ECOR 1010 INTRODUCTION TO ENGINEERING REDESIGNED WATER BOTTLE CAP

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1 ECOR 1010 INTRODUCTION TO ENGINEERING REVERSE ENGINEERING PROJECT REDESIGNED WATER BOTTLE CAP To: Project TA name From: Ayebabomo Dambo Lab Section: L3 Project Group Number: L3-02 Date: Dec 2, 2016 CARLETON UNIVERSITY

2 TABLE OF CONTENT Abstract 3 Introduction 4 Method 4 Results Manufacturing Material 4 Manufacturing Process 4 Discussion Failure Mode 4 Benefits of Redesign 5 Conclusion 5 References 5 Appendix IntelliCad Drawing 6 3D Rendered Model 7 2

3 ABSTRACT The purpose of this report is to explain what a student taking the Introduction to Engineering Course in Carleton University achieved during the Reverse Engineering and Redesign Project. The reverse engineering process was carried out to understand the reasons for the underlying technological features of a water bottle cap. The water bottle cap was also modified to improve its function as a seal enabling more protection from spills and contamination. This report focuses primarily on the analytical and theoretical processes involved in the reverse engineering and redesign of the water bottle cap. A water bottle cap is an essential part of a water bottle that seals its opening, prevents water/liquid spillage, preserves the content of the bottle, and prevents contamination of the bottle content. This water bottle cap was made from a plastic known as polypropylene. The water bottle cap has a small hole in it for holding and a threaded open cylinder that is inserted into the bottle opening. The improved part has an extra cylinder attached to the bottom of the handle to protect liquid from spilling and being contaminated when wear of the threaded part occurs. 3

4 INTRODUCTION Water bottles are usually created to hold water or any other liquid. The need for the water/liquid to be kept safe, fresh and free of contamination calls for a water bottle cap. Water bottle caps come in various shapes. The shape of the water bottle cap in this project is a unique one adapted to provide more protection to the content of a water bottle. METHOD The first stage of the project involved developing a scaled model for manufacture. The dimensions of the water bottle cap were determined by measuring the bottle cap. PTC Creo Parametric CAD software was used to create a 3D model of the redesigned water bottle cap. This model was then scaled to a volume less than 1 in 3 (this was the constraint placed on the model so that the prototype could be produced), converted to a stereolithographic file and sent to a 3D printer available in Carleton University which produced a prototype of the model. The software was also used to create a 2D working drawing of the bottle cap. RESULTS Reverse engineering the water bottle cap provided information about the manufacturing materials and process employed in its production. Manufacturing Material: The raw materials used in the production of the water bottle cap include polypropylene, a thermoplastic material. There is no change in material for the redesigned part. Polypropylene is used because it is durable, yet soft. This makes it possible for the material to be moulded easily into the desired shape. Propylene is also used because it is cheap and recyclable [1]. Manufacturing Process: The water bottle cap is manufactured using the injection molding process. The polypropylene is melted in an extruder and the extruder screw is used to inject the plastic into a mold of the desired water bottle cap shape, where it is cooled. Highly pressurized air is now passed through the mold to stretch the material yielding a better shape of the product. The mold is cooled quickly so that it take the shape of the redesigned water bottle cap. The material is then removed from the mold [2]. DISCUSSION Failure Mode: Propylene is prone to wear [3]. Because this material is used also in the thread of the cap, wear occurs after a long time due to the frequent movement when opening and closing the water bottle. When this happens, it means, material from the thread gets removed and thus, leakage starts to occur. 4

5 Benefits of Redesign: The redesigned cap is composed of an extra cylinder, sealing the water bottle properly and preventing leakage and contaminations that would otherwise take place without this extra cylinder when the thread starts to wear off. A cylindrical shape was chosen to be used as the extra protection in contrast to other shapes so that it can fit well when used to cover the bottle. If otherwise, leakage may still occur as the shape would not match. CONCLUSIONS Conclusively, it is important to note that as humans, we need fresh water to survive. Even after our source of water has been modified to produce this fresh water, if we do not store it well (free from contaminations), then there is no point. Also, it is necessary to prevent leakage from our water bottles as it can cause wastage and can cause damage to materials placed near it. In essence, this redesigned water bottle cap will provide the necessary protection for our drinking water. REFERENCES [1]"Klean Kanteen Customer Service: Frequently Asked Questions (FAQs)", Klean Kanteen, [Online]. Available: [Accessed: 30- Nov- 2016]. [2]"Injection Molding Process", Dow.com, [Online]. Available: [Accessed: 30- Nov- 2016]. [3]Friction and Wear of Polymers, 1st ed. Zeus Industrial Products, Inc., 2005, pp

6 INTELLICAD DRAWING 6

7 CREO PRO/E RENDERED SOLID MODEL 7

International Journal of Advance Engineering and Research Development

Scientific Journal of Impact Factor (SJIF): 5.71 e-issn (O): 2348-4470 p-issn (P): 2348-6406 International Journal of Advance Engineering and Research Development International Conference on Creativity