FACULTY OF MECHANICAL ENGINEERING

UNIVERSITI TEKNOLOGI MARA (UiTM), SHAH ALAM

BACHELOR OF ENGINEERING (HONS) MECHANICAL (EM220)

EMD5M7A

MANUFACTURING PROCESSES

MEM560

INDIVIDUAL ASSIGNMENT

PRODUCT : BE COOLER ULTRA

PREPARED FOR :

MOHAMAD MAZWAN BIN MAHAT

PREPARED BY :

NAME : HARIZ SAUFI BIN MOHD SUMARI

STUDENT ID : 2020483594

GROUP : EMD5M7A

SUBMISSION DATE :

7 JANUARY 2022

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 TABLE OF CONTENT

NO. CONTENT PAGES

1 1.0. INTRODUCTION 3

2 2.0. OBJECTIVE 4

3 3.0. FINDINGS 5

4 3.1. MATERIALS 5

5 3.2. MANUFACTURING PROCESSES 6

6 3.3. JOINING PROCESSES 9

7 3.4. MATERIAL DEFECT 10

8 4.0. RECOMMENDATION 12

9 5.0. REFERENCES 13

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1.0 INTRODUCTION

Fan is a device used to create a movement of air using a rotation mechanism. The rotation
was created using an electric motor to create an air-fluid stream which result in thermal
comfort. In the modern society, to achieve thermal comfort they will use an air conditioner but
it is expensive in terms of price per product and the operation cost. Fan are widely used in
factory to provide clean air to the designated space and to exhaust the dust particle out of the
designated space. It has also become a common appliance in every home. In this past few
decades, technology has evolved so much that many electrical components can be design to be
much smaller and more power efficient for daily basis usage. As the motor become smaller,
the fan can be design to be more compact which then lowering cost for production. Nowadays,
there are also a mechanical fan that is powered using battery and can be carried anywhere.
Table fan and stand fan can also be considered to be portable but it requires a lot of storage
area and still uses a large amount of electricity. There are a few examples of fan that can be
found in the market.

NO. TYPES DETAILS

Industrial Fan This fan is used to provide large amount of air flow or
gas flow in industries. The fan that is driven by an
electric motor are usually connected to a hub and shaft.
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This fan is also known as a blower. The industries in
general uses two type of industrial fan which is axial fan
and centrifugal fan.
Ceiling Fan Ceiling fan is a fan that is mounted to a ceiling. The fan
uses electricity to rotates its blades which can be
controlled by a regulator. This can be found majorly in
2 home, shop and hall. It is used to reduce the air
temperature and humidity in the space which help
evaporates water such as sweat and actively increase
efficiency in convection process of heat transfer.

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 Table Fan Table fan are generally use to ventilate a small room. It
uses a single-phase induction motor powered by

3 alternating current to rotate the blade. It function fairly

similar to a ceiling fan but at a lower scale.

USB Fan Universal Serial Bus (USB) fan is a modern technology

fan that uses direct current (DC) to spin the small electric
motor. It is design to specifically for low power
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consumption and portability. It consumes as low as 5
Volt to operate and can basically be powered by power
bank and smartphones.

2.0 OBJECTIVE

1. Understanding the proper application of the manufacturing process in the industries.

2. Able to experience and explore the manufacturing process firsthand.
3. Promotes ideas for creativity by observing manufactured product in the market.
4. To encourage student to explore and learn about modern manufacturing process.
5. To explore the defect of product caused by the manufacturing process and how to
minimize and prevent it.

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3.0 FINDINGS
3.1 MATERIALS

Power Button
Filter
Fill Tank
USB Cable

120mm Fan

Adjustable Air
Vent
Filter Case
Filter Port Side Panel

Figure 1: Portable Cooling Fan

NO. PARTS MATERIAL PROPERTIES

1 Power Button ❖ Favorable resistance against

impact, great toughness and
2 Fan
rigidity
Polycarbonate /
3 Air Vent
❖ Resistance to weak aqueous
Acrylonitrile butadiene
4 Side Panel acid
styrene
5 Fill Tank ❖ Moderately high operating
temperature (up to 80℃)
6 Filter Port
❖ Good electrical resistance
7 Filter Case

❖ Fatigue, tear, abrasion and

8 USB Cable Thermoplastic Elastomer
electrical resistance

❖ Excellent cushioning, thermal

9 Filter Polyurethane
and sound insulation
Table 1: Materials and properties of parts

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 3.2 MANUFACTURING PROCESSES

Manufacturing process is a process of turning raw materials into desired product. In this case,
the product to be studied is the portable cooling fan. Seeing that producing product as a whole
is complicated, the products are divided into several part. To produce these parts, certain
manufacturing process are needed so that the part can be shape according to the desired
dimension.

The manufacturing process varies according to the raw materials used. The portable cooling
fan raw materials are varieties of thermoplastic. Below is a table of manufacturing process
involve in producing the product parts.

MANUFACTURING
PARTS DETAILS
PROCESS

Fill Tank

Side Panel

❖ Injection molding is used to produce thin-walled plastic

Injection Molding
Fan Cover part. There are also internal and external injection
molding which is usually used to produce cables. The
machine involve have three compartment which are
injection unit, mold and clamping unit. It is generally
Filter Port
used to mass produce certain complicated product.
❖ The hopper is filled with thermoplastic pellet which is
then melted to be able to enter the screw section. As the

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 molten accumulated in the screw, it is then moved to fill
USB Cable
the mold cavity. Once the cavity is full, the screw stops
and the shaped product is left to cooldown before ejected
from the mold.

Air Vent

Fill Tank Lid

Power Button

Compression Molding ❖ Compression molding is a process that involve the

thermoset plastic to be placed inside the heated mold. The
mold is then compressed with a high-pressure hydraulic
press for the material to take the shape of the mold. It is
then cured inside the mold. The completed part is then
ejected from the mold.

Fan Blade

❖ Rotational molding is a production process to form any

Rotational molding hollow parts that vary in sizes. It is cost effective when
involving a large size product.
❖ The thermoplastic is added into the heated mold which is
then slowly rotated in both vertical and horizontal
direction. This help the material to occupy all the inner
surfaces of the mold. This result in the product to have
seamless parts and uniform wall thickness. Once the

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 materials cooldown, the rotation stops and the product is
removed from the mold.

Advantages of the manufacturing process:

1. Injection Molding
• Have high efficiency for fast production which leads to become cost effective
• Can handle an extremely complex shape object while maintaining uniformity
• Produce high strength product with low cost materials
• Maintain the flexibility and color of the material
• The process help reduce waste of material during production
• Involve relatively low labor cost

2. Compression Molding
• It is a much simpler process compared to injection molding
• Have much lower tooling cost
• Very suitable in producing product with large size and thickness
• A good replacement for insert molding and multi-color molding
• Very cost effective with short production run

3. Rotational Molding
• Low operating pressure cause low in tooling cost
• Produce product with consistent wall thickness
• Can produce complex double-wall without secondary processing
• Introduce high durability product as it is manufactured as one piece
• Product have high strength due to thicker corner
• Accommodate good surface finish

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 3.3 JOINING PROCESSES

There are three types of joining which are mechanical, welding and adhesive joining. The
portable cooling fan involve only mechanical joining as the material are mostly plastic. This
involve in the use of screw, bolts, rivet and fastener which can be called as a semi-permanent
joining. Below are the type of mechanical joining for the portable cooling fan.

JOINING DIAGRAM DETAILS

TYPE

❖ The same sets of screw is used for this

product. The screw is a truss head
screw. This type of screw are usually
Screw used to secure thin membrane. Due to
its low-domed shaped head, it make
the process of removing it become
difficult.

❖ Snap joint is a mechanical joint system

where the part-to-part attachment is
Snap joint done with locating and locking
features.

❖ Soldering is a process where a wire are

connected to the circuit board using
filler metal. The filler metal have a
relatively low melting point and have
Soldiering
a good electrical conductivity
property. The metal used as filler is tin
which sometimes added with other
metal such as lead.

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 ❖ The product uses the same concept as
slider joint which provide linear
movement between two bodies using
Slider
prismatic joint. But in this application,
the two parts are just placed for easy
access.

3.4 MATERIAL DEFECT

Defects in manufactured product are very common in industries. The defect may cause the
ecstatic part of the product and sometimes may affect the mechanical properties of the product
which can later cause failure. This defect occurs are not intentionally happen during
manufacturing, thus it can be prevented. Below is the table of the possible defect that can occur
during the manufacturing process.

DEFECTS DETAILS

Flash ❖ It occurs when the molten materials

manage to seep through the parting
line of the mold cavity.
❖ This is cause by high pressure during
injection, not enough clamping force
between mold and uneven flow in
multi-cavity tool
❖ To prevent flash, clean off any dirt
from mold, check mold vent size for
proper air removal, make sure mold
are clamp with proper pressure and
use material with low viscosity.

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 Bubbles ❖ Bubbles are caused by trapped air,
moisture and vapor. This happen due
to high injection temperature, and
presence of moisture in material.
❖ To prevent this defect, material
should be dried properly before
process and decrease the temperature
of material injected into mold.

Ejector Pin Mark ❖ Ejector pin mark is caused by the

process of ejecting the parts before
the materials are completely cured.
❖ The way to prevent the defect are to
avoid excessive injection of melt,
reduce injection pressure, smoothen
the surface after ejection and apply
the mold-release agent on the mold.

Sink Mark ❖ Sink marks occur typically at thick

area where it does not solidify evenly
with other area.
❖ To prevent the defect, make sure that
the pressure applied are enough,
avoid high temperature on mold and
design the mold properly.

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4.0 RECOMMENDATION

As technology advancement increases faster than two decades ago, it is recommended that
manufacturer keep an insight on the developing method that are much more effective than old
manufacturing method. The aim is to produce the best product in the market will keeping the
cost on manufacturing at a minimum wall while having a maximum profit. Good product in
the market will always be the choice from the customer as they value the quality of the product.

It is also recommended that in the future, the product should be power by battery to eliminate
the use of cable. This will help increase the mobility of the cooling fan and make the product
more ergonomic for the user. All the defect on the product are barely visible which means that
the manufacturing process are properly controlled.

Last but not least, the manufacturer should use a better 120mm fan with much faster speed but
with much lower noise. This will help boost the product value in the market due to its higher
efficiency at a reasonable price range.

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5.0 REFERENCES

1. Jason Mazurek. (April 16th 2019). Arctic Air Ultra Review: Will This One Work?.
Youtube.com. Retrieved from https://www.youtube.com/watch?v=9SXeCBNT_O4
(Accessed in 4 January 2022)
2. Fan (machine). Retrieved from https://en.wikipedia.org/wiki/Fan_(machine) (Accessed
in 4 January 2022)
3. Industrial Fan Types. Retrieved from https://www.axair-fans.co.uk/all-technical-
information/industrial-fan-types/ (Accessed in 5 January 2022)
4. USB Cable Manufacturing Process. Retrieved from https://koincable.com/usb-cable-
manufacturing-process/ (Accessed in 5 January 2022)
5. Acrylonitrile butadiene styrene. Retrieved from
https://en.wikipedia.org/wiki/Acrylonitrile_butadiene_styrene#Properties (Accessed in
6 January 2022)
6. Injection Molding. Retrieved from
https://www.custompartnet.com/wu/InjectionMolding (Accessed in 6 January 2022)
7. Rotational Molding. Retrieved from https://en.wikipedia.org/wiki/Rotational_molding
(Accessed in 4 January 2022)
8. Compression Molding. Retrieved from
https://www.sciencedirect.com/topics/materials-science/compression-molding
(Accessed in 6 January 2022)
9. What Is a Truss Head Screw?. Retrieved from
https://www.hunker.com/12424944/what-is-a-truss-head-screw (Accessed in 6 January
2022)

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