3.1 Introduction
The intended purpose of the research phase is to assess the influences that the design constraints will have on the creation of a design solution, and to examine any potential ramifications that may arise during the course of the design process.
Adequate research will also help ensure that the design constraints are adhered to as effectively as possible.
Adequate research will also help ensure that the design constraints are adhered to as effectively as possible.
3.2 Data Collection
3.2.1 Issues associated with the design constraints
Of the eight constraints that define the design boundaries of the project, several have the potential to introduce difficulties into the design process.
As the finished piece will hold a lit candle, the constraint surrounding safety is the most important. No wax must be able to spill from the holder, nor should the support system be able to tip over or otherwise become unstable.
As maximum overall dimensions are also given, care must be taken not to go beyond them and produce an unsuitable design or solution.
Also listed are production methods that must be incorporated; specifically welding and the use of a custom-made bending jig. Any welding joints must be within the abilities of the designer to produce, and should not be so large or intricate that they introduce heat-related stresses into the solution that may result in warping or irrecoverable damage. Similarly, any curvatures must be within the capability of the bending jig - they must not be of such a large or small radius that they cannot be easily produced.
Given that materials for the project are supplied, the designer must familiarise themselves with the attributes of those materials. The grade of the provided steel flat bar is unknown but can reasonably be assumed to be 1022 mild steel, given that it is supplied with a coating of millscale (denoting a hot rolled production process). Interlloy (2011) details 1022 as having excellent weldability, good machineability, and a 350Mpa yield strength, suggesting good cold forming ability.
As the project also incorporates a number of turned aluminium parts, the machining properties of the supplied alloy, 6061, should be investigated; Interlloy (2011) rates it's machineability as excellent, and further states that if it is in the T6 annealed state (which the supplied material is believed to be), tungsten carbide tooling should be employed where possible.
Datasheets detailing the above information are attached as Appendices 2 & 3.
Should a finishing product be applied, the one chosen must be chemically stable and inflammable, to avoid posing a risk to users.
25/10/16 - A black satin spray has been chosen to finish the solution. The provided MSDS states that the product is hazardous in the as-sold aerosol state, but does not list any hazard or safety data for the product in the cured state. The MSDS is attached as Appendix 4.
3.2.2 Existent products
Although the design constraints do not make any mention of the need to produce a solution that meets any innovational or cosmetic criteria, inspiration can still be drawn from current-market products to produce a solution that has a unique appearance. To this end, images of a variety of cast and wrought iron products were gathered. These products incorporate a variety of design features, many of which can be used as influences for frame designs.
Of the eight constraints that define the design boundaries of the project, several have the potential to introduce difficulties into the design process.
As the finished piece will hold a lit candle, the constraint surrounding safety is the most important. No wax must be able to spill from the holder, nor should the support system be able to tip over or otherwise become unstable.
As maximum overall dimensions are also given, care must be taken not to go beyond them and produce an unsuitable design or solution.
Also listed are production methods that must be incorporated; specifically welding and the use of a custom-made bending jig. Any welding joints must be within the abilities of the designer to produce, and should not be so large or intricate that they introduce heat-related stresses into the solution that may result in warping or irrecoverable damage. Similarly, any curvatures must be within the capability of the bending jig - they must not be of such a large or small radius that they cannot be easily produced.
Given that materials for the project are supplied, the designer must familiarise themselves with the attributes of those materials. The grade of the provided steel flat bar is unknown but can reasonably be assumed to be 1022 mild steel, given that it is supplied with a coating of millscale (denoting a hot rolled production process). Interlloy (2011) details 1022 as having excellent weldability, good machineability, and a 350Mpa yield strength, suggesting good cold forming ability.
As the project also incorporates a number of turned aluminium parts, the machining properties of the supplied alloy, 6061, should be investigated; Interlloy (2011) rates it's machineability as excellent, and further states that if it is in the T6 annealed state (which the supplied material is believed to be), tungsten carbide tooling should be employed where possible.
Datasheets detailing the above information are attached as Appendices 2 & 3.
Should a finishing product be applied, the one chosen must be chemically stable and inflammable, to avoid posing a risk to users.
25/10/16 - A black satin spray has been chosen to finish the solution. The provided MSDS states that the product is hazardous in the as-sold aerosol state, but does not list any hazard or safety data for the product in the cured state. The MSDS is attached as Appendix 4.
3.2.2 Existent products
Although the design constraints do not make any mention of the need to produce a solution that meets any innovational or cosmetic criteria, inspiration can still be drawn from current-market products to produce a solution that has a unique appearance. To this end, images of a variety of cast and wrought iron products were gathered. These products incorporate a variety of design features, many of which can be used as influences for frame designs.
3.2.3 Survey
To gain a better idea of shapes, styles and colours that potential users may find appealing, a small survey was conducted:
To gain a better idea of shapes, styles and colours that potential users may find appealing, a small survey was conducted:
Table 2: User preference survey
Although the sample size was very small, the survey still provides valuable data that can assist in guiding the general 'look' of the solution.
3.3 Bending Jig
As a precursor to and requirement of this project, a bending jig was created. A range of skills and processes were employed in its creation, including welding, turning, drilling, and hand-filing. The jig, seen in a completed state in Image 1, incorporates two vertical scrolling pins; one at Ø20mm and one at Ø25mm. These pins allow the formation of a variety of radii and curvatures to be formed, with the horizontal bar between the pins acting as a friction brake to prevent the workpiece from moving unnecessarily.
Drawings were provided for the creation of the jig, which may be viewed at the link below.
Drawings were provided for the creation of the jig, which may be viewed at the link below.
Due to material supply difficulties, several parts of the jig use a different thickness of steel than specified; it should be noted that design authorities do not consider these differences as being an obstruction to proper functioning of the jig.
In any case, adequate testing should be undertaken to ensure that the 'intricacies' of the jig are known prior to commencing construction of the solution.
In any case, adequate testing should be undertaken to ensure that the 'intricacies' of the jig are known prior to commencing construction of the solution.
Photo 1: Completed bending jig. Author: Simpson, A.
3.4 Summary of data
After gathering information from several sources, several conclusions can begin to be drawn about the likely direction that the design will take, and the types of characteristics that possible solutions might employ.
The diverse range of current market offerings provide excellent guidance around the types of bends that are used in industry, in addition to demonstrating that a traditional-type look is prevalent; this identifies an opening for a less conventional style of design.
The user survey also provides some direction for the use of design features. A variety of responses were received, but point generally towards a design that is intricate and simple, modern looking, features multiple large and small radius bends, and has a paint or lacquer finish.
The diverse range of current market offerings provide excellent guidance around the types of bends that are used in industry, in addition to demonstrating that a traditional-type look is prevalent; this identifies an opening for a less conventional style of design.
The user survey also provides some direction for the use of design features. A variety of responses were received, but point generally towards a design that is intricate and simple, modern looking, features multiple large and small radius bends, and has a paint or lacquer finish.
3.5 Interpretation of the collected data
Formative evaluation
The 'perfect' solution will integrate the stipulations of the design brief and constraints, in conjunction with research data. As the brief gives the designer a good amount of freedom in the creation of a solution, the solution may take any form. The solution must also stay within the limitations set out by the design constraints, and incorporate data wherever possible; this will ensure that the solution is as effective as possible.
The 'perfect' solution will integrate the stipulations of the design brief and constraints, in conjunction with research data. As the brief gives the designer a good amount of freedom in the creation of a solution, the solution may take any form. The solution must also stay within the limitations set out by the design constraints, and incorporate data wherever possible; this will ensure that the solution is as effective as possible.
3.6 Analysis of collected data in terms of design constraints
Interaction analysis
Table 3: Interaction analysis
Interaction analysis key
Image 9: Interaction net
Examination of constraint interaction can be quite helpful in determining how these interactions can affect the overall outcomes of the design process. As an example, the interaction between size and safety is rated as desirable, while the interaction between size and material is rated as essential - only a limited amount of frame material is provided.
Carrying out interaction analysis can help determine which particular design factors hold a greater importance, and will be of a correspondingly greater influence in generating a solution.
Carrying out interaction analysis can help determine which particular design factors hold a greater importance, and will be of a correspondingly greater influence in generating a solution.
3.7 Conclusions drawn from interaction analysis
Formative analysis
The interaction table and net shows the need to examine constraint connections and the impacts that these connections can have on the creation of a solution. As an example of this, the relationship between the manufacturing location and production methods can be seen to have a stronger influence than manufacturing location and size.
The interaction table and net shows the need to examine constraint connections and the impacts that these connections can have on the creation of a solution. As an example of this, the relationship between the manufacturing location and production methods can be seen to have a stronger influence than manufacturing location and size.
3.8 Conclusion
In closing the Research phase of the documentation, the data shows that a solution can take any number of forms, but ideally it will be within the bounds of design constraints, and incorporate research knowledge wherever possible.