Design and Fabrication of a 15x15x15 Inch Mechanical Prototype

Using Grinding, Welding, Drilling, and Cutting Processes

By:
Ladisla, Jhurem Rjell F.

In completion to
MEC 0212.1-2 - 20241 - WORKSHOP, THEORY AND PRACTICE
 I. Introduction

In the field of mechanical engineering, the design and fabrication of prototypes play a critical
role in understanding the practicality and feasibility of manufacturing processes. This project
focuses on the creation of a 15x15x15 inch metal storage box using essential mechanical
fabrication techniques such as grinding, welding, drilling, and cutting. The project aims to
combine theoretical knowledge with hands-on experience, providing an opportunity to evaluate
the precision and accuracy of these processes.

The fabrication of the prototype serves not only as a practical learning exercise but also as a way
to explore real-world challenges in producing a functional structure. Through this project, the
discrepancy between theoretical design and actual fabricated dimensions can be examined,
highlighting the importance of precise execution in engineering projects. The AutoCAD software
will be used to design the box, ensuring accurate measurements prior to production. This
prototype offers insight into how these common mechanical processes can be optimized for
better accuracy and effectiveness in future projects.

II. Reason for the Prototype

The purpose of this project is to design and fabricate a simple metal storage box prototype with
external dimensions of 15x15x15 inches. This project provides a practical application of the
fundamental mechanical processes of grinding, welding, drilling, and cutting. The box can serve
as a prototype for larger industrial containers, and the fabrication methods will help in evaluating
the accuracy of these processes in real-world applications.

III. Design and Measurement

(Insert Photo and Details Here)

• Dimensions: The storage box will have a cubic shape, with external dimensions of 15 inches for
length, width, and height. The material thickness will be 0.5 inches, leaving an internal volume
slightly less than 15 inches on each side.
• Materials: Mild steel sheets (0.5-inch thick) will be used for the box. Mild steel is chosen for its
strength and ease of fabrication.
• CAD Design: The design will be created using AutoCAD to ensure precise measurements and
correct fit for all sides of the box.
 IV. Fabrication Process
• Cutting: Steel sheets will be cut into five square pieces for the sides of the box (top,
bottom, and four sides). Each square will be 15x15 inches in size.
• Welding: The pieces will be welded together at the edges to form the box. Care will be
taken to maintain sharp corners and proper alignment during welding.
• Drilling: Holes will be drilled on two opposite sides of the box for attaching hinges or
handles. This adds functionality to the storage box.
• Grinding: After welding, the edges and joints will be ground smooth to eliminate any
sharp or rough edges and to ensure a neat appearance.

AutoCAD Drawing: (The AutoCAD drawing will display all five sides of the box with exact
dimensions and locations for holes to be drilled).

V. Theoretical Vs Actual

VI. Calculation of Percentage Theoretical Vs Actual Measurement

The percentage difference between theoretical and actual measurements is calculated using:

𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 − 𝐴𝑐𝑡𝑢𝑎𝑙
𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝐷𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑐𝑒 = ( ) 𝑥100
𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙

For the length:

15 − 14.92
𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝐷𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑐𝑒 = ( ) 𝑥100
15

This formula is applied to calculate the percentage difference for the width and height as well.
 VII. Discrepancy Analysis

• Welding: The heat from welding can cause slight warping, leading to minor reductions in
dimensions. These changes are especially common around the welded joints.
• Grinding: Material removal during grinding may slightly reduce the overall dimensions
of the box if care is not taken to grind only the welded sections.
• Cutting: Variations in cutting precision, especially when done manually, can lead to
slight discrepancies between theoretical and actual dimensions.

These small discrepancies are expected in typical manufacturing processes and are within
acceptable tolerances for non-precision storage boxes.

VIII. Conclusion

• Project Purpose: This project was created to practice and evaluate common mechanical
engineering fabrication techniques, such as grinding, welding, drilling, and cutting, while
creating a functional metal storage box. By comparing theoretical and actual
measurements, we can assess the effectiveness of these fabrication processes.

• Effectiveness: The project was successful in achieving its primary objective of creating a
metal storage box with minimal discrepancies between theoretical and actual dimensions.
The slight deviations in measurements were due to material deformation from welding
and material removal during grinding. Overall, the processes used were effective in
maintaining accuracy within acceptable tolerances for this type of fabrication.