Production 2

BACHELOR OF PRODUCT DESIGN MANUFACTURING TECHNOLOGY DESN 6270 Project 2 Alexey Efimov ID 1161546

Mobile Display Stands This document reflects the choice of materials and technologies to build Mobile Display Stands for entrance hall in Building 1 at UNITEC to show students work.

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Materials

Aluminium I have chosen Aluminium 1060 as one of the prime materials according to its physical properties and ecological features. Aluminium is moderately strong and very light metal. Aluminium has several major ecological features:1. Mining and Smelting - Mining areas are re-established with the original flora and fauna. Primary smelters use extensive pollution control equipment and operate under conditions laid down by national inspectorates. Over 60% of the world's aluminium is produced from hydro-electric power which does not generate the emission of greenhouse gases. 2. Service Life - As aluminium has an exceptional resistance to corrosion, aluminium products can have a very long service life, often without the repeated painting required for less corrosion-resistant metals or wood. 3. Recycling - Aluminium is repeatedly recycled without any loss of quality, with an energy consumption of only 5% of that required to produce the same weight of metal in a primary smelter. 4. Energy Savings - Though primary production of aluminium requires considerable energy, the energy saved by using light-weight aluminium in applications such as transport can be considerable. When energy savings through recycling are added to the energy reduction achieved through the use of aluminium products, the time needed to realise real energy savings can be reduced even further. 5. Down-Gauging - Thinner, stronger products are being used with less metal, less energy and more savings in weight. Wrought aluminium alloy 1060 specifications Chemical composition: Si=0.25%, Fe=0.35%, Al = 99.6% min Modulus of elasticity 69 GPa Thermal expansion (20 ºC) 23.6*10-6 ºC Specific heat capacity 900 J/(kg*K)

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Electric resistivity 2.81*10-8 Ohm*m

Thermal conductivity 231 W/(m*K)

Tensile strength (annealed) 69 MPa Yield strength (annealed) 28 MPa Elongation (annealed) 43 %

Shear strength (annealed) 48 MPa Fatigue strength (annealed) 21 MPa Hardness (annealed) 19 HB

Cork Natural cork is another prime material I have chosen for display units, natural, renewable and recyclable material. The tree forms a thick, rugged and corky bark. Over time this bark can develop considerable thickness and this can be harvested every 9 to 12 years as cork. The harvesting of cork does not harm the tree and a new layer of cork regrows, making it a renewable resource. The tree is widely cultivated in Spain, Portugal, Algeria, Morocco, France, Italy and Tunisia. Cork Oak forests cover approximately 25,000 square kilometres in those countries. Portugal accounts for 50% of the world cork harvest. Cork Oaks cannot legally be cut down in Portugal, except for forest management felling of old, unproductive trees. Cork Oaks live about 150 to 250 years. Virgin cork (or 'male' cork) is the first cork cut from generally 25 year old trees. Another 9 to 12 years is required for the second harvest, and a tree can be harvested twelve times in its lifetime. Cork harvesting is done entirely without machinery. The European cork industry produces 340,000 tonnes of cork a year, with a value of €1.5 billion and employing 30,000 people. Wine corks represent 15% of cork usage by weight but 66% of revenues. Cork Oaks are sometimes planted as individual trees, providing a minor income to their owners. The tree is also sometimes cultivated for ornament. Hybrids with Turkey Oak (Quercus cerris) are regular, both in the wild in southwest Europe and in cultivation; the hybrid is known as Lucombe Oak Quercus × hispanica. Some cork is also produced in eastern Asia from the related Chinese Cork Oak (Quercus variabilis) http://en.wikipedia.org/wiki/Cork_oak GS8400 cork sheet GS8400 cork sheet made of clean granulated cork mixed with resin binder, which is compressed to form block, then split into sheets. The sheet has properties of good resilience, good resistance to water, oil and solvents, and good compressibility etc.

Granule grade Granules size Tensile strength

Middle 12~24/inch 12kg/cm2

Small 30~60/inch 12kg/cm2

Compressibility (100psi load) 15~40%

10~30%

5~25%

Recovery Flexibility multiple

75% 15

65% 12

60% 15

Boiling water resistance

3hours

5hours

5hours

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Big 8~12/inch 8kg/cm2

MDF board The third material of my choice is Medium Density Fibre board which is very common natural fibre based material. Manufacturers of MDF trying optimise processes and chemical composition, to reduce environmental impact. Nelson Pine Industries takes the environment seriously with production processes in place that minimise dust, water use, effluent and noise. We have developed techniques which have reduced the amount of water required in the production process by two thirds despite having trebled the output of GoldenEdge MDF. About 70% of the energy used on site is generated by burning wood waste in high efficiency furnaces. The remainder is from electricity. Since the mid 1980s Nelson Pine Industries have been leading the way in significantly reducing formaldehyde levels of GoldenEdge MDF. In February 2003 a new Japanese Industrial Standard (F) was introduced for a Super Low Formaldehyde MDF. Two months later Nelson Pine Industries became the first Australasian MDF producer to achieve certification to the F standard. In 2005 Nelson Pine Industries became the first MDF manufacturer to offer only F products to the Japanese market.

Physical properties

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Property

Value/Unit

Density

725 kg/m3

Internal Bond

960 kPa

Modulus of Rupture

44.0 MPa

Modulus of Elasticity

3000 MPa

24 Hour Thickness Swell

4.7 %

Moisture Content

8.0 %

Production in Unitec workshop

The display boards of this design can be easily built by technicians in Unitec workshop. Tools required for assembly is drop saw with aluminium cutting disc, cordless drill (or normal drill) and drill bits 3, 4 and 8.5 mm diameter, welder to weld aluminium parts together, table saw or skill saw to cut MDF and craft knife to cut cork. Following the assembly plan aluminium (UA1205) profiles A, B and C cut with drop saw and welded perpendicular to one another. Part B welded to A and part B1 to A1. Parts B and B1 connected with C part to one another using welding. OEM (CTV50P) castors fixed to the parts A and A1 through stem and marked holes. Aluminium ( UA5756) channels D,D1,E and F mitre cut with drop saw. Channel E fixed to part C using marked holes and (TKW 812C2) metal screws. Channels D fixed to part B and D1 fixed to B1 using metal screws. I considered reducing the width of the main sandwich due to standard width of the available MDF board, and cork board 1220 mm. Standard 2440x1220x18mm MDF panel cut to size 2000x1220x18mm using table saw part H. Cork roll (GS8400) cut to sheets size 2000x1220x4mm parts G and G1. Cork sheets G and G1 glued to MDF panel H on both sides with Liquid Nails glue and press for 12 hours. Slide composite G, H, G1 panel between D and D1 channels into E channel. Fix D and D1 to panel using (TF832Z) wood screws through marked holes. Fix F part to the panel using wood screws through marked holes. Insert (14-NPSQ30) inserts into open ends of A, A1, B, and B1 parts. As optional finish acrylic paint can be used for panel and enamel or anodising for aluminium parts.

Alternative low tech materials A possible low tech alternative to aluminium structure is wooden structure with increased thickness of the frame. Instead of sandwich panel I considered using of thick multilayer corrugated cardboard covered with thick fabric and wooden edging. Wheels can be made out of plywood or due to lightness of unit no wheels required.

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BOM (bill of materials) Company name Ullrich Aluminium co LTD

Rex Industrial Equipment LTD

Unimax international limited Nelson Pine Industries LTD

Manufacturing Suppliers LTD

HI-Q Electronics LTD

Selleys LTD

Material/ Batch/ amount Aluminium Square tube UA1205- 5.6m Aluminium Channel UA5756- 6.4 m Castors CTV50P- 4pcs

Price

Contact details

NZ$ 53.78 x 5m NZ$ 80.67+GST x 7.5m NZ$60.00x 5m NZ$90.00+GST x7.5m NZ$10.50+gst for 1 NZ$9.50 for 100

Auckland 118 Wiri Station Rd, Manukau City, New Zealand [email protected] Phone: 09-444 4533 119 Diana Dve Glenfield Auckland http://www.rexproducts.co.n z P. O. Box 810, Cixi, Ningbo, Zhejiang, China [email protected]

Cork sheet (roll) GS8400– 1220x4100mm 4mm MDF board Golden Edge 1220x2440x18mm

NZ$40 for 1220x1000 NZ$160 for 4m

Screws TKW812C2 11pcs Screws TF832Z – 14pcs

Metal screws NZ$ 23 for 100

Square inserts (black Polyethylene) 14NPSQ30 -6pcs

80c for 1

Liquid Nails High Strength 2lt

NZ$8 for 375ml

NZ$60 for 1

Wood screws NZ$ 7 for 100

Cork glue 4lt can Placemakers

NZ$98 for 4lt Total: ~NZ$1057.30 inc GST for 2

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Lower Queen Street, Richmond, Nelson, New Zealand Phone: 03 543 8800 [email protected] Auckland 560 Rosebank Road, Avondale PO Box 15445, New Lynn Phone 09 828 2777 sales.akld@fortressfastene rs.co.nz PO Box 302 015, North Harbour, Auckland, New Zealand Ph 9 415 3333 [email protected] The Gate, 373 Neilson Street, Onehunga, Auckland PO Box 1109, Auckland Ph: 0800 SELLEY (735 539)