Hello It’s me Amir. My Email is (Removed by Freelancer.com Admin) I am doing Master in Mechanical Engineering. I am given a project to redesign the flexytool ( a special Spanner) made from Hardox 500. This spanner is in one piece and it has some flexibility , due to its flexibility, flexytool’s arms or legs are compressed with hand’s fingers and thumb to grip a nut and then turn it to loosen or tighten the nut or bolt. I will send pics of this tool and its dimension. I don't have to actually redesign this tool physically. I only have to make a design report. I will send document stating theory on how to make this design report and a similar project of a senior student to redesign a pulley is attached. Background of this project is that there is company called Pro Seal in Sweden that have a sub-company called Akuma tools making this flexytool says that this tool has very low sale due to very high price. High price of flexytool is associated with the high price of its material Hardox 500 and highly priced manufacturing method of laser cutting. Currently flexytool is being manufactured by Laser cutting. The things I have to do in this project are Following ....Flow of these things can be different depending upon complete project compilation.(1) I have to change Hardox 500 material with other cheap materials having similar mechanical properties as Hardox. (2) I have to use different manufacturing method for manufacturing this flexytool like waterjet cutting, CNC wire cutting, Forging. (Note: You will use your own knowledge of mechanical engineering and skills to check which manufacturing methods (also all other aspects) will be best so that my project can get highest grade.) (3) I have to make a model of this flexytool on a design software (like Catia, Solid works) with little design changes to show and approve that these changes will helpful in better design and lower price. (4) Solid mechanics calculations given below together with FEM Analysis. Hand Solid mechanics Calculations and FEM analysis should have almost same results.
In your analysis, you should include
Bending stresses (due to deflection of handle plus required torque)…
…applied to the stress concentration in the critical point of the tool design, the notch (you need to find a notch-type similar to your design in a handbook)
Relevant safety factor (how far from yield point is enough)
Relevant torque required to loosen a bolt (e.g. you can use torque data of high grade bolts in a bolt manual of your choice)
Fatigue analysis based on relevant load cycles and including aspects of size, surface roughness, and environment where the tools should be used
Do your analysis on the bolt/tool size M8, Deflection force is 116N.
Compare your analysis with material data of Hardox 500; is there room to select a less expensive material?
What material properties are critical? What material properties are less critical?