Week 16: Wildcard Week

During Wildcard Week, I focused on designing and fabricating a functional and aesthetic shawarma grill using laser cutting and press brake techniques. This project allowed me to explore advanced manufacturing processes and apply them to create a practical device for food preparation.

Project Overview

The primary objective of this project was to design and fabricate a functional and aesthetically pleasing shawarma grill. The design aimed to achieve a combination of durability, heat resistance, and ease of assembly. Key features of the grill include a rotating spit for uniform cooking, a heat shield for safety and efficiency, and a sturdy base for stability during operation.

Purpose and Goals

The shawarma grill was designed to meet several essential objectives:

• Durability: Ensuring the grill can withstand high temperatures and prolonged use without compromising structural integrity.
• Efficiency: Incorporating features like a heat shield to optimize heat distribution and reduce energy consumption.
• Ease of Use: Designing components that are easy to assemble, disassemble, and maintain.
• Safety: Implementing a heat shield and stable base to prevent accidents and ensure user safety.
• Aesthetic Appeal: Creating a professional and sleek design suitable for both commercial and home use.

Design Features

The shawarma grill incorporates several innovative features:

• Rotating Spit: A motorized spit ensures even cooking of meat, enhancing flavor and texture.
• Heat Shield: Positioned to reflect heat back towards the food, improving cooking efficiency and protecting users from direct exposure to high temperatures.
• Sturdy Base: The base is designed for stability, with anti-slip pads to prevent movement during operation.
• Modular Design: Components like the spit, heat shield, and drip tray are detachable, simplifying cleaning and maintenance.
• Compact Size: The grill is designed to maximize cooking space while minimizing its footprint, making it suitable for various settings.

Material Selection

Materials were carefully chosen to meet the project’s requirements:

• Stainless Steel: Selected for its heat resistance, corrosion resistance, and aesthetic appeal.
• High-Durability Plastics: Used for non-heat-exposed components to reduce weight and cost.
• Tempered Glass: Incorporated in certain sections for visibility and added safety.

Fabrication Process

The fabrication process involved a combination of advanced manufacturing techniques:

• Laser Cutting: Used for precision shaping of stainless steel components, ensuring tight tolerances.
• Press Brake Bending: Applied to create smooth and uniform bends in metal parts, adding structural strength.
• Welding and Assembly: Components were welded and assembled to create a cohesive structure.
• Surface Finishing: Brushed finishes were applied to metal parts for a sleek, professional look.

Testing and Validation

The shawarma grill underwent rigorous testing to ensure performance and safety:

• Heat distribution tests confirmed uniform cooking across the grill surface.
• Structural integrity tests validated the durability of the base and rotating mechanism under load.
• User trials highlighted the ease of assembly and maintenance, with minor adjustments made based on feedback.

Design Workflow

The design and fabrication process followed these steps:

• Conceptualization: Brainstormed the key features of a shawarma grill, including a rotating spit mechanism, heat shield, and vent holes for heat management.
• CAD Design: Designed the grill components using Fusion 360, including:
  • The base structure to hold the grill steady.
  • The heat shield to reflect heat evenly onto the meat.
  • Precise slots and tabs for easy assembly.
• Material Selection: Used 2mm stainless steel sheets for durability, heat resistance, and corrosion protection.

Laser Cutting Process

The stainless steel components were fabricated using a laser cutter. The process included:

• File Preparation: The CAD design was exported as a DXF file and imported into the laser cutter’s software.
• Machine Setup: A fiber laser cutter was used, configured with the following settings:
  • Power: 90%
  • Speed: 10 mm/s
  • Focus: Adjusted for 2mm stainless steel
• Cutting: The laser precisely cut the base, heat shield, and spit holder, ensuring clean edges and accurate dimensions.

Press Brake Process

The press brake was used to form the heat shield and base. The steps included:

• Setup: Configured the press brake with a wide V-die for smooth bends on stainless steel.
• Bending: The heat shield was bent into a curved shape for optimal heat reflection, while the base was bent into an L-shape for stability.
• Testing: Assembled the bent parts to ensure alignment and functionality before welding.

Assembly

The components were assembled using screws and spot welding. The spit mechanism was integrated with a manual rotating handle. Vents were aligned with the heat source for efficient airflow.

Challenges and Solutions

Key challenges and solutions encountered during the project:

• Challenge: Burrs on the edges post-laser cutting.
  Solution: Edges were deburred using a handheld grinder for a smooth finish.
• Challenge: Ensuring precise alignment of bent components.
  Solution: Used alignment jigs during bending and assembly for accuracy.
• Challenge: Balancing heat distribution.
  Solution: Added adjustable vents to control airflow and optimize heat reflection.

Documentation

The following documentation is provided to replicate the project:

• Hero Shot: High-resolution images of the completed shawarma grill showcase the final product.
  
• Mismatch of the grill Design : the corners didn't match so had to make a new Design.



• Final Ouptput: This is the final outcome of this wildcard week.


• Design Files: The CAD files (SoliWorks and DXF) are included for laser cutting and bending.
• Download SolidWorks File
• Download DXF File

Learning Outcomes

This project highlighted the potential of combining laser cutting and press brake techniques for functional designs. Key takeaways include:

• Understanding the properties and behavior of stainless steel during fabrication.
• Mastering the integration of laser cutting and bending for structural integrity and aesthetics.
• Addressing and solving real-world challenges in heat management and component alignment.

The shawarma grill stands as a testament to the versatility and precision of these manufacturing methods, with practical applications in culinary and industrial settings.