1. CAD Applications Final Project
Pankaj Sharma
Department of Mechanical Engineering
University at Buffalo

2. Problem Statement:
“ Product Design & Analysis of flap mobile
phone”
Design Goal:
 Flap Analysis (basic motion simulation, stress analysis
while applying different pressure forces on flap)
 Drop test of complete body
 NEW USP (unique selling point) generation
 Battery mechanism & Location
 Customer feedback

3. Market Survey of flap cell phones
References:
[3] http://www.lg.com/us/mobile-phones/LG-LX550.jsp,Nov-20-2010
[4] http://us.blackberry.com/smartphones/blackberrypearl8200,Nov-20-2010
[5] http://www.gsmarena.com/nokia_2760-1975.php,Nov-20-2010
[6]http://www.buy.com/prod/alcatel-elle-flip-phone-with-camera-
unlocked/q/loc/12435/204735396.html,Nov-20-2010

4. Why Cell Phone Project:
Existing Problems:
 The cell phone get fall down on floor at least 2 times in day and
many were complaining about body wear and tear, LCD crack
 Coming out of the battery whenever cell phone drops on floor.
 Flap becomes loose after some usage or fall down.
 Buttons get hang
 Needs wire (port connection) to transfer the data from cell phone
to computer.

5. Idea Generation Phase:
Concept Design: Overall cell phone body surface
concept

6. Comparison of Alternative Designs
Parameters Concept 1 Concept 2
Pros Aesthetical looks better Aesthetical ok
Aesthetics Excellent Good
Surface finish Good Excellent
Durability Good Very good
Mock up
Response from 5(Very High) 4(High)
Customers
Cons
Manufacturing Mold design of such design will be little bit Flap shaft mechanism will
Issues complicated be complicated
Quality Maintainability will be a major issue
Cost High (Due to complicated profile) Moderate

7. Idea Generation for New Unique Selling point in Cell
phone

8. Comparison for new features concepts
Compact Tube Light Retractable USB Drive
Pros
Students problem of loosing USB
We can read while walking and travelling
drive will be resolved
Easiness of use
Users do not need to carry cable for
data transfer
Cons
Complicated and delicate product
More chances of breakage of tube light Care while using
Cost $7 $6

9. Decision Making Table
Decision table for cell phone concepts:
KPOV
Ease of
Total
Manufacturing Cost of Quality Final Cost Score(10
Parameters (30%) (20%) (50%) 0)
KPIV
Concept 1 20 15 40 75
Concept 2 25 17 45 87
Please note that Final cost high means less value for decision
matrix table
Decision table for USP:
KPOV
Ease of Manufacturing Customer Final Cost Total
KPIV
Parameters (20%) Response (30%) (50%) Score
Mini Light 20 15 35 70
USB Drive 25 15 37 77

10. Sketches

11. Sketches

12. Sketches

13. Sketches

14. Detailed 2D drawing of Flap body

15. Detailed 2D drawing of Main Body

16. Complete Assembly Exploded View

17. Flap Assembly Exploded View

18. Main Body Assembly Exploded View

19. Design Optimization Flow Chart for analyzing von messes stress
for different materials at various flap angles
Start
Choose the material for
Engineering Analysis
Apply the material properties on the mobile assembly in the
simulation mode of SolidWorks and set the model for analysis
Set the Flap angle and apply variable
pressure force on the flap
No
Meshing
Yes
If meshing is done smoothly run the simulation study
Take the plot reading for Von messes stress generation
and strain reading and check the major area of stresses
Update the excel sheet for von messes stress obtain at particular angle
and for a particular material and repeat all the iterations from the step3
Stop

20. Plots Analysis: data comparison for various plastics.
Von Messes Stress(PSI) Strain
Pressure Acrylic Acrylic Plastic
Flap Angles Force(psi) Plastic Nylon 6 Material Nylon 6
Max Max Max Max
90 40.4 42.2 7.36E-05 2.06E-05
110 83 94 1.19E-04 3.43E-05
0.01
130 77.9 88 9.79E-05 3.43E-05
150 76.4 87.3 1.14E-04 3.19E-05
90 2017.9 2108 3.60E-03 1.03E-03
110 4147.6 4699 5.99E-03 1.71E-03
0.5
130 3895.5 4421 4.89E-03 1.36E-03
150 `3822 4365 5.70E-03 1.59E-03

21. Von Messes Stresses at various flap Angles at Variable Pressure
Forces
Von Messes Sress at various flap angels at
variable applied pressure forces
5000
4500
4000
Von Messes Stress(psi)
3500
3000
2500
2000
1500
1000
500
0
90 º Flap 110 º Flap 130 º Flap 150 º Flap
Angle Angle Angle Angle
Acrylic at 0.01 pressure force 40.4 83 77.9 76.4
Nylon 6 at 0.01 pressure force 42.2 94 88 87.3
Acrylic at 0.5 pressure force 2017.9 4147.6 3895.5 3822
Nylon 6 at 0.5 pressure force 2108 4699 4421 4365

22. Von Messes Stress, Strain at 150 degree Angle at Pressure Forces of 0.5
psi.

23. Animations of the Engineering Analysis
results
 A : Motion Simulation of Flap based
cell phone  B :Pressure Force
Analysis
 Virtual Drop Test Simulation

24. Virtual Drop Test Simulation
 B : 0.02 “
 A : 0.01 “ thickness
thickness
 A : 0.03 “ thickness

25. Von Messes Stresses of body casing for shell thickness 0.03inch
 With ribs addition, reduction
in stresses about 40 percent
(from 0.5 to 0.3 MPa).

26. Challenges Faced During the Project
 Surfacing
Meshing of this bodies
Meshing for complete Body
Drop Test Failures on SolidWorks in
Furnas Lab
Solutions
 Surfacing: Model Simplification and new tools
learning
Meshing : simplification of the model
Drop Test Failures : Theoretical Hypothesis
developed and 1 Newton impact force applied for
analysis purpose.

27. Questions ?