1 ABSTRACT

This report gives a brief explanation of redesign and 3D printing of the

Wrench. The main aim is to redesign Wrench according to improve any of the
following characteristics such as Function - Performance - Aesthetics - Costs –
Production Requirements.

Wrench has to be redesigned in order to improve characteristics mentioned

above with in the manufacturing techniques. Appropriate material is selected for
every component according to their requirement.

All the components are designed in CAD application so called

SOLIDWORKS and assembled with in the constraint boundaries. Individual parts of
the product are 3D printed using G-Codes obtained from KISSlicer software.

Finally by using ASHA 3D Printer prototypes are made and the conclusion
explains the different possible ways to improve the design for better productivity and
gives the overview of the way in which the Wrench can be designed even better.

1
Table of Contents
1 ABSTRACT ........................................................................................................... 1

2 INTRODUCTION TO CAD .................................................................................. 4

2.1 COMPUTER-AIDED DESIGN (CAD): ........................................................ 4

2.2 INTRODUCTION CATIA V5-R20................................................................ 5

2.2.1 SKETCHER ............................................................................................. 5

2.2.2 CREATING A NEW SKETCH ............................................................... 6

3 RAPID PROTOTYPING TECHNOLOGIES ....................................................... 7

3.1 INTRODUCTION ........................................................................................... 7

3.1.1 YEAR OF INCEPTION TECHNOLOGY .............................................. 7

4 BASIC PRINCIPLE OF RAPID PROTOTYPING PROCESSES ........................ 8

4.1 GENERALIZED ILLUSTRATION OF DATA FLOW IN RP ................... 10

4.2 STEREO LITHOGRAPHY .......................................................................... 11

4.3 SELECTIVE LASER SINTERING .............................................................. 13

4.4 FUSED DEPOSITION MODELING ........................................................... 14

4.5 LAMINATED OBJECT MANUFACTURING ........................................... 14

5 PART FINISHING .............................................................................................. 17

5.1 INTRODUCTION TO WRENCH ................................................................ 18

5.2 TYPES OF WRENCHES ............................................................................. 19

5.3 MODELING FEATURE CREATION ......................................................... 32

5.4 CREATION OF SOLID/SURFACE BODIES ............................................. 32

5.4.1 Designing Crope (Handle) ..................................................................... 32

5.4.2 Designing Dente (Jaw) ........................................................................... 35

5.4.3 Connecting Rod Assembly .................................................................... 38

6 3D PRINTING ..................................................................................................... 39

2
Figure 1 SOLIDWORKS ............................................................................................... 6
Figure 2 RP process chain showing fundamental process steps .................................... 8
Figure 3 Tessellation of a typical surface of cad model ................................................ 9
Figure 4 RAPID PROTOTYPING PROCESSES ....................................................... 10
Figure 5: Classification of RP Processes ..................................................................... 11
Figure 6 Stereo Lithography ........................................................................................ 12
Figure 7 Selective Laser Sintering System .................................................................. 13
Figure 8 Fused Deposition Modeling Process ............................................................. 14
Figure 9 Laminated Object Manufacturing Process .................................................... 15
Figure 10 Applications of RP Technologies ................................................................ 16
Figure 11 ...................................................................................................................... 17
Figure 12 Loft Operation to Create Handle ................................................................. 33
Figure 13 Extrude Base Operation for Round End ...................................................... 33
Figure 14 Basic Sketch Profile .................................................................................... 34
Figure 15 Hole Operation Using Extrude Cut ............................................................. 34
Figure 16 Final Design................................................................................................. 35
Figure 17 Basic Sketch Profile .................................................................................... 36
Figure 18 Guide Design ............................................................................................... 36
Figure 19 Support Design ............................................................................................ 37
Figure 20 Helical Cut ................................................................................................... 37
Figure 21 Final Design................................................................................................. 38
Figure 22 Assembly Features....................................................................................... 38
Figure 23 Exploded View ............................................................................................ 39
Figure 24 Final Assembly ............................................................................................ 39
Figure 25 ...................................................................................................................... 40
Figure 26 ...................................................................................................................... 41
Figure 27 ...................................................................................................................... 41
Figure 28 ...................................................................................................................... 41
Figure 29 ...................................................................................................................... 42

3
2 INTRODUCTION TO CAD

2.1 COMPUTER-AIDED DESIGN (CAD):

It also known as computer-aided design and drafting (Cadd), is the use of
computer technology for the process of design and design-documentation. Computer
aided drafting describes the process of drafting with a computer. Cadd software, or
environments, provides the user with input-tools for the purpose of streamlining
design processes; drafting, documentation, and manufacturing processes. Cadd output
is often in the form of electronic files for print or machining operations. The
development of Cadd-based software is in direct correlation with the processes it
seeks to economize; industry-based software (construction, manufacturing, etc.)
typically uses vector-based (linear) environments whereas graphic-based software
utilizes raster-based environments.

Cadd environments often involve more than just shapes. as in the manual
drafting of technical and engineering drawings, the output of cad must convey
information, such as materials, processes, dimensions, and tolerances, according to
application-specific conventions.

CAD may be used to design curves and figures in two-dimensional (2d) space;
or curves, surfaces, and solids in three-dimensional (3d) objects.

CAD is an important industrial art extensively used in many applications,

including automotive, ship building, and aerospace industries, industrial and
architectural design, prosthetics, and many more. CAD is also widely used to produce
computer animation for special effects in movies, advertising and technical manuals.
The modern ubiquity and power of computers means that even perfume bottles and
shampoo dispensers are designed using techniques unheard of by engineers of the
1960s. Because of its enormous economic importance, cad has been a major driving
force for research in computational geometry, computer graphics (both hardware and
software), and discrete differential geometry.

Current computer-aided design software packages range from 2d vector-based

drafting systems to 3d solid and surface modelers. Modern cad packages can also
frequently allow rotations in three dimensions, allowing viewing of a designed object
from any desired angle, even from the inside looking out. Some cad software is

4
capable of dynamic mathematic modeling, in which case it may be marketed as cadd
— Computer-Aided Design and Drafting.

CAD is used in the design of tools and machinery and in the drafting and
design of all types of buildings, from small residential types (houses) to the largest
commercial and industrial structures (hospitals and factories).

CAD is mainly used for detailed engineering of 3d models and/or 2d drawings

of physical components, but it is also used throughout the engineering process from
conceptual design and layout of products, through strength and dynamic analysis of
assemblies to definition of manufacturing methods of components. It can also be used
to design objects.

CAD has become an especially important technology within the scope of

computer-aided technologies, with benefits such as lower product development costs
and a greatly shortened design cycle. CAD enables designers to layout and develops
work on screen, print it out and save it for future editing, saving time on their
drawings.

2.2 INTRODUCTION CATIA V5-R20

SolidWorks is a modern computer aided design (CAD) program. It enables
designers to create a mathematically correct solid model of an object that can be
stored in a database. When the mathematical model of a part or assembly is associated
with the properties of the materials used, we get a solid model that can be used to
simulate and predict the behavior of the part or model with finite element and other
simulation software. The same solid model can be used to manufacture the object and
also contains the information necessary to inspect and assemble the product. The
marketing organization can produce sales brochures and videos that introduce the
product to potential customers. SolidWorks and similar CAD programs have made
possible concurrent engineering, where all the groups that contribute to the product
development process can share information real-time.

2.2.1 SKETCHER
Sketcher is used to create two-dimensional representations of profiles
associated within the part. We can create a rough outline of curves, and then specify

5
conditions called constraints to define the shapes more precisely and capture our
design intent. Each curve is referred to as a sketch object.

2.2.2 CREATING A NEW SKETCH

To create a new sketch, chose start sketcher then select the reference plane or
sketch plane in which the sketch is to be created.

Sketch plane: The sketch plane is the plane that the sketch is located on. The sketch
plane menu has the following options:

Face/plane: With this option, we can use the attachment face/plane icon to select a
planar face or existing datum plane. If we select a datum plane, we can use the reverse
direction button to reverse the direction of the normal to the plane.

FRONT, TOP, and RIGHT with these options, we can create a sketch on one
of these planes. If we use this method, a datum plane and two datum axes are created
as below.

Figure 1 SOLIDWORKS

6
3 RAPID PROTOTYPING TECHNOLOGIES

3.1 INTRODUCTION
Prototyping or model making is one of the important steps to finalize a
product design. It helps in conceptualization of a design. Before the start of full
production a prototype is usually fabricated and tested. Manual prototyping by a
skilled craftsman has been an age old practice for many centuries. Second phase of
prototyping started around mid-1970s, when a soft prototype modeled by 3d curves
and surfaces could be stressed in virtual environment, simulated and tested with exact
material and other properties. Third and the latest trend of prototyping, i.e., rapid
prototyping (RP) by layer-by-layer material deposition, started during early 1980s
with the enormous growth in computer aided design and manufacturing (CAD/CAM)
technologies when almost unambiguous solid models with knitted information of
edges and surfaces could define a product and also manufacture it by CNC machining.
The historical development of rp and related technologies is presented in below.

3.1.1 YEAR OF INCEPTION TECHNOLOGY

1770 mechanization

1946 first computer

1952 first numerical control (nc) machine tool

1960 first commercial laser

1961 first commercial robot

1963 first interactive graphics system (early version of ca d)

1988 first commercial rapid prototyping system

7
4 BASIC PRINCIPLE OF RAPID PROTOTYPING
PROCESSES
RP process belong to the generative (or additive) production processes unlike
subtractive or forming processes such as lathing, milling, grinding or coining etc. in
which form is shaped by material removal or plastic deformation. In all commercial
RP processes, the part is fabricated by deposition of layers contoured in a (x-y) plane
two dimensionally. The third dimension (z) results from single layers being stacked
up on top of each other, but not as a continuous z-coordinate. Therefore, the
prototypes are very exact on the x-y plane but have stair-stepping effect in z-direction.
If model is deposited with very fine layers, i.e., smaller z-stepping, model looks like
original. RP can be classified into two fundamental process steps namely generation
of mathematical layer information and generation of physical layer model. Typical
process chain of various RP systems is shown

Figure 2 RP process chain showing fundamental process steps

8
 It can be seen from figure that process starts with 3d modeling of the product
and then STL file is exported by tessellating the geometric 3d model. In tessellation
various surfaces of a cad model are piecewise approximated by a series of triangles
and co-ordinate of vertices of triangles and their surface normals are listed. The
number and size of triangles are decided by facet deviation or chordal error as shown
in figure. These STL files are checked for defects like flip triangles, missing facets,
overlapping facets, dangling edges or faces etc. and are repaired if found faulty.
Defect free STL files are used as an input to various slicing software’s.

At this stage choice of part deposition orientation is the most important factor
as part building time, surface quality, amount of support structures, cost etc. are
influenced. Once part deposition orientation is decided and slice thickness is selected,
tessellated model is sliced and the generated data in standard data formats like SLC
(stereo lithography contour) or CLI (common layer interface) is stored. This
information is used to move to next step, i.e., generation of physical model.

The software that operates rp systems generates laser-scanning paths (in

processes like stereo lithography, selective laser sintering etc.) or material deposition
paths (in processes like fused deposition modeling). This step is different for different
processes and depends on the basic deposition principle used in RP machine.
Information computed here is used to deposit the part layer-by-layer on RP system
platform. The generalized data flow in RP is given in figure

Figure 3 Tessellation of a typical surface of cad model

9
 The final step in the process chain is the post-processing task. At this stage,
generally some manual operations are necessary therefore skilled operator is required.
In cleaning, excess elements adhered with the part or support structures are removed.
Sometimes the surface of the model is finished by sanding, polishing or painting for
better surface finish or aesthetic appearance. Prototype is then tested or verified and
suggested engineering changes are once again incorporated during the solid modeling
stage.

4.1 GENERALIZED ILLUSTRATION OF DATA FLOW IN RP

Figure 4 RAPID PROTOTYPING PROCESSES

The professional literature in RP contains different ways of classifying RP

processes. However, one representation based on German standard of production
processes classifies RP processes according to state of aggregation of their original
material and is given in figure

10
 Figure 5: Classification of RP Processes

Here, Few Important RP Processes Namely

 Stereo Lithography (SL),

 Selective Laser sintering (SLS)
 Fused Deposition Modeling (FDM)
 Laminated Object Manufacturing (LOM)

4.2 STEREO LITHOGRAPHY

In this process photosensitive liquid resin which forms a solid polymer when
exposed to ultraviolet light is used as a fundamental concept. Due to the absorption
and scattering of beam, the reaction only takes place near the surface and voxels of
solid polymeric resin are formed. A SL machine consists of a build platform
(substrate), which is mounted in a vat of resin and a UV helium-cadmium or argon ion
laser. The laser scans the first layer and platform is then lowered equal to one slice
thickness and left for short time (dip-delay) so

In new SL systems, a blade spreads resin on the part as the blade traverses the
CATIA. This ensures smoother surface and reduced recoating time. It also reduces
trapped volumes which are sometimes formed due to excessive polymerization at the
ends of the slices and an island of liquid resin having thickness more than slice
thickness is formed (Pham and demo, 2001). Once the complete part is deposited, it is
removed from the vat and then excess resin is drained. It may take long time due to

11
high viscosity of liquid resin. The green part is then post-cured in a UV oven after
removing support structures.

Figure 6 Stereo Lithography

That liquid polymer settles to a flat and even surface and inhibits bubble
formation. The new generative manufacturing processes slice is then scanned.
Schematic diagram of a typical stereo lithography apparatus is shown in figure

Stereo lithography overhangs or cantilever walls need support structures as a

green layer has relatively low stability and strength. These overhangs etc. are
supported if they exceed a certain size or angle, i.e., build orientation. The main
functions of these structures are to support projecting parts and also to pull other parts
down which due to shrinkage tends to curl up (Gephardt, 2003). These support
structures are generated during data processing and due to these data grows heavily
specially with STL files, as cuboids shaped support element need information about at
least twelve triangles. a solid support is very difficult to remove later and may damage
the model. Therefore a new support structure called fine point was developed by 3d
systems (figure 6) and is company s trademark. Build strategies have been developed
to increase build speed and to decrease amount of resin by depositing the parts with a
higher proportion of hollow volume. These strategies are devised as these models are
used for making cavities for precision castings. Here walls are designed hollow
connected by rod-type bridging elements and skin is introduced that close the model
at the top and the bottom. These models require openings to drain out uncured resin.

12
4.3 SELECTIVE LASER SINTERING
In selective laser sintering (SLS) process, fine polymeric powder like
polystyrene, polycarbonate or polyamide etc. (20 to 100 micrometer diameter) is
spread on the substrate using a roller. Before starting CO2 laser scanning for sintering
of a slice the temperature of the entire bed is raised just below its melting point by
infrared heating in order to minimize thermal distortion (curling) and facilitate fusion
to the previous layer. The laser is modulated in such a way that only those grains,
which are in direct contact with the beam, are affected (Pham and demon, 2001).
Once laser scanning cures a slice, bed is lowered and powder feed chamber is raised
so that a covering of powder can be spread evenly over the build area by counter
rotating roller. In this process support structures are not required as the unsintered
powder remains at the places of support structure. it is cleaned away and can be
recycled once the model is complete. The schematic diagram of a typical SLS
apparatus is given in figure.

Figure 7 Selective Laser Sintering System

13
4.4 FUSED DEPOSITION MODELING
In Fused Deposition Modeling (FDM) process a movable (x-y movement)
nozzle on to a substrate deposits thread of molten polymeric material. the build
material is heated slightly above (approximately 0.5 c) its melting temperature so that
it solidifies within a very short time (approximately 0.1 s) after extrusion and cold-
welds to the previous layer as shown in figure various important factors need to be
considered and are steady nozzle and material extrusion rates, addition of support
structures for overhanging features and speed of the nozzle head, which affects the
slice thickness. More recent FDM systems include two nozzles, one for part material
and other for support material. The support material is relatively of poor quality and
can be broken easily once the complete part is deposited and is removed from
substrate. In more recent FDM technology, water-soluble support structure material is
used. Support structure can be deposited with lesser density as compared to part
density by providing air gaps between two consecutive roads.

Figure 8 Fused Deposition Modeling Process

4.5 LAMINATED OBJECT MANUFACTURING

Typical system of laminated object manufacturing (LOM) has been shown in
figure 9. it can be seen from the figure that the slices are cut in required contour from
roll of material by using a 25-50 watt co2 laser beam. A new slice is bonded to
previously deposited slice by using a hot roller, which activates a heat sensitive
adhesive. Apart from the slice unwanted material is also hatched in rectangles to
facilitate its later removal but remains in place during the build to act as supports.

14
Once one slice is completed platform can be lowered and roll of material can be
advanced by winding this excess onto a second roller until a fresh area of the sheet
lies over the part. After completion of the part they are sealed with a urethane lacquer,
silicone fluid or epoxy resin to prevent later distortion of the paper prototype through
water absorption.

Figure 9 Laminated Object Manufacturing Process

In this process, materials that are relatively cheaper like paper, plastic roll etc.
can be used. Parts of fiber-reinforced glass ceramics can be produced. Large models
can be produced and the building speed is 5-10 times as compared to other RP
processes. The limitation of the process included fabrication of hollow models with
undercuts and re-entrant features. Large amount of scrap is formed. There remains
danger of fire hazards and drops of the molten materials formed during the cutting
also need to be removed.

15
 Figure 10 Applications of RP Technologies

RP technology has potential to reduce time required from conception to

market up to 10-50 percent (Chua and Leong, 2000) as shown in figure 10. It has
abilities of enhancing and improving product development while at the same time
reducing costs due to major breakthrough in manufacturing (Chua and Leong, 2000).
Although poor surface finish, limited strength and accuracy are the limitations of RP
models, it can deposit a part of any degree of complexity theoretically. Therefore, RP
technologies are successfully used by various industries like Aerospace, Automotive,
Jewelers, Coin making, Tableware, Saddletrees, and Biomedical etc. it is used to
fabricate concept models, functional models, patterns for investment and vacuum
casting, medical models and models for engineering analysis (Pham and Demon,
2001). Various typical applications of RP are summarized in figure 10.

16
 Figure 11

5 PART FINISHING
Poor surface quality of rp parts is a major limitation and is primarily due to
staircase effect. Surface roughness can be controlled below a predefined threshold
value by using an adaptive slicing (Pandey et al., 2003b). Further, the situation can be
improved by finding out a part deposition orientation that gives minimum overall
average part surface roughness (Singhal et al., 2005). However, some RP applications
like exhibition models, tooling or master pattern for indirect tool production etc.
require additional finishing improving the surface appearance of the part. This is
generally carried by sanding and polishing RP models which lead to change in the
mathematical definitions of the various features of the model. The model accuracy is
mainly influenced by two factors namely the varying amount of material removed by
the finishing process and the finishing technique adopted. A skilled operator is
required as the amount of material to be removed from different surfaces may be

17
different and inaccuracies caused due to deposition can be brought down. A finishing
technique selection is important because different processes have different degrees of
dimensional control. For example models finished by employing milling will have
less influence on accuracy than those using manual wet sanding or sand blasting.

 Thicker Bottom Layer

 Deformed Hole Boundary

This is one of the crucial decisions taken before slicing the part and initiating the
process of deposition for a particular RP process. This decision is important because it
has potential to reduce part building time, amount of supports required, part quality in
terms of surface finish or accuracy and cost as well. Selection of part deposition
orientation is process specific where in designer and RP machine operators should
consider number of different process specific constraints. This may be a difficult and
time consuming task as designer has to trade-off among various conflicting objectives
or process outcomes. For example better part surface quality can be obtained but it
will lead to increase in the building time. Pandey et al. (2004b) handled conflicting
situation of the abovementioned two objectives and proposed use of multi-objective
genetic algorithm for finding out optimum part deposition orientations (Pareto
Optimal Solutions) for FDM process. In their work, amount of support structures were
also minimized implicitly. Thrimurthullu et al. (2004) converted multi-objective
problem into single objective problem and then solved by using real coded genetic
algorithm. Singhal et al. (2005) made an attempt to find out optimum part deposition
orientation for sl process by using optimization tool box of matlab 6.5 for minimizing
overall part surface roughness. Except these, researchers suggested to find out a
suitable part deposition orientation for objectives like maximum accuracy, minimum
building time, support structure or cost. A thorough review of the various part
deposition orientation studies has been done by Pandey et al. (2004a). Pham and
Demov (2001) discussed guidelines for selection of part deposition orientation for SL
and SLS processes.

5.1 INTRODUCTION TO WRENCH

A wrench (or spanner outside of North America) is a tool used to provide grip
and mechanical advantage in applying torque to turn objects usually rotary fasteners,
such as nuts and bolts or keep them from turning.

18
 In Commonwealth English (excluding Canada), spanner is the standard term.
The most common shapes are called open-ended spanner and ring spanner. The
term wrench is generally used for tools that turn non-fastening devices (e.g. tap
wrench and pipe wrench), or may be used for a monkey wrench - an adjustable
spanner. In North American English, wrench is the standard term. The most common
shapes are called open-end wrench and box-end wrench. In American
English, spanner refers to a specialized wrench with a series of pins or tabs around the
circumference. (These pins or tabs fit into the holes or notches cut into the object to
be turned.) In American commerce, such a wrench may be called a spanner wrench to
distinguish it from the British sense of spanner.

Higher quality wrenches are typically made from chromium-

vanadium alloy tool steels and are often drop-forged. They are frequently chrome-
plated to resist corrosion and for ease of cleaning.

Hinged tools, such as pliers or tongs, are not generally considered wrenches in
English, but exceptions are the plumber wrench (pipe wrench in British English)
and Mole wrench (sometimes Mole grips in British English).

5.2 TYPES OF WRENCHES

Image American Description Group

name

A one-piece wrench with a U-shaped

opening that grips two opposite faces of
the bolt or nut. This wrench is often
double-ended, with a different-sized
open-end opening at each end. The ends are
common
wrench generally oriented at an angle of around
15 degrees to the longitudinal axis of the
handle. This allows a greater range of
movement in enclosed spaces by flipping
the wrench over.

19
Image American Description Group
name

A one-piece wrench with an enclosed

opening that grips the faces of the bolt or
nut. The recess is generally a six-point or
twelve-point opening for use with nuts or
bolt heads with a hexagonal shape. The
box-end twelve-point fits onto the fastening at
common
wrench twice as many angles, an advantage where
swing is limited. Eight-point wrenches are
also made for square-shaped nuts and bolt
heads. Ring spanners are often double-
ended and usually with offset handles to
improve access to the nut or bolt.

A double-ended tool with one end being

like an open-end wrench or open-ended
combination
spanner, and the other end being like a common
wrench
box-end wrench or ring spanner. Both
ends generally fit the same size of bolt.

A wrench that is used for gripping the nuts

on the ends of tubes. It is similar to a box-
end wrench but, instead of encircling the
nut completely, it has a narrow opening
flare-nut
just wide enough to allow the wrench to fit
wrench
over the tube, and thick jaws to increase common
tube wrench
the contact area with the nut. This allows
line wrench
for maximum contact on plumbing nuts,
which are typically softer metals and
therefore more prone to damage from
open-ended wrenches.

A type of ring spanner, or box wrench,

ratcheting box whose end section ratchets. Ratcheting can
common
wrench be reversed by flipping over the wrench,
or by activating a reversing lever on the

20
Image American Description Group
name

wrench. This type of wrench combines

compact design of a box wrench, with the
utility and quickness of use of a ratchet
wrench. A variety of ratcheting
mechanisms are used, from simple pawls
to more complex captured rollers, with the
latter being more compact, smoother, but
also more expensive to manufacture. The
one pictured also features a drift pin on the
tail.

Similar in concept to a socket wrench. A

Saltus wrench features a socket
permanently affixed to a handle. Sockets
are not interchangeable as with a socket
flex-head wrench. The socket often rotates around
socket wrench the handle to allow the user to access a common
Saltus wrench fastener from a variety of angles.
Commonly a Saltus wrench is part of a
double-ended wrench, with an open-end
type head on the opposite side from the
socket head.

spanner
wrench or A wrench with one or several pins or
simply spanner hooks, designed to drive spanner head
[referring to screws, threaded collars and retainer rings,
any of these]; shafts, and so on. Note the difference in
[when common
the American and British senses of the
specifying pin word "spanner". In American English,
vs hook vs C, "spanners" are a subset of the class of
the same tools called "wrenches".
terms are used
as in British

21
Image American Description Group
name

English]

This is a specialized thick, short, stocky

wrench with a block end to the handle
specifically designed for use with a
hammer, enabling one to impart great
striking face force. Used commonly with large
box wrench fasteners, especially a nut and stud which
slammer both have index marks: the nut is screwed
wrench hand-tight, then further tightened with the
common
slugger striking wrench a known number of index
wrench marks calculated from the elasticity of the
hammer bolt or stud, thus giving precise torque
wrench (preload). Striking wrenches also provide
shock and high force used to release large
and/or stuck nuts and bolts; and when
space does not allow room for a large
wrench.

The most common type of adjustable

wrench in use today. The adjustable end
wrench differs from the monkey wrench in
that the gripping faces of the jaws are
adjustable displaced to a (typically) 15 degree angle
wrench relative to the tool's handle, a design
adjustable end feature that facilitates the wrench's use in adjustabl
wrench close quarters. The modern adjustable end e
Crescent wrench was invented by Johan Petter
wrench Johansson [3]of Bahco. The common use
of "Crescent wrench" to describe this
design is derived from the Crescent brand,
owned by Apex Brands, Inc. Apex Tool
Group, LLC.

22
Image American Description Group
name

self-adjusting With a serrated jaw which is self- adjustabl

wrench tightening. e

An old type of adjustable wrench with a

monkey straight handle and smooth jaws whose
historical
wrench gripping faces are perpendicular to the
handle.

A tool that is similar in design and

appearance to a monkey wrench, but with
self-tightening properties and hardened,
adjustabl
pipe wrench serrated jaws that securely grip soft iron
e
pipe and pipe fittings. Sometimes known
by the original patent holder's brand name
as a "Stillson wrench".

A hollow cylinder that fits over one end of

a nut or bolt head. It may include a handle,
if it does not then it is often just referred to
as a socket and is usually used with
various drive tools to make it a wrench or
spanner such as a ratchet handle, a tee bar
socket wrench socket
(sliding tommy bar) bar or a knuckle bar
(single axis pivot). It generally has a six-
point, eight-point or twelve-point recess,
may be shallow or deep, and may have a
built-in universal joint. (The photo shows
both ratchet and sockets.)

breaker bar This tool is a long non-ratcheting bar that

break-over allows the user to impart socket

handle considerable torque to fasteners,

especially in cases where corrosion has

23
Image American Description Group
name

resulted in a difficult-to-loosen part.

A type of wrench designed to use the same

drive sizes as socket wrenches, but non-
cylindrical in shape. The ends are the
same as those found on the open-end, box-
end, or the flare-nut wrenches. These
crowfoot
wrenches are used when torque must be
wrench
measured, or when the application socket
crow's-foot
precludes the use of a regular socket or
wrench
wrench. Also used in place of
conventional open/box wrenches where
the wrenches are large, usually at a lower
cost, or for when space and weight
restrictions are critical.

It contains a one-way mechanism which

allows the socket to be turned without
removing it from the nut or bolt simply by
ratchet wrench socket
cycling the handle backward and forward.
(The photo shows both ratchet and
sockets.)

A crank-shaped handle that drives a

socket. The socket-driving analog of the
brace used to drive a drill bit. Used instead
of a ratchet in a few contexts when it can
save substantial time and effort—that is,
speed handle
when there is a lot of turning to be done socket
speed wrench
(many fasteners), ample room to swing the
handle, ample access to the fastener heads,
etc. Has less leverage than a conventional
ratchet wrench. Used occasionally in
automotive repair or job shop work.

24
Image American Description Group
name

A socket wrench drive tool that is

employed to impart a precise amount of
torque wrench torque to a fastener, essential in many socket
cases during the assembly of precision
mechanisms.

A wrench used to turn screw or bolt heads

designed with a hexagonal socket (recess)
to receive the wrench. The wrenches come
in two common forms: L-shaped and T-
Allen wrench
handles. The L-shaped wrenches are
Allen key
formed from hexagonal wire stock, while keys
hex key
the T-handles are the same hex wire stock
L wrench
with a metal or plastic handle attached to
the end. There are also indexable-driver-
bits that can be used in indexable
screwdrivers.

Another wrench designed for internal

Bristol wrench socket-head screws and bolts. The cross-
Bristol spline section resembles a square-toothed gear. keys
wrench Not a common design, it is chiefly used on
small set screws.

An internal socket-head screw design. The

cross-section resembles a star. Commonly
used in automobiles, automated
Torx wrench equipment, and computer components as it keys
is resistant to wrench cam-out and so
suitable for use in the types of powered
tools used in production-line assembly.

25
Image American Description Group
name

A formerly common type of wrench that

was popular with mechanics, factory
workers, and farmers for maintenance,
alligator
repair and operations tasks in the days historical
wrench
when fasteners often had square rather
than hex heads. The wrench's shape
suggests the open mouth of an alligator.

A thin open-end wrench used to fit narrow

wrench flats of adjustable bearing bicycle
hubs. Called a "cone" wrench because it
fits wrench flats of the cone section of a
"cup and cone" hub, this tool is also used
cone wrench with some other adjustable hub bearings. specialty
The wrench is very thin so has little
strength; to compensate, cone wrenches
typically have a large head. Most bicycle
front hubs use a 13 mm; most rears use
15 mm.

A double-handled wrench for turning

die-stock the dies used in threading operations
specialty
[4]
die wrench (cutting the male threads such as on a
bolt).

A small, square-head socket wrench used

drum key
on drum (percussion musical instrument)
lug wrench specialty
tuning lugs and fasteners. This key is often
drum wrench
interchangeable with radiator bleed keys.

spark plug A tube with six-sided sockets on both

wrench ends. It is turned with a short length of rod common
(tommy bar or T bar) inserted through two

26
Image American Description Group
name

holes in the middle of the tube.

A tool commonly used to open bungs on

drum wrench
large 55-gallon drums (cylindrical specialty
bung wrench
containers).

The hose connection has a threaded collar

fire hydrant
with a protruding pin. From the handle of
wrench (hose specialty
the wrench an arc has at its end a loop to
connection)
engage the pin.

This is a pentagonal (five-sided) box

wrench. The unusual shape of the lug
fire hydrant
makes the valve tamper-resistant: with the
wrench (valve specialty
opposite faces nonparallel, unauthorized
operator)
opening of the hydrant is more difficult
without a suitable tool.

This is a wrench for opening and closing

valves on municipal water pipes (often at
curb key the curb, hence the name). The valve specialty
usually has a rectangular lug and is set
deep into the ground, requiring the key.

A T-handle wrench with two pins and

golf shoe
clearance for the spike—allows removal specialty
spike wrench
and insertion of spikes in shoes.

A flat wrench with a circular hole and two

inward protruding pins to engage slots in
head nut
the nut. This type of nut is used on specialty
wrench
bicycles to secure the front fork pivot
bearing to the headpiece of the frame.

27
Image American Description Group
name

4-way lug
wrench
wheel lug
A socket wrench used to turn lug nuts
cross wrench specialty
on automobile wheels.
cross rim
wrench
spider wrench

A type of wrench for removing cylindrical

oil-filter
oil filters. It may be either a strap-type specialty
wrench
wrench or a socket.

plumber A tool to screw (rotate with force)

specialty
wrench various pipes during plumbing.

A spanner can be used in attaching riggers

to rowing boats with offset to allow users
? specialty
fingers to keep grip when flush with boat.
10 mm at one end, 13 mm at the other.

A self-tightening wrench mounted at the

basin wrench end of a shaft with a transverse handle at
specialty
sink wrench the opposite end. Used to tighten or loosen
fasteners located in recesses.

28
Image American Description Group
name

dogbone A compact spanner for multiple sizes,

specialty
wrench usually used for bicycles

A wrench with a clearance slot for a wire

wheel spoke such as a bicycle wheel and a
drive head for the adjustment nipple nut.
The handle is offset to make the wrench
spoke wrench specialty
more convenient to grip, and the handle is
short to fit between spokes, allowing the
wrench to turn 360 degrees without being
removed.

A steel erecting tool which consists of a

normal wrench at one end and a spike
spud wrench (drift pin) at the other, used for lining up specialty
bolt holes (typically when mating two pipe
flanges).

A self-tightening wrench that engages the

teeth of a chain drive sprocket, and used
typically to remove bicycle cogsets.
chain whip Similar to a strap wrench, but uses specialty
positive engagement rather than friction,
and so needs to grab only one end of the
chain.

A self-tightening wrench with either a

chain or strap of metal, leather, or rubber
strap wrench
attached to a handle, used to grip and turn specialty
chain wrench smooth cylindrical objects (such as
automotive oil filters). It relies entirely on
friction between the strap or chain and the

29
Image American Description Group
name

object to be manipulated. Similar to a pipe

wrench, but uses a chain similar to a drive
chain or strap, instead of an adjustable
jaw. The links of the chain have extended
pegs which fit into grooves in the front of
the handle, with one end of the chain
attached permanently to the handle. This
is used in situations where pipe wrenches
cannot maintain a proper grip on an object
such as a wet or oily pipe. Larger versions
of chain wrenches are sometimes known
as "bull tongs" and are used with large
diameter pipe such as is used deep wells.

A double-handled wrench for turning the

tap wrench square drive on taps used in threading
tap handle operations (cutting the female threads specialty
T-handle such as within a nut) or a
precision reamer.

A spanner of small to moderate size

constructed similarly to an open ended
wrench, but with a thinner cross section.
Its purpose is to apply torque to the
fasteners found on the valve trains of older
engines, especially automobile engines,
where the valve train required adjustment
tappet wrench of the tappets (also known as lifters). specialty
Tappets, push rods, rocker arms and
similar adjustable pieces are often
equipped with locknuts which are thinner
than standard nuts, due to space
limitations. Frequently, the hex section of
the adjustment is contiguous to the lock
nut, thus requiring a thinner "tappet

30
Image American Description Group
name

wrench" to be used.

A socket wrench used to tune some

stringed musical instruments. Similar, and
tuning wrench in some cases identical to drum tuning specialty
keys, but often provide greater torque due
to the higher tension of strings.

A tool specifically for use with wing nuts,

allowing the application of greater torque
than is possible by hand. It is generally
wing nut
advised[by whom?]
not to use such spanners specialty
wrench
for tightening the wing nut, but rather only
for loosening. It is a "hand saver" more
than anything else.

An adjustable wrench with a small number

graduated
(usually 2–4) of discrete sizes. This is
wrench[citation
sometimes used as an inexpensive
needed]
substitute for a monkey wrench.

A broad type of wrenches that use

power wrench electricity or compressed air to power the power
wrench.

A powered wrench which delivers quick,

repeated impulses of torque. Typically
powered by air, but can also be electric.
Most people have heard its familiar rap-
impact wrench rap-rap noise while being used in an auto
power
impact driver repair shop. Although many professionals
use them to tighten lug nuts on vehicle
wheels, do-it-yourselfers should use a
torque wrench since an impact wrench can
often over-torque and damage the threads

31
5.3 MODELING FEATURE CREATION
“Feature” is an all-encompassing term that refers to all solids, bodies and
primitives used in Solidworks Form Features are used to supply detail to the model in
the form of standard feature types. These include hole, Extrude Boss/Cut, Swept
Boss/Cut, Fillet. We can also create our own custom features using the User Defined
option. All of these features are associative.

Reference Feature sallow creating reference planes, reference lines and

reference points. These references can assist in creating features on cylinders, cones,
spheres and revolved solid bodies. Reference planes can also aid in creating features
at angles other than normal to the faces of a target solid. Dress up Feature options lets
modify existing solid bodies and features.

These include a wide assortment of options such as edge fillet, variable fillet,
chamfers, draft, offset face, shell and tapers. Surface design lets us create surface and
solid bodies. A surface body with zero thickness, and consists of a collection of faces
and edges that do not close up to enclose a volume. Most Free Form Feature options
create surface bodies.

Figure 12 Features

5.4 CREATION OF SOLID/SURFACE BODIES

5.4.1 Designing Crope (Handle)

We can create solid bodies by padding the sketch geometry to create associative
features or Creating primitives for the basic building blocks, then adding more
specific features (for example, holes and slots etc.).

Shafting the sketch and non-sketch geometry lets us to create a solid body with
complex geometry. This method also gives us total control over the editing of the

32
body. Editing is done by 23 changing the swept creation parameters or by changing
the sketch. Editing the sketch causes the swept feature to update to match the sketch.

Dress-up features are used to modify the part bodies according to given
specifications these are the most important features to modify the objects.

Figure 12 Loft Operation to Create Handle

Figure 13 Extrude Base Operation for Round End

33
 After a couple of operations like Fillets, Revolve Cut, Mirror the final product
looks as follows. This part is assembled with the rest of the components to produce
the final assembly.

Figure 14 Basic Sketch Profile

Figure 15 Hole Operation Using Extrude Cut

34
 Figure 16 Final Design

5.4.2 Designing Dente (Jaw)

We can create solid bodies by padding the sketch geometry to create associative
features or Creating primitives for the basic building blocks, then adding more
specific features (for example, holes and slots etc.).

Shafting the sketch and non-sketch geometry lets us to create a solid body with
complex geometry. This method also gives us total control over the editing of the
body. Editing is done by 23 changing the swept creation parameters or by changing
the sketch. Editing the sketch causes the swept feature to update to match the sketch.

Dress-up features are used to modify the part bodies according to given
specifications these are the most important features to modify the objects.

A tool that is similar in design and appearance to a monkey wrench, but with
self-tightening properties and hardened, serrated jaws that securely grip soft iron pipe
and pipe fittings. Sometimes known by the original patent holder's brand name as a
"Stillson wrench".

35
Figure 17 Basic Sketch Profile

Figure 18 Guide Design

36
 Figure 19 Support Design

After a couple of operations like Fillets, Revolve Cut, Mirror the final product
looks as follows. This part is assembled with the rest of the components to produce
the final assembly.

Figure 20 Helical Cut

37
 Figure 21 Final Design

5.4.3 Connecting Rod Assembly

After all the required parts are designed they brought together in the assembly
work bench and assembled with the help of assembly features like coincident, parallel
etc as shown below.

Figure 22 Assembly Features

38
 Figure 23 Exploded View

Figure 24 Final Assembly

6 3D PRINTING
Here we are getting 3d object by using (Fused Deposition Modeling Process)

Step 1- To Develop the Cad Model

39
 Designing the 3d model with the help of 3d modeling software like CATIA,
CREO, SOLIDWORKS, UNI GRAPHICS, by using modeling tools.

Step 2- Converting the Cad Model into .STL File Format

In this step we will save the cad model in .STL format. Go to the file--save as-
-give the name and choose the file format as .STL.

Figure 25

Step4- Generating the G-Codes to the Cad Model by Using Kisslicer Software

Open the .STL in Kisslicer and import the model. Choose the required
machine settings

40
 Figure 26

Select open and browser to .STL file then click ok.

Figure 27

Specify height for scale or limit of the printer

Figure 28

Then click on slice then save the file in format of g code.

41
 Figure 29

Step 5- we will give coding to machine throw pen drive or memory card. Then
machine will print the object.

42
 References
Jump up^ "Ask Oxford". Retrieved 2010-04-20.

Jump up^ Henry C. Mercer, Ancient Carpenters' Tools:

Illustrated and Explained, Together with the Implements of the
Lumberman, Joiner and Cabinet-Maker, 1928, reprint Courier
Corporation - 2013, pages 271-272

Jump up "Undoing stripped nuts with 6 point

wrenches". Rtstools.com. Retrieved 2017-09-30.

Jump up http://www.bahco.com/en/about/

Jump up^ "McMaster-Carr Catalog". Www.mcmaster.com. McMaster-

Carr. Retrieved October 10, 2016.

Jump up^ "Drill Chuck Keys & Keyleashes". Retrieved 13 April 2016.

Jump up^ "World Wide Words: Church key". World Wide

Words. Retrieved 13 April 201

43