CHAPTER 2

PROCESS PLANNING AND DESCRIPTION

This chapter will explain about the process planning of the project, a gantt chart for timeline
reference, and process flow of the project.

2.1 Process Planning and Gantt Chart

Actual Planning

Week
No Task
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Selection of assistant
1 engineer and attend IDP
talk

2 Fill registration form

3 Preparation of proposal

4 Consultation

5 Submission of Proposal

Material purchasing, and

6
planning works

Development works on
7
prototype.

8 Project costing

9 Sustainability and DFX

Preparation of technical
10
report.

11 Prototype testing

Poster preparation &

12 Preparation of technical
report
Oral presentation &
13
Prototype Exhibition

14 Report preparation

Submission of final report

15
and logbook.
Figure below represents the process flow throughout the process in developing our prototype.

Figure below represents the process flow throughout the process in developing our
prototype.

START

Topic Selection

Internet & Library search

Improvement is required

Project screening
NO

YES

Proposal submission

Material purchasing, planning works

Development works on prototype

Project Costing

Fabrication of
prototype
Sustainability and DFX

Development works on prototype and product analysis

Preparation of technical report

 Prototype testing & product analysis

Poster preparation & preparation of technical report

Oral presentation & prototype exhibition

Report preparation

Submission of final report and logbook / group folder

END
Material Requirement Planning

In this project, there are two type of manufacturing process that involve are non-
conventional manufacturing processes and conventional manufacturing processes. For non-
conventional manufacturing processes, Electric Discharge Machining (EDM), Abrasive Jet
Machining (AJM) and laser beam cutting have chosen to apply to the project.

Electric Discharge Machining (EDM)

Electric Discharge Machining (EDM) is used to manufacture the air cutter. The product has
hard material part that need to be shaped, that part can be produced by using EDM die sinker
such as the slope or drain in some area of the project.

Abrasive Jet Machining (AJM)

Abrasive Jet Machining is a process uses high pressure of gas to help streaming abrasive
particles and it is effective to the work surface. During the project, the parts for making holes
for fastener or screw will be assembled. Thus, AJM machining process is chosen to make the
hole as the holes are sometimes have smaller and complex precision that only non-conventional
process like AJM can be used.
Laser beam cutting

Laser beam cutting is the chosen one of the cutting process that need to implement to produce
the certain part such as cutting the nozzle holder and hand holder part. Laser beam cutting is a
thermal process that possess high melting point with the assistant of high-pressure gas and
involvement of coherent light. The function of high-pressure gas is to remove the melted
materials from the beam path. The output beam usually pulsed to very high peak power in order
to increase the travel speed of the cutting operation.
For conventional manufacturing processes, milling, welding process and fastener have been
used to apply into this project.

Milling process

Milling is the cutting operation that removes metal by feeding the work against a rotating,
cutter having single or multiple cutting edges. Flat or curved surfaces of many shapes can be
machined by milling with good finish and accuracy. Milling process use to create slot on the
table to let the nozzle holder to slide over the table.

Welding process

In this project, welding process use to join the table and stand together because welding process
can make the structure more stable and durable. Therefore, the welding machine TIG is use in
this project.
Fastener

Fastener is a hardware device that mechanically joins or affixes two or more objects together.
In general, fasteners are used to create non-permanent joints that can be removed or dismantled
without damaging the joining components. The fastener that use in this process is tapered screw
and it is use to joint the part of the project.