
iii. Disposal-2203.736 ii. Transportation-3515.655
iv. Total- 23693.92 iii. Disposal-2002.858
Sustainability Report iv. Total- 21145.157
i. no energy release during Sustainability Report
usage. i. no energy release during
ii. 22% of material able to usage.
recycle. ii. 21% of material able to
recycle.
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iii. 6.1% material is iii. 6.1% material is
incinerated. incinerated
iv. 72% material end up in iv. 73% material end up in
landfill. landfill
v. High carbon footprint, total v. High carbon footprint, total
energy consumed and the energy consumed and the
water eutrophication during water eutrophication
the material extraction during the material
process. extraction process.
vi. No environmental impact vi. No environmental impact
during useful time. during useful time.
Mechanical Jaw Piece Jaw Piece
analysis i. Maximum stress: 5.67e+06 i. Maximum stress: 5.67e+06
N/m2 N/m2
ii. Minimum stress: ii. Minimum stress:
4.041e+01 N/m2 4.041e+01 N/m2
iii. Maximum strain: 5.677e-05 iii. Maximum strain: 5.677e-
N/m2 05 N/m2
iv. Minimum strain: 4.11e-10 iv. Minimum strain: 4.11e-10
N/m2 N/m2
v. Maximum factor of safety: v. Maximum factor of safety:
1.130e+07 1.130e+07
vi. Minimum factor of safety: vi. Minimum factor of safety:
9.233e+01 9.233e+01
Adjustable angle plate Adjustable angle plate
i. Maximum stress: i. Maximum stress:
5.347e+04 N/m2 1.414e+10 N/m2
ii. Minimum stress: ii. Minimum stress:
6.333e+01 N/m2 9.338e+05 N/m2
iii. Maximum strain: 1.796e-07 iii. Maximum strain: 1.31e-01
N/m2 N/m2
N/m2 N/m2
137
9.719e+08 2.278e+02
1.16e+04 1.049e-02
Handle Handle
i. Maximum stress: i. Maximum stress:
1.015e+05 N/m2 1.015e+05 N/m2
ii. Minimum stress: 2.117e-06 ii. Minimum stress: 2.117e-06
N/m2 N/m2
iii. Maximum strain: 4.782e-07 iii. Maximum strain: 4.782e-
N/m2 07 N/m2
N/m2 N/m2
2.931e+14 2.931e+14
6.113e+03 6.113e+03
Cost analysis Material cost per unit Material cost per unit
i. RM87.92 i. RM76.38
Labor cost per unit Labor cost per unit
i. RM150 i. RM150
Fixed cost per unit Fixed cost per unit
i. RM270 i. RM270
Total manufacturing cost Total manufacturing cost
i. RM507.92 i. RM496.38
Selling price Selling price
i. RM660.30 i. RM645.29
Break-even (unit) Break-even (unit)
i. 4.71 i. 4.75
Break-even (point) Break-even point
i. RM3114.73 i. RM3065.13
ROI ROI
i. 1.3 i. 1.3
138
Ergonomic RULA analysis RULA analysis
analysis i. Score 3 i. Score 2
Push-pull analysis Push-pull analysis
i. Push force- 331.89N i. Push force- 328.55N
ii. Pull force- 269.574N ii. Pull force- 257.1N
Based on Table 4.12, it shows that the design F is better than design D. From the point
of features, design F able to produce angle holes with high accuracy and production rate
compare to design D. Design F does not require any additional tools to perform drilling process
but there is limited on the type of angles holes able to produce. Besides, design F has an extra
feature compare to design D which is design F able to rotate 360 degrees horizontally.
From the perspective of material, the material for the jaw piece is the same but different
for adjustable angle plate. Design F used low alloy steel but design D used cast iron. Cast iron
has a better material performance in term of fatigue strength, hardness young’s modulus, easy
to machine and have a higher level of vibration damping than steel, thus cast iron is more
suitable for the angle plate.
Furthermore, the assembly time for the design F which is 419.8s is shorter compare to
design D which is 441.54s. The longer the assembly time, the higher the assembly cost per unit.
The reason for design D has longer assembly time is because it uses more screw to tighten the
part. The screw is used to connect the jig, fixture and fixture base, the angle plate and fixture
base and also the screw thread forming block and sliding jaws. Thus, the assembly time for the
design D is longer.
From the view of sustainability, design F is more sustainable compare to design D. First,
from the product life cycle and eco-design web, it is clearly shown that the design D used 6
materials, but design F only have 5 material. The less the type of material used, the less the
mining process, thus the less the environmental impact. Although from the eco indicator table
it shows that design F (23693.92) is higher compare to design D (21145.157) but from the
sustainability report generate by the SolidWorks, it stated that the percentage of material to be
recycled for design F (22%) is higher compare to design D (21%) and the percentage of material
end up in the landfill for design F (72%) is lower compare to design D (73%). The higher the
percentage of recycling, the lower the percentage of the landfill, thus the lower the
environmental impact during the end of life of the product.
Furthermore, the mechanical analysis is taken part and it is also proven that the design
F is better than design D. The jaw piece and handle have the same analysis result for both
139
designs. It is different from the angle plate. The angle plate for design F has lower stress, strain
but a higher factor of safety. It means that during the drilling process, the angle plate for design
F will have less opportunity to fracture compare to design D as it contains low stress and strain.
The higher factor of safety for design F causes it more durable compare to design D.
On the other hand, from the cost analysis, it shows that the cost for the design D is
slightly lower compared to design F. Although the cost for design F is slightly higher than D,
the break-even per unit and cost is almost same. Furthermore, the rate of return for design F
and D is the same which is 1.3.
The last analysis which is ergonomic analysis shows that the ergonomic of design D is
slightly better than the design F. From the RULA analysis, the design F get the score of 2 but
design D gets the score of 3. Besides, from the push-pull analysis, it shows that the design D
needs lesser push full force to compare to the design F.
In short, although the design F is slightly less ergonomic and the better material for
angle plate compare to the design D, design F which have more advantages is better. Design F
has more features which cause high accuracy and production rate, less assembly cost and time,
more sustainable and high mechanical properties. The ergonomics can be improving by job
rotation to prevent the worker from repeating the same movement continuously throughout the
day. Besides, rest break should be provided for all workers. Stretching the body during breaks
is encouraged to keep the muscle and tendons from becoming strained. Besides, although the
cost for design F is slightly higher compare to the design D, the break-even point is almost the
same and the rate of return is the same for both designs. Furthermore, the design F has a higher
cost but it smoothed the drilling process by providing additional 1 feature and decreases the
use of additional tools. Lastly, the material for the angle plate can be changed to cast iron to
allow the jig and fixture with adjustable angle have a better performance.
140
CHAPTER 5
PROCESS PLANNING
5.0 Overview
This chapter will include the details explanation on the manufacturing process to
produce the part. Besides, the Gantt chart of the manufacturing process is also included in this
section.
5.1 Process Selection

5.1.1 Machining Process
Machining is a manufacturing term encompassing a broad of technologies and

technique. It is a process of removing unwanted material from the workpiece by using a power-
driven machine so that the workpiece will shape into the desired shape. Most of the metal
component and part require machining during the manufacturing process. There are many type
machining tools such as cutting machine, milling machine, turning machine, drilling machine
and welding machine. The major categories of machining tools are as below:
1) Milling tools: A milling tool employs a rotating cutting surface with several blades to
create non-circular holes or cut unique designs out of the material.
2) Drilling tools: This category consists of two-edged rotating devices that create a round
hollow parallel to the axis of rotation.
3) Turning tools: These tools rotate a workpiece on its axis while a cutting tool shapes it
to form. Lathes are the most common type of turning equipment.
141
4) Cutting tools: These tools cutting on the workpiece on the X and Y axis using CNC
machining.
The part component of jig and fixture with adjustable angle that undergoes this milling
process and cutting process are the base, fixture, jig, sliding jaws and jaws. The step for milling
is to shape the base, need to mill the block raw material layer by layer until getting the desired
shape and desired dimension as in design Solidwork. For the turning process, it is used to
machine the component such as rotating screw thread and handle. The step for turning process
is to turn the surface of the rod from the raw material into a cylinder with the required diameter
and length.
5.1.2 Welding
Welding is the process by which two pieces of metal can be joined together. As shown
in Figure 5.1, it used high heat to melt part together and allowing to cool causing fusion. There
are many welding methods such as spot welding, metal inert gas (MIG) and tungsten inert gas.
For the jig and fixture component, the team used a welding process to join the middle base,
rotating base and middle fixture.
Figure 5.1: Welding process
The advantages used welding process as below :

1. Good strength with a permanent joint
2. High load-carrying capacity
3. Applicable to many materials
4. Leakproof joining
142
5. Possibility to alter mechanical properties
5.1.3 Non-Conventional Manufacturing Processes
Non-conventional manufacturing processes also called advanced manufacturing

processes in a variety of process that removes unwanted material by different techniques such
as mechanical, thermal, electrical or chemical energy or combinations of these energies. In the
non-conventional manufacturing process, there are no sharp cutting tools included. The non-
conventional manufacturing process able to cut extremely hard and brittle material. Non-
traditional machining processes are employed where traditional machining processes are not
feasible, satisfactory or economical due to special reasons as outlined below
• Very hard fragile material difficult to clamp for traditional machining
• When the workpiece is too flexible or slender
• When the shape of the part is too complex
Therefore, for this jig and fixture with adjustable angle the appropriate non-
conventional process to be used is Laser Cut. This is because Laser Cut can cut on the metal
part.
5.1.3.1 Laser Cut
Laser cutting which is shown in Figure 5.2 is one of the best ways and commonly used
in industries to cut metals. Various types of metals such as mild steel, aluminium plate and
stainless steel are suitable to be cut using laser cutting. Laser cutting can cut accurately and
precise dimensions and produce good quality. Laser cutting is mainly a thermal process in
which a focused laser beam is used to melt material in a localised area. For the angle plate
component, our team used laser cutting because it more accuracy, edge flat and very suitable
for a complex part.
143
Figure 5.2: Laser cut
The advantage of laser-cut is shown as below:

1. It is easier to keep the workpiece in the right position.
2. Short obtained by laser cutting does not take long and are extremely accurate. The whole
cutting process is easily achieved in less time compared to traditional scissors.
3. As the section is produced, there is not direct contact of the workpiece.
4. High accuracy that can achieve high precision.
5.2 Manufacturing Process Involved in Parts
Table 5.1: Manufacturing process involved in manufacture jig and fixture with adjustable
angle
No Manufacturing Process and Detail Information Parts through the
Machine information process
1. Cutting process Bandsaw machine was used to Main base, middle
cut the raw material of the base, rotating base,
Machine: components into a specific middle fixture, fixture
Bandsaw steel machine dimension and shape added base, fixture, hinge,
with some tolerances. cylindrical metal, jig,
Tolerance is needed to adjustable angle plate,
prevent overcut to the product screw thread forming,
when cutting the material. The sliding jaw, handle, jaw
tolerance given is +/- 0.2mm. piece, bolt and nut,
screw, screw threading
144
forming block and
hinge rod.
2. Milling process The milling machine is used Main base, middle

to cut the parts such as jig, base, rotating base,
Milling machine: fixture, sliding jaws, jaw middle fixture, fixture
piece and others into more base, fixture, hinge, jig,
accurate desired dimension adjustable angle plate,
and at the same time reduce sliding jaw, jaw piece,
the surface roughness of parts. screw threading
For the parts which have angle forming block
and curvature such as main
base, middle base, rotating
base, CNC machining is used
to produce since it is more
accurate.
.
3. Laser Cutting Process The laser-cut is used to cut the Main base, middle
complex shape part such as base, rotating base,
Laser cutting machine: the adjustable angle plate into middle fixture, fixture
the desired shape. Laser-cut base, Adjustable angle
machining is more accurate. plate
4. Turning process The turning machine is used Cylindrical metal,

to cut the cylindrical shape screw thread forming,
Turning table lathe machine: parts such as the screw thread handle, bolt and nut,
forming, cylindrical metal and screw.
handle into the desired
diameter. The turning
machine is also used to cut the
145
screw thread on the
cylindrical shape part.
5. Drilling process Drilling Machine Drilling

Next, the manual drilling Cylindrical metal,
Manual drilling machine: machine is used to create a fixture base, jig,
small and shallow hole on the fixture, hinge.
parts. It is because the force to
drill the hole on prototype
workpiece with the drill bit by
manual drilling machine is
small when compared to the
milling machine. Therefore, it
can prevent the small
diameter drill bits from
Milling machine:
broken inside our workpiece.
Milling Machine
As for the milling machine, it
is used to drill parts with deep
holes and bigger diameter by Milling
changing the cutter head of Middle base, rotating
the milling drill cutter. CNC base, middle fixture,
milling machine is used to fixture base, fixture,
drill angle holes of the angle jig, adjustable angle
part to get a more accurate plate, screw thread
result. forming, sliding jaw,
screw threading
forming block.
6. Taping Using the taping to taper the Middle base, fixture

holes of screw thread forming base, fixture, jig,
Taping holder: for the handle into the shape adjustable angle plate,
146
of the thread of the screw and sliding jaw, screw
the desired diameter of the threading forming
hole. The tapper holder is block.
Taping: used to hold the taping during
tapering. When tapering the
holes, make sure the tapping
is parallel with the hole and
too much force on tapering is
strictly avoided as this would
cause the taping head to break
inside the drilling hole.
Taping process is in a
clockwise direction to tighten
it, on the other hand,
anticlockwise direction as to
loosen it.
7. Joining process Welding Welding
The welding processes a Main base and fixture
Welding machine: permanent joining process based. The main base
which is used to weld the part and fixture base
main base and middle based to part are welds together
ensure that the parts stick onto for a better grip to
its position. Personal prevent the fixture
protective equipment is sliding.
Bolting: needed to perform welding.
Bolting
Bolting is a temporary joining Bolting
for the metallic parts are Middle base, rotating
joined by using the bolts, base, middle fixture,
screw and nut. The bolt is fixture base, fixture,
used to join the middle base hinge, jig, adjustable
and rotating base and allow angle plate, sliding jaw,
147
360-degree rotation in the x- handle, jaw piece,
axis. It also used to join the screw threading
adjustable angle plate and forming block.
fixture base. Besides, the
screw is used to join the
fixture base and fixture to
allow angle movement.
Furthermore, the screw is
used to join the screw thread
forming and the sliding jaw by
allowing the rotation of the
screw thread forming.
8. Polishing Finally, the sandpaper is used Main base, middle

to polish the surface of the base, rotating base,
Sandpaper: product to create more middle fixture, fixture
smoothly and shiny surface of base, fixture, hinge,
the product. The polishing bolt, cylindrical metal,
action should always in a jig, adjustable angle
uniform direction to increase plate, screw thread
the aesthetic value. forming, sliding jaw,
handle, jaw piece, bolt
and nut, screw, screw
threading forming
block.
148
5.3 Gantt Chart for Manufacturing Process
Figure 5.3: Gantt Chart for Manufacturing Process of Jig and Fixture with Adjustable Angle
149
Table 5.2: Manufacturing Process of Jig and Fixture with Adjustable Angle
Task Start Date Days to complete
Introduction of IDP 10/12/2020 2
Discussion with SV and Proposal Writing 10/14/2020 5
Product Design 10/19/2020 2
Material Choice of Jig and Fixture 10/21/2020 9
Technical Report Preparation 10/30/2020 77
Preparation of the material 11/1/2020 2
Cutting Process 11/3/2020 5
Milling Process 11/9/2020 16
Laser Cutting 11/26/2020 8
Turning Process 12/4/2020 5
Drilling Process 12/10/2020 6
Taping Process 12/17/2020 4
Polishing the product 12/22/2020 2
Joining the product 12/25/2020 2
Testing the product 12/27/2020 3
Designing Pamphlet for the product 12/26/2020 5
Preparation on the video presentation 12/16/2020 15
Presentation Video of Product and Q&A session with the
panel 1/6/2021 1
Figure 5.3 shows the Gantt Chart of the manufacturing process from the beginning to
the end of the product and Table 5.2 shows the duration of the manufacturing process of the
team to produce the product. The team will start the engine after the IDP coordinator brief
about the proposal. Next the team must determine the product design and the material choice
is selected using CES software and an also online survey. After determining the material choice
for all part, the team will prepare the material for fabricating jig and fixture with adjustable
angle.
The team will prepare 5 materials which are cast iron, mild steel, high tensile steel, die
steel and stainless steel. Most of the materials are taken from the FKP lab. Cutting process
using bandsaw will be carried out after the material is well prepared. The workpiece will be
measured and cut into the desired dimension based on the technical drawing that has been
drawn. After that, the milling process will take part to cut away the unwanted material and
shape into the desired shape. There are some of the parts needs laser cutting after milling such
as main base, middle base, rotating base, middle fixture, fixture base, adjustable angle plate as
these parts contains curve shape which is difficult performed by the milling machine. After the
laser cutting process, the turning process will take part to form the desired shape on the
150
cylindrical workpiece. Drilling process using the drilling machine will take part to drill a
dimensioned hole on the workpiece. This step is a compulsory step to produce a hole with a
screw thread. Tapping process is the continuation step of the drilling step to provide the desire
thread inside the hole that has been drilled during the drilling process. After the tapping process,
it comes with the polishing process which in this step the product will be polished to make it
shiny. The part will join together using the joining technique, which is welding, screw and bolt.
To decrease the assembly time, all the size for screw and bolt is the same. The parts will
assemble and test to ensure that it can perform its function smoothly. Besides, the jig and fixture
with adjustable angle will be tested by drilling an angled hole on a workpiece and measure the
angled hole. The testing result shows that the jig and fixture with adjustable angle can produce
accurate angle holes. After testing the jig and fixture with adjustable angle, the team will design
the pamphlet and prepare the video for presentation. There will be a question-and-answer
session during the presentation. Lastly, along the time for fabricating the jig and fixture with
adjustable angle, the team will also prepare the final report. The report consists of engineering
analysis such as material analysis, DMFA, sustainability analysis, mechanical analysis, cost
analysis and also ergonomic analysis. The analysis is performed by different software such as
SolidWorks, Catia, CESeduPack software and others. By the guidance of the supervisor, Sir
Akramin, and the cooperation among the team, the team able to fabricate the product and
complete the report within the time frame given.
151
CHAPTER 6
CONCLUSION
As a summary, the team eventually have the final design of jig and fixture that has
fulfilled the objective and well suited to its usage. All the material that is chosen match to
characteristics that is needed which is strong to hold the workpiece. From the selection of
material, the team can understand the importance of materials, processing, economic and
aesthetic decision which are required before any product can be manufactured. The team also
must consider the impact that the environment will have and not just think about making a
profit through the product itself. The design that is used also is very accurate because the
purpose of the product is to give an accurate angle. The design has been finalized so the next
step is to produce the prototype of the jig and fixture.
By using the tools of the design for environment, the life cycle of every part of the jig
and fixture with adjustable angle is listed and it can be calculated and analyzed so that it can
be improved to a better product. The eco indicator of the jig and fixture with adjustable angle
is quite high since it is made from metal but jig and fixture with adjustable angle can recycle
afterlife. By using material which can be recycled, it able to decrease the cost of disposal thus
the social and economic value can improve.
Besides, there are a few differences between team design and others in term of strength.
The first and the most important one is the accuracy of the angle of the jig and fixture. The
design has one of the most accurate angles compare to other design. The team designs also can
be rotated at 360° horizontally. Some other design cannot be rotated at 360° horizontally. The
design that the team is made up from 100% metal but 22 % of the material be recycled thus the
environmental effect is reduced. But the manufacturing process of the metal into the product
will produce some chemical smoke that will affect the environment. In this generation, the
concern of citizen to the environmental issue has increased day by day since the pollution of
the world become more serious. Citizen has the intention to decrease the pollution level of the
152
word, thus the designer should take the responsibility to invent a product which is greener and
more sustainable to the environment.
Moreover, the team manage to overcome the lack and flaw of the design using the
software used. By using the CES Edupack software, the team can easily search the suitable
material for the product which has characteristics needed. The report also analyses the flow
chart of making the product from the material selection until it becomes the prototype. The
team also draw the design using SolidWorks Software is used to produce a technical drawing.
Drawing is important tools which allow communication among technical personal through the
proper drawing. From the drawing, the team can see the product in 3D which give fully image
of it. Choosing the right process is an important part of understanding a product. By bringing
the safety, ergonomics, aesthetics, functionality, cost, quality and many more into the
consideration make design concept fulfil all the requirements and criteria. Besides, the cost
also being explained in the report to show how money needed to produce the product. It also
calculates the selling price of the product. So, the product can be sold at reasonable because,
throughout the calculation, the team can reduce the cost.
Lastly, other than analysis of the product, the team have compared the original design
with the design D in the scoring and screening concept by using the engineering analysis. After
comparing it is found that the design F is better compared to the design D. Design F has more
features which cause high accuracy and production rate, less assembly cost and time, more
sustainable, high mechanical properties. Thus, the team has chosen design F as the final product.
6.1 Suggestion
Based on the survey result, there are a few suggestions to improve the product. First,
the jig and fixture movement can move 360° in horizontal and vertical. So, people do not need
to move the workpiece. The time taken to finish the job can be reduced. The product weight
can be reduced by changing into the lighter material. Then, only a small amount of force needed
to move it and it can easily be lifted and it does not need many people to do it. Moreover, the
size of the housing of the fixture can be bigger. So, many size and shape of the workpiece can
be put into it. Other than that, the angle of jig and fixture can be made more accurate. The user
will have many choose the most suitable angle for their product. Furthermore, the jig can have
adjusted hole for the drilling process. It will help the user to make many sizes of the hole
without using another tool. Besides, rubber can be put at the handle so the user can hold it more
easily and do not slippery. The improvement will make the product has many new uses and
153
faster the job. Furthermore, by considering the environmental factor, the waste can be reduced
by changing the material or weight optimization. The material could be changed to stainless
steel which has better material properties compared to the metal used in the current design.
Besides, the stainless steel able to recycle 100% without reducing the material properties. But
there is a disadvantage for stainless steel which is stainless steel has higher cost compare to
others. If cost is taken into consideration, the weight optimization may carry out to minimize
the material used, the less the material used, the less the material needed to be recycled.
154
REFERENCES
1. Nanthakumar, K. and Prabakaran, V., 2014. Design and Fabrication Testing of

Combined Multipurpose Jig and Fixture. IOSR Journal of Mechanical and Civil
Engineering, 11(4), pp.86-91.
2. Kaija, T. and Heino, P., 2006. The optimization of on-wafer shield-based test fixture
layout. IEEE Transactions on Microwave Theory and Techniques, 54(5), pp.1975-1982.
3. Hamad Mohammed Abouhenidi, 2014, “Jig and Fixture Design”, (IJSER), Volume 5,
Issue 2, Page no.: 142 – 153
155
Appendix
Appendix A- 2D drawing for components
A1- Main Base - Design F
156
A2- Middle Base - Design F
157
A3- Rotating Base - Design F
158
A4- Middle Fixture - Design F
159
A5- Fixture Base - Design F
160
A6- Bolt - Design F
161
A7- Hinge - Design F&D
162
A8- Hinge Rod - Design F&D
163
A9- Sliding Jaw - Design F&D
164
A10- Jig - Design F&D
165
A11- Screw- Design F&D
166
A12- Handle - Design F&D
167
A13- Handle Cap - Design F&D
168
A14- Jaw Piece- Design F&D
169
A15- Fixture- Design F&D
170
A16- Thread Forming Block- Design F&D
171
A17- Screw Thread Forming - Design F&D
172
A18- Cylindrical Metal- Design F
173
A19- Adjustable Angle Plate- Design F
174
A19- Adjustable Angle Plate- Design D
175
A20- Cylindrical Metal- Design D
176
A21- Nut- Design D
177
A22- Fixture base- Design D
178
Appendix B- PDM report
https://drive.google.com/file/d/1Xajq6DDNoDazDQZTS_jNLaT0Y-
GZyc6o/view?usp=sharing
179
Appendix C- Product Pamphlet
180

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BMFU 3223 | 2020 | Doc No.

FAKULTI KEJURUTERAAN PEMBUATAN

REPORT EVALUATION FORM FOR EXAMINER

PROJECT TITLE: JIG AND FIXTURE WITH ADJUSTABLE ANGLE

SUPERVISOR: EN. NOR AKRAMIN BIN MOHAMAD

No Student Name Matric no.

1. EUNICE NG XIN HUI B051820035

PLEASE CIRCLE THE SCORE FOR EACH EVALUTION CRITERIA

To solve the problem requires moderate depth understanding of engineering

Excellent – Objectives and scopes are very clear and informative. 5

Students correctly calculate:

Sustainability/Environment/ Safety Consideration (LO3) (WP2)

Students MEET THE REQUIREMENTS in applying computer aided engineering

SEMESTER/ YEAR: I / 2020/2021

GROUP 8 IDP FINAL REPORT- JIG AND FIXTURE WITH ADJUSTABLE

NAME MATRIX # SECTION

EUNICE NG XIN HUI B051820035 4

SITI ZUBAIZAH BT AHMAD B051820066 4

MAHMUD NABIL B MOHAMAD B051820054 4

GROUP SUPERVISOR: EN. NOR AKRAMIN BIN MOHAMAD

Integrated Design Project (IDP) is an important subject of higher education degrees

Figure 1.1: Jig and fixture in 2D design .................................................................................... 2

Table 3.1: Design of requirement for jaw piece ...................................................................... 25

Manufacturing duplicate parts accurately can be done by the production-work holding

1.4 Problem Statement

1.6 Report Explanation

Figure 1.3: Product Enhancement Instruction

2.1 Jig and Fixture with Adjustable Angle- Working Mechanism

Figure 2.3: Main base

Figure 2.4: Middle base

Figure 2.5: Rotating base

Figure 2.6: Middle fixture

Figure 2.7: Fixture base

Figure 2.8: Hinge

Figure 2.9: Hinge rod

Figure 2.10: Sliding jaws

Figure 2.11: Jig

Figure 2.12: Handle

Figure 2.13: Handle cap

Figure 2.14: Jaw piece

Figure 2.15: Fixture

n) Thread Forming Block

Figure 2.16: Thread forming block

Figure 2.17: Screw thread forming rolls

p) Bolt and nuts

Figure 2.18: Bolt and nuts

Figure 2.19: Cylindrical metal

r) Adjustable angle plate

Figure 2.20: Adjustable angle plate

Figure 2.21: Screw

Figure 2.23: 3D view of jig and fixture with adjustable angle-design F

2. Adjustable Angle plate

3.1 Material Selection

The material selection process is a vital process in manufacture a product as a wrong

Figure 3.1: Jaw piece (Material Selection)

3.1.1.1 Material Selection Jaw Piece

Table 3.1: Design of requirement for jaw piece

Table 3.1 shows the design requirement of the jaw piece.

Figure 3.3: Potential material chosen for the jaw piece

Table 3.2: Comments on the materials for jaw piece

3.1.1.2 Material selection Adjustable Angle Plate

Table 3.3: Design of requirement for adjustable angle plate