CAPSTONE PROJECT

Design and Simulation of Coffee Mug

APRIL 29, 2022

KHALID ALANAZI
 Capstone Project | Khalid Alanazi

Design and Simulation of Coffee Mug

Table of Contents
Abstract ...................................................................................................................................... 3

Objective .................................................................................................................................... 3

Planning/Methodology............................................................................................................... 3

Analysis...................................................................................................................................... 4

Mathematical Equations......................................................................................................... 4

Modelling ............................................................................................................................... 5

Base .................................................................................................................................... 5

Inside Part of Mug ............................................................................................................. 6

Outside Part ........................................................................................................................ 7

Cover Mug ......................................................................................................................... 8

Handle ................................................................................................................................ 8

Assembly............................................................................................................................ 9

Simulation ............................................................................................................................ 10

First Prototype.................................................................................................................. 10

Second Prototype ............................................................................................................. 10

Third Prototype ................................................................................................................ 10

Fourth Prototype .............................................................................................................. 11

Result ....................................................................................................................................... 11

Fabrication of Prototype .......................................................................................................... 12

Conclusion ............................................................................................................................... 12

Appendix .................................................................................................................................. 13

First Prototype...................................................................................................................... 13

Second Prototype ................................................................................................................. 14

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Third Prototype .................................................................................................................... 15

Fourth Prototype .................................................................................................................. 16

Table of Figures
Figure 1: 2D dimension of the base ........................................................................................... 5
Figure 2: 3D Model of Base....................................................................................................... 5
Figure 3: 2D Dimensions of Inside Part .................................................................................... 6
Figure 4: 3D Model of Inside Part of Coffee Mug .................................................................... 6
Figure 5: 2D Dimension of Outside Part ................................................................................... 7
Figure 6: 3D Model of Outside Part of Coffee Mug .................................................................. 7
Figure 7: 3D Model of Mug Cover ............................................................................................ 8
Figure 8: 2D Dimension of Handle ............................................................................................ 8
Figure 9: 3D Model of Handle ................................................................................................... 9
Figure 10: 3D Model of the Coffee Mug ................................................................................... 9
Figure 11: Fabricated Prototype............................................................................................... 12
Figure 12: Temperature Distribution I ..................................................................................... 13
Figure 13: Heat Flux I .............................................................................................................. 13
Figure 14: Temperature Distribution II.................................................................................... 14
Figure 15: Heat Flux II ............................................................................................................ 14
Figure 16: Temperature Distribution III .................................................................................. 15
Figure 17: Heat Flux III ........................................................................................................... 15
Figure 18: Temperature Distribution IV .................................................................................. 16
Figure 19: Heat Flux IV ........................................................................................................... 16

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 Capstone Project | Khalid Alanazi

Abstract
Create a metal coffee cup design and choose an appropriate material. The design should be
economical. The design will be straightforward and adaptable. The design should be user-
friendly and practical in terms of size. First and foremost, research will be conducted to locate
previous studies on the design of a metal coffee cup. The many designs and their aspects will
be studied in order to determine which component will be the most important when designing
the metal coffee mug. In addition, research will be conducted on the coffee mug's substance.
After completing all of the following activities, the cost effectiveness will be evaluated. After
that, the project model went on to fabrication and created a real prototype.

Objective
The capstone project has the following goals:

• Create a metal coffee cup design and use a good material.

• The design should be affordable.
• The design will be straightforward and adaptable.
• The design should be user-friendly and practical in terms of size.

Planning/Methodology
The project was broken down into the following steps:

• First, research will be conducted to locate previous studies on the design of a metal
coffee cup.
• Different designs and their aspects will be analyzed to determine which factor will be
the most important in designing the metal coffee mug.
• The design will be built on SolidWorks.
• Simulation will be done to reduce the heat loss from the coffee cup.
• Simulation will be done to determine the best material as well
• After completing all of the above activities, the project will proceed to manufacturing
and kind of fabrication.

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Analysis
Mathematical Equations
A series of algorithms was created in order to estimate the heat transfer behavior. These
methods make it possible to calculate solutions numerically. For each time step, the heat
equation is connected with the moving boundary owing to a phase shift caused by melting. The
procedure entails applying an explicit scheme of the Finite Difference Method (FDM) for the
heat equation to update the temperature distribution, as follows:

𝑇𝑖𝑡+∆𝑡 − 𝑇𝑖𝑡 𝑡
𝑇𝑖−1 − 2𝑇𝑖𝑡 + 𝑇𝑖+1
𝑡
=
∆t (∆x)2

At time t, with L = nx being the biggest discretization point below S(t) and the vector T(t) =
[T1(t)Tn(t)], the space discretization is (0, x, 2x..., nx). In discretization points, T represents
the temperature vector: [T(0, t),T(nx, t)]T(t) = [T(0, t),T(nx, t)]T

The heat flux will be calculated as follows for coffee mug:

The convection and radiation will be ignored as we focused to determine the conduction of
heat through the material.

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Modelling
The modelling of the mug is done in Solidworks. The complete assembly of coffee mug is
consisted on 5 components which is illustrated one by one in the following:

Base
The below sketch is drawn to make the base of coffee mug. The radius of the base is 1.35 inches
with the height of 0.8 inches with other detailing to give the shape for base.

Figure 1: 2D dimension of the base

The revolve command is given to make the 3D base and selected material for the base is plastic
material to keep the heat inside. The hole is also drawn with 2.19 inches diameter giving the
thickness base of 0.255 inches.

Figure 2: 3D Model of Base

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Inside Part of Mug

The below diagram shows the 2D dimensions of inside part of coffee mug which has the outer
radius of 2.19 inches to fit in base and the height of the mug is 6.01inches.

Figure 3: 2D Dimensions of Inside Part

The 3D model is made by revolving command and the inside part is made up of plastic material
which is same material used in the base of mug

Figure 4: 3D Model of Inside Part of Coffee Mug

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Outside Part
The 2D dimension of sketch to make the outside part of coffee mug is shown below with the
same outside radius of base and same height given to the inside part to fit it properly.

Figure 5: 2D Dimension of Outside Part

The revolve command is given as done in inside part to make it as a 3D model and fillet is
applied to give the proper shape to the upper and below side of the mug. The material of outside
is metal material.

Figure 6: 3D Model of Outside Part of Coffee Mug

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Cover Mug
The outside radius of the cover is 2.76 inches with 0.12 inches side thickness. The thickness of
cover is 0.2 inches and hole is made for a straw of a radius of 1.18 inches as shown below. The
3D diagram is shown as a lot of sketches are drawn to make the shape of cover.

Figure 7: 3D Model of Mug Cover

Handle
The 2D dimension is complex to make handle and illustrated below in diagram:

Figure 8: 2D Dimension of Handle

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The 3D model of the handle is shown below and the material is same as for cover, base and
inside part of coffee mug:

Figure 9: 3D Model of Handle

Assembly
The assembly of these part is done by using coincident and coaxial to join all the component
to make 3D model of the Coffee Mug.

Figure 10: 3D Model of the Coffee Mug

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Simulation
First Prototype
The material used in the first prototype of coffee mug is given in the table:

Component Material
Base ABS Plastic
Inside Part ABS Plastic
Outside Part Cast Alloy Steel
Handle ABS Plastic
Cover ABS Plastic
The inside temperature is 200 Fahrenheit and outside temperature is room temperature. The
result of simulation shows the characteristics of ABS plastic which is retaining heat inside the
cup for every prototype.

Second Prototype
The material used in the second prototype of coffee mug is given in the table:

Component Material
Base ABS Plastic
Inside Part ABS Plastic
Outside Part Aluminum Alloy
Handle ABS Plastic
Cover ABS Plastic

Third Prototype
The material used in the third prototype of coffee mug is given in the table:

Component Material
Base Polyethylene
Inside Part Polyethylene
Outside Part Cast Alloy Steel
Handle Polyethylene
Cover Polyethylene

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Fourth Prototype
The material used in the third prototype of coffee mug is given in the table:

Component Material
Base Polyethylene
Inside Part Polyethylene
Outside Part Aluminum Alloy
Handle Polyethylene
Cover Polyethylene

Result
The prototype will be simulated for temperature distribution and heat flux. If the lowest
temperature of the prototype is high and maximum heat flux is low, that will be the best
prototype for coffee mug which will waste minimum heat. The following table compared the
parameter to determine the best prototype:

Parameter Maximum Heat Flux Minimum Temperature

(Btu/s.in^2) (Fahrenheit)

First Prototype 0.0795 65.705

Second 0.9881 60.466

Prototype

Third Prototype 0.07951 67.453

Fourth 0.9106 51.74

Prototype

The first prototype is best as it shows the minimum heat flux means low heat flow towards the
outside of the mug. This prototype will be manufactured and fabricated.

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Fabrication of Prototype
The first prototype is selected and went for fabrication. The following diagram shows the
fabricated prototype which is made up of ABS plastic and cast alloy steel.

Figure 11: Fabricated Prototype

Conclusion
The main aim of the project to make a metal coffee cup design and select a suitable material.
The design should be cost-effective. It will be simple and versatile in design. In terms of size,
the design should be user-friendly and functional. The first step will be to undertake research
to uncover existing studies on the design of a metal coffee cup. When developing the metal
coffee cup, the many designs and their elements will be analyzed in order to identify which
component will be the most significant. In addition, the material of the coffee cup will be
studied. The cost effectiveness will be assessed when all of the following actions have been
completed. The project model was then sent to manufacturing, where it was turned into an
actual prototype.

Temperature distribution and heat flow will be modelled for the prototype. The greatest
prototype for a coffee cup that wastes the least amount of heat is one with a high lowest
temperature and a low maximum heat flow. The first prototype is the greatest since it
demonstrates that a low heat flux indicates a low heat flow towards the mug's exterior. The first
prototype selected for fabrication (which is made up of ABS plastic and cast alloy steel) which
was shown in fabrication section.

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Appendix
First Prototype

Figure 12: Temperature Distribution I

Figure 13: Heat Flux I

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Second Prototype

Figure 14: Temperature Distribution II

Figure 15: Heat Flux II

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Third Prototype

Figure 16: Temperature Distribution III

Figure 17: Heat Flux III

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Fourth Prototype

Figure 18: Temperature Distribution IV

Figure 19: Heat Flux IV

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