DESIGN AND FABRICATE A FLEXIBLE TOILET HOSE WITH SPOOL ABDULLAH MUNZIR BIN ZUL SAFARUDDIN UNIVERSITI MALAYSIA PAHANG

DESIGN AND FABRICATE A FLEXIBLE TOILET HOSE WITH SPOOL ABDULLAH MUNZIR BIN ZUL SAFARUDDIN UNIVERSITI MALAYSIA PAHANG

UNIVERSITI MALAYSIA PAHANG BORANG PENGESAHAN STATUS TESIS JUDUL: DESIGN AND FABRICATE FLEXIBLE TOILET HOSE WITH SPOOL SESI PENGAJIAN: 2011/2012 Saya, ABDULLAH MUNZIR BIN ZUL SAFARUDDIN (910509-08-6525) (HURUF BESAR) mengaku membenarkan tesis Projek Tahun Akhir ini disimpan di perpustakaan dengan syarat-syarat kegunaan seperti berikut: 1. Tesis ini adalah hakmilik Universiti Malaysia Pahang (UMP). 2. Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi. 4. **Sila tandakan ( ) SULIT TERHAD (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972) (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi / badan di mana penyelidikan dijalankan) TIDAK TERHAD Disahkan oleh: (TANDATANGAN PENULIS) (TANDATANGAN PENYELIA) Alamat Tetap: 39, Psrn Wira Jaya Barat 34, AT TASNEEM BT MOHD AMIN Tmn. Ipoh Jaya Timur, (Nama Penyelia) 31350 Ipoh, Perak Tarikh: 5 JANUARI 2012 Tarikh: 5 JANUARI 2012 CATATAN: * Potong yang tidak berkenaan. ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD. Tesis dimaksudkan sebagai tesis bagi Diploma secara penyelidikan atau disertai bagi pengajian secara kerja kursus.

DESIGN AND FABRICATE A FLEXIBLE TOILET HOSE WITH SPOOL ABDULLAH MUNZIR BIN ZUL SAFARUDDIN Report submitted in partial fulfilment of the requirements for the award of Diploma in Mechanical Engineering Faculty of Mechanical Engineering UNIVERSITI MALAYSIA PAHANG JANUARY 2012

ii SUPERVISOR S DECLARATION I hereby declare that I have checked this project report and in my opinion this project is satisfactory in terms of scope and quality for the award of Diploma in Mechanical Engineering. Signature: Name of Supervisor: At-Tasneem binti Mohd Amin Position: Lecturer Date: 5 th January 2012

iii STUDENT S DECLARATION I hereby declare that the work in this report is my own except for quotations and summaries which have been duly acknowledged. The report has not been accepted for any degree and is not concurrently submitted for award of other degree. Signature: Name: Abdullah Munzir bin Zul Safaruddin ID Number: MB09097 Date: 5 th January 2012

vii TABLE OF CONTENTS SUPERVISOR S DECLARATION STUDENT DECLARATION ACKNOWLEDGEMENT ABSTRACT ABSTRAK TABLE OF CONTENTS LIST OF TABLES LIST OF FIGURES LIST OF ABBREVIATIONS Page ii iii iv v vi vii ix x xi CHAPTER 1 INTRODUCTION 1.1 Background of Project 1 1.2 Problem Statement 1 1.3 Objective 2 1.4 Scopes 2 1.5 Gantt Chart 3 CHAPTER 2 LITERATURE REVIEW 2.1 Introduction 4 2.2 Types of Toilet Hose 4 CHAPTER 3 2.2.1 Rubber Toilet Hose 5 2.2.2 Flexible Toilet Hose 6 METHODOLOGY 3.1 Introduction 7 3.2 Flow Chart 8

viii 3.3 Concept Selection 11 3.3.1 Concept 1 11 3.3.2 Concept 2 12 3.3.3 Concept 3 12 3.3.4 Concept Screening 13 3.4 Designation Method 13 3.5 Fabrication Method 14 CHAPTER 4 3.5.1 Material Selection 14 3.5.2 Shearing 14 3.5.3 Cutting 15 3.5.4 Roll Bending 16 3.5.5 Welding 16 3.5.6 Drilling 17 3.5.7 Grinding 18 3.5.8 Filing 19 3.5.9 Finishing 20 RESULT AND DISCUSSION 4.1 Introduction 22 4.2 Final Product Design 22 4.3 Final Product 24 4.4 Discussion 25 4.4.1 Literature Review 25 4.4.2 Material Preparation 25 4.4.3 Designation Process 26 4.4.4 Fabrication Process 26 4.4.5 Material Wastage 26 CHAPTER 5 CONCLUSION AND RECOMMENDATION 27 REFERENCES 28 APPENDIX A SolidWorks parts drawing with dimensioning 29

ix LIST OF TABLE Table No. Page 1.1 Gantt Chart 3 3.1 Concept Screening 13 3.2 List of Materials 14

x LIST OF FIGURES Figure No. Page 2.1 Rubber toilet hose 5 2.2 Flexible toilet hose 6 3.1 Project flow chart 8 3.2 Concept 1 11 3.3 Gardening hose 11 3.4 Concept 2 12 3.5 Concept 3 12 3.6 Shear machine 15 3.7 Cutting sheet metal using hand saw 15 3.8 Roll bending process 16 3.9 MIG welding machine 17 3.10 Drilling using drill press 18 3.11 Cutting grinder 19 3.12 Filing tools (From left: Triangular bastard, flat bastard, and 20 round smooth) 3.13 Spray paint can 21 4.1 CAD drawing using SolidWorks 2011 Software 22 4.2 Orthographic view of project design using SolidWorks 2011 23 4.3 Exploded view of project design using SolidWorks 2011 23 4.4 Front view of fabricated product 24 4.5 Side view of fabricated product 24 4.6 Top view of fabricated product 25

xi LIST OF ABBREVIATIONS FYP CAD PVC D R BD OD MIG Final Year Project Computer Aided Design Polyvinyl chloride Diameter Radius Bore diameter Outer diameter Metal inert gas