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RAMAIAH INSTITUTE OF TECHNOLOGY

(Autonomous Institute, Affiliated to Visvesvaraya Technological University,
Belagavi) MSR Nagar, MSRIT Post, Bengaluru-560 054

report on

Product design internship

Submitted in partial fulfillment of the

requirement for the award
of

BACHELOR OF ENGINEERING
in
MECHANICAL ENGINEERING
Submitted by

R Karan Beeshm
1MS18ME130

DEPARTMENT OF MECHANICAL ENGINEERING RAMAIAH

INSTITUTE OF TECHNOLOGY, BENGALURU – 560054

2021-2022
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RAMAIAH INSTITUTE OF TECHNOLOGY

(Autonomous Institute, Affiliated to Visvesvaraya Technological University,
Belagavi) Bengaluru-560 054

DEPARTMENT OF MECHANICAL ENGINEERING

DECLARATION
I HERBY DECLARE that the topic entitled “Product design internship” is an original
preparation done by myself and have not plagiarized the efforts of anyone else. This
presentation is made by R Karan Beeshm (1MS18ME130) in partial fulfillment of the award of
the Degree of Bachelor of Engineering in Mechanical Engineering during the Academic Year
2021-2022.

Signature of the student with date

Examiners:

Name Signature with Date

1.
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Table of Contents
Abstract...........................................................................................................................4
About the comany...........................................................................................................5
Introducion......................................................................................................................6
1.Client-1........................................................................................................................ 7
1.1.1. Task-1............................................................................................................... 8
1.1.2. Task-2............................................................................................................... 9
1.1.3.Task-3.............................................................................................................. 10
1.1.4.Task-4.............................................................................................................. 11
2.Client-2...................................................................................................................... 19
3.Failed product............................................................................................................ 24
4.Conclusion................................................................................................................. 25
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ABSTRACT

“Product design deals with conversion of ideas into reality and, as in other forms of
human activity, aims at fulfilling human needs. A designer does not usually produce
the goods or services which immediately satisfy client's needs. Rather, he produces
the prototype which is used as a sample for reproducing the particular product or
services as many times as required.”
Keeping the above guideline for a product design in mind we communicated with
client and understood his product needs, after which iterative design process begin
and various test were conducted to optimize the design here optimization technique
were majorly based on intuition and trial and error modelling rather than optimization
by numerical algorithm due to limited amount of time.
During this internship period I worked with 2 clients and on an In-house product.
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About the company

Somadisha Consultants And Solutions Private Limited is a Private incorporated on 02

May 2008. It is classified as Non-govt company and is registered at Registrar of
Companies, Bangalore. Its authorized share capital is Rs. 500,000 and its paid up
capital is Rs. 100,000. It is involved in Other computer related activities [for example
maintenance of websites of other firms/ creation of multimedia presentations for other
firms etc.]

Somadisha Consultants And Solutions Private Limited's Annual General Meeting

(AGM) was last held on 31 December 2020 and as per records from Ministry of
Corporate Affairs (MCA), its balance sheet was last filed on 31 March 2020.

Directors of Somadisha Consultants And Solutions Private Limited are Ramaiah

Prattipati, Suneetha Prattipati.

Somadisha Consultants And Solutions Private Limited's Corporate Identification

Number is (CIN) U72900KA2008PTC046296 and its registration number is 46296.Its
Email address is suneetaprattipati@gmail.com and its registered address is A301
GROUND FLOOR SHOBHA ORCHID JAKKUR BANGALORE Bangalore KA
560064 IN .
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Introduction

The definition of product design describes the process of imagining, creating, and
iterating products that solve users’ problems or address specific needs in a given
market.
The key to successful product design is understanding the end-user customer, the
person for whom the product is being created. Product designers attempt to solve real
problems for real people by using empathy and knowledge of their prospective
customers’ habits, behaviors, frustrations, needs, and wants.
Ideally, product design’s execution is so flawless that no one notices; users can
intuitively use the product as needed because product design understood their needs
and anticipated their usage.
Good product design practices thread themselves throughout the entire product
lifecycle. Product design is essential in creating the initial user experience and product
offering, from pre-ideation user research to concept development to prototyping and
usability testing.
But it doesn’t end there, as product design plays an ongoing role in refining the
customer experience and ensuring supplemental functionality and capabilities get
added in a seamless, discoverable, and non-disruptive manner. Brand consistency and
evolution remain an essential product design responsibility until the end of a product’s
lifespan.
And it’s much more than just what users see on their screens. System design and
process design are critical behind-the-scenes components that eventually drive users
to see and interact with the interface design.

Product design phases I went through during my internship period-

Empathize with client

Define the problem
Ideate a solution
Build a prototype
Test the solution
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1.Client 1

Bubble nut wash- soapnut product

Product required by the company- a liquid dispenser which would dispense 4 types of
liquid

Design challenges - the liquid should not get clogged and the machine should be of
low cost and should consume less power
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1.1.Illustration of the initial design

Fig 1.1 Front view

Fig 1.2 Isometric view

Initial this is what we had planned for the product aesthetic were the display would be
placed on the side of the dispenser which was rather unusual, later as designed
progressed adequate change to the placement of the display were made.
1.1.1.Task -1
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Idea for dispensing liquid

1 Syringe mechanism
Dimensions of the cylinder are: length 16.8 cm, diameter 8.7 cm with a
capacity of 1000cc after analysis it was found that the motor needed for dispensing
high viscous fluid was same as the motor used in peristaltic pump
2 use of gear pump
Were not used as it is prone to clogging
3 use of peristaltic pump
Elements of the motor has no direct contact with the working fluid hence no
corrosion and the motor has same power output that of the motor used in syringe.
Therefore peristaltic pump were used for the dispenser.

1.1.2.Task-2
Problem - liquid dispenser had to be made such that it can be mounted on a wall.
This leads to the design of a backplate which should be able to withstand the weight
of the machine present inside the shell

Fig 1.3 case study 1

The material selected for the backplate was polycarbonate which has a yield strength
of 39-40 MPa . but from intial design crosses these limit hence further changes were
made by carefully placing ribs and varying its thickness until a satisfactory result is
obtained
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Fig 1.4 Case study 2

Fig 1.5 Case study 3

Fig 1.6 Case study 4

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The image in previous page show the evolution of the back plate
Max deformation (mm) Max stress (MPa von mises)
Design 1 23.53 37.016
Design 2 7.56 20.314
Design 3 3.43 10.42
Design 4 3.67 12.422

From table we see that as design progress the max stress and deformation reduced

Fig 1.7 Keyshot design 4 of the back plate

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1.1.3.Task -3 Design of tank

Fig 1.8 keyshot design of tank

Tank material - polyethylene
Capacity - 25000 cc

Fig 1.9 Ansys simulation

Material yield stress is 12MPa and it can be seen that from analysis the max stress is
3.1 MPa near the mounting region hence the shape of the tank was finalized.
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1.1.4.Task - 4
Designing the product for manufacturing, a brief description about this is presented
below
Design for Manufacturing (DFM) is the process of designing parts, components or
products for ease of manufacturing with an end goal of making a better product at a
lower cost. This is done by simplifying, optimizing and refining the product
design. The acronym DFMA (Design for Manufacturing and Assembly) is sometimes
used interchangeably with DFM.
Ideally, DFM needs to occur early in the design process, well before tooling has
begun. In addition, properly-executed DFM needs to include all the stakeholders —
engineers, designers, contract manufacturer, moldbuilder and material supplier. The
intent of this “cross-functional” DFM is to challenge the design — to look at the
design at all levels: component, sub-system, system, and holistic levels — to ensure
the design is optimized and does not have unnecessary cost embedded in it.
The following chart offers an excellent visual representation of the effect of an early
DFM. As the design progresses through the product life cycle, changes become more
expensive, as well as more difficult to implement. Early DFM allows design changes
to be executed quickly, at the least expensive location.

5 PRINCIPLES OF DFM
 PROCESS
 DESIGN
 MATERIAL
 Some material properties to consider during DFM include:
 Mechanical properties - How strong does the material need to be?
 Optical properties - Does the material to be reflective or transparent?
 Thermal properties - How heat resistant does it need to be?
 Color - What color does the part need to be?
 Electrical properties - Does the material need to act as a dielectric (act as an
insulator rather than a conductor)?
 Flammability - How flame/burn resistant does the material need to be?
 ENVIRONMENT
 COMPLIANCE/TESTING
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FACTORS THAT AFFECT DFM

The goal of DFM is to reduce manufacturing costs without reducing performance. In
addition to the principles of DFM, here are five factors that can affect design for
manufacturing and design for assembly:
1 | Minimize Part Count
Reducing the number of parts in a product is the quickest way to reduce cost because
you are reducing the amount of material required, the amount of engineering,
production, labor, all the way down to shipping costs.
2 | Standaradize Parts and Materials
Personalization and customization are expensive and time-consuming. Using quality
standardized parts can shorten time to production as such parts are typically available
and you can be more certain of their consistency.
Material is based on the planned use of the product and it's function. Consider:
How should it feel? Hard? Soft?
Does it need to withstand pressure?
Will your part or product need to conduct heat, electricity?
3 | Create Modular Assemblies
Using non-customized modules/modular assemblies in your design allows you to
modify the product without losing its overall functionality. A simple example is a
basic automobile that allows you to add in extras by putting in a modular upgrade.
4 | Design for Efficient Joining
Can the parts interlock or clip together? Look for ways to join parts without the use of
screws, fasteners or adhesives. If you must use fasteners, here are a few tips:
Keep the number, size and variation of fasteners to a minimum
Use standard fasteners as much as possible.
Use self-tapping and chamfered screws for better placement.
Stay away from screws that are too long or too short, separate washers, tapped holes,
round heads and flatheads.
5 | Minimize Reorientation of Parts During Assembly & Machining
Parts should be designed so that a minimum of manual interaction is necessary during
production and assembly.
6 | Streamline Number of Manufacturing Operations/Processes
The more complex the process of making your product, is the more variables for error
are introduced. Remember what Jeff said: All processes have limitations and
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capabilities. Only include those operations that are essential to the function of the
design.Based on the above knowledge below parts were created

Fig 1.10 Modular frontpanel for easy assembly.

Fig 1.11 Latch connecting back and front panel which improves maintenance
capability
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Fig 1.12 Special tooling required to open the tank which prevents adulteration of the
fluid.

Fig 1.13 Bottom sliding lock ensures adequate stiffness is provided during handling of
the liquid dispenser
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Final render of the product depicting front and top view of the product. A wastage
collection tray has been added to the machine to collect spilt liquid.
After the preliminary design we had to show it to the client unfortunately the pricing
for manufacturing the prototype was not feasible for the client and he wanted the
machined to be made using wood as it would go with the brand image therefore we
had to redesign the product to accommodate the suggested changes
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Fig .14 (a) Testing of the peristaltic pump and optimization of the motor speed to
compensate fluid flow for different viscous liquid (b) jerry can being used instead of
custom tank (c) test model

Final design of the product

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2.Client 2

Product required by the company- smart locker which is controlled using Bluetooth
module
From preliminary study sheet metal was considered an ideal choice for the current
product

Below guidelines were used while designing the product for the company

Minimum Distance from Extruded Hole to Part Edge

Extruding metal is one of the most extreme pressure applications in press working and
generates lot of friction and heat. If an extruded hole is too close to the part edge, it
can lead to deformation or tearing of the metal. It is recommended that the minimum
distance between the extruded holes to part edge should be at least three times the
thickness of sheet.

Minimum Distance Between Extruded Holes

Certain distance should be maintained between two extruded holes in sheet metal
designs. If extruded holes are too close it can lead to metal deformation. It is
recommended that the minimum distance between two extruded holes should be six
times the thickness of sheet metal.

Minimum Distance Between Extruded Holes

Certain distance should be maintained between two extruded holes in sheet metal
designs. If extruded holes are too close it can lead to metal deformation. It is
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recommended that the minimum distance between two extruded holes should be six
times the thickness of sheet metal.

Minimum Hole Diameter

The diameter of the hole in sheet metal part should not be very small, small holes are
created by piercing operation and for manufacture small holes, small sizes punches
are required. Small hole size in sheet metal requires smaller size punching tool which
may leads to break during the operation. It is recommended that the diameter of the
hole should be equal or more than the thickness of the sheet metal.

Maximum Embossment Depth

Embosses are small, shallow formed projections on the surface of stamped parts.
During this operation, stretching is the main deformation mode resulting in high
tension. Thereby the metal is subject to excessive thinning or fracturing.
Consequently, the depth of the embossed feature is restricted by the material’s
thickness and ability to stretch in addition to the emboss geometry.It is recommended
that the maximum depth of embossment be less than or equal to three times material
thickness.

Minimum Bend Radius

Minimum bend radii requirements can vary depending on applications and material.
For aerospace and space applications, the values may be higher. When the radius is
less than recommended, this can cause material flow problems in soft material and
fracturing in hard material. Localized necking or fracture may also occur in such cases.
It is recommended that minimum inner bend radius should be at least 1 times material
thickness.

Curl Feature Guidelines

Curling sheet metal is the process of adding a hollow, circular roll to the edge of the
sheet. The curled edge provides strength to the edge and makes it safe for
handling. Curls are most often used to remove a sharp untreated edge and make it
safe for handling.It is recommended that:
The outside radius of a curl should not be smaller than 2 times the material thickness
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A size of the hole should be at least the radius of the curl plus material thickness from
the curl feature
A bend should be at least the radius of the curl plus 6 times the material thickness
from the curl feature

Hem Feature Guidelines

Hemming is nothing but to fold the metal back on itself. In Sheet Metal hems are used
to create folds in sheet metal in order to stiffen edges and create an edge safe to touch.
Hems are most often used to remove a sharp untreated edge and make it safe for
handling. Hems are commonly used to hide imperfections and provide a generally
safer edge to handle. a combination of two hems can create strong, tight joints with
little or minimal fastening. Hems can even be used to strategically double the
thickness of metal in areas of a part which may require extra support. It is
recommended that:
For tear drop hems, the inside diameter should be equal to the material thickness.
For open hem the bend will lose its roundness when the inside diameter is greater than
the sheet metal thickness.
For bends, the minimum distance between the inside edge of the bend and the outside
of the hem should be 5 times material thickness plus bend radius plus hem radius.

Notch Feature Guidelines

Notching is a shearing operation that removes a section from the outer edge of the
metal strip or part. In case, distance between the notches to bend is very small then
distortion of sheet metal may take place.To avoid such condition notch should be
placed at appropriate distance from bend with respect to sheet thickness. Notching is a
low-cost process, particularly for its low tooling costs with a small range of standard
punches. DFMPro sheet metal design recommendations for Notch Feature:
Notch width should not be narrower than 1.5 * t
Length of notches can be up to 5 * t
Recommended corner radius for notches should be 0.5 * t
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Fig 2.1 Electronically controlled door mechanism using Concealed hinge

- The opening force is applied to the olive green crank via a GT2 20T 6 mm pulley
and a servo motor

Fig 2.2 Design of the storage unit

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Fig 2.3 structural support for the machine with space left for the integration of
control unit, Bluetooth module
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3. Failed product
In house product
Description- Sanitizer box

(a)

(b)
Fig 3.1 (a) different view of the product (b) left design of hinge 1 right design of
hinge 2

The initial design of the hinge had failed during prototype mainly due to less
capability of the workshop later the design of the hinge was updated.
Next, step was to build test model but before proceeding further a second feasibility
study was carried out due to the change in the dynamics of the market, which resulted
in discarding of the product.
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Fig 3.1 defect part

4.Conclusion
During my internship one of the biggest thing which I learnt was people can come up
with many solution to defined problem but solution which are scalable from R&D to
large scale manufacturing with the addition of the solution being cheap is a difficult
task.
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Somadisha Consultants and Solutions

Pvt.Ltd
CIN U72900KA2008PTC046296 No.301
,Sobha Orchid,
Jakkur Main Road,Jakkuru,
Bengaluru-560064

Date:21/12/2020

TO WHOM IT MAY CONCERN

This is to certify that R Karan Beeshm, a student of RAMAIAH INSTITUTE OF TECHNOLOGY, has
undergone his internship with our organization, under the supervision of Rajarshi Prattipati from July
5, 2020 to December 13, 2020.

During the internship, he designed and optimized the body shell of an industrial liquid dispenser
using FEM. Further designed the structure, mechanical components, and the door mechanism for a
smart locker.

He has excellent written and verbal communication skills and can work independently. He is also able
to effectively and creatively problem solve for any solution and visualize it, with his proficiency in 3D
modeling software and mechanical systems.

It was a pleasure to work with him. We wish Mr. R Karan Beeshm all the best for his career and future
endeavors.

To verify the authenticity of this certificate, please email us at - rishiprattipati@gmail.com

Rajarshi Prattipati
(CEO)