ENGINEERING SCIENCE PROJECT ON FABRICATION AND INSTALLATION OF WORKSHOP METAL DOOR 2022

FABRICATION AND INSTALLATION OF WORKSHOP METAL DOOR

IN PARTIAL FULFILMENT OF THE REQUIRMENT FOR THE AWARD OF NATIONAL DIPLOMA IN MECHANICAL ENGINEERING TODEPARTMENT OF MECHANICAL ENGINEERING,FACULTY OF ENGINEERING, THE POLYTECHNIC, IBADAN.
JULY, 2021

This is to certify that this project titled “Fabrication And Installation of Metal Door” was carried out by following under listed students.
ADEROGBA ABDULAHMED ADENIYI 2018232060016
ADETAYO OLAMILEKAN DAVID 2018232060017
AFOLABI VICTOR AYOMIDE 2018232060019
AHMED JUBRIL OLAMILEKAN 2018232060021

In partial fulfillment of the requirement for the award of National Diploma certificate in the Department of Mechanical Engineering , Faculty of Engineering of The polytechnic, Ibadan, Oyo State.
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ENGR. ADIO, T.A DATE

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ENGR. OKE, D.B DATE

DEDICATION

This project is dedicated to Almighty God, the creator of all the creatures, whose mercy embraces all things, and strength dominates whatever exists in any form. It is also dedicated to our parents.

ACKNOWLEDGEMENT

Firstly, we give thank to God Almighty the author and the finisher of our faith for his protection over us through out the course of our life and our stay in this institution. We acknowledge the immense contribution of our parents who ensured our stay in the institution was fruitful and our fellow colleagues and supervisor in the department who has been helping through out the construction of the project, we say thank you all, we express our sincere gratitude to you all.
Also, special thanks goes to our project supervisor in person of Egnr, Adio, T.A and Mr. Oyedeji O., Who had been magnanimous enough in correction and suggestion which enable the success of this project. Thanks for been such a wonderful and understanding supervisor God bless you sir. Favor and blessing are the house hold of our mighty God, may that favors and blessing never depart from each one of us Amen.

ABSTRACT

This project is based on fabrication of metal door. A metal door is a movable structure used to close off an entrance typically consisting of a panel that swings, slide or rotate.
This metal door more reliable and strong and has much good working appearance than other doors like, wooden door, glass door, leather door and so on. Various fabrication processes such as marking out, cutting, bending, joining or welding, grinding, spraying and so on were adopted and implemented in the fabrication of this twin leaf metal door, peep hole was fixed on the door to screw visitor and admit on choice, the main purpose is to ensure safety and protection.
The material used to make this project to be a well strong design are as follows: galvanized metal plate, square pipe, lockset key, paint, hinges guage, 2electrode and grinding disk and the major reason of using the material is to provide good making features of the door which will meet up with now adays demand and designs, and in order to expose students on how to use different types of simple tools and some machines. The special features on the door are as follows, pinhole, lockset key, hinges small, square pipes, paint which is use to coat the door against rusting.

CHAPTER ONE

INTRODUCTION
The existence of metal door can be traced back to the olden days when our fore fathers constructed the cross planks on their windows. The aim of these is to prevent any kind of intruders into their houses. Due to the advancement in the nature of nowadays, the cross planks is unfit for such a task any more(Water,2002) .
Due to some societal problems such as metal door act ,man now devices a better way of protecting their lives and property by using an iron made materials, for their door.
In this project, we are dealing with the usage of the sheet metal for metal door.
Types of door
Wooden door: This is type of door made from wood of different types carried to beautify houses and offices.
Metal door: This is a type of door made from steel which compromised either of polyurethane or polystryrenecore, hollow pipe is placed over the top of the constructed door.
Aluminum door: This is the type of door made from aluminum metal and it is commonly use in many residential and official buildings. This is due to the light density, corrosion resistance, aesthetic, with optional fix wood texturing and long lasting finished. Aluminum is the lighter and less expensive than steel but more prone to dent.
Fiber glass door. Fiber glass door represent a small segment of the market. This panels, which are encased in aluminum frames can be painted to overcome great resistance to salt water corrosion the other garage door materials which make a good choice for coaster location.

Research Problem.

In the past decade, the upsurge income rate has been a recurring problem in the country adjust as measure needs to be installed. The introduction of metal door in place of wooden door for automobile workshop in order to improve security measures and forceful entry.
Wooden doors unlike metal doors are prone to spoilage easily when being exposed to excess sunlight, rainfall, insects(termites) can actually feeds on it and causes it to get damaged.

Aim and Objective

Aim
The project has been fabricated and installed at the automobile workshop.
Specification Objective
The specification objectives of this project is to
To select appropriate materials for the construction of meetal door
To fabricate metal door on (i) to department specifications (ii) compliance with all required specification, standards and proper construction procedures
Scope and Limitation
Scope
The scope is based on the various construction operation carried out in the production of metal door such as marking out, cutting, bending and assembling. The material used is based on the cost and environmental influence of the automobile workshop
Limitations.
There is rusting n metal frames and metal sheet
It is impossible to present in architectural vies.
Expected Contribution To Knowledge.
Serves as source of encouragement to man power development.
It also improve the protection of lives and properties.
It encourage the use of locally fabricated (metals) door in the society.

CHAPTER TWO

LITERATURE REVIEW
Doors date back from ancient Egyptian era, there are painting which serves as historical records of door architecture. The climate in Egypt was hot and dry enough, that there was not any fear of war print that the wood used for doors were just that, slaps of wood or hinges.
Doors were invented as a means of providing security for lives and property through locking up. The oldest door in England can be found in the west minister Abbey. The earliest Renaissance door in France are those of the cathedral of (St. Sauveur at Six (1503) returning to Italy).
In most places due to change of temperature and humidity. Doors usually have to be framed. Others historical records of doors include king Solomon’s temple doors. They were made of olive wood, as many doors of the past. In India, there were ancient stone door found. These had pivots on each end, which then fit into sockets. These doors swung open and sheet, similar to saloon door of old west but not as quickly. The greek and Romans used many styles of doors; single, double and folding. These doors are as well as many others found through out Europe’s past were made of bronze. This seemed to be going of today market can be made from any material just found on earth, wood, plastic, metal, glass, Paper and even fabric. They usually serve the purpose of keeping something in and or out.
Franklin o. Joues (2007) defines metals solid materials that are typically hand, shinning, malleable feasible, and ductile with a good electrical and thermal conductivity some metal, forms barrier layer of oxide on their surfaces which cannot be penetrated by further oxygen molecules and they retain their shining appearance and food conductivity for many decades e.g aluminum, magnesium, and steel which are titans.
Ran rah shah(2002) defined metal as a substance that has a bright lust and is good conduction of electricity. Metal having varying degree of hardness, density/malleability and ductility ( being malleable) to be will out and hammered.
Porter Catherine(2011) also said that a metal has a definite melting points and will fuse with other metals to form alloys with the exception of mercury. All metals are found in pure state but most of them are found in combination ores are lead, zinc, iron, copper, chromium, nickel and Mercury.
Ancient and Medieval periods: Few doors have been preserved from the period of antiquity. Those of some important building were bronze but seem unlikely that most does could have jambs and support an entablature. Finally a full or broken pediment or triangular or segmental or scroll form may crown the entablature. Pediment discharge reinforce to the slide of the doctor instead of allowing it to drip down in form of door ways for this type appears in the Renaissance during the fifteenth century in Italy and continued in latter styles through the early twentieth century. A fairly elaborate example is the door ii ovens in Rome Criacomo Della portal is where triangular pediment are set within a large segmental pediment (Giacomo1995).
According to Chapman (1970) theory of bending the cost and simplicity of which tools are designed and made will depend on the scale of the output envisages. For example a firm out to procure common articles such as safety pin or picture hood expect the market to absorb large quantities and should provide tools with high output and long life.

2.1 DOORS

One of the weak sports through thieves often try to make their way into a home is door. Only doors fashioned from study materials, fitted with a security lock and inside a solid frame with a quality lock, retainer and window still are burglary proof.(Philip Willekens,2007).
Door and frame should always form whole. This is the only way to tend burglars powerless!
2.1.1 Definition of a Door
A door is a hinged or otherwise movable barrier that allows ingress into egress from an enclosure. The created opening in the wall is a door way or partial. Door are commonly attached by hinges, but can move by other means such as slides or counter balancing.
2.1.2.Forcefield
Force field is an area of energy, such as magnetic energy, surrounds an object or place. A force field analysis is a development in social science. It provide a frame work for looking at the factors that influence in a situation, originally social situation it looks at forces that are either driving movement toward a goal or blocking movement toward a goal.
2.1.3.Contactforce
A contact force is any force that acquires contact to occur. Contact forces are ubiquitous and are responsible for most visible interaction between macroscopic collections of matter.
2.2 Types of Door
I. Wooden door
ii. Fiber glass door
III. Steel door
iv. Aluminum door
Wooden door
Wooden doors or timber doors are primarily used for interior door applications. Timber is the oldest material used for the doors and timber never seems out of fashion. There are many good reasons for using wood such as wooden doors provide sound proofing. Insulation and security. They are easy to install and clean. They have long life. Being natural material, they have a different appeal. They do look elegant. They are very costly.

Fig 1.1 A wooden door
Fiber glass door
Fiber glass garage doors represent a small segment of the market. The panels, which are encased in aluminum frames, can be painted and offer, greater resistance to dents than steel.
Fiber glass is very light, a poor insulator, and can fade from weather exposure. But it is more resistance to salt water corrosion than other garbage door materials, which makes it a good choice for coastal location.

Fig 1.2 Finer glass door
Steel doors
Steel doors are compromised of either a polyurethane or polystyrene core with a steel skin over the top. A solid steel door would be prohibitively heavy and would mostly likely tear out the hinges. Steel between 16 and 24 gauge is used for the skin of the door.
Steel doors have additional pvc vinyl layer adhered to the steel skin which gives the door a certain look or color,. typically wood gain, it should be noted that these pvs vinyl layers are hard to paint if you later decide that you want different colour. They are 500% better at blocking unwanted heat and cold than are wood doors.

Fig 1.3 Steel door
Aluminum doors
Aluminum doors share many of the characteristics of steel, with optional fax wood texturing and long lasting finishes. Aluminum of lighter and less expensive that steel, but it is more likely to dents.

Fig 2.4 Aluminum door
2.3.1 Advantages of metal door
Metal door provides the following benefits
This door is effortless to handle.
It can only be placed on a door frame with durability and easy installation.
Using paints, we can keep it for a long time.
As the price is not high, all classes of people can afford it.
The metal doors comes in various form.
Fire rated metal door is a great way to include extra light in a room, providing additional security.
2.2.3 Disadvantage of metal doors
The disadvantage of metal door are:
It has a rusting problem.
It cannot give an architectural view.
This might be heavy in weight.
2.4 Definition of Welding
Welding is a fabrication or sculpture process that joins materials, usually metals or thermoplastics by causing coalescence. This is often done by melting the work pieces and adding a filter material to form a pool of molten material (the weld pool) that cools to become a strong joint, with pressure sometimes used in conjunction with heat, or by itself, to produce the weld. This is in contrast with soldering and brazing, which involve melting a lower melting point material between the work pieces to form a bond between them without melting the work pieces.(Lincoln Electric,1994).

2.5 Types of Welding

1. Arc welding: These processes use a welding power supply to create and maintain an electric are between an electrode and the base material to melt metals at the welding point. They can use either direct current (DC) or alternating current (AC), and consumable or non-consumable electrodes.
2. Gas welding: The most common gas welding process is oxy-fuel welding, also known as oxyacetylene welding. It is one of the oldest and most versatile welding processes, but in recent years, it has become less popular in industrial applications. It is widely used for welding pipes and tubes, as well as repair work.
3. Resistance welding: These involves the generation of heat by passing current through the resistance caused by the contact between two or more metal surface. In general, resistance welding methods are efficient and cause little pollution, but their applications are somewhat limited and the equipment cost could be high.
4. Solid-state welding: This is the joining of base metals (Metals, alloys, ceramics etc.) by chemical bond formation without heating the base metals above their respective melting point.