Design and prototyping of machine for manual shoe making assistance

1. :Under:
Prof. B. Guroomurthy & Prof. A. Ghoshal
By: Ashveen//Harshala
Centre for Product Design and Manufacturing,
Indian Institute of Science, Bangalore
Assistance for Manual Shoe
Making

2. Contents
• A Retrospective
• The Stepping Stones
• The Chosen One
• Magnifying Glasses
• The Fires of Industry
• Cost
• Lessons Learnt
• Acknowledgements

3. A Retrospective (Till Now)
Manual Shoe Making
Initial Concepts Towards Solution
Design of The Mechanism
Detailed Design of The Final Assembly
Analysis

4. The Stepping Stones (Stages of project)
• Background and User Analysis
• Prior Art
• Initial Ideas and Concepts
• Finalization of Concept
• Detailed Design
• Modeling, Analysis and Testing
• Modifications, Updates and Finalization
• Drawing Release
• Manufacturing
• Assembly Tryouts
• Finalization and Finishing
• Painting/ Plating/ Coating
• Testing and Tryouts
• Scope of Improvement

5. The Chosen One (The Final Concept)

6. In flesh & blood (Manufactured prototype)

7. components QTY
1 BASE PLATE 1
2 PILLAR BASE 1
3 PILLAR 1
4 TOP PART PILLAR 1
5
TOP PILLAR BLOCK-TRAINGULAR PLATE
BLOCK 1
6 PIN FOR TRAINGLE PLATE 1
7 spacer for triangle pin 2
8 FRAME 2
9 TRAINGLE PLATE 1
10 PEDAL BLOCKS 2
11 PEDAL 1
12 LONGEST LINK 2
13 GUIDE BLOCK 1
14 LINER FOR GUIDE BLOCK 1
15 LONG MIDDLE LINK 1
16 LINK BELOW 1
17 LINK ABOVE 1
18 BOLT FOR PILLAR BASE 4
19 TABLE 1
20 TABLE ATTACHMENT 1
21 GUIDE SHAFT 1
22 triangle plate + middle link BOLT 1
23 3 links joining 1
24 rod + lower link 1
25 base plate + pedal blocks 2
26 pin 1
27 nut 2
28 spacer 2
29 pin for triangle + long link 1
30 nut for the above 2
31 bolt
32 nut
33 bolt
34 nut
35 NEEDLE 1
36 SPRING 2
37 arm 1

8. The Magnifying Glasses (Exploded Assembly)

9. The Fires of Industry (Manufacturing)
• While manufacturing many different operations and processes were
used
• Gas Cutting
• Saw Cutting
• Milling
• Turning
• Welding
• Brazing
• CNC Laser Cutting
• Filing
• Deburring
• Degreasing
• Electroplating (Zn-Blue)
• Blackening
• Powder Coating
• Center Grinding
• Drilling
• CNC Sheet Bending

10. • The progress of the project was as follows
• Surface milling the base plate
• End turning the main pillar
• Laser cutting for table, triangle link and the side frames
• Welding of the pillar and main top block
• Milling of the top block
• Manufacturing the main plunger
• Manufacturing the two split arrest blocks
• Manufacturing the arm
• Welding the paddle assembly
• Turning the spacers
• Turning of the pins required
• Grinding the main plunger, pins and surface grinding of the spacers
• Milling and turning the main guide block with Phosphorous Bronze Bush
• Milling the three links
The Fires of Industry (Manufacturing)

11. • Throughout the project there has been a great
deal of learning involved-
– Starting from Scratch and Taking till Final Prototype
Manufacturing
– Integration of multiple manufacturing methodologies
– Cross communication and time management among
the teams, both design and manufacturing
– Manufacturability, Fits and Tolerance, Drawing
– Using software skills to speed the entire process up
– Multiple software essential for design such as-
SolidWorks, ADAMS, MD-NASTRAN, AutoCAD, Adobe
Photoshop
The Lessons (Learnings throughout the project)

12. • First of all to Pro. B Gurumoorthy and Pro. A.
Ghoshal for the great opportunity of doing the
project and generously supporting all the
students
• Our most sincere thanks to Mr. John and Mr.
Venkatachalam, without whom manufacturing
the product would not have been possible
• Our thanks to Mr. Prakash and Mr. Kumar for
helping us with many contacts and market
purchases
Acknowledgements (A small vote of thanks)