ASSESSMENT AND CONSTRUCTION OF MANUAL TILE CUTTER WITH BORING SAW

ABSTRACT

This project was on design and fabrication of a manual tile cutter with boring saw whose operational principle centers on the process of scoring and breaking. In the light of purpose of this project, the design was drafted in accordance with the specifications and principles guiding the operation of manual tile cutters. Materials were carefully selected and tested in accordance with the standard in order to meet the expectations of the device in terms of its functionality and durability; such materials are mild steel, aluminum, among others. Following appropriate drafting of the working drawings, the project was constructed in strict adherence to Engineering and Technology design processes. Thus guided by the operational guidelines and principles, due attention paid to manufacturing specifications that agree with those principles stipulated by Chapman 1972 and Ghand 2008. Use was also made of appropriate engineering analysis and applications to determine the effect of compression forces which occur in different dimensions using in the machine: such as bending stress, torque, shearing stress, working stress, section modulus as well as the maximum compression stress of the cutter which equals 0.34Mpa. The calculated maximum force required of the cutter for high efficiency is 72N after assembly. Perpendicular, transverse and circular cuts were made on several tiles without breakage. The cutter was tested and its efficiency was rated 72.5 indicating an appreciable degree of efficiency. This result evidently acknowledged that the cutter has the ability to make series of consecutive clean cuts on tiles without fracture. The impact of the project in relation to contributions to knowledge was highlighted while some recommendations were made.

TABLE OF CONTENTS

Content Page

TITLE PAGE i

CERTIFICATION ii

DEDICATION iii

ACKNOWLEDGEMENTS iv

TABLE OF CONTENTS v

ABSTRACT vii

CHAPTER ONE: INTRODUCTION 1

Background to the Study 1

Statement of the Problem 2

Purpose of the Project 4

Significance of the Project 5

Assessment Research Questions 7

CHAPTER TWO: REVIEW OF RELATED LITERATURE 8

Conceptual Framework 8

Theoretical Framework 12

Principles of Operation of Tile Cutter with Boring Saw 12

Classification 16

Review of Related Empirical Studies 23

Summary of Review of Related Literature 28

CHAPTER THREE: PROJECT DESIGN AND CONSTRUCTION 31

Performance Specifications/Calculation 31

Young Modulus of Elasticity 32

Torque required to rotate the Handle 36

Design/Schematic Diagrams 38

Efficiency of the Machine 39

Construction Procedure 43

Working Material and Specifications 48

Required Tools and Equipment 49

Assembly Drawing 51

CHAPTER FOUR: DATA PRESENTATION 52

Project Testing 52

Test Results 52

Finding Employing Structured Interview 53

Assessment Research Question 58

Major Findings of the Study 64

Limitations to the Project Design 67

Contributions to Knowledge 68

CHAPTER FIVE: DISCUSSION, CONCLUSION AND RECOMMENDATION 70

Discussion Structured Interview 71 Discussion Assessment Result 72

Adaptation of the Project 74

Conclusion 75

Recommendations 76

REFERENCES 78

APPENDICES Appendix A: Material Selection 82

Appendix B: Cost of Materials 83

Appendix C:Transmittal Letter 84