KONDA REDDY_R101276_IMPLEMENTATION DESIGN FOR INSPECTION OF O-RINGS

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IMPLEMENTATION DESIGN FOR INSPECTION OF
O-RINGS
A SUMMER INTERN REPORT
Under the esteemed guidance of
Mr. SUFIAN JALILI
MANAGER (QA)
TML DRIVELINES LIMITED
Submitted by
S.KESAVULU
Roll No: R101276
In partial fulfillment of Summer Internship for the award of the degree
Of
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
RAJIV GANDHI UNIVERSITY OF KNOWLEDGE TECHNOLOGIES
(RUGKT)
RUGKT R.K VALLEY CAMPUS
R.K Valley, YSR District,
Andhra Pradesh.516330
July 2015

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ACKNOWLEDGEMENT
I owe many thanks to all people who helped and supported me for the completion of project
effectively in TML Drivelines Ltd, and it was wonderful opportunity for me to enhance my
practical knowledge, industrial skills and professional development.
First of all ,I express my deepest thanks to Mr.Sufian Jalili, Manger(Quality Assurance), TML
Drivelines Limited(UNIT-B)for giving me an opportunity to carry out this project under
his supervision. He has been very enthusiastic and patient while suggesting me the
outlines of this project. I thank him for his overall support and encouragement and guidance.
I sincerely express our humble thanks to Ms. Deepti Maheswari Senior HR, TML drivelines
Limited for her blessings and encouragement throughout my course of study.
First I would like to express my sincere gratitude to our beloved director Mr. Venugopal Reddy,
for giving his moral support for the completion of my project.
I express my sincere gratitude and thanks to Mr. Imran Shareef, Head of the Department
Mechanical Engineering for his valuable words, support.
I am heartily thankful to Dr. B. Konda Reddy, Mechanical department for encouragement,
guidance throughout out my course of project.
I sincerely thanks to entire team of TML Drivelines Ltd for their kind cooperation and support.
Finally I wish to express thanks to my family, friends and seniors who were involved in this
project work directly and indirectly.

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INDEX
S No CONTENTS PAGE No
1 Title 1
2 Certificate 2
3 Acknowledgements 3
4 Abstract 6
5 TML Drivelines
Company Profile 7
6 Machining
Metal Cutting and Finishing, Gear Profile Grinding, Hard
Turning of Gears, Shifter stop milling, V- Chamfering,
Shaving operation, Shaping operation, Hobbing operation.
8
7 Heat Treatment
Continuous Carburizing and Hardening furnaces, Sealed
quench operations
9
8 Assembly
Gear assembly line 9
9 Transmission
Features of gear boxes 10
10 Gear box Assembly Testing Methods
i)Flushing Testing Machine
ii)Load Testing Machine
10
7 Quality Control tools 13
11 Technical Information
i)Problem Statement
ii)Objective
iii)Observation
13
12 Introduction
a. Gauge and Gauge Design 14
b. Limits and Tolerance
13 Procedure
i. O rings
ii. O ring Material
iii. Viton Material
iv. Shore Hardness
v. Manufactured Methods of O rings
vi. Sizes
vii. Functions of O rings
15

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14 Applications 17
a. Typical Applications 18
O rings using in Gear bob Rear hub Assembly
Quality Standards 18
Problems Facing during assembly and testing due to O rings
Inspection methods of O rings 19
i. Inspection Steps
ii. Visual Examination
15 Design
Drawings 20
i. Design of Taper mandrel 1
ii. Design of Taper mandrel 2
iii. Design of Taper mandrel 3
iv. Design of Taper mandrel 4
v. Design of Taper mandrel 5
vi. Design of Taper mandrel 6
21
Laser Marking 22
16 Conclusion 23
Reference 23

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ABSTRACT
Inspections are of two types Direct and Indirect inspection. There are variety of measuring
devices available in the market today to measure O-rings including digital calipers,
micrometers, and a variety of measuring gauges, tape and cones. These methods, being very
manual, are all relatively low cost items but require both a certain skill level and time. In turn,
they are very limited when it comes to testing multiple parts quickly and accurately.
Measuring the O-rings with above mentioned devices leads to an elongation of O-ring. This is
the main problem with direct measuring devices. Because of this problem we preferred to
indirect measuring.
O-rings are not manufactured in their exact dimensions; their manufacturing size should be in
the specified tolerance range. For the determining of O-ring Sizes we need to consider the limits
and tolerances. This leads to design of Taper Mandrel with specified marking of an upper and
lower limit which is based on the given ‘Tolerance Zone’.
The mandrel is tapered at one end, hollow shaped, and laser marked device which is used to
measure the actual size of an O-ring. While measuring an O-ring, we simply drop the O-ring
onto the mandrel, if the inner diameter of the ring is in the specified range, then it goes to the
assembly for fitting. Otherwise, the ID of an O-ring below the lower limit, it is consider as
compressed one and ID of an O-ring is above the upper limit, it is consider as expanded one
these both cases O-rings are rejected.

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COMPANY PROFILE
TML Drivelines Limited is predominantly in the business of manufacturing Axles &
Transmissions for Commercial Vehicles. In the year 2000, the erstwhile Axle & Transmissions
manufacturing divisions of Tata Motors, were spun off as 100% subsidiaries HVAL & HVTL
respectively. The key intent of incorporation was to give specialist focus on development and
supplies of Axles and Transmissions for Tata Motors, while Tata Motors concentrated on
Vehicle Design, Integration & Marketing. HVTL was accordingly amalgamated with HVAL
and HVAL was then renamed as TML Drivelines Limited in FY2011-12. It continues to cater
to more than 90% of the Axle & Gear-box requirements in the M&HCV Range to TML by
supplying to all three locations of TML - Jamshedpur, Lucknow & Pune.
Axles & Transmissions as aggregates are very critical for Tata Motors, and TML Drivelines
provides these aggregates to Tata Motors with a distinct advantage in terms of quality, cost
and new products which dovetails with their core competence. TML Drivelines is organized
into three verticals viz. Axles, Transmissions and Forge. Transmission vertical has Gear Soft,
Heat Treatment, Gear-Hard and Assembly. TML Drivelines possesses all the modern
technologies and facilities required for axles and gearbox manufacturing.
Tata Motors - M&HCV OEM manufacturing is the primary market for TML Drivelines.
Vehicles manufactured by Tata Motors with TML Drivelines' Axles and Transmissions, are
sold both in domestic & international markets. Apart from that, Axle & Transmission related
Spare Parts and Trailer Axles are sold through LOB4 (Spare Parts Business - Non Vehicular
Business) of Tata Motors. Axles & Transmissions and their parts for Army requirements are
also routed through Tata Motors.
For Financial year 2012-13, TML drivelines reported revenues (net of excise) of Rs. 435.77
crores. The total sales volume in 2012-13 is 284,556 units of axles and 125,451 units of
gearboxes. As on 31st March 2013, the Gross Fixed assets stood at 1123.76 crores.
As an OHSAS certified company, TML Drivelines ensures and always strives to improve
health, safety, and security of its workforce. It is OHSAS 18001:2007 certified. TML
Drivelines proactively conducts health check-ups to senior employees and administers required
medical support.

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Mission statement of Tata Motors
Infrastructure and facilities
TML Drivelines is equipped with all the modern technologies and facilities required for the
manufacturing of axles & transmissions. At present, it occupies 201993 sq. m. of space inside
Tata Motors premises in Jamshedpur. Tata Motors is the primary customer for axles &
transmissions.
In line with the philosophy of "Growth with Quality", new facilities are strategically acquired
to enhance the core competency. To this end, investments have been made in a broad spectrum
of state-of-the-art facilities, technologies & equipment for machine shop, heat treatment,
assembly, forge, laboratories and ERC Proto shop.
MACHINING
METAL CUTTING & FINISHING
Machine shop at TML Drivelines has a variety of high productive CNC/ SPM Machines which
are capable of undertaking processes like power skiving, shaping, hobbing, shaving,
chamfering, drilling, milling, broaching, rounding, threading & swaging for gear generation &
processes like auto straightening & crack detection, gear grinding, shaft grinding & lapping,
hard turning, honing, Profile grinding to achieve high surface finish within close tolerance
after heat treatment for consistently generating quality axles and transmission components.

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These machines are supported with automation for consistent component quality and enhanced
productivity.
HEAT TREATMENT
TML Drivelines has a range of heat treatment furnaces with automatic controls for operation
and product quality.
Sealed Quench Furnaces, Continuous Carburizing & Hardening Furnaces, Rotary Hearth
Furnaces, Induction hardening & Quenching Presses with robotic handling systems
supplemented by shot blasting & shot peening machines ensure consistent product quality.
These furnaces also provide the company with the additional benefit of flexibility in
manufacturing.
ASSEMBLY
The installation of highly flexible assembly lines facilitates in the assembly of multiple variants
of axles & transmissions while keeping the capital investment low. Since 2007, all assembly
facilities have been upgraded with the objective of eliminating manual assembly practices
which for enhanced operator safety, as well as for high productivity & improved quality. Super
markets are available in each line to ensure a pull system for material supply and kitting system
has been established for single piece flow assembly of sub-assemblies. There are two lines each
for front axle assembly, rear axle assembly & gearbox assembly.
Gear box assembly process block diagram
This block diagram shows us the whole process which involved in gear box assembly process.

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TRANSMISSION
TML Drivelines has various types of gear box manufacturing facility currently 3 types of gear
boxes are manufacturing, several of features are there mainly direct drive option for better
wheel traction in tough terrain, high power transmission, designed for higher reliability - Profile
Ground Gears. Twin cone synchro with carbon lining for enhanced shift performance, durable
performance with fast, easy and smooth shifting. Rod and cable selection /shift mechanism
compatibility and also Pneumatic power assistance adaptability
I. 9 Speed Synchromesh Transmission for 1150
Nm input Torque
II. 6 Speed Synchromesh Transmission for 750
Nm input Torque
III. G-600 Nm Gear box
Gear Box Testing Methods
Dip testing
Dip Testing is process in which pressurized air at about 0.5atm is filled into the gear box and
then the gear box is dipped inside liquid to check whether there is any leakage from casing or
any other parts
Flushing testing machine
The flushing testing machine is fully automated machine which flush the whole gear box
automatic in limited time period. This machine will take 3 to 4 minute to do whole flushing
process. The monopoly of this test is to minimize the friction between the gear engagements.
The flushing is done with the help of oil having grade of 80 W 90 which provide enough viscous
to the small metal particle to come out from the gear box. The oil also help in overcoming the
friction at the time of gear engagement which gives smoothness to the gear such that gear move
easily. The flushing process is done in two process means the gear engagement with oil and
after removal of oil engagement, in both way the gear is engage from neutral to six for some
second such that if there are some noise means the gear is not perfect. In testing if noise occur
means the gear is not engaged properly or there may be some waste which prevent the gear to
engage. The flushing test is best process and less manpower used.

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Process in flushing testing machine
Note: The above block diagram is step process for flushing testing machine for first to last
Time for each gear engagement by block diagram
The engagement is done for each and every gear such that it will give the proper working of
gear in gearbox. The time for each engagement is listed in block diagram. The gear is engage
after filling the oil such that help in providing smoothness to the gear. It also help in removing
the small metal particle which come in between the gear box at the time of making. The same
gear engagement is done at checking for noise, at this process same time will provided for each
gear.
Note: Block diagram of time for each gear engagement
1.fit drain plug
before re-fitment
2.oil flling check (oil
grade-80 w 90)
3.tight filler plug
and drain plug
6.checking for cable
mounting length
with lever in power
shift
5.check for smooth
gear shifting
4.wipe the drain
plug
7.checking for noise
at the time of
engagement in G.B
8.reverse gear
engagement in G.B
9.speedometer
working process
check for smooth
gear shifting
first we check for
reverse gear for
10.76 s
shifted to 1st gear
and check for 7.16
s
shifted to 2nd gear
and check for 6.42
s
shifted to 3rd gear
and check for 4.13
s
shifted to 4th gear
and check for 3.13
s
shifted to 5th gear
and check for 3.03
s
shifted to 6th gear
and chech for 2.80
s
checking for cable
mounting length
with lever in power
shift

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Load testing machine
The load testing machine is also fully automated machine which help in giving the exact value
of torque for different load condition
This machine is very helpful in predicting the nature of gear which can bear different load or
not.
We should follow Set up procedure before machine start up, like ensure that proper
flange and input adaptor is assembled, proper profile has to be loaded and also the gear box
should be located in the pallet correctly if not check once or twice. Ensure that all the drivers
should glow in only green color if it is glow in red c
Machine start up procedure
The test transmission gear box will be banded on the conveyor from the crane and the bar code
scanner will scan transmission’s label. PLC will give output based on the type of transmission
scanned. The gear box oil filling motor gets ON and starts to fill test transmission required
quality of oil flow inside transmission will be sensed through the sensor. This oil flow will be
indicated through oil fill indicating lamp throughout the flow. Flow sensor rating is 54.6 pulse
/lit (pump rating 27 LPM, so ppl will be equal to [(60/27)*(54.6)] PLC will sense this pulse
output or with time period based transmission type and stops oil filling motor. Now conveyor
motor (0.33KW & 1.5KW) will get ON simultaneously to transfer this transmission towards
testing station. In cross transfer station this transmission will be transferred to cross conveyor
station. Now transmission reaches the cross conveyor station end pallet presence proximately
will sense this.
Process in load testing machine
loading on the test
machine with outlet
flange
test test the gear box
for different gear on
the test bed and
observe the condition
checking for gear
noise and abnormal
noise
checking for oil
leakage
checking for gear
slippage by applying
load
checking for
seepage / no trace
of oil
wipe out oil from
drain / filler plug
gose for mounting
goes for other check
and dispatching area

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7 Quality Control Tools
PROBLEM STATEMENT
In the assembly line, where the gearboxes are assembled, O-rings are fitted at the rear-hub
assembly. Sometimes, improper fitment of O-rings can lead to leakage problem. To avoid this
improper fitment, we need to determine exact sizes of O-rings. Currently, there is no gauge to
calculate the actual dimensions of the O-rings.
OBJECTIVE
In order to overcome this problem, we need to design, manufacture and implement a gauge to
determine the actual dimensions of the O-rings.
OBSERVATION
During the dip testing of the Transmission system of G1150 it was noticed that there were some
leakage problem at the rear hub assembly.

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INTRODUCTION
Gauge and Gauge Design
Manufactured parts must be checked to determine whether they are according to the
specifications or not, and also to control their dimensions. There several methods are available
for the control of dimensions of the manufactured parts. The dimensions of the component can
be checked with the various precision measuring instruments, which measure the actual
dimensions of the part. The measured dimension is then compared with the standard specified
dimension to decide whether the components are acceptable or not. In mass production, where
large number of similar components is produced, to measure the dimensions of each part will
be a time consuming and costly process. Therefore, in mass production instead of measuring
actual dimension of each part the conformance of the part with tolerance specification can be
checked by Gauges.
Gauges are scale less inspection tools at rigid design, which are used to check the dimensions
of manufactured parts. They also check the form and relative positions of the surfaces of the
parts. They do not determine (measure) the actual size or dimensions of part. They are only
used to determine whether the inspected part has been made with the specified limits. These
gauges consist of two sizes corresponding to their maximum and minimum limits.
Gauges are easy to employ and can be used in many cases by unskilled operators. For checking
the component with a gauge it is not necessary to make any calculations or to determine the
actual dimension of the part, the time involved for checking /inspection is thus considerably
reduced. For these reasons they find wide application in engineering particularly for mass
production.
Gauges differ from measuring instruments in the following respects
(1) No adjustment is required in the use.
(2) They are not general purpose instruments but are specially made for some particular
component, which is to be produced in sufficiently large quantities.
(3) They give quick results about the conformance or non-conformance of the part with the
specified tolerances.
Limits:
In mass production, where large numbers of parts are to be made by different operators on
different machines, it is impossible to make all parts exactly alike and to exact dimensions. The
difference in dimensions does exist because of these variables.
It is, therefore, obvious that some permissible variation in dimension has to be allowed to
account for variability. The dimension of the manufactured part can thus only be made to lie
between two limits, maximum and minimum.
Therefore, the ranges of permissible difference in dimension have been standardized under the
name limits. The limits of size of a dimension of a part are two extreme permissible sizes,

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between which the actual size of the dimension may lie. They are fixed with reference to the
basic size of that dimension.
The high limit (upper limit) for that dimension is the largest size permitted and the low limit is
the smallest size permitted for the dimension.
Tolerance:
The permissible variation in size or dimension is called tolerance. Thus, the word tolerance
indicates that a worker is not expected to produce the part to exact size, but a definite small
size error is permitted. The difference between the upper limit and lower limit of a dimension
represents the margin for variation in workmanship, and is called a “Tolerance Zone”.
Tolerance can be also be defined as the amount by which the job is allowed to go away from
accuracy and perfectness without causing any functional trouble, when assembles with its
mating part and put into actual service.
PROCEDURE
O rings
An O-ring, also known as a packing, or a toric joint, is a mechanical gasket in the shape of a
torus; it is a loop of elastomer with a round cross-section, designed to be seated in a groove and
compressed during assembly between two or more parts, creating sealant the interface.
The O-ring may be used in static applications or in dynamic applications where there is relative
motion between the parts and the O-ring. Dynamic examples include rotating pump shafts and
hydraulic cylinder pistons.
O-rings are one of the most common seals used in machine design because they are
inexpensive, easy to make, reliable, and have simple mounting requirements. They can seal
tens of megapascals (thousands of psi) of pressure.
O-ring Material
O-ring selection is based on chemical compatibility, application temperature, sealing pressure,
lubrication requirements, durometer, size and cost.
Elastomers are commonly used for O-ring materials. Elastomer materials are used due to their
resiliency (memory to return to their original shape). Other materials may also be used to form
and O-ring seal (PTFE, Nylon etc…). A key characteristic for elastomers is material hardness.
Elastomer hardness is typically measured in Shore A points. The harder the material, the higher
the Shore A reading will be.
Common Elastomer used in O rings
TML Drivelines limited imported O-rings which is mainly manufactured by VITON material.

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VITON Material:
Viton is a brand of synthetic rubber and fluoro polymer elastomer commonly used in O-rings,
chemical resistant gloves and other molded goods. The fluorine content of the most common
Viton grades varies between 66 to 70%.
Shore Hardness
Each of these is a method of testing the hardness of a rubber sample by pressing an indenter
into a rubber sample and measuring the force or amount of penetration. Shore A is the most
common method of measuring rubber hardness. Shore D is typically used for very hard rubber
compounds and plastics (50 Shore D is approximately 90 Shore A). Shore M is specialized for
use on O-rings. We can control each batch of rubber by measuring the Shore A hardness.
Manufacturing methods of O rings
O-rings can be produced by extrusion, injection molding, pressure molding or transfer molding.
Sizes
An O-ring has two characteristics, geometry (shape) and material. These two characteristics
will dictate how an O-ring will perform in a given application.
The geometry of the O-ring is defined by two primary dimensions, the inner diameter (I.D.)
and the cross section diameter (C.S.). The outer diameter (O.D.) is defined by the I.D. and C.S.
dimensions.
O-rings come in a variety of sizes. Typical part number for a metric O-ring - ID x CS [material
& shore hardness] 2x1N70 = defines this O-ring as 2mm id with 1mm cross section made from
Nitrile rubber which is 70Sh BS O-rings are defines by a standard reference.
Different types O rings:

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TML Drivelines ltd mainly used O-ring sizes:
O RING PART NO CS ID
271526207702 5.3 66.04
271526207703 2.65 20.3
271526207704 1.8 9.3
271526207705 2.65 21.69
271526207706 3.53 66.21
271526207707 1.8 17.17
271526207708 1.8 82.27
271526207709 2.65 12.37
271526407701 3.53 72.62
271526407702 3.55 60
Note: All dimensions are in mm
Functions of O rings
An O-ring seal has two components:
• The O-ring
• The O-ring gland (mating components)
The compression of the O-ring in the O-ring gland and the retention of the O-ring in the O-ring
gland provide the sealing function.
An O-ring functions as a seal through the mechanical deformation of the elastomeric compound
by mating metal surfaces. This creates a condition of “zero” clearance which blocks the liquid
or gas being sealed. The pressure which causes the O-ring to move is supplied by mechanical
pressure generated by proper gland design, material selection, and by the system pressure
transmitted by the fluid itself.
APPLICATIONS
Typical applications of O rings
Successful O-ring joint design requires a rigid mechanical mounting that applies a predictable
deformation to the O-ring. This introduces a calculated mechanical stress at the O-ring
contacting surfaces. As long as the pressure of the fluid being contained does not exceed the
contact stress of the O-ring, leaking cannot occur. Fortunately, the pressure of the contained
fluid transfers through the essentially incompressible O-ring material, and the contact stress
rises with increasing pressure. For this reason, an O-ring can easily seal high pressure as long
as it does not fail mechanically. The most common failure is extrusion through the mating parts.
The seal is designed to have a point contact between the O-ring and sealing faces. This allows
a high local stress, able to contain high pressure, without exceeding the yield stress of the O-
ring body. The flexible nature of O-ring materials accommodates imperfections in the

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mounting parts. But it is still important to maintain good surface finish of those mating parts,
especially at low temperatures where the seal rubber reaches its glass transition temperature
and becomes increasingly crystalline. Surface finish is also especially important in dynamic
applications. A surface finish that is too rough will abrade the surface of the O-ring, and a
surface that is too smooth will not allow the seal to be adequately lubricated by a fluid film.
O-rings using in gearbox assembly
The O-rings mainly used in the 1150 gearbox, especially in the Rear Hub Assembly.
1) O-ring along with grease can be inserting into the planet carrier spacer assembly.
2) O-ring can be inserting into the Assembly of rear housing.
3) O-ring can be inserting into the Piston and Piston Cover in the assembly of piston
cover.
4) Inlet pump housing (IPH)
5) Oil pump plate
6) Oil gallery hole
7) Rexorth
8) Range element
Quality Standards
1) O-ring should be properly fit in the planet ring spacer.
2) O-ring and spray tube should be fitted properly.
3) Check the condition of an O-ring before placing it around the piston and piston cover.
Problems facing during assembly and testing:
1) Missing of O-ring while gearbox assembly
2) O-ring might be cut
3) Not proper fitment of O-ring in assembly
4) Fitting of O-ring along with Dust while assembly
5) Fitting of elongation or compressed O-ring instead of proper O-ring
Inspection Methods of O rings
Inspection steps
 Receiving a material at store
 Confirming quantity at store and checking parts as per quality plan
 Recording of Dimensions
 Rejection to be given if component dimensions not proper
 Defect Recording(Coding, Reason for rejection, Quantity and Defect
type)
An inspection is most generally, an organized examination or formal evaluation exercise. In
engineering activities inspection involves the measurements, tests, and gauges applied to
certain characteristics in regard to an object or activity. The results are usually compared to

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specified requirements and standards for determining whether the item or activity is in line with
these targets, often with a Standard inspection Procedure in place to ensure consistent checking.
Inspections are usually non-destructive.
O-rings are not manufactured in exact size; their manufacturing size should be in the specified
tolerance range. For the determining of O-ring Sizes we need to consider the limits and
tolerances. This leads to design of Taper Mandrel with Specified marking of upper and lower
limits.
Visual Examination
As it doesn't liquefy even at very high processing temperatures and cross-linking reactions
during the molding process are able to increase its viscosity significantly. An industrial
production of O-rings is always connected to a high cost pressure. A certain percentage of O-
rings don't meet the user’s requirements regarding dimensions and surface quality. Therefore,
the final inspection is an important part of O-ring production as the rejects have to be separated
from the good parts. There are different ways of doing the final inspection like sampling
inspection, band inspection, and table inspection.
Thus, an important characteristic to distinguish a good O-ring producer from a bad one is the
kind and the frequency of defects in his delivered O-rings. The illustrations manufacturing
defects with a very distinctive non-conformity. As an effective counteraction we recommend
to perform sampling inspections regularly, regarding dimensional and surface defects in the
context of incoming goods inspections.
Design
Because an O-ring is designed to seal between two or more parts it is vital to understand how
the O-ring surface interacts with these parts. For example, if the O-ring surface is too rough it
could cause abrasive wear, on the other hand if the surface is too smooth it can create problems
with the seal. Understanding surface roughness/finish is just one of many surface parameters
that are vital to quality control and the ultimate success of an O-ring. Other such parameters
include: surface shape, form and topography defect among others. To insure the quality control
of such parameters will heavily rely upon quantifiable, reproducible and reliable inspection of
the O-ring surface. Precise measurement and evaluation of an O-ring surface can lead to the
best selection surface roughness/finish and control measure. After analyzing the
problems and considering the needs, we made a design similar to a tapered shape mandrel as
per the given dimensions. Based upon different sizes of O-rings, we made a design of two taper
mandrels. Each mandrel consists of five different O-ring sizes. Then considering the weight,
size of mandrel and for purpose of easy carrying and hand usage they suggested us design of
six mandrels instead of two mandrels design, those are hollow and laser marked for measuring
accurately.

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DRAWINGS
Design of Taper mandrel 1
For sizes of ID are 9.3mm and 12.37mm. After considering the tolerance, they given
that tolerance is +-0.2 in the range of 6-30mm of ID.
a) For ID of 9.3mm: Maximum limit is – 9.3+0.2 = 9.5
Minimum limit is – 9.3-0.2 = 9.1
b) For ID of 12.37mm: Maximum limit is – 12.37+0.2 = 12.57
Minimum limit is – 12.37-0.2 = 12.17
Design of Taper Mandrel 2
For sizes of ID are 17.17mm, 20.3mm and 21.69mm. After considering the tolerance,
they given that tolerance is +-0.2 in the range of 6-30mm of ID.
Minimum limit is – 17.17-0.2 = 16.97
Minimum limit is – 20.3-0.2 = 20.1
c) For ID of 21.69mm: Maximum limit is – 21.69+0.2 = 21.89
Minimum limit is – 21.69-0.2 = 21.49

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For sizes of ID are 60mm and 66.04mm. After considering the tolerance, they given
that tolerance is +-0.3 in the range of 30-120mm of ID.
a) For ID of 60mm: Maximum limit is – 60+0.3 = 60.3
Minimum limit is – 60-0.3 = 50.7
Minimum limit is – 66.04-0.3 = 65.74
For size of ID is 66.27mm. After considering the tolerance, they given that tolerance is
+-0.3 in the range of 30-120mm of ID.
Minimum limit is – 66.27-0.3 = 65.97

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Minimum limit is – 72.62-0.3 = 72.32
Minimum limit is – 82.27-0.3 = 81.97
Note: above all dimensions are in mm
Laser Marking
Laser marking is used as a way of permanently marking a physical item for tracking, either for
security of quality control reasons. Rather than using a vibrating or rotating toll to engrave a
mark on the item, high powered laser is used.
While most forms of engraving result in a loss of some of the marked material when it is etched
away, laser marking results in essentially no loss of material. Instead, the laser is used to create
a shift in the color of the material, creating a visible, virtually indestructible mark with minimal
real impact to the item.

23 | P a g e
An added benefit of laser marking is environmental with no links or solvents used, the impact
is very minimal. As costs lower, this factor becomes a decisive one for many environmental-
conscious companies and individuals. An added benefit is that the markings can be applied in
difficult to reach areas; all that is required is a direct line-of-sight for the laser beam.
Laser technology is a reliable choice for industrial applications thanks to it’s:
 State of the art of technology
 Durability
 Maintenance-free operation
 High contrast (HD) marking
 permanent, high quality marks;
 high efficiency and low operation cost;
 good accessibility, even to irregular surface;
 non-contact marking and no special working environmental needed;
 easy to automate and integrate (direct writing of patterns can established using
computer-controlled movement of the beam or sample);
 precise beam positioning and a beam highly localized energy transfer to the work piece;
 high reproducibility and high speed ;
 Contamination - free
CONCLUSION
The present invention provides a new and improved method of inspecting O-rings. This taper
mandrel gauge is exclusive for given 10 different sizes of O rings. The method enables the
dimensions of a resiliently deflectable O-ring. O ring part numbers can be found by matching
with the different taper mandrels, smaller O rings are placed around the small size taper
mandrel and big size O rings are placed around the appropriate taper mandrel gauges. O-Ring
gauge and material tools to assist maintenance personnel with their O-Ring selection,
installation and checking requirements. This taper mandrel gauges measure actual dimension
of O ring within tolerance limits. Proper identification and markings appear on the gauge,
making the device easy to read.
The drawings were sent for manufacturing and will get manufactured by the month of August.
REFERENCE
http://www.tmldrivelines.com/
http://www.rgukt.in/
http://www.o-ring-lab.com/
Book reference: Metrology by Mahajan
Drawings design software CATIA
http://en.wikipedia.org/wiki/O-ring

KONDA REDDY_R101276_IMPLEMENTATION DESIGN FOR INSPECTION OF O-RINGS

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