DESIGNING AND FABRICATION OF RACKET TEST RIG. SURAJ s/o VIJANATHAN Report submitted in partial fulfillment of the requirements for the award of Diploma of Mechanical Engineering Faculty of Mechanical Engineering UNIVERSITI MALAYSIA PAHANG JUNE 2013 vi ABSTRACT This thesis deals with the designing and fabrication of racket test rig. Test rig is a useful device as it is an apparatus used for assessing the performance of a piece of mechanical equipment. The main objective of this final year project is to design and fabricate a racket test rig for further study of the performance of a racket. This thesis describes the methods of designing and fabricating the mechanical part of the test rig. There are many steps taken to design and fabricate the mechanical parts of this test rig. The structural three-dimensional solid modeling of the test rig was developed by using the SolidWorks engineering drawing software. The fabrication process also undergoes many steps such as material marking, cutting, drilling, welding, milling, turning, grinding and finishing of the test rig by painting. The results of the testing of the performance of racket and how far the shuttlecock can reach with certain applied force and angle on the racket also discussed in this thesis. vii ABSTRAK Tesis ini membincangkan tentang mereka bentuk dan fabrikasi pelantar ujian raket. Pelantar ujian adalah alat yang berguna kerana ia adalah satu alat yang digunakan untuk menilai prestasi sebuah peralatan mekanikal. Objektif utama projek tahun akhir ini adalah, untuk mereka bentuk dan memfabrikasikan suatu pelantar ujian raket untuk kajian selanjutnya tentang prestasi raket. Tesis ini juga menerangkan kaedah mereka bentuk dan pembuatan setiap bahagian mekanikal pelantar ujian tersebut. Terdapat beberapa langkah yang diambil untuk mereka bentuk dan membuat bahagian-bahagian mekanikal pelantar ujian ini. Pemodelan tiga dimensi struktur pelantar ujian telah dibuat dengan menggunakan SolidWorks yang merupakan perisian lukisan kejuruteraan. Proses fabrikasi juga mengalami banyak langkah seperti menanda, memotong, penggerudian, kimpalan, “milling”, “turning”, pengisaran dan kemasan pelantar ujian dengan cat. Keputusan ujian prestasi raket dengan sejauh bulu boleh mencapai dengan kuasa tertentu digunakan dan sudut pada raket juga dibincangkan dalam tesis ini. viii TABLE OF CONTENT Page SUPERVISOR’S DECLARATION ii STUDENT’S DECLARATION iii DEDICATION iv ACKNOWLEDGEMENT v ABSTRACT vi ABSTRAK vii TABLE OF CONTENT viii LIST OF TABLES xiii LIST OF FIGURES xiv LIST OF SYMBOLS xvii LIST OF ABBREVATIONS xviii ix CHAPTER 1 INTRODUCTION 1 1.1 Introduction 1 1.2 Problem Statement 2 1.3 Objective 2 1.4 Project Scope 3 CHAPTER 2 LITERATURE REVIEWS 4 2.1 Introduction 4 2.2 Types of Racket Test Rig 5 2.2.1 Rebound Impact Testing Machine 5 2.2.2 Racket Pressure Tester 7 2.2.3 Racket Twisting Strength Tester 8 2.2.4 Racket Drop Tester 9 2.3 Types of Materials Used In This Project 11 2.3.1 Stainless Steel 11 2.3.2 Mild Steel 12 2.3.3 Sheet Metal 13 2.4 The Fabrication Method 14 2.4.1 Grinding (Cutting) 14 2.4.2 Welding 15 2.4.3 Shearing 16 2.4.4 Bending 18 2.4.5 Drilling 19 x 2.4.6 Milling 20 2.4.7 Lathe (Turning) 21 2.4.8 Finishing 22 CHAPTER 3 METHODOLOGY 23 3.1 Introduction 23 3.2 Flowchart 24 3.3 Concept Generation 27 3.3.1 Concept Design No.1 27 3.3.2 Concept Design No.2 28 3.3.3 Concept Design No.3 29 3.4 Concept Scoring 30 3.5 Concept Finalization 31 3.5.1 Control Box 32 3.5.2 Racket Holding Arm 32 3.5.3 The Static Body and Adjustable Body 33 3.5.4 The Base 33 3.6 List of Materials 34 3.7 Fabrication Planning 35 3.7.1 Measuring and Marking Process 35 3.7.2 Cutting Process 36 3.7.3 Drilling Process 37 xi 3.7.4 Welding Process 37 3.7.5 Riveting and Bending 38 3.7.6 Milling Process 39 3.7.7 Turning Process 39 3.7.8 Grinding and Coating Process 40 CHAPTER 4 RESULTS AND DISCUSSION 41 4.1 Introduction 41 4.2 Final Product 42 4.2.1 Overview of Product 42 4.2.2 Overview of Control Box and Spring System 43 4.2.3 Overview of the Body 44 4.2.4 Overview of the Arm 45 4.2.5 Overview of the Base 45 4.3 Result 46 4.3.1 Hitting Test 46 4.4 Problems 47 4.4.1 Problems Faced During Progressing the Project 47 4.4.3 Problems At The Racket Test Rig 48 xii CHAPTER 5 CONCLUSION AND RECOMMENDATION 49 5.1 Introduction 49 5.2 Conclusion 50 5.3 Recommendation 51 REFERENCES 52 APPENDICES 53 A Figures of machines 53 B Personal protective equipment 57 C Figures of Drawing Each Part 59 xiii LIST OF TABLES Table No. Page 2.1 Specification of Racket Twisting Strength Tester 8 2.2 Specification of Racket Drop Tester 10 3.1 Gantt Chart 27 3.2 Concept Scoring 31 3.3 Material List 35 4.1 Hitting Results for Method 1 46 4.2 Hitting Results for Method 2 46 xiv LIST OF FIGURES Figure No. Page 2.1 Parts of a Badminton Racket 5 2.2 Feather Bat and Net Bat Rebound Impact Testing Machine 6 2.3 Racket Pressure Tester 7 2.4 Racket Twisting Strength Tester 9 2.5 Racket Drop Test 10 2.6 Stainless Steel 11 2.7 Mild Steel 12 2.8 Aluminum Sheet Metal 13 2.9 Grinding Cutting Process 15 2.10 Welding Process 16 2.11 Shearing Process 17 2.12 Shearing Machine 17 2.13 Schematic of Air Bending with a Back Gauge 18 2.14 Drilling Process 19 2.15 Vertical Milling Machine 20 2.16 Lathe Machine 21 2.17 Hand Grinder 22 2.18 Spray Paint 22 3.1 Process Flowchart 24 3.2 Design Concept 1 27 xv 3.3 Design Concept 2 28 3.4 Design Concept 3 29 3.5 3D Concept Design 3 31 3.6 Control Box 32 3.7 Racket Holding Arm 32 3.8 Static Body 33 3.9 Adjustable Body 33 3.10 The Base 33 3.11 Measuring Material 35 3.12 Marking Material 35 3.13 Cutting Material 36 3.14 Grinding Cutting 36 3.15 Shearing Process 36 3.16 Drilling Process 37 3.17 Welding Process 38 3.18 Riveting Process 38 3.19 Bending Process 38 3.20 Milling Process 39 3.21 Turning Process 40 3.22 Grinding Process 40 3.23 Coating Process 40 4.1 Overview of the Racket Test Rig 42 xvi 4.2 Control Box 43 4.3 Spring System 43 4.4 The Body 44 4.5 Method 1 Arm 45 4.6 Method 2 Arm 45 4.7 The Base 45 xvii LIST OF SYMBOLS Kg Kilogram m Meter MPa Megapascals Rpm rotation per minute mm Milimeter Ø Diameter R Radius Psi pounds per square inch d diameter Pi (3.1242) xviii LIST OF ABBREVIATION UMP Universiti Malaysia Pahang MASUM Majlis Sukan Universiti Malaysia SMAW Shielded Metal Arc Welding GMAW Gas Metal Arc Welding MIG Metal Inert Gas PPE Personal Protective Equipment 3D Three Dimension CHAPTER 1 INTRODUCTION 1.1.1 INTRODUCTION A racket or racquet is a sports implement consisting of a handled frame with an open hoop across which a network of cord is stretched tightly. It is used for striking a ball in such games as squash, tennis, racquetball, and badminton. Collectively, these games are known as racquet sports. The frame of rackets for all sports was traditionally made of laminated wood and the strings of animal intestine known as catgut. The traditional racket size was limited by the strength and weight of the wooden frame which had to be strong enough to hold the strings and stiff enough to hit the ball or shuttle. Manufacturers started adding non-wood laminates to wood rackets to improve stiffness. Non-wood rackets were made first of steel, then of aluminum, and then carbon fiber composites. Wood is still used for real tennis, rackets, and xare. Most rackets are now made of composite materials including carbon fiber, fiberglass, metals such as titanium alloys or ceramics. Gut has partially been replaced with synthetic materials including nylon, polyamide, and other polymers. Rackets are restrung when necessary, which may be after every match for a professional or never for a social player. A racket base game is mostly just the same where we should hit the object coming towards us with the racket. In my project I focused more into the swinging hitting method as most of the racket game r played by swinging to hit the object. 2 1.2 PROBLEM STATEMENT Many of the existing racket test rig doesn’t have any machine that tests a racket by using a swinging method. Most of the machine built is to test the string band of the racket and also the strength of the racket itself. Plus it is hard to determine the actual hitting power of the racket without using the swinging method. The reason is that during any racket game is played the will be an error where the players will hit the object such as the shuttlecock with the frame of the racket. 1.3 OBJECTIVE From the problem statement an objective had had been done which is to design and fabricate a racket test rig that can test the hitting force, angle and the distance of the shuttlecock after hitting from the racket by using swinging method.