Research

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On-Site Steel Volumetric Module Fab Self-jigging Node for Site Cheap-Accuracy Volumetric Module Fabrication De sign for M anufac ture Final Pro g r a m Dongze Luan

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Modularity Group 3

Tutor

Tutor

Student

Scully, Peter

Prior, Arthur

Dongze, Luan

A million thanks to Arthur and Peter for their patient guidance and advice during the design project. In addition, thanks to Lucy, Claudia, Melis, Hamish, and Mark for passing on their knowledge and meticulously help during the fabrication process.

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Foreword Modular integrated construction as an Industrialized off-site prefabrication method has the advantages of materials saving, costefficiency, high speed, safe construction, and is not delayed by weather. But it also falls into the dilemma of its own limitations.

According to the thesis research, the most limitations is following by the "off-site" modular factory such as high carbon emission and cost of transportation, module size limited by the traffic rules, higher investment in modular factory, which makes the modularity construction difficult to achieve scale economy.

Besides, the concept of on-site industrialized construction was developed to optimize the separation between the factory with site. In standardized modular fabrication, node assembly should be utilized to reduce equipment dependence for factory fabrication to accommodate areas where modular factories are not available.

The use of nodal products to reduce the non-standard component dependency, mechanical equipment dependency, and skill dependency of modular steel construction becomes a simplified intermediate technology that allows for simplicity and convenience for construction contractors to self-builders so that it can be adapted to a wider range of contexts.

Contents Chapter 1 Research Introduction

Chapter 3-1 Prototype Casting

• Context Introduction • Scattered and Complex Supply Chain • Folding Structure Making • Jig and Accuracy • Steel Structure Prefab Strategies • "Cheap-Accuracy" • Research Question • Aims and Objective

• Prototype for Casting Design • Multi-Mould Design and Manufacture • Casting Manufacture

Chapter 2 Prototype Evolution • Self-Jigging Principle • Prototype Design • Evolution by Manufacture

Chapter 3-2 Prototype Machining

• Prototype for Machining Design • Machining Fabrication

Chapter 4 Final Project • Self-Jigging Experiment • Welding Fabrication • Filling Experiment • Module Connection

Chapter 5 Conclusion • Question Answer • Discussion • If Research Continue...

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[CHAPTER 1] Research Introduction "On-Site Manufacture" For so many years, people have wanted to manufacture houses like automobiles.

However, architecture is different from automobiles, and off-site prefabricated constructions were slow developed due to their own limitations.

Is construction only able to be transformed into manufacturing off-site? What about on-site?

Figure of Context: "On-Site Manufacture" Source From NASA

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[CHAPTER-01] RESEARCH INTRODUCTION

Chapter Abstract

Poor Productivity of Construction Industry

Foldable Structure

Transportation

Characteristic of Construction Industry

Conflict Current Industrialized Construction (Off-Site)

Potential of Productivity Evolution

Skill Labor

"On-Site" Cheap Accuracy Fab

Research Question 2

Self-Jigging Node

Volumeteric Module On-Site "Easy" Welding

Factory Cost

Research Question 1

"Easy" Fab Principle

Steel Structure

The nature of the construction industry itself leads to low productivity over time. Off-site prefabrication is an exciting productivity gain, but it has encountered similar obstacles in different countries, making its widespread use difficult. The main reason is that prefabrication plants lengthen the construction supply chain to a certain extent. Prefabricated factories have a high initial investment and a small range of factory supply due to transportation constraints. Prefabrication plants have tried 2D modules and folding structures to address these issues, but with little success. This chapter proposes a strategy for the on-site production of structural steel volumetric modules based on temporary plants and local fabrication that have been realized for concrete structures, and presents research questions aimed at enabling the production of structural steel volumetric modules from raw materials that can be sourced close to the temporary plant on site and that can be used directly in the production of the raw materials.

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[CHAPTER-01] RESEARCH INTRODUCTION

Traditional Construction Industry: Poor-Performance

Past Two Decades the Labor-Productivity Total

Manufacture

Construction

Average Annual Growth Rate

3.6%

1%

2.8%

0

1

2

3

4

Low Productivity but 13% of the world’s GDP, 40% of the energy consumption, 565 million housing needed in 2030 The construction sector is one of the largest in the world economy. However, the construction's productivity has trailed that of other sectors for decades. Besides, many countries are facing problems of insufficient productivity and declining productivity.

Source: 1.McKinsey&Company Reinventing construction: A route to higher productivity

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[CHAPTER-01] RESEARCH INTRODUCTION

Construction Industry Current Situation Today’s Construction Industry

Project 1

A highly complex, fragmented, and project-based construction process...

Development Design and Engineering

Material Fab

Component Fab

Distribution

Construction and Assembly

Final Building

Development Design and Engineering

Material Fab

Component Fab

Distribution

Construction and Assembly

Final Building

Development Design and Engineering

Material Fab

Component Fab

Distribution

Construction and Assembly

Final Building

Development Design and Engineering

Material Fab

Component Fab

Distribution

Construction and Assembly

Final Building

Project 2

Project 3

Project 4

The construction process is highly projected based-developed from unique customer specification, using designs planned from scratch, and with limited degree of repetition.

The value chain and player landscape are local and highly fragmented vertically and horizontally, resulting in a multitude of players involved at each step and major interface frictions.

Source: 1.McKinsey&Company Reinventing construction: A route to higher productivity 2.McKinsey&Company The next normal in construction

Construction is performed by generalists on-site in hostile environments, with a large part of the workforce being temporary and manual.

Limited use of end-to-end digital tools and processes as well as a captical-light delivery approach.

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[CHAPTER-01] RESEARCH INTRODUCTION

[ Ideal ] of Off-Site Prefabrication Ideal Off-Site Construction

Project 1

Development

A more standardized, consolidated and integrated construction process...

Project 2

Material Manufacture

Logistics coordinator

Assembly

Final Building

Logistics coordinator

Assembly

Final Building

Logistics coordinator

Assembly

Final Building

Logistics coordinator

Assembly

Final Building

Product Development

Development

Project 3

Development

Component Manufacture

Off-Site Manufacturing

Delayering and consolidation within steps of the value chain

Project 4

Development

Players to increase control of value chain, either digitally or via vertical integration (eg, off-site manufacturing, supply chain, assembly, and operations of final building)

The construction process is increasingly product based, meaning structures will be products and manufactured off-site by branded product houses specializing in certain end-user segments.

Developers choose entire designs or specific components from a library of options developed in house or offered externally on the market.

Source: 1.McKinsey&Company Reinventing construction: A route to higher productivity 2.McKinsey&Company The next normal in construction

Value chain is more consolidated, both vertically (delayering) and horizontally, with increased degree of internationalization

Disintermediation takes place through digital marketplaces and direct channels.

Contractors focus on lean, on-site execution and assembly of products

Data and analytics on customer behavior generated after completion to optimize total cost of ownership and future designs.

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[CHAPTER-01] RESEARCH INTRODUCTION

Exciting Ideal and Depressing Reality Current Off-Site Construction

Project 1

Modular Plants have high initial costs and limited radiation coverage due to transportation restrictions

Product Development

Logistics coordinator

Development

Site

Final Building

Material Manufacture

Project 2

More logistics coordinator

Development

Project 3

Far site

Final Building

Component Manufacture Much more logistics coordinator

Development

Far site

Final Building

Project 4

Development

•

Off-Site Manufacturing

Traffic limitation

Site 4

The reality, however, is that the scale of use • Material suppliers and processors at all levels • At the same time, the transportation of • The size of the construction module is also Disintermediation takes Contractors focus on lean, Data and analytics on Value chain is more consoliThe construction process is increasDevelopers choose entire of prefabricated construction, especially remain decentralized and need to be preconstruction modules is inefficient and limited by truck dimensions and traffic place through digital marketon-site execution and customer behavior generated dated, both vertically ingly product based, meaning strucdesigns or specific compomodules with high prefabrication rates, is still assembled by construction prefabrication requires heavy trucks to transport, making regulations, and design adjustments and places and direct channels. assembly of products after completion to optimize (delayering) and horizontaltures will be products and manufacnents from a library of cost of ownership ly,construction with increased degree of transportation costs and carbon emissions limited. factorys, lengthening the changes cannottotal be made in the field. and tured off-site by branded product options developed in house future designs. internationalization houses specializing in certain end-usor offeredsupply externally on the chain. significantly higher compared to traditional er segments. market. methods.

Source: 1. Jesús Ortega, Harrison A. Mesa, Luis F. Alarcón, (2023) The interrelationship between barriers impeding the adoption of off-site construction in developing countries: The case of Chile, 2. Serdar Durdyev & Syuhaida Ismail (2019) Offsite Manufacturing in the Construction Industry for Productivity Improvement, 3. Xin Hu, Heap-Yih Chong, Xiangyu Wang, (2019)Sustainability perceptions of off-site manufacturing stakeholders in Australia, 4. Hani Aburas (2017) Off-Site Construction in Saudi Arabia: The Way Forward 5. Emna Attouri, Zoubeir Lafhaj, Laure Ducoulombier, Bruno Linéatte, (2022) The current use of industrialized construction techniques in France: Benefits, limits and future expectations,

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[CHAPTER-01] RESEARCH INTRODUCTION

The Barrier of Off-Site Prefab Construction I have no choice.

Raw Material Sales Site 03 Prefab is so good.

Element Factory Site 01 I prefer more directly.

Traditional construction methods, while inefficient, allow for the proximity of building materials as well as manpower to build on site. Prefabricated modules, while efficient, also lengthen the already fragmented supply chain structure of the construction industry.

Modular factories are not easily accessible and it is not practical to invest in large-scale modular factories everywhere.

Investing a new prefab factory here is expensive.

Site 02 Space Prefab Factory Element Factory

Raw Material Sales

Source: 1. Jesús Ortega, Harrison A. Mesa, Luis F. Alarcón, (2023) The interrelationship between barriers impeding the adoption of off-site construction in developing countries: The case of Chile, 2. Serdar Durdyev & Syuhaida Ismail (2019) Offsite Manufacturing in the Construction Industry for Productivity Improvement, 3. Xin Hu, Heap-Yih Chong, Xiangyu Wang, (2019)Sustainability perceptions of off-site manufacturing stakeholders in Australia, 4. Hani Aburas (2017) Off-Site Construction in Saudi Arabia: The Way Forward 5. Emna Attouri, Zoubeir Lafhaj, Laure Ducoulombier, Bruno Linéatte, (2022) The current use of industrialized construction techniques in France: Benefits, limits and future expectations,

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[CHAPTER-01] RESEARCH INTRODUCTION

The Solution from Prefab Part but still limited Limited Off-Site Solution

Volumetric Folding Modular Structure

Element and Panelized Modular Structure

Prefabrication brings high productivity at the same time, as two sides of a coin, it also brings transportation logistics constraints and high initial factory costs, both folding structures and modular units and panels can not fully solve their own shortcomings of off-site prefabrication, which is amplified in the extremely decentralized construction industry.

Increasing the cost of module to decrease the cost of transportation, also bring the challenge to manufacture and flexibility.

Increasing the assemble difficulty to decrease the cost of transportation, also decrease the manufacture difficulty of prefab to save the investment of factory.

Broad Holon Building using folding structure to increase transportation efficiency. The Structure can be unfolded on site to get double area.

ConXtech structures are designed with tapered, “lower & locking” steel connections that enable safe and rapid assembly.

The folding structure developed by Zhu Jingxiang's team was manufactured in a Chinese factory for the MCEDO School project in Nairobi, Kenya.

Broad Sustainable Building (230000 sqaure meter factory) completed the construction of the J57 Mini Sky (57-storey building) in three weeks using panelized modular structure.

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[CHAPTER-01] RESEARCH INTRODUCTION

On-Site Concrete Manufacture Already be Achieved. Steel Prefab Why not?

On-Site Manufacture of Concrete Structure According to the On-Site Manufacture theory, On-Site Manufacture adopted several advanced Industrialized Construction techniques.

On-Site Manufacture Practices

On-Site Manufacture Theory

1. Technique Process of Pre-assembly Automatic Lifting Platform (PALSP)

Basic Principles

Each standard floor is a production unit, and the whole construction site forms a temporary factory in the vertical direction.

Standardization: technical process standardization

For instance, pre-assembly automatic lifting support platform (PALSP), prefabricated aluminum formwork system (PAFS), and precast concrete partition (PCP).

The concrete casting structure can achieve on-site manufacture, which shown the potential of on-site industrialization of construction industry.

Thus, the steel prefab construction why not?

Transform the construction site into a mobile temporaray factory towards industrialized construction

Prefabrication: focus on prefabricated molds and rebars Modular: module elements are integrated and done all at once Pre-assembly sample

PALSP attached to the Closed space created by Enclosure of PALSP buidling structure PLASP

2. Technique Process of Prefabricated Aluminum Formwork System (PAFS)

Lean Principle: continuous construction process workflow Sustainablility: stakeholder co-benefits

PAFS through the repeated assembly, casting, disassembly, and transfer to the next standard floor to repeat this cycle, to achieve the production of standard units one by one.

Inudstrialized technology

Integration of various industrialized technologies Preassembly technology: to creat a temporary mobile factory Prefabricated mold: standardized flexible production line Pre-assembly sample

PAFS assembly process PAFS system with the Temporary factory with concrete cast PAFS

3. The Precast Concrete Partition (PCP)

Industrialized cast-in-situ: continuous pumping of concrete Precast concrete: as a non-vertical load bearing component

PCP is the main prefabricated concrete component of this system. Since PCP is not load-bearing, it can be installed after the main-structure construction is finished.

Production process management Construction as a manufacturing process Lean process: standard construction cycle Precast concrete patition storage

Precast concrete patition installed as palor wall

Concurrent engineering: interspersed construction

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[CHAPTER-01] RESEARCH INTRODUCTION

Project Proposal Easy Accurate Fab Principle

Project Proposal: On-Site Module Manufacture

Proven On-Site Manufacture

On-Site Easy Accurate Welding?

The principle of aluminium extruction which can be “no-machine” assemble to required structure is easy-accurate.

The volumetric modular construction require high-accuracy of each module due to the accumulate process of construction.

The on-site concrete casting manufacture prove the feasibility of on-site manufacture construction.

Volumetric Modular Construction

Logistic Limatation

Previously “Limited Solution”

Volumteric Modular Construction is a efficient method for industrialized construction, but it limited by the logistic and factory investment.

The construction industry is fragmented in land and suppliers, and the prefab method makes trasportation and logistics more complex, which limited the modular construction.

The folding structure and element prefab tried to solve the logistic limitation, but it is still considered from the direction of off-site prefab and fails to solve the shortcomings that come with off-site prefab.

As folding modules and 2D modules still do not revolutionize the limitations imposed by off-site prefabrication. Also the in-situ fabrication of buildings has been proven by the standardized pouring of concrete structures in temporary factories. Thus, this project's explores the possibility of in-situ fabrication of volumetric modules for steel structures.

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[CHAPTER-01] INTRODUCTION OF OFF-SITE CONSTRUCTION

Although on-site manufacturing has been proven to be feasible, temporary factories for on-site manufacturing cannot have the same specialized production equipment as professional off-site factories, and on-site manufacturing requires a simpler and more efficient manufacturing process, which needs to continue to be researched. Can on-site factories also use more accessible raw materials for precise production and assembly on-site?

Research Question:

To what extent can design remove the need for factory prefabrication before material gets to site?

Aim:

Using self-jigging nodes assembled and fabricated directly from basic industrial products (steel hollow section) into volumetric modules.

Objective:

On-site "cheap accuracy" fabrication from basic material using the industrial product.

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[CHAPTER-01] RESEARCH INTRODUCTION

Research Methodology

Folding Structure for Transportation (TQ1) Chapter 1

Barrier of Industrialized Construction (RQ1)

Casting Manufacture (TQ2)

On-site Cheap Accuracy (RQ2) Chapter 1

Chapter 1

Chapter 3-1

Self-jigging Node for On-Site Volumetric Module Fabrication

Final Project Volumetric Module Fabrication (TQ4)

Disscussion and Conclusion

Machining Manufacture (TQ3) Chapter 2

Chapter 2 first describes the difficulty of accurately welding and machining the steel raw materials into volumetric modules in the ground, for the original off-site prefabricated module connection nodes, and prototypes the on-site fabrication nodes based on the off-site prefabricated module nodes. Chapter 3 shows the manufacturing process of the prototype as well as the technical problems and solution ideas, while the feedback from the manufacturing in turn influences the next design. Chapter 4 shows the fabrication assembly and experimentation of the unfinished final prototype with plans for the next work. Finally, in Chapter 5 the entire project design, research and fabrication is discussed and summarized.

Chapter 3-2

Chapter 4

Chapter 5

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[CHAPTER 2] Prototype Evolution "Easy-Accuracy Assemble" Steel structures need to be manufactured in off-site factories with the help of large-scale equipment due to the difficulty and accuracy of machining.

At the same time, can the principle of using features to achieve easy accuracy, which is a basic element of off-site assembly, be applied to the on-site production of steel volume modules to improve their processing efficiency and accuracy?

Figure of Context: "Easy Accurate Assemble" Source From Pinterest

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[CHAPTER-02] PROTOTYPE EVOLUTION

Chapter Abstract

Industry Manufacture Way of Steel Node

State of Art

Fast Single Piece Manufacturing

Modular Connection Self-Jigging Node 1.0

Casting Manufacture

Self-Jigging Node 2.0

Machining Manufacture

Self-Jigging Node 3.0

Module Experiment (Welding Manufacture)

Jigging Assemble Chapter 3-1

Intial Proposal

Use Aluminum to Test & Prove

Chapter 3-2

Simplify Vertical Structure

Steel for Next Welding Step

Chapter 4

More Accuracy at Rough Element

What are the similarities between the connection nodes of an on-site prefabricated module and the nodes of an off-site prefabricated module?

In addition is there any other functionality that needs to be implemented? How to optimize the number of dimensions of steel sections and the number of nodes to facilitate the management of on-site fabrication as the forces are different for different heights of floors?

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[CHAPTER-02] PROTOTYPE EVOLUTION

Before Prototype: Folding Structure Designing and Making

Full expansion

Full folding

This folding structure is more stable than the vertically oriented folding structure of the Nairobi School and is also able to be unfolded on the ground, which is safer than the folding structure of the Fargo Living Building, which is unfolded at high altitude.

Folding Diagram

The columns are subjected to greater pressure than the beams at each level, so the position of the folded structure was chosen to be folded horizontally. This folded structure significantly reduces the transportation volume of the steel volume modules. At the same time, it can be unfolded and secured during assembly by means of bolt locking.

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[CHAPTER-02] PROTOTYPE EVOLUTION

Before Prototype: Folding Structure Designing and Making Rotate

Support

Water jet cutting pieces

Rotate structure for folding

Folding form

Lock

Support

Welding together

Locking by bolt

The folding structure manufacture is complex than the general structure. Why the steel module must be m a n u f a c t u r e d o ff - s i t e , a n d w e h a v e t o i n c r e a s e t h e manufacture cost to reduce the transportation cost. What is the barrier of manufacture steel module on-site?

Unfolding form

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[CHAPTER-02] PROTOTYPE EVOLUTION

Project Proposal: Why We Manufacture Steel Module Off-Site?

Idealised dimensions

Actual dimensions B

B C D

H

H

A

A: Out of Verticallity ≤ H/500 B: Length Tolerance ≤ H/500 C: Width Tolerance ≤ H/500 Datum Position

D: Bow ≤ H/500

Datum Position

The steel structure module manufacture require high accuracy in welding process. In the off-site factory, the workers rely on huge jig to achieve 0.3mm tolerance. But if on mud in a location, at most 19mm tolerance, which not meet the requirement of precision. For example when the H=5000mm, the tolerance should be less than 10mm.

However, the autowelding machine development provide the potential of standardization welding and also the tolerance of steel section is much smaller than the requirement, the barriers between off-site and on-site welding is the accurate jig.

Thus, can we design a node can achieve self-jigging which can remove the requirement of huge structural jig in the factory.

C

[CHAPTER-02] PROTOTYPE EVOLUTION

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Accuracy: Welding and Jigging

The huge structural jig helps welder can accurate position and fix before the welding. Also, the factory environment is better than the site welding. This is the reason why the off-site steel module manufacture. But the on-site manufacture environment is not impossible which be proven by the concrete temporary factory. But on-site temporary factory can not have all the equipment of professional factory which need to be simplified.

[CHAPTER-02] PROTOTYPE EVOLUTION

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Before Porototype: Using "Special" Jig to Replace "Universal" Jig

The volume module of steel structure can not be applied to the huge and bulky general jig, due to the standardization of steel structure welding only need to complete a single kind of welding fixation, so a simple jigging was made to test the fixation effect, and the experiment proved that it can be used to replace the general jig by a specific jig fixation.

[CHAPTER-02] PROTOTYPE EVOLUTION

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State of Art: Vector Block "Node of Off-Site Manufacture"

Research Connection Feature + Jigging Feature + Filling Feature + Tolerance Feature

The Vecror block is a state-of-the-art connector for off-site prefabricated modules that enables not only steel profile connections, but also vertical and horizontal connections between modules. However, as this research project is a connector for in-site fabricated modules, is it possible to realize the function of self-jigging of raw steel profiles at the same time on the basis of the connector?

Source: 1. Thai, Huu-Tai, Tuan Ngo, and Brian Uy. A Review on Modular Construction for High-Rise Buildings 2.Dhanapal, Jothiarun, Hossein Ghaednia, Sreekanta Das, and Jonathan Velocci. Structural Performance of State-of-the-Art VectorBloc Modular Connector under Axial Loads

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[CHAPTER-02] PROTOTYPE EVOLUTION

Prototype 1.0 Design: "Node for On-Site Manufacture" Design Connection Feature + Jigging Feature + Filling Feature + Tolerance Feature

Lock Bolt Jigging Feature Lower Block Ceiling Beam

Floor Beam Registration Pin Gusset Plate Upper Block

Column

The prototype 1.0 design improves on the vector block connector by adding features for self-jigging of the steel section. The prototypes are first fixed to the anchor bolts, and the steel section is cut at an angle so that it is self-fixing by using the features of the prototypes, thus enabling accurate on-site welding.

[CHAPTER-02] PROTOTYPE EVOLUTION

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Filling Problem (Both Prototype 1.0 and State of Art) and Prototype 2.0 Evolotion

The lower floors are under more pressure than the higher floors, so in the steel volumetric modules, the size of the steel columns and nodes in the lower floors are progressively larger than those in the higher floors, which is not in line with the requirements of modularization. The prototype 2.0 design improves the features of the positioning of the module to the module, so that the modules can be packed before or after the installation after the production of the module is completed, which makes it possible to obtain a different load carrying capacity, and to reduce the types of the nodes and the steel profiles in the on-site manufacture.

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[CHAPTER-02] PROTOTYPE EVOLUTION

Prototype 2.0 Design Design Connection Feature + Jigging Feature + Filling Feature + Tolerance Feature

In Prototyping 2.0, the use of bolts to lock the prototype nodes to the steel profiles before welding after installation was also attempted to make the welding process more precise. And the removal of the duplicate function feature makes the prototyping more simplified and easier to produce. For the diagonal cutting of steel, the main purpose is to facilitate the installation as well as to provide support in the vertical direction before welding, so that it can be positioned by its own gravity in the desired position during installation.

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[CHAPTER-02] PROTOTYPE EVOLUTION

Prototype 3.0 Design Design Connection Feature + Jigging Feature + Filling Feature + Tolerance Feature

Filling Feature

Column

Connection Bolt Floor Beam Lock Bolt Gusset Plate Position Feature

Ceiling Beam

Lower Block Upper Block

In Prototyping 3.0, the self-jigging structure was upgraded based on feedback from the manufacturing process, making it easier to machine and avoiding problems with positioning and mounting accuracy caused by inaccuracies in the steel profiles themselves. In addition, the limitation of holes in the steel profiles allows for errors in angular and dimensional cuts of the steel profiles so that they do not affect the final mounting accuracy. Unnecessary machining accuracy is discarded, and the steel profile can be precisely positioned and locked as long as the dimensions of the openings are accurate. Moreover, the bolt locking structure has been moved to the vertical direction, simplifying the machining direction of the part. Reduction of turning and repositioning during machining.

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[CHAPTER 3-1] Prototype Casting Manufacture "Mass Production " Mass production is a mode of production that enables the efficient production of large quantities of products.

Casting, as used in this chapter, is one form of mass production.

Although the initial mold design and manufacturing is costly and time-consuming, but for the production of a large number of similar or identical products. Can reduce production costs and improve efficiency.

Figure of Context: "Standardized Manufacture Design" Source From Sinence Museum Group

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[CHAPTER-03-1] PROTOTYPE CASTING MANUFACTURE

Chapter Abstract

Technical Question 1

Technical Question 3

Technical Question 2

Mould Milling

Prototype Modification for Casting

Mould Design

Mould Modification for Machining

Mould Burring and Assemble

Casting Manufacture

Mould Hore Making

Simplify Geometry

Pieces Division for Demould and Make

Less Flip on the Machine

Mould Fitting

In the case of the prototype steel parts for this project, the manufacturing method in the real industrial process is casting. Therefore, this chapter conducts a manufacturing study of the casting process as a way of designing, manufacturing and rethinking the cycle of manufacturing the prototype steel parts. Instead of using iron as the casting material, aluminum, which is easier to cast, was chosen due to the conditions of B-Made, and iron was used as the mold material for milling. Casting is done by analyzing and changing the model and then designing the mold. Both casting principles and milling principles are considered in mold design.

Casting Promotion and Experiment

[CHAPTER-03-1] PROTOTYPE CASTING MANUFACTURE

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Manufacture Workflow, Technical Question and Problem Solution

The reason of low productivity in construction industry a

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[CHAPTER-03-1] PROTOTYPE CASTING MANUFACTURE

Manufacture Workflow, Technical Question and Problem Solution

Technical Question: How to achieve an accurate multi-mode allumium casting at B-made workshop?

Hard

Prevent Tool Breakage

Lower thermal Conductivity

Temperature Control

Ductile

4 Flute Mill Machining Challenge

Chip Control

Mould Material

Steel

Use Coolant

More Flute Less Cut Work of each More Flute More Clogging Chip Flushing

Tight Fix

Cooling Tool Avoid Move

Conservative

Lower Feed and Speed Programe

Less Quiver For Nice Surface Finishing and Accuracy

Roughing and Finishing

"Tool Box" Selection

Accuracy Billet

Stock Facing For Accuracy Setup

Tool Deformation Control

Less Step Down, Overhang Cut and Tiny Tool

Exchange in different Machine

Clamping Part and Cut off

Less Set Up

Design Processing Order for Less Filp

Tool Feature for Nice Surface

Higher Helix Tool

Accuracy Manufacture

Metal Casting

Accuracy Machining Casting Material

Alluminium (Prove and Experiment)

Multi-mould Design

Mould Connection System

Position Pin and Connection Bolt

Demould Geometry

Draft Angle

Milling Geometry

Mould Divide Feature Control Mass Production Reason

Shrinkage Control Surface Quality

Casting Challenge

Pressures Air Exhaust

Higher Casting Import Tiny Air Hore

Good Flowability

Allumium and Mould Temperature

Clean Mould

Clean

Shrinkage and Flow Way Design

Less Filp, Less Design Changes, and Fillet

More Temperature More Cooling Down Time

More Temperature Less Mould Lifetime Less Temperature Less Flowability

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[CHAPTER-03-1] PROTOTYPE CASTING MANUFACTURE

Casting: Mass Production by Mould 6mm Bolt

Air hole Remove details and flip side Take out component Choose block to fabrication

Casting in

Casting out Manufacture feature

6mm Position pin

Position hole

Tapping hole

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[CHAPTER-03-1] PROTOTYPE CASTING MANUFACTURE

Mould Design: Position and Connetion Demould WorkFlow

Bolt Hole

Position Hole

Bolt Position Pin

Step 1: Cooling Tap Hole

Position Hole

Step 3: Top and Bottom Demould

Mould Connection System In mold assembly, each mold connection is precisely positioned using two locating pins and secured with one bolt for locking.

During the demolding process, the bolts are removed, then the top and base can be demolded vertically, and then the surrounding mold can be demolded to achieve the desired casting geometry.

Step 2: Unbolt

Step 4: Side Demould

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[CHAPTER-03-1] PROTOTYPE CASTING MANUFACTURE

Manufacture Machine (3 Axis)

Current Mode Program Display Z Axis Head

Power On & Power Off Buttons

Tool Magazine

Coolnt

Spindle

Display

Speeds and Feeds Information

Position Display

User Messages/Status Bar

Command Input

E-Stop

Machining Place

Display Keys

X Axis Table

Function Keys

Mode Keys

Handle Jog Dial Jog Keys

Y Axis Table

Cursor Keys Alpha Keys

Override Keys

Base

Numeric Keys

Cycle Start & Feed Hold Buttons

CNC Machine

Control Panel

B-Made uses a 3-axis CNC for milling, which imposes greater constraints on mold design and milling. Because of the limited machining direction of the 3-axis, complex shapes need to be flipped and clamped multiple times. Therefore, in the mold design in this chapter, the design is based on the principle of reducing the number of clamping to improve the efficiency of mold manufacturing. Meanwhile, the internal rounding angle of vertical milling is deliberated and adjusted.

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[CHAPTER-03-1] PROTOTYPE CASTING MANUFACTURE

Manufacture Design: Machining Direction and How to hold it ?

Machining Direction

End Mill Component Extra for Fixing

Parallels

1. CNC

Vice

Holded Extra on CNC Machining Direction Milling requires clamping of the part to keep the workpiece stable during machining.

Clamping Face Mill also reduces the movement of the workpiece during machining to ensure machining accuracy. When programming the toolpath, it is important to reserve the clamping size, if the clamping size is not calculated, the loading will occur, as shown in Component the figure on the right.

Parallels Vice

Facing off Holded Extra

2. Bridge-Port

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[CHAPTER-03-1] PROTOTYPE CASTING MANUFACTURE

Billet Prepare: Roughing and Finishing

Steel Plate

Rough Cutting

Finish Facing

Numbered Records

Accurate Billet

Before milling, the billet needs to be prepared and also the accuracy of the billet will affect the milling accuracy. The billet needs to be rough cut to the right size before finishing and then moved to a manual milling machine for face milling. After obtaining the accurate blank, it is moved to the CNC for clamping.

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Select a Tool Group

Select the proper tool set for roughing and finishing combinations to complete the entire milling and drilling manufacture.

[CHAPTER-03-PROTOTYOE FABRICATION]

[CHAPTER-03-1] PROTOTYPE CASTING MANUFACTURE

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[CHAPTER-03-1] PROTOTYPE CASTING MANUFACTURE

Milling Path Programming Black Part Set up 1 (1)

1. Drill-1: [T3] 8mm Spot Drill 2. Drill-2: [T7] 2mm Drill Bit

3. Drill-3: [T4] 6.5mm Drill Bit 4. Drill-4: [T6] 5.5mm Drill Bit 5. Adaptive: [T10] 12mm End Mill

6. Reaming: [T5] 6mm Reamer 7. 2D Contour: [T10] 12mm End Mill 8. Flat: [T10] 12mm End Mill 9. Ramp: [T2] 6mm Ball Nose 10. Contour: [T11] 3.18mm7°Taper

In the milling process, it is necessary to pay attention to the feed and speed of the tool, as well as the correctness of the tool hitting the table and clamping, in order to ensure the accuracy of milling. In addition to check the fastening of the tool to prevent the tool from moving during the machining process, which can lead to errors in the dimensions of the workpiece.

In addition, in the machining of such sizes of iron parts to choose four flute tool to reduce the amount of cutting per flute at the same time to prevent too much flute brought about by the narrowing of the groove affecting the chip removal.

Blue Part Set up 1 (2)

1. Adaptive: [T10] 12mm End Mill 2. Flat: [T10] 12mm End Mill

3. Parallel: [T2] 6mm Ball Nose

1. Adaptive: [T10] 12mm End Mill 2. Flat: [T10] 12mm End Mill

3. Parallel: [T2] 6mm Ball Nose 4. 2D Contour: [T10] 12mm End Mill

Cyan Part Set up 1 (2)

Orange Part Set up 1 (2)

1. Adaptive: [T10] 12mm End Mill 2. Flat: [T10] 12mm End Mill 3. 2D Contour: [T10] 12mm End Mill 4. Parallel: [T2] 6mm Ball Nose 5. Contour: [T2] 6mm Ball Nose

Yellow Part Set up 1 (3)

1. Adaptive: [T10] 12mm End Mill 2. Flat: [T10] 12mm End Mill

Flip

Yellow Part Set up 2 (3)

1. Adaptive: [T10] 12mm End Mill 2. Flat: [T1] 6mm End Mill

3. 2D Contour: [T1] 6mm End Mill

4. Parallel: [T2] 6mm Ball Nose

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[CHAPTER-03-1] PROTOTYPE CASTING MANUFACTURE

Milling Path Programming Green Part Set up 1 (2)

1. Adaptive: [T1] 6mm End Mill

2. Flat: [T1] 6mm End Mill

3. 2D Contour: [T1] 6mm End Mill

1. Adaptive: [T1] 6mm End Mill

2. 2D Contour: [T1] 6mm End Mill

3. Flat: [T1] 6mm End Mill

1. Face: [T10] 12mm End Mill

2. Drill-1: [T3] 8mm Spot Drill

3. Drill-2: [T8] 5mm Drill Bit

4. Drill-3: [T6] 5.5mm Drill Bit

5. Adaptive: [T10] 12mm End Mill

6. Bore: [T1] 6mm End Mill

7. Flat: [T1] 6mm End Mill

8. 2D Contour: [T10] 12mm End Mill

9. Parallel: [T2] 6mm Ball Nose

10. Contour: [T11] 3.18mm7°Taper

11. Reaming: [T5] 6mm Reamer

Red Part Set up 1 (2)

Gray Part Set up 1 (1)

12. Tap: [T9] 6mm Right Hand Tap

[CHAPTER-03-1] PROTOTYPE CASTING MANUFACTURE

Milling Feed&Speed

The spindle speed and feed rate should be adjusted according to the tool size and cutting volume. Calculations are made with reference to industrial standards in toolpath programming to obtain more reasonable cutting data.

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[CHAPTER-03-1] PROTOTYPE CASTING MANUFACTURE

Set Up Tools and Stock

Set Up Tools

Set Up Billet X&Y

Set up is basic and simple, but it is very important, and mistakes in set up can lead to all sorts of machining errors. When running the toolpath, run it slowly and compare it with the computerized toolpath to make sure it is correct before milling at full speed.

Set Up Billet Z

[CHAPTER-03-1] PROTOTYPE CASTING MANUFACTURE

Machining Process

Black Pieces Milling Process

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[CHAPTER-03-1] PROTOTYPE CASTING MANUFACTURE

Face off Holded

Machining Direction

End Mill Component Extra for Fixing

Parallels

1. CNC

Vice

Holded Extra on CNC Direction When setting up the Machining workpiece, first put the workpiece on the parallel, then lightly lock the vise, then use the rubber hammer or copper hammer to strike the bottom of the workpiece to make full contact with the parallel, and then lock the vise. This is one of the functions of the parallel, after Face Mill tapping on the parallel try to move the parallel to make sure the parallel is tight enough to set up in Component place.

Parallels Vice

Facing off Holded Extra

2. Bridge-Port

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[CHAPTER-03-1] PROTOTYPE CASTING MANUFACTURE

Back to CNC Hore Making Pecking Depth and Chip Control in Hore Making Drilling Direction

Drilling Direction

Drill Bit

Vice

Drill Bit Component

Component

Drill Tip

Faced Shim

Parallels

Vice

No Space to Through All

Parallels

Shim for Through All

Breaking Direction

Tool Retract Component

Target Hore

Pecking Depth

Chip Breaking

When drilling deep holes, use to increase hole accuracy and extend bit life. In particular, chip control is used to prevent the cutter slot from being clogged, preventing the coolant from entering and damaging the cutter at too high a temperature. Also, in hole machining, due to the geometry of the drill, reamer, and tap, overcutting is required to obtain a complete target hole. The workpieces will collide with parallel if they are overcut, so pads are made to be overcut.

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[CHAPTER-03-1] PROTOTYPE CASTING MANUFACTURE

Hore Making Programming Green Part Set up 2 (2)

1. Drill-1: [T3] 8mm Spot Drill

Red Part Set up 2 (2)

1. Drill-1: [T3] 8mm Spot Drill

Blue Part Set up 2 (2)

1. Drill-1: [T3] 8mm Spot Drill

Orange Part Set up 2 (2)

Yellow Part Set up 2 (2)

Cyan Part Set up 2 (2)

1. Drill-1: [T3] 8mm Spot Drill

1. Drill-1: [T3] 8mm Spot Drill

1. Drill-1: [T3] 8mm Spot Drill

2. Drill-2: [T4] 6.5mm Drill Bit

2. Drill-2: [T4] 6.5mm Drill Bit

2. Drill-2: [T4] 6.5mm Drill Bit

2. Drill-2: [T4] 6.5mm Drill Bit

2. Drill-2: [T4] 6.5mm Drill Bit

2. Drill-2: [T4] 6.5mm Drill Bit

3. Drill-3: [T6] 5.5mm Drill Bit

3. Drill-3: [T6] 5.5mm Drill Bit

3. Drill-3: [T6] 5.5mm Drill Bit

3. Drill-3: [T6] 5.5mm Drill Bit

3. Drill-3: [T6] 5.5mm Drill Bit

3. Drill-3: [T6] 5.5mm Drill Bit

4. Reaming: [T5] 6mm Reamer

4. Reaming: [T5] 6mm Reamer

4. Reaming: [T5] 6mm Reamer

4. Reaming: [T5] 6mm Reamer

4. Reaming: [T5] 6mm Reamer

4. Reaming: [T5] 6mm Reamer

[CHAPTER-03-1] PROTOTYPE CASTING MANUFACTURE

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Before Casting: Mould Burring and Assemble

After the workpiece is machined on the CNC, it is manually deburred and a small chamfer is applied to the hole using a contour sink to prevent the workpiece edge from being too sharp and excess burrs from affecting the assembly. The molds are also test-fitted, and minor machining flaws and errors affecting assembly are repaired manually.

[CHAPTER-03-1] PROTOTYPE CASTING MANUFACTURE

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Aluminum Component Casting Process The mold and aluminum powder are heated first, and once heated, the mold is first removed and assembled. Then pour out the aluminum water to preheat the "casting spoon".

Preheat a spoon and pour the aluminum water in it (the temperature has been lowered) into the pre-prepared recycling mold.

Then the official casting pour takes place. In fact, during this process, the temperature of the mold has begun to drop and is no longer at the temperature it was when it was removed from the preheating furnace. And will affect the casting result.

When a successful pour is ensured, the remaining aluminum water is channeled into the recycling mold, the casting spoon is placed, and the mold and casting are left to cool down and be dismantled for the next casting.

[CHAPTER-03-1] PROTOTYPE CASTING MANUFACTURE

Casting Process

Casting process

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[CHAPTER-03-1] PROTOTYPE CASTING MANUFACTURE

Casting Experiment Casting Experiment Introduction

When pouring, aluminum water will flow in from one side and out the other. The temperature of the aluminum water decreases during the flow, which results in poor fluidity to the point where the casting appears incomplete with missing features. At the same time, the mold has a shrinkage area at the pouring inlet, which produces a large shrinkage, which reduces the shrinkage of the aluminum part in the real casting part to ensure the dimensional accuracy.

Low Feature Quality Aluminum Out Direction Casting Line by Mould

Aluminum Out Direction

Low Feature Quality Feature Quality Change High Feature Quality

Low Temperature Low Temperature Main Casting Shrinkage Aluminum In Direction Steel Oxidative discoloration

Aluminum In Direction

Second Casting Experiment

First Casting Experiment

Temperature Decrease

Temperature Decrease

Aluminum Out Direction Roughly Higher Mould Test

Aluminum In Direction

Aluminum Out Direction

More Pressure by Gravity

Accurate Casting Size High Feature Quality

Low Feature Quality Aluminum cannot Flow In

Better Feature Quality Aluminum cannot Flow In

Low Feature Quality

Aluminum In Direction Accurate Casting Size High Feature Quality

Better Feature Quality

Quality Change Dividing Line

Rough Surface due to Dirty Mould

First casting experiment used 700 degree melt aluminum, 260 degree mould, and low hight mould (pressure). The result shows it need to higher pressure and mould temperature to achieve higher quiality feature.

First casting experiment used 700 degree melt aluminum, 300 degree mould, and higher hight mould (pressure). The result shows the improvement method is working, but the rough mould just for test is dirty, which makes the casting pieces have the rough surface.

Casting Experiment Conclusion According to the experiments, it was possible to increase the mold temperature and the mold height (pressure) again to obtain a better casting quality, and a formal mold raise was made for this purpose using a bridgeport, but the experiments were forced to be aborted due to the stoppage of the mold preheating furnace. But, the experiments proved the castability of the prototype design, and the project then shifted to an iterative approach to workpiece iteration using more agile manufacturing milling.

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[CHAPTER-03-1] PROTOTYPE CASTING MANUFACTURE

Highten part Making: Understand Machining through Bridge-Port Interaction Bridgeport Like a manual CNC machine, we were able to mill some simple shapes on the Bridgeport.

Likewise, we have to pay attention to temperature control, pecking depth, chip removal, feed and speed when milling, just like on a CNC machine.

Performing these controls manually will help us

Main Spindle Motor Tool Head Variable Speed Control

understand the cutting actions programmed into the CNC machine.

Quill Feed Hand Level

Quill Spindle

Ram Ram Adjust Handle Digital Read Out

Coolnt

Table Stop Dogs Table Lock Handle

Knee

Saddle

Table Tranverse Handle

Vertical Knee Traverse Handle Power Switch

Coolnt Tank Base Emergency Buttom

Screw Jack

[CHAPTER-03-1] PROTOTYPE CASTING MANUFACTURE

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Highten part Making: Understand Machining through Bridge-Port Interaction

Step Down and Step Over Milling

Chip Breaking After the billet has been machined, the holes are drilled and then milled.

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[CHAPTER 3-2] Prototype Machining Manufacture "Customized Production" Customized production is a type of production method whose main feature is to produce customized products according to the specific needs and, of the customer.

Compared to casting, milling is a type of customized production, which is more agile and faster in prototyping, in terms of manufacturing single or fewer parts, allowing for faster prototype iterations and updates.

Figure of Context Source From Archdaily

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[CHAPTER-03-2] PROTOTYPE MACHINING MANUFACTURE

Chapter Abstract

Technical Question 4

Prototype 2.0 Modification for Machining

How to hold it?

Split to 3 Machinable Feature

3 Axis Machine Fab Limitation

Technical Question 5

Thickness ±0.5mm Width ≤ ±1%

Milling Flatness Error

Box-Section Tolerance bring Inaccuracy

Machining Manufacture

Less Flip on the Machine

Tolerance Test

Problem Solve

Tring to Position with the Secondary Fab Feature to Control Tolerance

Long and Thin Tool Deflection

Technical Question 6

The design and fabrication of Prototype 2.0 was smoother due to the fact that an understanding of the principles of milling had already been established as a result of having previously fabricated casting molds using milling. It is worth noting that after the milling of Prototype 2.0 was completed, it was time to start formally facing and thinking about tolerances, which are mainly made up of steel profiles as raw material tolerances (greater than machined part tolerances and casting tolerances), and to further optimize the design.

Jigging with Accurate Position Hore on section (Prototype 3.0)

[CHAPTER-03-2] PROTOTYPE MACHINING MANUFACTURE

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Prototype for Machining Design

In 3-axis cnc milling, as shown in the figure there are many shapes that cannot be machined in a single clamping, and multiple clamping is required to obtain the perfect target shape (no cutting fillet). In order to reduce the number of fixtures and increase efficiency, during prototype 2.0 manufacturing, we chose to machine it in 3 pieces and then bolt them together to achieve the same function.

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[CHAPTER-03-2] PROTOTYPE MACHINING MANUFACTURE

Tool Path Programme

Set Up: 01 Drill-1: T3 8mm Spot Drill

Drill-2: T7 4.2mm Drill Bit

Drill-3: T7 4.2mm Drill Bit

Drill-4: T8 6mm Drill Bit

Adaptive-1: T10 12mm Flat End Mill Adaptive-2: T1 6mm Flat End Mill

Overhang Milling Problem

Adaptive-3: T1 6mm Flat End Mill Flat-1: T1 6mm Flat End Mill

Flat-2: T5 4mm Flat End

Flat-3: T5 4mm Flat End Mill

Parallel-1: T2 6mm Ball Nose Mill Parallel: T2 6mm Ball Nose Mill

Contour-2: 4.7 7° Taper End Mill

Tap: 5mm Right Hand Tap

2D-Contour: T10 12mm Flat End Mill Contour-1: T1 6mm End Mill

Flip

Set Up: 02 Adaptive: T10 12mm Flat End Mill Adaptive-2: T1 6mm Falt End Mill 2D Contour: T1 6mm Flat End Mill Flat: T1 6mm Flat End Mill

Contour: T1 6mm Flat End Mill

[CHAPTER-03-2] PROTOTYPE MACHINING MANUFACTURE

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Machining Process

Prototype2.0 Milling Process The reason for drilling before milling is because the center of the hole is on a slant or in an area that is being cut away, which would make it impossible to locate if drilling is done later. In addition, this time the workpiece is large, you need to double-check and check whether the tool length is enough, the size of the shank, and whether the shank will cause collision during the cutting movement to prevent the occurrence of collision.

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[CHAPTER-03-2] PROTOTYPE MACHINING MANUFACTURE

OverHang and Tiny Tool Milling, Reprograme Tool Path to Repair Reason

Problem

Solution

Overhang Milling

Can not Hold by Vice after Flip

Multi Depth Milling

Overhang Milling

Vice Holded Area not Flat

Multi Depth Milling

After the front face milling was completed, a milling size discrepancy was discovered during flip-face clamping, resulting in a failure to clamp after flip-face. After analyzing the problem, it was found that the 4mm and 6mm milling cutters did not control the stepdown, which led to the tilting and deformation of the cutter in cutting, thus leading to the size inconsistency and surface roughness problems. After finding the problem, we reprogrammed the toolpath design and then reclamped and milled to fix the dimensional error.

[CHAPTER-03-2] PROTOTYPE MACHINING MANUFACTURE

Prototype for Machining 1:5 Manufacture Model

Assembled Prototype 2.0

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[CHAPTER-03-2] PROTOTYPE MACHINING MANUFACTURE

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Steel Section Tolerance

There is a certain amount of manufacturing error in the steel profile itself, but in the case of steel profiles with structural dimensions in the building, the manufacturing error itself is less than the accuracy required for module assembly, and as long as it is accurately positioned, the steel profile's own error can be accepted. There are welded seams inside the steel profiles, which should be taken care of when connecting with the prototype. Moreover, in order to make the processing of the steel profiles more cheap accuracy, improvements have been made in the final prototype design.

Source: 1. https://www.tatasteelbluebook.com/en-gb/building-codes/bs-5950/tolerances/hot-finished-shs-and-rhs/

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[CHAPTER-03-2] PROTOTYPE MACHINING MANUFACTURE

The Tolerance Assemble Design with Box-Section Section Assemble

Section Tolerance

Feature For Fillet

Section Thickness Tolerance Section Fillet Tolerance Section Size Tolerance

Welding Line Feature for Welding Line

Prototype Box Section View Direction

When assembled, it was found that the dimensionally accurate prototype and steel section did not match perfectly and that there were tolerances. For welding line, For weld seams, the gap position is also designed to enable easy assembly.

[CHAPTER-03-2] PROTOTYPE MACHINING MANUFACTURE

Manufacture Model Assemble

Assemble Process

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[CHAPTER 4] Final Project "Experiment and Provement" Verify and demonstrate easy accuracy in research purposes using final project and assembly experiments.

Also test the effect of different assembly and welding sequences on overall accuracy. And then experiment with the pouring sequence of the filler. Due to time constraints, the final assembly could not be completed before the submission of the portfolio.

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[[CHAPTER-04] FINAL PROJECT

Final Prototype: Design for Easy Accuracy Manufacture Prototype 2.0 Problem of Manufacture and Tolerance Component Connection Bolt

Manufacture Difficulty-01

Section Fix by Gravity

Manufacture Difficulty-02

Section Fit Problem-01 Section Fit Problem-02

Manufacture Difficulty-03

Section Fit Problem-03

Prototype 2.0

Prototype 2.0

The prototype 2.0 design has square pockets, which are relatively difficult to machine and do not solve the problem of how to fit the weld protrusions when connecting with steel profiles horizontally.

Final Prototype Evolution for Manufacture and Tolerance Section Fix Bolt

Section is able to Fix by Bolt

Easy Manufacture-01 Fit with Section Hore

Easy Manufacture-02

Component Connection Bolt

Prototype 3.0

Prototype 3.0

The final prototype was re-optimized in terms of manufacturing difficulty and tolerance matching to make it more consistent with the principle of easy accuracy.

[CHAPTER-04] FINAL PROJECT

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Final Project

Concrete Core Structure

Concrete Podium Structure Final Project at Fifteen Show

The figure shows the overall structure of the volumetric modular steel building, which consists of steel modules together with a cast concrete core (to carry the horizontal forces) and a podium (to carry the overall gravity). The final project will intercept one of the sections shown in red for connection, assembly and packing experiments.

[CHAPTER-04] FINAL PROJECT

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Design For Section Manufacture Industrial Factory Manufacture

Section Lazer Cutting Machine In practical industrial production, laser tube cutters are used for precise cutting of steel profiles, welding bevels and precise opening of holes.

B-Made Workshop Manufacture

Horizental Saw Bridge Port In the B-Made Workshop, a horizontal saw is used to make the angle cuts, which are then moved to the Bridgeport to make the holes. It is important to note that the horizontal saw can only accomplish angled cuts from 0-60 degrees, and the final prototype's miter angle is designed to fit within this machining limitation.

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[CHAPTER-04] FINAL PROJECT

Final Fabrication Workplan

Ground Plate and gusset Manufacture

Section Hore Manufacture Module Assemble Order Experiment

Module Welding

Connection Assemble

Final Prototype Manufacture

It will consist of one week for workpiece milling, one week for profile opening, and one week for assembly and welding experiments and pouring sequence experiments. In the final assembly experiments, more fabrication feedback will be obtained, as well as information and conclusions that will bring insights to the next research.

Filling Order Experiment

Final Project

Conclusion

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[CHAPTER 5] Conclusion "Cheap Accuracy Work Package for On-Site Manufacture" Like IKEA's furniture work packages, which can be assembled cheaply and accurately by either humans or robots, thanks to inexpensive and accurate node-designed products, On-site Manufacture will also rely on such Selfjigging nodes for precise installation purposes.

On-site Manufacture will also rely on these Selfjigging nodes for precise installation, reducing the need for large assembly equipment and making the onsite manufacturing temporary factory "smaller" and "lighter".

Figure of Context Source From NTU

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[CHAPTER-05] CONCLUSION AND REFLECTION

Address the Research Question

Content of Project Research •

•

•

Steel section welding for volumetric module is a stadardized process, it can use node to achieve less 2mm (150mm*150mm Column) cheap-accuracy welding on-site.

By the no-machine principle to remove welding process from prefab factory, which can shorten the supply chain.

And also this principle is significant for "on-site factory" fabrication with construction.

The nodal design simplifies the reliance on off-site factory machining equipment, as well as realizing the goal of accurate assembly directly from raw materials. This requires raw steel suppliers to be able to offer simple laser tube cutting services or angle cutting and drilling services, or to be able to weld raw materials for inexpensive and accurate on-site assembly in a temporary plant that can be manufactured on-site, using only equipment such as laser tube cutters and hoists. It can be said that in the case of assembly and welding production of structural steel volume modules, more than 80% of off-site prefabrication work can be eliminated by design, and standardized welding accuracy can be achieved by on-site production.

In addition to the self-jigging feature, the otherwise blank filling allowable nodes (for which theoretical approaches exist only in the essay) were also studied and fabricated.

Simplification of material size categories also allows for more concise production scheduling and inventory management for in-situ fabrication, increasing the viability of on-site steel volume modules.

Limitation of Project Research •

The final project and assembly experiments could not be completed to provide more information at this time on the effect of mounting sequence steps in self-fixed nodes on accuracy.

•

Precise welding of the main structure is an important part of fabricating steel volume modules in situ, but in addition to this there is the installation of enclosure and load-bearing panels, water supply and drainage, as well as mechanical and electrical, curtain walling and other building elements. The design project failed to take into account the assembly and nodal design of the other elements.

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The development of various types of hand-held laser welding equipment has led to increased weld yields, reduced processing difficulty, and standardization. However, welding is still more difficult to operate than bolting, the project only studied the manufacturing steps of volume module frame welding, but failed to consider bolting, if the self-jigging node can be realized at the same time the raw material bolting and inter-module bolting, which will greatly reduce the processing difficulty.

[Page 69-UCL-Design for Manufacture-Final Project-Self-Jigging Node for Site Volumetric Module Fabrication]

[CHAPTER-05] CONCLUSION AND REFLECTION

Reflect on the Potential Impact of the Research?

Positive Impact •

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There are many advantages in on-site fabrication and construction. But, the on-site fabrication with construction is also has difficulty than the off-site factory. It is depends on the site location and the supply chain and factory distance.

The industrialized construction is different with the car industry, The answer is not we just put high percentage work off-site. The manufacture, fabrication, and construction strategies should be consider clearly. To what extent can design remove the need for factory prefabrication before material gets to site? And how to exchange and divided the element work between unmovable factory, movable site factory, and manual work to meet the different situation?

These will be questions for a long time.

This potential impact is the big company has the ability to produce, arrange and organize the fabrication of building will bring the technological and elements standardization to the construction industry and the scale economy will lower the price, however the small company can not get benefits with scale economy will facing the risk.

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The design project provides new solutions for areas that cannot be covered by modular factories, enabling modular factories to split work packages and to manufacture off-site and on-site in conjunction with each other, thus allowing for greater economies of scale in modular volume construction, and thus making the construction of high-rise buildings, in particular, somewhat more cost-effective and sustainable.

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The steel structure itself is still very deficient compared to wood in terms of carbon emissions, and the steel structure as a pioneer material for modular buildings may provide insights into the modular construction of timber structures.

When timber's price and deforestation issues have been resolved, lean on-site manufacturing may have real potential for low-carbon construction.

[Page 70-UCL-Design for Manufacture-Final Project-Self-Jigging Node for Site Volumetric Module Fabrication]

[CHAPTER-05] CONCLUSION AND REFLECTION

How Could the Research Continue?

Research In The Future •

How nodes can be accurately positioned and assembled directly using raw materials, and can avoid installation errors caused by raw material errors and minimize machining steps, this project ultimately chose to open holes and cut corners to achieve the two ways, but this is not the only answer, which is still worth investigating in the context of on-site manufacturing.

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In manufacturing, there are many ingenious clamping configurations from which self-jigging can draw inspiration, so that nodes and raw materials can be tightened with a wrench in the same way as turning or milling clamps to create precise connections that can be welded or bolted.

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The effect of the assembly sequence of the structural steel modules on the accuracy needs to be experimented, whether the filler should be poured before the modules are installed or after the multiple modules have been installed and connected, these issues will be further investigated in the final project.

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What if it's not welded? Bolting is a simpler method, but how feasible is it? What if it's not steel? What should happen to timber that cannot be welded?

[Page 71-UCL-Design for Manufacture-Final Project-Self-Jigging Node for Site Volumetric Module Fabrication]

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