Track: Product Design and Development

Abstract

This paper is on the design of an automated mirror cutting machine for a developing economy which targets small to medium enterprises. The current problem is high cost of such machines hence local car industries cannot afford them. Through careful analysis of current machines, use of alternative cheaper materials, it was possible to come up with a low cost and efficient solution. Research on types of mirrors and car manufacturing industries was conducted on the internet, and also industrial visits to local car manufacturing industries. Firstly the experiment was conducted in the lab and the force F=2.7kN required to break the mirror was found, this force was used to calculate the deflection y=39.44mm and bending stress . In the design process a cylinder of internal diameter d=75mm and a solenoid valve with flow factor  were selected. The maximum von Mises in each of the tested components were below the yield stresses of the respective components hence this machine will not fail under normal operations. The maximum von Mises stress=  for the cutting wheel is less than the design stress= , therefore the design is safe. In this project an Arduino board will be able to read the input (pressure) by the use of the pressure sensors and turn it into the output, when the pressure from the compressor is great than 10.5bar the red LED light will be turned ON, then the operator of the machine will witch it OFF. Above all the operator of this automated machine should be well skilled and wear goggles during the operation of the machine. An automated mirror cutting machine was designed within a budget of USD$4 221.34 and the machine can cut mirrors ranging from 20mm*20mm up to 500mm*500mm as stated from the objectives.