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Page 1: Final Report PUK - Household Mechanical Sharpener Machine - Oktavianus P.M.

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Household Knife Sharpener Machine

Final Report

Fundamental of Mechanical Design MS 4101

Created by:

Oky Eldyagusta (OKY) 13106036

Pungky R. Prihono (PRP) 13106108

Oktavianus P. Mulalinda (OPM) 13106138

MECHANICAL ENGINEERING DEPARTMENT

FACULTY OF MECHANICAL ENGINEERING AND AEROSPACE

BANDUNG INSTITUTE OF TECHNOLOGY

2010

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PREFACE

One of the important skills that must be owned by an engineering student is the ability to

design. Without excellent design, any products will not working properly or even cannot be

manufactured. To achieve good design, the engineers have to consider many aspects, in addition

to technical aspect, that support the design process including manufacturability of the design,

materials selection, cost estimation, etc.

Our topic for this task is “Household Knife Sharpener Machine”. This report will

describe the design process and mechanism of household knife sharpener machine including all

aspects that have already stated.

At last but not least, we want to thank Prof. Dr. Ir. Komang Bagiasna for his guidance

and patience that he gave us during this class. We hope that our report could give benefit for us.

Bandung, January 2010

Authors

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Table of Contents

Cover .............................................................................................................................................. 1

Preface ............................................................................................................................................ 2

Table of Contents ....................................................................................................................................... 3

Table of Pictures ......................................................................................................................................... 5

Table of Tables ........................................................................................................................................... 6

Chapter 1 Introduction ............................................................................................................................... 7

1.1. Background ...................................................................................................................................... 7

1.2. Problem Identification ..................................................................................................................... 7

1.3. Assignment Purpose ........................................................................................................................ 8

1.4. Assignment Benefit .......................................................................................................................... 8

1.5. Research Methodology .................................................................................................................... 8

1.6. Working Diagram Schematic ............................................................................................................ 8

Chapter 2 Design Requirement and Objectives ...................................................................................... 10

2.1. Design ............................................................................................................................................. 10

2.1.1. Introduction ............................................................................................................................ 10

2.1.2. Household Knife Sharpener Machine Design ......................................................................... 10

2.2. Requirement and Objectives ......................................................................................................... 16

Chapter 2 Calculation for Safety and Functionality ................................................................................ 17

3.1. Safety Introduction ........................................................................................................................ 17

3.2. Component Safety Evaluation........................................................................................................ 18

3.2.1. Gear Literature ........................................................................................................................ 18

3.2.2. Gear Calculation ...................................................................................................................... 19

Chapter 4 Main Component Manufacturing ........................................................................................... 28

4.1. Manufacturing Introduction .......................................................................................................... 28

4.2. Main Component Manufacturing and Assembly ........................................................................... 29

4.2.1. Casing ...................................................................................................................................... 29

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4.2.2. Bevel and Spur Gear ............................................................................................................... 29

4.2.3. Crank ....................................................................................................................................... 30

4.2.4. Feeding Mechanism Tools ...................................................................................................... 31

4.2.5. Sprocket and Chains ............................................................................................................... 31

4.2.6. Shaft, Swing Arm, and Spring .................................................................................................. 31

4.2.7. Grindstone .............................................................................................................................. 32

Chapter 5 Cost Estimation........................................................................................................................ 33

5.1. Cost Introduction ........................................................................................................................... 33

5.2. Cost Evaluation .............................................................................................................................. 33

Chapter 6 Enclosure ................................................................................................................................. 34

6.1. Conclusion ...................................................................................................................................... 34

6.2. Suggestion ...................................................................................................................................... 34

Appendix ................................................................................................................................................... 35

Drawing..................................................................................................................................................... 36

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Table of Pictures

Figure 1.1. Mechanical design flowchart ........................................................................................... 9

Figure 2.1. Knife sharpener mechanism .......................................................................................... 10

Figure 2.2. Feeding mechanism ...................................................................................................... 11

Figure 2.3. Projected view of feeding mechanism (front and side) ................................................... 12

Figure 2.4. Feeding Mechanism (isometric view) ............................................................................. 13

Figure 2.5. Upper position of gear rack ........................................................................................... 14

Figure 2.6. Down position of gear rack............................................................................................ 14

Figure 2.7. Mechanism of rack gear ................................................................................................ 15

Figure 3.1. Top View ...................................................................................................................... 20

Figure 3.2. DAK Engineering’s Spur Gear Calculator ......................................................................... 21

Figure 3.3. Geometry factors J for straight bevel gears .................................................................... 24

Figure 4.1. Casing ........................................................................................................................... 29

Figure 4.2. Spur and Bevel Gear ...................................................................................................... 30

Figure 4.3. Crank ............................................................................................................................ 30

Figure 4.4. Feeding Mechanism Tools ............................................................................................. 31

Figure 4.5. Household Knife Sharpener System ............................................................................... 32

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Table of Tables

Table 3.1. Dimensional calculation table......................................................................................... 19

Table 3.2. Parameters for bevel gear bending stress ....................................................................... 23

Table 3.3. Bevel gear bending stress calculation ............................................................................. 24

Table 3.4. Mechanical properties for acetal delrin .......................................................................... 25

Table 3.5. Specification for delrin acetal spur gear .......................................................................... 26

Table 3.6. Specification for delrin acetal bevel gear ........................................................................ 27

Table 5.1. Cost Estimation .............................................................................................................. 33

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CHAPTER I

INTRODUCTION

1.1. Background (OKY)

Knife is one of the tools that are still used up to this day in history of human life.

During the prehistoric time, human used axe as knife to meet the necessities of human

beings. Even today, when the world filled by modern technology, human still use knife.

From that, we just know that the existing of knife is so necessary.

But, as is known, the sharpness and the effectiveness of knife will be decreased

by the time. In order to prevent it, we use a knife sharpener to restore the sharpness of

knife.

A grindstone can process the higher hardness materials, such as hardened steel,

carbide and also process brittle materials such as glass, granite. Grinder can carry out

High-precision grinding and a small surface roughness grinding , also carry out high-

efficiency grinding, such as strong grinding. Therefore, a grinder should be made of

materials that have properties of high hardness, such as sandstone.

Sandstone is a sedimentary rock primarily composed of sand-size mineral or

rock grains. Most sandstone is formed by quartz or feldspar because the minerals are

most numerous in the skin of the earth. Sandstones are resistant to the weather but it is

easy to be formed. In addition, because of the similarity measure of hardness and grain

size, sandstone became very good material to be made into a whetstone (grindstone) and

it is used to sharpen knives and many other purposes.

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1.2. Problem Identification (OKY)

At this time, there are many types of knife sharpener, from the mechanism of work, we

can classify them into two types, manual and automatic. Manual sharpener is cheaper

than automatic sharpener. They need human power to sharp the knife. Meanwhile,

automatic sharpener work more practical than manual sharpener. They using electric

power to drive their components and then sharp the knife. In fact, there is no a sharpener

has been found that can work practically but not expensive.

Start from that, we try to find a technological solution that can solve this problem. And

finally, we have an idea to make a sharpener that created by two expected element from

two type of sharpener, cheap and practically.

1.3. Assignment Purpose (PRP)

Purpose for writing this report is:

1. Complete the assignment of Fundamental of Mechanical Design (MS 4101)

2. Share knowledge about household knife sharpener machine

3. To create a design alternative for household knife sharpener machine that is easier to

use and more energy efficient

1.4. Assignment Benefit (PRP)

1. To know the process of designing a tool and how to analyze

2. To determine the factors that must be considered in designing a tool

3. Recall again about the courses that ever taken

4. Gain more knowledge that we never get in the class

5. Applicate our knowledge to solve problems, especially in this assignment

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1.5. Research Methodology (OPM)

We explore the topic and design the tool by some kind of methods like literature study,

interview, and group discussion.

1.6. Working Diagram Schematic (OPM)

The guideline for mechanical design is showed at mechanical design flowchart below:

Figure 1.1 Mechanical design flowchart

DESIGN PROBLEM

S T A R T

BRAINSTORMING

GATHER INFORMATION AND DATA

FIND ALTERNATIVE SOLUTIONS

CHOOSE THE DESIRED SOLUTION

ANALYZE AND SYNTHESIZE DESIGN, SUCH AS STRENGTH OF MATERIAL,

MATERIAL SELECTION, PRODUCTION PROCESS

SATISFYING

SOLUTION

DESIGN DETAILS

PRODUCTION, TESTING, AND PROTOTYPE

DEVELOPMENT

F I N I S H

NO

YES

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CHAPTER 2

DESIGN REQUIREMENT AND OBJECTIVE

2.1. Design (OPM & PRP)

2.1.1. Introduction

The selected design in the design of this tool is to use a mechanical drive gear ratio and

uses a swing arm mechanism and the mechanism back and forth on the knife holder.

This design uses millstone for sharpening knives. This design uses alternating

mechanism on the handle of a knife that is expected to facilitate the use of this tool in

sharpening knives. The use of swing arm aims to be pressing millstone surface so as to

hone the knife blade properly.

2.1.2. Household Knife Sharpener Machine Design

Figure 2.1. knife sharpener mechanism

Power from the hand of the operator use to move crank. Transmitted power from the

crank are divided to the two mechanisms, cutting mechanism and feeding mechanism.

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cutting mechanism consists of a combination of spur gear and bevel gear, also pulley

and belt. This is done to turn the grinding speed becomes much higher than the

rotational speed of human hands.

For feeding mechanism can be seen more clearly in the picture below.

Figure 2.2 feeding mechanism

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With the top and bottom teeth then the feeding motion that will occur is back and forth,

while the input is one-way move. Rack gear connected to the iron rod on it. The iron rod

is floating and can move freely against the cylinder casing. This mechanism is inspired

from the in and out mechanism on retractable pen. Below is the overall picture motion

feeding mechanism.

Figure 2.3. projected view of feeding mechanism (front and side)

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Figure 2.4. Feeding mechanism (isometric view)

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Figure 2.5. Upper position of gear rack

Shown in the picture above the teeth are in a “upper” position. In this condition the knife

(the workpiece) will move forward to the grindstone. Whereas in the picture below is the

condition where the teeth was downstairs. In this case the knife will move back away

from the grindstone.

\

Figure 2.6. Down position of gear rack

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The declining of rack gear can occur because the elastic rod support colliding with a

casing so that no components that support the rod in the cylinder, consequently the gear

rack will going down.

While the rising mechanism of rack gear can be seen in the picture below.

Figure 2.7. Mechanism of rack gear

Forward movement desired if the tip of the knife has reached the point of grinding. In

this condition there is no longer a pressing force to the spring (because the knife is

backwards), then the potential force of the spring will push the gear rack up, so the gear

rack would be supported by the elastic support again, and also knives will eventually

move forward. Then the cycle will be repeated until the knife sharpened, then the

grinding will stop. Due to the gap between the grinding stones are larger than the blade

thickness.

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2.2. Requirement & Objective (OKY, PRP, & OPM)

Must criteria:

• Can be use to sharpen various types of knives

• Portable

• User friendly

Wish criteria:

• Price should be less than Rp. 500.000,-

• 1 Year life time

• Low weight

• Sharpening process less than one minute

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CHAPTER 3

CALCULATION FOR SAFETY AND FUNCTIONALITY

3.1. Safety Introduction (OKY)

Safety means freedom from danger, risk, or injury. But, to keep human stay safe from so

many things that could go wrong, they have to be aware because an accident is any

unforeseen or unexpected event that may or may not result in injury or damage to

property or equipment. Educating our self and others about safety issues will not only

keep accidents to a minimum, it will help to save lives. We can do more to protect our

self by constantly thinking and practicing accident prevention than we can by

memorizing all of the rules, regulations, and safeguards ever written or invented. We

must think before we act.

The criteria that’s usually used to represent a machine safe or not, is safety factor.

To achieve condition, minimum safety factor is bigger than one.

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3.2. Component Safety Evaluation (PRP&OPM)

3.2.1. Gear Literature

Gears are machine elements that transmit motion by means successively engaging teeth.

Gears are used to transmit torque and angular velocity in a wide variety of applications.

There are several characteristics of gear:

a. Power transmition

b. Increasing or decreasing torque

c. Increasing or decreasing speed

d. Constant velocity ratio

e. No slip

Gears also have several basic equations that can be used to its analysis, they are:

a. Torque (T)

b. Power (P)

c. Gear Ratio (MG)

Where : NG = Number of teeth on gear

NP = Number of teeth on pinion

d. Module (m)

Gear and pinion have to have same module.

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3.2.2. Gear Calculation

F hand (F) 50 N calculation

r crank ( r ) 0.15 m iteration

ω hand (60rpm)

6.28318

5 rad/s data

specific energy

(u) 68

J/mm3

Material Removal Rate=d.w.v 0.6

mm3/

s

depth of cut (d) 0.005 mm power required=MRR.u 40.8 Watt

width of cut (w) 30 mm

feed rate (v) 4 mm/s power generated=F.r.ω

47.1238898

1 Watt

diameter grind

(d) 0.15 m power grind=d/2.ωg.Ft.2 41.4 Watt

ω grind (ωg) 92 rad/s

F tangential (Ft) 3 N F thrust =1.3Ft 3.9 N

r gear 1 6 cm

Rotational speed ratio

=ωgrind/ωhand

14.6422547

6

D bevel 2 1.2 cm r gear 2

1.63909181

9 cm

D bevel 1 4.8 cm

Table 3.1 dimensional calculation table

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Figure 3.1. Top view

In the first calculation above obtained Material Removal Rate (MRR). With the MRR for the

specific energy and 68 J/mm3 (steel), then get the power needed for grinding operations with

these parameters. Grinding power is used for iteration, thus obtained dimensions and parameters

for grinding.

From the data power and rotational speed of human hand with radius selection of bevel and gear

1, then obtained the gear radius of 1.5 cm 2. Thus calculations using rotational speed ratio.

Calculation of tension in the Spur gear

(mm)

(mm/s)

AGMA bending Stress:

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For bending stress calculation we use the software “DAK Engineering’s Spur Gear Calculator”:

Figure 3.2. DAK Engineering’s Spur Gear Calculator

The results of the calculation from software that can be used for the analysis is:

Power transmitted by the gear pair =6.300268E-02 Hp

Rotational speed of the pinion =225 RPM

Rotational speed of the gear =870.968 RPM

Velocity ratio of the gear pair =0.258

Diametral pitch =12

Number of teeth the in the pinion =120 teeth

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Number of teeth in the gear =31 teeth

Center distance =6.292 inches

Pitchline speed =589.04 feet/min

Transmitted load on the teeth (Wt) =3.53 lb

Torque on pinion shaft =17.65 in-lbs

Face width =0.35 inches

Dynamic factor Kv =0.830

Application factor Ka =1

Load distribution factor Km =2

Enclosure type =Open

Size factor Ks =1

Rim thickness factor Kb, pinion =1

Rim thickness factor Kb, gear =1

Geometry factor J, pinion =0.452

Geometry factor J, gear =0.398

AGMA quality number =8

Computed stress in pinion teeth =645 PSI

Computed stress in gear teeth =732 PSI

Computed contact stress on the teeth =18,531 PSI

The standard method for determining induced bending stresses in bevel gears comes from the

American Gear Manufacturers Association and is based on the equation below.

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Symb

ol Name

Notes / How can we simplify these terms for static loading of

normal gears

σ Max bending

stress in tooth

Compare to gear material strength to determine if the gear will

break

Wt

Transmitted

tangential load

Taken at large end of tooth

Ka

Application

factor

Accounts for probability of greater-than-design-load occurrences.

This is not something we expect, so neglect this, and set Ka = 1

Kv Dynamic factor Accounts for dynamic effects and velocity of tooth contact. For

static loading, which is an assumption we will make, since we are

dealing with relatively low speeds, neglect this term,and set Kv = 1

P Diametral pitch N/D

F Face width

Ks size factor

Accounts for unusually sized gears. Not applicable for normal

gears. Set Ks = 1

Km

Load-

distribution

factor

Accounts for shaft misalignment and shaft bending. Build your

gearbox carefully, so you can neglect this term and set Km = 1.

J Geometry factor Similar to Lewis form factor used for spur gears. Obtain from chart

based on number of teeth on gear and pinion.

Table 3.2. Parameters for bevel gear bending stress

After setting those factors that do not apply to 1 (see notes above), we can come up with a

simplified AGMA equation.

This equation is highly simplified to allow for fast calculation with minimum table look-ups. It

is not for use on critical applications, high speed gears, or gears of unusual materials.

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Figure 3.3 Geometry factors J for straight bevel gears.

Preliminary calculations obtained for pinion gear ratio is 4:1. We use a pinion teeth 40 and gear

teeth 10 following the calculation of bending stress for the bevel gear.

Pinion

P 1 σ 33.71593 kPa

F 8.2 mm

J 0.17

Wt 47 watt

Gear

P 1 σ 24.92047 kPa

F 8.2 mm

J 0.23

Wt 47 watt

Table 3.3. Bevel gear bending stress calculation

From the data calculated above, we can choose materials based on the stress data for the pinion

and gear (gear 1 and gear 2).

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We chose to use a polymer material which is Acetal Delrin. Material properties can be seen in

the table below.

Table 3.4. Mechanical properties for acetal delrin

Can be seen in the table that the ultimate tensile strength of 8000 psi. Compared with the

calculated stress (<1000 psi), it is quite sufficient material to be used. Here are the gear products

that we will use.

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Table 3.5. specification for delrin acetal spur gear

We will use part No. GR1M120 for pinion and GR1M032 for gear.

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Table 3.6. Specification for delrin acetal bevel gear

We will use bevel gear pair Part No. GB1M410040 (4:1 Ratio)

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CHAPTER 4

MAIN COMPONENT MANUFACTURING

4.1 Manufacturing Introduction (OKY)

Manufacturing, in its broadest sense, is the process of converting raw material into some

product. There are many things that affect the process of manufacturing a product. The

things that affect the process of manufacturing a product include product design,

component of these products, the selection of raw materials, and intended use of these

products.

The more complicated the design then the manufacturing processes will be more

difficult. So is the component where the more components are used for a product also

requires more manufacturing process. Moreover, the selection of raw materials and

intended use of these products also affect the manufacturing process.

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4.2. Main Component Manufacturing and Assembly (PRP & OPM)

4.2.1. Casing

Figure 4.1 Casing

To reduce the total mass of the tool is then we used casing made of plastic material. This

is because the chassis does not need a very strong material and plastic material has

another advantage that is easy to set up and the price is cheap and also lightweight. The

process of manufacture for casing is by molding in accordance with the desired.

4.2.2. Bevel Gear and Spur Gear

After calculating the stress, then by adjusting the availability of gear on the market, we

choose a gear with Delrin Acetal material. This material selection is based on the need

to reduce manufacturing costs for gears and reduces the total mass of this product.

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Figure 4.2. Spur and Bevel Gear

4.2.3. Crank

Figure 4.3. Crank

This crank-making process by using the casting and the forming and. After that use

surface finishing.

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4.2.4. Feeding Mechanism Tools

Figure 4.4 Feeding mechanism tools

For feeding mechanism tools, the manufacturing processes there are variety. Gear rack

systems using milling process. In the connecting rod using C45 steel with milling

process. So is the cradle using the same process and using welding and bolt for

connections.

4.2.5. Sprocket and chains

Manufacturing process for sprocket is hobbing. For chain we use standard chain.

4.2.6. Shaft, swing arm and spring

Manufacturing process for swing arm and shaft is milling from C45 plate steel material.

For spring we use standard spring with appropriate stiffness.

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4.2.7. Grindstone

For grindstone we use the grind stone that has been sold commercially.

Figure 4.5. Household knife sharpener system

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CHAPTER 5

COST ESTIMATION

5.1 Cost Introduction (OKY)

In business, retail, and accounting, a cost is the value of money that has been used up to

produce something, and hence is not available for use anymore. In economics, a cost is an

alternative that is given up as a result of a decision.[1]

In business, the cost may be one of

acquisition, in which case the amount of money expended to acquire it is counted as cost.

In this case, money is the input that is gone in order to acquire the thing. This acquisition

cost may be the sum of the cost of production as incurred by the original producer, and

further costs of transaction as incurred by the acquirer over and above the price paid to the

producer. Usually, the price also includes a mark-up for profit over the cost of production.

Costs are often further described based on their timing or their applicability.

5.2 Cost Evaluation (OKY)

Component Price (IDR)

Gear box 200,000

Pulley 50,000

Belt 10,000

Shafts 100,000

Plastic Casing 50,000

Gerindstone 20,000

Bearing 60,000

Spring 12,000

Sprocket 60,000

Chain 40,000

Welding service 50,000

Bolts and nuts 8,000

Total 660,000

Tabel 5.1 Cost estimation

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CHAPTER 6

ENCLOSURE

(OKY,PRP &OPM)

6.1 Conclusion

1. From the design, we conclude that this mechanism is very complicated. But

relatively cheap and have auto feeding mechanism.

2. This design can sharpened a regular blunt knife for approximately one minute.

3. From our estimation, the price of this design is Rp 660.000

6.2 Suggestion

1. Gear system is not the best design for knife sharpener. So that the others design have

to reconsider.

2. For increasing the efficiency of the system, we suggested for using electrical system.

3. To improve the endurance and reliability of the design, we suggested to reconsider

the material and dimension of the system.

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APPENDIX

- Callister. 2001. Material Science and Engineering. McGraw-Hill: Singapore.

- Dieter, G. E. 2000. Engineering Design. McGraw-Hill: Singapore.

- Kalpakjian, Serope. 2000. Manufacturing Engineering And Technology Fourth Ed.

Singapore: Addison Wesley Longman

- Norton, Robert L. 2003. Machine Design “An Integrated Approach”.

Prentice Hall : New Jerse

- Shigley, Joseph Edward. 2004. Mechanical Engineering Design Seventh Ed. Singapore:

McGraw Hill

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DRAWINGS

(PRP & OPM)

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