Design of Mechanical Tire-Rim Separator-1.pdf

Design of Mechanical Tire-Rim Separator 2015
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ABSTRACT
Tire servicing – separating tire and the rim in the locality is perform by the use hammer and
chisel or pry bar. With this process rubber tire as well as the wheel rim could get damage. The
tire technicians apply manual hammering to separate the parts consuming more time and efforts.
The better way to improve the process is the design of mechanical tire-rim separator.
The purpose of the mechanical car tire-rim separator provides a firm base on which to be
removing and fit the tire. It is dimension; shape should be suitable to adequately accommodate
the particular tire-rim required for the vehicle.
This project reports the presence of detailed design analysis of every part of mechanical tire rim
separator. Each part includes formulas, pictures, and part drawing for its best clarification for
better understanding and manufacturing purposes. Understanding the basic concepts on
designing of mechanical tire –rim separator machine allows to manufacture the machine locally
and to extend development of new systems. Therefore mechanical tire –rim separator is one of
the techniques used to remove the tire and fit easily ,low cost with in short time satisfy the
costumer, easy to handle able to remove correctly without affect the tire and rim.
Key word Handle ,Bead breaker ,Turntable.

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ACKNOWLEDGEMENT
We are grateful and would like to express our sincere gratitude to our advisor Mr. engineer
Carlos for providing this interesting and exciting topic and then providing his guidance,
assistance and encouragement throughout the duration of the project. We appreciate his
consistent support from the first day of the project to these concluding moments.
Sincere thanks to staff of the Mechanical Engineering Department, who helped us in many ways
and providing equipment and information sources that assisted our studies and projects.
To all our friends and classmates, thanks for the comments and suggestions given which is
crucial for the successful completion of this project.
Dawud Yimer ,Tesfaye Shiferaw, Assefa Bahiru and Siseyi Tesfaye
ITR/287/03,ITR/909/03,ITR/153 /03,ITR/ 828/03
BSC, Mechanical Engineering
Kombolcha Institute of Technology, 2015

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Contents
ABSTRACT...................................................................................................................................................i
ACKNOWLEDGEMENT ............................................................................................................................ ii
List of Figure................................................................................................................................................. vi
List of Table................................................................................................................................................. vii
CHAPTER ONE...........................................................................................................................................1
INTRODUCTION ........................................................................................................................................1
1.1 STATEMENT OF PROBLEM...........................................................................................................2
1.2 OBJECTIVE OF THE PROJECT.......................................................................................................3
1.2.1 General Objective ........................................................................................................................3
1.2.2 Specific Objective.........................................................................................................................3
1.3 SIGNIFICANCE OF THE PROJECT ................................................................................................4
1.4 SCOPE OF THE PROJECT ......................................................................................................................4
1.5 METHODOLOGY .............................................................................................................................5
1.6 ORGANIZATION OF THE PAPER..................................................................................................6
CHAPTER TWO ..........................................................................................................................................7
LITERATURE REVIEW .............................................................................................................................7
2.1GENERAL INTRODUCTION TO TIRE............................................................................................7
2.1.1 Components of tire......................................................................................................................8
2.1.2Tire Sidewall information............................................................................................................10
2.2 TIRE- RIM SEPARATOR MACHINES OR TIRE CHANGER .....................................................................11
2.2.1ELECTRIC –HYDRAULIC TIRE CHANGER.......................................................................................12
2.2.2 Hydrualic tire changer...............................................................................................................13
2.2.3 PNEUMATIC TIRE CHANGER ..............................................................................................13

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2.2.4 Hammering by man power ........................................................................................................14
CHAPTER THREE..........................................................................................................................................16
3. DESIGN OF MECHANICAL TIRE- RIM SEPARATOR...................................................................................16
3.1 Introduction ......................................................................................................................................16
3.2 GEOMETRICAL ANALYSIS ..................................................................................................................16
3.3 SELECTION OF HANDLE MECHANISM...............................................................................................17
3.4 FORCE ANALYSIS ON THE HANDLE....................................................................................................19
3.5 DESIGN OF EACH COMPONENT ........................................................................................................21
3.5.1 DESIGN OF HANDLE ...................................................................................................................21
3.5.2 DESIGN OF CONNECTING BAR ...................................................................................................26
3.5.3 DESIGN OF BEAD BERAKER ........................................................................................................26
3.5.4 DESIGN OF TURN TABLE.............................................................................................................27
3.5.5 Design of Rotating Shaft ............................................................................................................32
3.5.6 Selection of Bearing...................................................................................................................34
3.5.7 Design of Mounting Head ..........................................................................................................35
3.5.8 Design of Mounting Bar .............................................................................................................36
3.5.9 Design of Swing Arm ..................................................................................................................39
3.5.10 Design of Vertical Column............................................................................................................42
3.5.11 Design of Base..........................................................................................................................43
3.5.12 Design of bolts .........................................................................................................................44
3.5.12 Design of Welding....................................................................................................................45
3.6 MANUFACTURING PROCESS .............................................................................................................46
3.6.1 Manufacturing Process of Handle..............................................................................................46
3.6.2 Manufacturing Process of Base:- ...............................................................................................47
3.6.3Manufacturing Process of Shaft..................................................................................................47
3.6.4 Manufacturing Process for Turn table.......................................................................................47

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3.6.5 Manufacturing Process of Bolt and Nut:- ..................................................................................47
3.7 COST ESTIMATION ............................................................................................................................47
Table 5 cost estimation .......................................................................................................................48
3.8 Method of assembly .........................................................................................................................48
3.9 Lubrication system............................................................................................................................48
3.10WORKING PRINCIPLE OF MECHANICAL TIRE-RIM SEPARATOR.......................................................49
3.10.1 STEEP OF MECHANICAL TIRE –RIM SEPARATOR......................................................................49
3.11 DETAIL DRAWING............................................................................................................................50
3.12 ASSEMBLE DRAWING......................................................................................................................54
CHAPTER FOUR.......................................................................................................................................55
CONCLUSION AND RECOMMENDATION ....................................................................................................55
4.2 RECOMMENDATION .........................................................................................................................56
REFERENCE..................................................................................................................................................57

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List of Figure
Figure -2.1Tubeless tire………………………………………………………………………7
Figure -2.2 components of tire……………………………………………………………….8
Figure -2.3 wheel and rim…………………………………………………………………….8
Figure-2.4 wheel ……………………………………………………………………………..9
Figure-2.5 tire bead…………………………………………………………………………..10
Figure -2.6 side wall tire information………………………………………………………..10
Fig 2.7 electro –hydraulic tire changer…………………………………………………….....12
Figure -2.8 hydraulic tire changer…………………………………………………………….13
Figure-2.9 Pneumatic Tire Changer…………………………………………………………..14
Figure -2.10 hammering by man power………………………………………………………15
Figure3.1. Geometrical analysis………………………………………………………………17.
Figs 3.2 handle force analysis………………………………………………………………...19
Fig 3.3 handle ……………………………………………………………………………..…22
Fig3.4 bending diagram of the handle…………………………………………………..……34
Figure 3.5 bolt position………………………………………………………………………..31
Figure 3.6 patterns of the bolt on the rim……………………………………………...………32
Figure 3.7 rotating shaft……………………………………………………………..………...33
Fig 3.8- Thrust roller bearing………………………………………………………..…………35
Figure 3.9 mounting bar…………………………………………………………..……………37
Fig-3.10 vertical column………………………………………………………………………42
Figure 3.11 swing arm…………………………………………………………………………45
Figure 3.12-Swing arm…………………………………………………………………………50.
Fig 3.13 Bead breaker……………………………………………………………..……………50

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Figure -3.14 Pin coneector with bar………………………………………………..…………50
Figure-3.15 handle holder ……………………………………………………………..………51.
Figure-3.16 Handle with bead breaker…………………………………………………………51
Figure-3.17 handle……………………………………………………………………………...52
Figure-3.18 Column with swing arm…………………………………………………………..52
Figure -3.19 shaft………………………………………………………………………….........53
Figure-3.20 Turn table…………………………………………………………………………..53
Figure -3.21 pin connected……………………………………………………………………...53
Fig 3.22 assembly drawing………………………………………………………………….......54
List of Table
Table 1 tire dimension………………..…………………………………………………………11
Table 2 material selection for shaft……………………………………………………………..33
Table 3 standard trust bearing …………………………………………………………………..35
Table 4 bolt selection ……….…………………………………………………………………..44
Table 5cost estimation…………………………………………………………………………..48
Table 6 part list………………………………………………………………………………….54

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CHAPTER ONE
INTRODUCTION
Vehicle is an important machine in human daily life. Since vehicle is use to transport goods and
commodities from place to place as well as a mode of transportation of people .Nowadays, in our
country vehicle distribution is very large to make the transportation easy and faster. Tires for
most vehicles are pneumatic; air is held under pressure inside the tire. Until recently, pneumatic
tires had an inner tube to hold the air pressure, but now pneumatic tires are designed to form a
pressure seal with the rim of the wheel.
One of the problems of a vehicle is tire maintenance as it is related to safety of the vehicle and
the one who uses it. Tire maintenance is done by different tire maintenance shops that exist
locally.
Tire maintenance for motor vehicles is depended on by several factors. The main cause of tire
failure is friction from moving contact with road surfaces, causing the tread on the outer
perimeter of tires to eventually wear away. When the tire tread becomes too shallow, the tire is
worn out and should be replaced.
This project is used to make easy in changing of the tire form the rim. it works by mechanical
system by using man power without affecting the tire and the wheel during dismounting/removal
process.

1.1 STATEMENT OF PROBLEM
Today in our country in some automotive tire maintenance work shop when the tire maintenance
process required separating the tire from the rim for single rim type of the tire, mechanic separate
by using the help of hammer and chisel to loosen the tire bead from the rim. This separating
technique is harm full for the tire side wall as well as for the rim, and it takes high force and
more time.

1.2 OBJECTIVE OF THE PROJECT
1.2.1 General Objective
The major objective of this project is to design mechanical tire- rim separator for passenger car
tire that can be used in automotive tire maintenance work shop.
1.2.2 Specific Objective
 To design mechanical tire - rim separator which is used to separate the tire from the rim,
the rim diameter of the tire up to 20 inch.
 To design each component of the machine.
 To design the mechanical tire-rim separator that can work by the help of handle
mechanism.
 To design the machine by using locally available and low-cost materials.

1.3 SIGNIFICANCE OF THE PROJECT
After the designs of this project it uses for all automotive tire maintenance shop service to
separate tire from the rim. The tire changing process will become simple and fast thus
improvement in the workshop performance can be available through less time and effort and
more productive work can be undertaken
In addition, the design will have much importance to the workers by making the working area
simple, uncomplicated, safe and environmentally friendly as the machine creates less noise.
1.4 SCOPE OF THE PROJECT
The scope of this project is includes literature review and design every component of a machine
such as handle ,bead breaker, turn table and detail drawing for each part. It also needs some
knowledge and skill to finish the project.

1.5 METHODOLOGY
Methodology is one of the most important things to be considered to ensure that the project will
run smoothly and achieve the objective. Project methodology will describe the flow of the
project progress. The project methodology shows us how the project started, how data was
collected, and how the next steps done.
Data collection
In this project we collect data with two perspectives of data collection method, primary data
collections and secondary data collection.
Primary data
 Interview with concerned body
 Observation
Secondary data
 Different exercise book
 Internet

1.6 ORGANIZATION OF THE PAPER
The paper is organized from five chapters. Each chapter classified according to the approach
used to solve the problem raised.
THE FIRST CHAPTER- Deals with the introductory parts of the paper.
THE SECOND CHAPTER- Consists of the literature review that is used as a resource for
accomplishment of the project, the explain methodologies how to approach the problem and
solve it progressively and Geometric analysis of mechanical tire –rim separator
THE CHAPTER THREE- Deals with the detail design of mechanical tire –rim separator
components. This part of the paper is the solution for the problems that we have mentioned in the
statement of the problem.
THE LAST CHAPTER- puts the conclusion, recommendation, and reference

CHAPTER TWO
LITERATURE REVIEW
2.1GENERAL INTRODUCTION TO TIRE
A tire is a strong, flexible rubber casing attached to the rim of a wheel. Tires provide a gripping
surface for traction and serve as a cushion for the wheels of a moving vehicle. Tires are found
on automobile s, trucks, buses, aircraft landing gear, tractors and other farm equipment,
industrial vehicles such as forklifts, and common conveyances such as baby carriages, shopping
carts, wheel chairs, bicycles, and motorcycles.
The primary purpose of tires is to provide traction. Tires also help the suspension absorb road
shocks, but this is a side benefit. They must perform under a variety of conditions. The road
might be wet or dry or paved with asphalt, concrete, or gravel, or there might be no road at all.
The car might be traveling slowly on a straight road, or moving quickly through curves or over
hills. All of these conditions call for special requirements that must be present, at least to some
degree, in all tires. In addition to providing good traction, tires are also designed to carry the
weight of the vehicle, to withstand side thrust over varying speeds and conditions, and to transfer
braking and driving torque to the road.
According to the tire internal structure it can be classified as
 Tubeless tire: - does not use an inner tube tire and wheel from an airtight unit
 Tube-type tire:-use an inner tube to hold air pressure.
Tube less tire:-Tires for most vehicles are pneumatic; air is held under pressure inside the tire.
Until recently, pneumatic tires had an inner tube to hold the air pressure, but now pneumatic tires
are designed to form a pressure seal with the rim of the wheel.
Figure -2.1Tubeless tire

2.1.1 Components of tire
The main features of a passenger car tire are the tread, the body with sidewalls, and the beads.
The tread is the raised pattern in contact with the road. The body supports the tread and gives the
tire its specific shape. The beads are rubber-covered, metal-wire bundles that hold the tire on the
wheel.
A tire carcass is composed of several parts: the tread, bead, sidewall, shoulder, and ply.
Figure -2.2 components of tire
Wheel and Rim
A wheel is a combination of tire and rim. The rim is the metallic cylindrical part where the tire is
installed. It can be made from Steel, Aluminum and Magnesium
Figure -2.3 wheel and rim

The rim is the "outer edge of a wheel, holding the tire". It makes up the outer circular design of
the wheel on which the inside edge of the tire is mounted on vehicles such as automobiles.
Diameter (effective): distance between the bead seats (for the tire), as measured in the plane of
the rim and through the axis of the hub which is or will be attached, or which is integral with the
rim.
Width (effective): separation distance between opposed rim flanges. The flange-to-flange width
of a rim should be a minimum of three-quarters of the tire section width. And the maximum rim
width should be equal to the width of the tire tread.
Type: Depends on the type of vehicle and tire. There are various rim profiles, as well as the
number of rim components.
Modern passenger vehicles and tubeless tires typically use one-piece rims with a "safety" rim
profile. The safety feature helps keep the tire bead held to the rim under adverse conditions by
having a pair of safety humps extending inwardly of the rim toward the other tire bead seat from
an outer contoured surface of the rim.
Heavy vehicles and some trucks may have a removable multi-piece rim assembly consisting of a
base that mounts to the wheel and axle. They then have either a side ring or a side and lock ring
combination. These parts are removable from one side for tire mounting, while the opposite side
attached to the base has a fixed flange.
Vehicle performance: Because the rim is where the tire resides on the wheel and the rim supports
the tire shape, the dimensions of the rims are a factor in the handling characteristics of an
automobile.
To support the cylindrical rim structure, a disc is made by stamping a metal plate. It has to have
appropriate holes for the center hub and lug nuts. The radial outer surface of the wheel disk has a
cylindrical geometry to fit inside the rim. The rim and wheel disk are assembled by fitting
together under the outer seat of the rim and the assembly welded together. The disk is welded in
place such that the center of the wheel is equal to the center of the hub.
Figure-2.4 wheel

Tire bead is the term for the edge of a tire that sits on the wheel. Wheels
for automobiles, bicycles, etc. are made with a small slot or groove into which the tire bead sits.
When the tire is properly inflated the air pressure within the tire keeps the bead in this groove.
Figure-2.5 tire bead
2.1.2Tire Sidewall information
Figure -2.6 side wall tire information
The most important information on the sidewall of a tire is, the size number

The best way to describe and explain the information given on the sidewall of a tire is to look at
an example.
Table size description
2.2 TIRE- RIM SEPARATOR MACHINES OR TIRE CHANGER
A tire changer is a machine used to remove tires and mount tires onto wheels. Hydraulically-
operated, a tire changer uses compressed air and hydraulic fluid to compress a tire, breaking it
free of its seal to the wheel. Once the tire's bead has been broken, a tire tool is used to spin
between the tire and the wheel, literally peeling the tire off of the wheel. With the old tire
removed, it is time to place a new tire on the wheel and use the tire tool to squeeze the tire over
the wheel's outer lip and into position on the wheel. The tire is then inflated, sealing it to the
wheel's bead, and the air pressure is monitored by watching an air pressure gauge affixed to the
tire changer.
Prior to the invention of the tire changer, tires were changed by hand. This was accomplished by
breaking the tire's bead loose through the process of pounding it with a hammer, eventually
driving the bead down and out of place on the wheel. With the bead broken, two flat iron bars
were inserted between the tire and the wheel and the tire was then slowly worked up and over the
wheel's lip. This was a very labor-intensive job and could take hours to change a single tire.
The earliest version of the tire changer was a model that was completely powered by hand. The
basic design was very similar to the tire changer that came after; however, all of the machine's
actions were accomplished by a person pulling and pushing the attachments by hand. Instead of
having electric motors and compressed air to operate the machine, a mechanic simply slid the
attachment into position and then used his strength and determination to operate the tire changer.

Many times, the mechanic using the earlier machines would resort back to using a hammer out of
frustration over not being strong enough to push the tire changer attachment by hand. This
technique led to the nickname for a tire-changing worker to be called a tire buster and the act of
changing a tire to be known as busting a tire. The inclusion of the electric hydraulic system
accompanied by the use of compressed air to operate a tire changer made the job much less
physical.
The modern tire shop has several tire-changing machines tailored for special duties. Machines
for steel and aluminum wheels, motorcycle tires and even huge semi-tire changing machines are
common. The effectiveness of the modern machines makes changing tires a minimal-effort job.
2.2.1 Electric –Hydraulic Tire Changer
This type tire changer features simple mechanical operation and an auxiliary bead press arm to
aid in clamping, lubricating, demounting and mounting difficult wheel and tire combinations.
The bead press arm can be used to push a stiff sidewall tire into the drop-center of a rim and keep
it in position as the wheel rotates when demounting or mounting, greatly reducing lever effort
and risk of bead damage. The tire changer column height and distance from the table are
optimized to handle anything from ordinary steel wheels to large and light-truck off-road tires.
The tabletop clamping system safely and securely clamps 11- to 22-in. wheels and up to 26-in.
wheels with optional jaw extensions.
Fig 2.7 electro –hydraulic tire changer
Limitation of electro-hydraulic tire changer
It is needs the qualified person
It consists of a lot of parts
It is very expensive
It is heavy machine
It is used only in the presence of electric place there etc

2.2.2 Hydrualic Tire Changer
This tire changing machine is very important for remove the tire and rim each for he following
reason It is fast to separetor, Safe for handling machine andReliabiliy of the machine
Three important considerations:
Performance of desired function
Efficiency of operation
Safety of operation
Figure -2.8 hydraulic tire changer
Limitation of hydreulic machine
Not aviliable more
It is corroded due to its fluid
It consists of a lot parts to design
High cost
It needs qualified person etc.
2.2.3 Pneumatic Tire Changer
This type of tire changer is the same with hydraulic tire changer but it is different due to its
function

Figure -2.9 Pneumatic Tire Changer
Limitation of pneumatic tire changer
 Wear and tear of the tire
 More energy required
 High cost
 Needs qualified person
 It is problem of removal dust particle
 Consists of many parts to design
 It is heavy machine
2.2.4 Hammering by Man Power
Hammering is a local operation to separate tire from the rim. When this operation is happening
they may occur they damage the rim and wear of tires in contrary hammering defined as cheap
in cost and boring work. This type of tire-rim separator method is practiced in our country in
most automotive tire workshop power full and consuming time to change the tire
Limitation of hammering by man power
It is difficult to remove tire –rim each other
Wearing/damage of the tire and rim
Consuming more time
Needs high man power

Figure -2.10 hammering by man power

CHAPTER THREE
3. DESIGN OF MECHANICAL TIRE- RIM SEPARATOR
3.1 Introduction
During the dismounting process of tire from rim there are two types of process
Loosening the tire bead from the rim
Remove the tire totally from the rim
A mechanical tire rim separator separate the tire bead from the rim and demount totally out of
the wheel. It has two working mechanism one detaching mechanism the other is demounting the
tire from the rim, in the detaching mechanism it work by help of lever or handle to push the tire
surface to make down by using human force. This project is used to demount the passenger car
tire from the rim.
Specification of passenger car tire that used to this project is as follows
Maximum tire width 315mm
Maximum tire rim diameter 20 inch = 508mm.
By considering this specification the geometrical analysis is taken as follows
3.2 GEOMETRICAL ANALYSIS

Figure 3.1. geometrical analisis
3.3 SELECTION OF HANDLE MECHANISM
A handle or lever is a rigid rod or bar capable of turning about a fixed point called fulcrum. It is
used as a machine to lift a load by the application of a small effort. The ratio of load lifted to the
effort applied is called mechanical advantage.
Sometimes, a handle is merely used to facilitate the application of force in a desired direction.
The principle on which the handle works is same as that of moments. In engineering practice
according to the load and the effort three types mechanism exist. These are First type, Second
type and Third type.
In the first type of levers, the fulcrum is in between the load and effort. In this case, the effort
arm is greater than load arm, therefore mechanical advantage obtained is more than one. Such
type of handle are commonly found in bell cranked levers used in railway signaling arrangement,
rocker arm in internal combustion engines, handle of a hand pump, hand wheel of a punching
press, beam of a balance, foot lever etc.

.First type lever
In the second type of levers, the load is in between the fulcrum and effort. In this case, the effort
arm is more than load arm, therefore the mechanical advantage is more than one. The application
of such type of levers is found in levers of loaded safety valves.
Second type of hand lever
In the third type of levers, the effort is in between the fulcrum and load. Since the effort arm, in
this case, is less than the load arm, therefore the mechanical advantage is less that one. The use
of such type of levers is not recommended in engineering practice. However a pair of tongs, the
treadle of a sewing machine etc. are examples of this type of lever.
Third type of lever
From the above lever type a mechanical tire rim separator use the third type of lever mechanism
to detach or to loosen the tire bead from the rim.

3.4 FORCE ANALYSIS ON THE HANDLE
The handle is used to loosen the tire bead from the rim. From the data that is used to separate on
real world from garage worker
Length of the handle 1500mm,
The length from the fixed pin to the load 300mm,
To make different force required the handle the load position is three.
Fig 3.2 handle force analysis
Where Fc = man power on the handle
FB= force exert on tire bead
FA = force on the pin connection
The maximum man applied on the handle is four hundred (400N) for the operation
Reference from text book of machine design page 568
𝐹𝑦 =FA –FB - Fc =0 --------------eq (1)
∑MA = 0--------------------------------eq (2)
𝐹𝑌 =FA –FB - =0
To get the moment first find the perpendicular distance to the vertical axis

When the length of the bar from the point A up to B 300mm
X1=300×cos𝛼
X2=1500×cosα
Now the moment
At point B1
MA= 𝐹𝑐 × 1500𝑐𝑜𝑠𝛼 + Fb×300cos𝛼 --------------eq (2) the maximum moment will be at angle
0o
then
By considering the human force on the handle
𝑀𝑐 = 400 ∗ 1500𝑐𝑜𝑠𝜃 + 𝐹b*300cos𝜃
Fb=−
400∗1500𝑐𝑜𝑠𝜃
300𝑐𝑜𝑠𝜃
Fb=-2000N=2KN
The negative sign indicates the assume direction is not correct so the reaction force on Fb is
vertical it means the tire cannot resist this force it must go down ward.
Now by substituting in to equation 1
FA=Fb-p
FA=2000-400 =1600N
The force on Fc is upward this force lays on the pin

At point B2
When the length at 250mm
𝑀𝑐 = 0 = 400 ∗ 1500𝑐𝑜𝑠𝛼 + 𝐹b*250cos𝛼
Fb=−
400∗1500𝑐𝑜𝑠𝛼
250𝑐𝑜𝑠𝛼
FB= 2.4KN
FA=2000N
At point B3
When the length at 200mm
𝑀𝑐 = 0 = 400 ∗ 1500𝑐𝑜𝑠𝛼 + 𝐹b*200cos𝛼
FB=−
400∗1500𝑐𝑜𝑠𝛼
200𝑐𝑜𝑠𝛼
FB=3KN
FA=2600N
From the above force the human power can push the tire bead by using this handle
3.5 DESIGN OF EACH COMPONENT
3.5.1 DESIGN OF HANDLE
Material selection for handle:-
The handle is subjected to bending moment by considering Plain carbon steel 30c8
(sty=400N/𝑚𝑚2
).
Properties of plain carbon steel
 Good rigidity
 Best corrosion resistance
 High tensile strength
 Good stiffness

Fig 3.3 handle
The maximum bending is at the hole so to determine the diameter of the handle first we must
design the pin diameter
Design of pin on the handle
Material selection for the pin:
Forged steel with a property of
Shear stress = 60MPa.
Tensile stress= 75MPa
The pin is subjected to the reaction FB from the above force analysis. The force acting on the
boss of the lever and pin are equal and opposite. The dimension of pin diameter 𝑑 and length 𝑙
in the lever are determined by bearing consideration. There is a relative motion between the pin
and the boss of the lever and bearing pressure become the design criteria. The projected area of
the pin is 𝑑 × 𝑙 .
Therefore 𝐹𝐵 = 𝑝(𝑑 × 𝑙)
Where p is the permissible bearing pressure
Ratio of 𝑙 = 2𝑑
Since the pin is passed the handle diameter
Assumption

Length of the pin = 50mm
d=18mm
Bering stress of the lever at pin point B A.
Ab=thickness of the lever*diameter of the pin
=50*18=900mm2
Bering stress of the lever at pin point B
𝑝 =
𝐹
𝑑 × 𝑙
𝑝 =
3000
18×50
=4.63 N/mm2
The compressive stress at pin B can be calculated as follow
𝜍𝑐 =
𝑓𝑜𝑟𝑐𝑒 𝑎𝑡 𝑝𝑜𝑖𝑛𝑡 𝐵
𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑎𝑟𝑒𝑎
Area =
𝜋𝑑2
4
Diameter =18mm
A=
𝜋182
4
=254mm2
F= 3000N
The pin is subjected to double shear which is given by
𝜏 =
𝐹
2
𝜋𝑑2
4
𝜏 =
3000
2
𝜋182
4
=5.9 𝑀𝑝𝑎

Shear stress in pin A
From the above F=2600N
𝜏 =
2600
2
𝜋𝑑2
4
=5.1Mpa
All the above shear forces are less than the tensile strength of the material
𝜏<60 Mpa Therefore the design is safe.
The force on the fulcrum pin FA is comparatively less than the force acting on the pin FB
therefore the diameter 𝑑 and length 𝑙 of the pin at the fulcrum will be slightly less however, we
will assume both pins of the same diameter and length to facilitate interchangeability of parts and
variety reduction.
Since he handle is subjected to bending momentum:
The lever becomes weak due to the pin hole so it is necessary to check bending stress at the
critical stress.
The handle is subject maximum moment at the maximum force
The bending moment diagram for the liver it maximum at the pin for maximum force
MB= FC(1300-200)
=400× 1100
=440000N-mm
Fig3.4 bending diagram of the handle

𝜍 =
𝑀𝑏𝑦
𝐼
Where y=
𝑑
2
I=Moment of inertia for circular section is given by
I=
𝜋
64
(𝑑𝑜𝑢𝑡 − 𝑑𝑖𝑛 )4
𝜍𝑡 =
𝑀𝑏𝑦
𝐼
Let out side diameter of the handle 50mm
𝜍𝑡 = 44000 ∗
𝑑/2
𝜋(𝑑𝑜𝑢𝑡 − 𝑑𝑖𝑛 )4
64
𝜍𝑡 = 44000 ∗
50/2
𝜋(50 − 18)4
64
𝜍𝑡=213.8N/mm2
Now find factor of safety
Factor of safety=
𝑚𝑢𝑥𝑖𝑚𝑢𝑚 𝑠𝑡𝑟𝑒𝑠𝑠
𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠
=
400
213.8
=2
The design is safe because working stress is less than maximum stress of the materials
(213Mpa<400Mpa).

3.5.2 DESIGN OF CONNECTING BAR
The connecting bar used to connect the handle and bead breaker. it is subject to direct
compressive stress. Material for connected bar is plain carbon-steel of syt=400N/mm2
.from the
geometrical analysis the force on the bar 3kN, length is 300mm and diameter of connecting bar
is less than the handle diameter 40mm.
Area =
πd2
4
A=
π402
4
=1256mm2
Working stress =
3000
1256
=2.38Mpa
3.5.3 DESIGN OF BEAD BERAKER
Bead breaker is used to push the tire bead downward to loosen the tire bead from the rim. Bead
breaker receives the force from the handle and distributes the force on the surface of tire. The
shape of the bead breaker is like shovel the curvature of the bead breaker is determined by
curvature of the rim diameter. This curvature is important to loosen the tire easily.
Most passenger car tire rim diameter is from 14 inch 20 inch(381mm-508mm) by considering the
average of the rim diameter is taking 17inch so the center(radius) of curvature is 432mm.
From this information the circumference of the of the rim for 17 inch
𝑐 = 2𝜋𝑟
𝑐 = 2𝜋 × 432𝑚𝑚
=2712.96mm
Circumference of the rim =𝜃𝑟 by taking for bead breaker 𝜃 =30o
Where 𝜃=
𝜋
6
C=
𝜋
6
432mm C=226mm
top view of bead breaker
The height of the bead breaker = 80mm

Front view of bead breaker
The force transferred to the bead breaker directly on its thickness or at the tip of bead breaker
Area of the bead breaker tip= circumference × 𝑡𝑕𝑖𝑐𝑘𝑛𝑒𝑠𝑠
Area of the bead breaker tip= 226 × 𝑡
Maximum force comes from the handle=3000N
Material stainless steel 30cr13
Syt=60Mpa
for this part mechanical tire bead separator factor of safety =3
𝛿𝑎𝑙𝑙 = 𝛿𝑦 / 𝑛
=60Mpa/3
=20Mpa
Stress =
𝑑𝑖𝑟𝑒𝑐𝑡 𝑓𝑜𝑟𝑐𝑒
𝑐𝑟𝑜𝑠𝑠 −𝑠𝑒𝑐𝑡𝑖𝑛𝑎𝑙 𝑎𝑟𝑒𝑎
Area=
𝑑𝑖𝑟𝑒𝑐𝑡 𝑓𝑜𝑟𝑐𝑒
𝑠𝑡𝑟𝑒𝑠𝑠
226 × 𝑡 =
3000𝑁
20𝑁𝑚𝑚 2
t=0.66mm
This thickness is very small it may touch the tire and cut the tire so by considering this the
thickness of the bead breaker 20.
3.5.4 DESIGN OF TURN TABLE
In this mechanical tire rim separator turntable is rotated plate that is supported by shaft at the
center and used to carry the tire. at the surface of the table there are holes that used to fix the tire

rim in the time of rotation of the turn table. The diameter of turn table is by taking the diameter
the rim for passenger car for 20inch wheel.
Assumption
The diameter of turn table 540mm
The maximum tire weight that can be on the table 30Kg
Thickness of the turn table 20mm
Material for turn table Fe300 Syt=300N/mm2
The force of the tire is distributed on the surface of the turn table so the turn table is subjected to direct
stress.
Direct stress=
F
A
Force =tire weight × gravity
=30Kg×10N/mm2
=300N
to find area it is circular
A=
πd2
4
where d= diameter of turn table
σ =
F
A
=
300
πd2
4
σ=3.306×10-3
N/mm2
The turn table is only support at center to cheek the turn cannot bend by replacing the support by
using two support. The section is taken from the center of the table
where FA=shaft support
fig.table with its support

where FA=shaft support
Fload=tire weight
replaced force by two support
∑FY=0
RA+RB=300×0.54
RA+RB=162........................................................................eq.1
∑MA=0
0.54RA-300×0.54×0.54/2 =0
RA=81N
from equation one
RB=81N
Then by make section find the maximum moment
∑FY=0
81 -300x -VX VX=81-300X

∑Mx=0
MX-300x*
X
2
+81*x
MX=150X2
-81*x 0 ≤ x ≤ 0.54
at x=0 Vx=81N
at x=0 Mx=0
at x=0.27 MA=81× 0.27-150× 0.272
Mx=10.935Nm =10935Nmm2
at x=0.54
Mx=0
Now check the thickness can resist this applied force
By considering factor of safety 2
𝜍𝑎𝑙𝑙 =
𝑆𝑦𝑡
𝑓𝑠
𝜍𝑎𝑙𝑙 =
300
2
=150Mpa

𝜍 =
𝑀𝑏 y
𝐼
Mb=11Nm
I𝑥𝑥 =
b𝑕3
12
for rectangular cross section
Y=20/2 =10mm
h= thickness of the plate
b width of the plate(the diameter of the turn table at the center) =540mm
so I𝑥𝑥 =
b𝑕3
12
I𝑥𝑥 =
540×103
12
I𝑥𝑥 =45000
𝜍 =
11000×10
45000
𝜍=2.44Mpa
Working stress is less than allowable stress since the design is safe
to determine the position of the holes by taking the bolt position of the tire rim
Figure 3.5 bolt position
for most passenger car the bolt position holes are 4-6 bolts by considering this the turn table has
hole on its surface.

Figure 3.6 patterns of the bolt on the rim
The bolt circle is the notional circle determined by the positions of the bolts. The center of every
bolt lies on the circumference of the bolt circle. The important measurement is the bolt
circle diameter also called the pitch circle diameter.
This bolt pattern is important for the tire rim separator because in the time of mounting process
the wheel must fix on the table, so to fix the wheel this bolt position is important to put the pin.
From the three standards the diameter of the turn table has four bolts around the center
3.5.5 Design of Rotating Shaft
A shaft is a rotating machine element which is used to transmit power from one place to another.
The power is delivered to the shaft by some tangential force and the resultant torque (or twisting
moment) set up within the shaft permits the power to be transferred to various machines linked
up to the shaft.
In other words, we may say that a shaft is used for the transmission of torque and bending
moment. The various members are mounted on the shaft by means of keys or splines.
The shaft is used in this mechanical tire rim separator to support the table that hold the tire and
used to rotate the table in the time of mounting and demounting process of the tire and the rim.
The shaft is support the vertical load and it has twisting and bending moment
MATERIAL SELECTION FOR SHAFTS
The materials used for shafts should have the following properties:
 It should have high strength
 Have good Machinability
 It should have good notch sensitivity factor
 Have good heat treatment properties.
 It should have high wear resistance property.

The material used for ordinary shaft is carbon steel of grades 40c8, 45c8, 50c12 the mechanical
properties of these grades of carbon steel are given in the table below.
Indian standard designation Ultimate tensile strength(Mpa) Yield strength (MPa)
40c8 560-670 320
45c8 610-700 350
50c4 640-760 370
Table2 material selection for shaft
Fig front view of turn table with handle
Figure 3.7 rotating shaft
Let P = Force applied at the handle,=400N
L = Effective length of the lever, from the center to the end of the lever =1000mm
σt = Permissible tensile stress, and
τ = Permissible shear stress.
The shaft and the handle are integrated parts so to get the diameter of the shaft ( d ) is obtained
by considering the shaft at the center bearing d is obtained by the shaft in combined bending and
twisting.
We know that bending moment on the shaft
M = P × l
M=400× 1000=40000Nmm
Twisting moment,
M = p × l
Where l handles length

T = 400 × 1000
T=400×103
Nmm
The equivalent twisting moment
Te = M2 + T 2
Te = 400002 + 4000002
Te=401995Nmm
We know that equivalent twisting moment
Te=
πτd3
16
Carbon steel 40c8=320N/mm2
401995Nmm=
π×320×d3
16
The diameter of the shaft D=27mm from standard table take diameter =30mm
Since the shaft is subjected to direct stress on its end surface to check the stress on the shaft
𝜍 =
𝐹
𝐴
𝜍 =
300𝑁
πd2
4
=1.06Mpa
So from the above calculation the design is safe.
3.5.6 Selection of Bearing
A bearing is a machine element which supports another moving machine element (known as
journal). It permits a relative motion between the contact surfaces of the members, while
carrying the load. A little consideration will show that due to the relative motion between the
contact surfaces, a certain amount of power is wasted in overcoming frictional resistance and if
the rubbing surfaces are in direct contact, there will be rapid wear. In order to reduce frictional
resistance and wear and in some cases to carry away the heat generated, a layer of fluid (known
as lubricant) may be provided.
In this mechanical tire rim separator the bearing is used to allow the vertical shaft to rotate that
hold the tire when in dismounting.

THRUST BEARING: - selected for the design b/c thrust bearing can support axial load but
radial bearing can support only radial load.
bearing no. d(mm) d2(mm) D(mm) H(mm)
51104
51104
51105
⋮
20
25
30
⋮
20.2
25.2
30.2
⋮
35
42
50
⋮
10
11
12
⋮
Table 3: -standard thrust roller bearing Source: - engineering drawing and design
Cecil Jensen & jay d.helsel
Bearing selected for this design is
 Since the shaft diameter is 30 mm,
Bearing no.51105
d=30mm
d2=30.2mm
D=50mm
H=12mm
3.5.7 Design of Mounting Head
Mounting head used to mount and demount the tire bead from the rim. this mounting bar is
attached to at the tip of the rim during the mounting process. the shape of the mounting head is
small bit curve to fit the rim. It is fitted on the mounting bar and floats over the bead to remove

and mount tires quickly, easily and with minimal effort. Material selection for this is alloy steel.
By considering the thickness of the rim
3.5.8 Design of Mounting Bar
The mounting bar is a rod that is used to hold mounting head and it is connected to swing arm.
The mounting rod can move down ward and upward within the swing arm, at the surface of the
bar there is groove that used to fix the bar at the required position.
Material selection
Cast iron has low cost and high thermal conductivity as compared with ductile iron. However,
ductile is better able to withstand shock or impact loading. So to fulfill the considerations we
want we choose the material to be ductile cast iron.
 Yielding strength, 𝛿𝑌=276Mpa
 Ultimate strength, 200Mpa
The mounting bar is subjected to bending moment at the time of rotation. it must resist the
rotational moment.
From the turn table the maximum rotational moment M=40000Nmm
Assumption
The external diameter =50mm
Internal diameter =30mm
Length of the bar =90cm
The maximum length from the swing arm center to the tire bead 60mm

Figure 3.9 mounting bar
To resist the bending moment the force exist on the swing arm
F×r=M
Where r= the distance between the mounting head and swing arm 0.06m
∑M=0
=4-0.06×Fx
Fx=4/0.06
Fx=66.67N where Fx the force on the swing arm handle
I=Moment of inertia for circular section is given by
I=
𝜋
64
(𝑑𝑜𝑢𝑡 − 𝑑𝑖𝑛 )4
𝜍𝑡 =
𝑀𝑏𝑦
𝐼
𝜍𝑡 = 44000 ∗
𝑑/2
𝜋(𝑑𝑜𝑢𝑡 − 𝑑𝑖𝑛 )4
64
𝜍𝑡 = 40000 ∗
50/2
𝜋(50 − 30)4
64
𝜍𝑡=127.3Mpa
the working stress is lower than ultimate tensile strength the design is safe

Factor of safety=
𝑚𝑢𝑥𝑖𝑚𝑢𝑚 𝑠𝑡𝑟𝑒𝑠𝑠
𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠
=
276
127.3
= 2
Now to get the weight by using density of the material
Density of iron 7250Kg/mm3
Volume of the bar =A*l
A=
𝜋𝑑2
4
× 𝑙
=
𝜋0.042
4
× 0.9
To get the mass from the relation
m= 𝜌 × 𝑣
=
7250𝐾𝑔
𝑚3
×
𝜋×0.022
4
× 0.9𝑚
=2.04 Kg so it is small weight it can be handle
Locking mechanism is work by the help of
Pin on turning table
This pin is used when we maintain the tire in the work shop by help of mechanical tire rim-
separator. It reduces the tire slide on the turn table during separation of tire from rim, also this
pin uses for different type of tires, inspite of their difference we use different holes exist on turn
tables. During this operation at the same time two pins are used at different direction. The
material selected for this pin is the same with the pin on swing arm and handle.
Specification of pin on turning table
Length of pin = depends on the tire rim width
d= depends the hole diameter of tire

3.5.9 Design of Swing Arm
Swing arm is used to carry the mounting bar. At the name indicate it can move in one side by the
help of pin at the junction.
Material =ductile cast iron
 Yielding strength, 𝛿𝑌=276Mpa
 Ultimate strength, 200Mpa
Since the swing arm is used to hold the mounting bar by taking the clearance
Width of the handle =
FY = 0
FA-FB=0 -----------------eq1
Where
FA=force on the pin
FB=the summation of the force that creat at this position and+ weight of the mounting shaft components
The mounting bar components are mounting bar and mounting head so by considering the weight the
material
FB=66.6+33.4=100N
There is no other external force then FA=100N up
Bending moment
FY = 0
Vx+FA=0
Vx=FA v

Vx=100N
Mx =o
MB –FA×X at x=650mm
MB =65000N-mm or 65N
σ =
Mby
I
Where Ixx =
bh3
12
−
b1h1
3
12
where b1=b-2t h1=h-2t
b1=90mm
h1=70mm
Y=
h
2
= 0.05mm
Ixx =
80×1003
12
−
70×903
12
Ixx= 2.414*10-6
m4
=
σ =
65×0.05
2.414×10−6
σ=1.35Mpa
Design of pin at the end of swing arm

Forged steel with a property of
Shear stress = 60MPa.
Tensile stress= 75MPa
Therefore F = p(d × l)
Where p is the permissible bearing pressure
Ratio of l = 2d
Since the pin is passed through the swing arm diameter so, we can determine the length
d=10mm
Bering stress of the lever at pin point
p =
F
d × l
p =
100
10∗20
=0.5 N/mm2
The compressive stress at pin B can be calculated as follow
σc =
force at point A
cross section area
Area =
πd2
4
Diameter =18mm
A=
π102
4
=78.5mm2
F= 100N
The pin is subjected to double shear which is given by
τ =
F
2
πd2
4
τ =
100
2
π102
4
=0.6369Mpa

Working stress is less than allowable stress since the design is safe.
3.5.10 Design of Vertical Column
The vertical column is used to hold the mounting components. It is subject to bending moment at
the top side by the weight of swing arm components.
Material Cast iron has low cost
The shape of column is rectangular. Columns carry a force on the swing arm on the top
(F)=100N
Length of the of the column (L) = 1000mm
Width of the column (W) h = 90mm
b=70mm
Thickness=10mm
Fig-3.10 vertical column
By considering the swing arm weight 3kg
W=100+30=130N
The bending moment at the column
M=W×L
=130×1000
=130000Nmm

Material for the column FG200 Syt=200N/mm2
σ =
Mby
I
=
Y=h/2=45mm
Where Ixx =
bh3
12
−
b1h1
3
12
where b1=b-2t h1=h-2t
Where Ixx =
70×903
12
−
50×703
12
Ixx=2823333mm σ =
130000×45
2823333
σworking=2.07Mpa
Working stress is less than allowable stress since the design is safe.
3.5.11 Design of Base
The base or bench is used to hold the whole parts of the mechanical tire rim separator. The
maximum force is created on the base at the handle position.
From the geometric analysis the base is box shape the dimension is as follows
L=1000mm
W=600
H=400
Material selected for base is Cast iron
Tensile strength = 100Mpa
It is sheet metal type the maximum force is created at the handle side on the pin then by
considering the force on the pin.
The diameter of the pin =18mm
Force on the end pin=2600N
Factor of safety=2
𝜍𝑏 =
𝐹
𝐴
Where A= bearing surface contact with the base
A=d× 𝑡
𝜍𝑏 =
𝐹
𝑡 × 𝑑

𝑡 =
𝐹
𝜍𝑏 × 𝑑
𝑡=3mm
3.5.12 Design of bolts
Bolts used for tighten different components of the mechanical tire rim separator. from the force
analysis the force applied on the bolt is 2600N and we select materials is mild steel of maximum
tensile strength is 60MPa,the torque
And assume diameter of bolts is 30mm
Designatio
n
Pitch Nominal
diameter
Depth of the
diameter
Core of bolt
diameter
Depth of
the thread
Stress
area
Core of
nut
diamete
r
M8 2.25 8 7.188 6.466 0.767 36.6 6.647
M14 2 14 12.701 11.546 1.227 115 11.835
M20 2.5 20 18.376 16.933 1.534 192 17.294
M30 3.5 30 27.727 25.706 2.147 561 26.211
Table 4 bolt selection
From the above table
We select M30 d = 30mm, dP =28mm, bolt dc=26mm, dc nut =19.2mm,and depth of tread
bolt=2.147
The material is safe is mild seet 60MPa = 60N/mm2
Tensile stress due to stretching of bolt
bolts are designed on the basis of direct tensile stress with a large factor of safety in order to
account for the indeterminate stresses. The initial tension in a bolt, based on experiments, may be
found by the relation:
Stress area, A=561mm2
Where, dP= Pitch diameter, and
dc= Core or minor diameter
Safe tensile load Ps = Stress area × σt
Ps=561mm2
×60N/mm2
Ps=33.366KN

Shear stress across the threads
The average threads shearing stress for the thread(τs) isobtained by using the relation
𝜍𝑐=
P
π×dC×b×n
, n=4, b = 2.147
𝜍𝑐 =
33366N
π×28×2.147×4
𝜍𝑐=44MPa
Compression or crushing stress on threads
The compression or crushing stress between the threads (𝜍𝑐) may be obtained by using the
relation:
𝜍𝑐 =
p
π(d2
−dc2
)n
d = Major diameter,
dc= Minor diameter, and
n = Number of threads in engagement.
𝜍 =
33366N
π(302
−282
)4
𝜍𝑐=22MPa
3.5.12 Design of Welding
A welded joint is a permanent joint which is obtained by the fusion of the edges of the two
parts to be joined together, with or without the application of pressure and a filler material.
In this mechanical tire rim separator machine there is a welding to connect the swing arm
holder with vertical column.
Figure 3.11 swing arm
Terminology: t =throat thickness
S=size of welding
L=length of welding

𝜍𝑏 = 𝑏𝑒𝑛𝑑𝑖𝑛𝑔𝑠𝑡𝑟𝑒𝑠𝑠due to bending monment
𝜏 = 𝑑𝑖𝑟𝑒𝑐𝑐𝑡 𝑠𝑕𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑠𝑠
Area of throat A=t*l*2=2tl but t= .707S
A=2*.707*50=70.7𝒎𝒎𝟐
𝑺
𝜏 =
𝑃
𝐴
=
100
70.7𝑆
=1.4N/𝑚𝑚2
𝑆
Mb=p*e = 100*690=69000Nmm
Z=section modulus of the weld through throat=S*
𝑳𝟐
𝟒.𝟐𝟒𝟐
= 𝟓𝟎𝟐
*S/4.242=589.34S
𝝈𝒃 =
𝑴
𝒁
=
𝟔𝟗𝟎𝟎𝟎
𝟓𝟖𝟗.𝟑𝟒𝑺
=
𝟏𝟏𝟎.𝟑 𝑵/𝒎𝒎𝟐
𝒔
𝝉𝒎𝒂𝒙=1/2( 𝝈𝒃𝟐 + 𝟒 ∗ 𝝉𝟐)
Maximum shear of the materials is steel 4c8=10Mpa from the equation we get the size of weld
(S)=10mm.this weld is welded on the frame to connect pin with swing arm.
3.6 MANUFACTURING PROCESS
Design process can be a contemplation of planning for manufacture. Designer of any system
should always be concisions of the need to communicate with manufacturing department and
should ensure that the proposed manufacturing process is appropriate for the designed features.
Designing for manufacturing provides estimation and analysis tool to identify labour, assembly,
process, material and production variables that affect manufacturing operation and evaluate and
manage them for a design to be called the best. The designed components work successfully not
affecting the characteristics of the assembly if the dimension of the component is produced
within the compactable variation.
Operation that used to manufacture the mechanical tire –rim separator components are the
following
a) Cutting
b) Shaping
c) Drilling
d) Boring
3.6.1 Manufacturing Process of Handle
 The handle is made from plain carbon steel by forging or casting method in the required
dimension by considering machining allowance.

 Then, machining process (facing, turning) is applicable to get the required specific
dimensions and good surface finish.
3.6.2 Manufacturing Process of Base:-
 The base of the mechanical tire-rim separator machine is made from cast iron by casting
process in the required dimensions including machining allowance.
 Turning and facing is takes place to get good surface finish and required specific
dimensions.
 Filet may be applicable to decrease Sharpe edge.
 Drilling is used to make the hole for bolt tie.
3.6.3Manufacturing Process of Shaft
Shaft are generally manufactured by hot rolling and finished to size by cold drawing or turning
and gridding .the cold rolled shaft are stronger than hot rolled shafts but with higher residual
stresses the residual stresses may cause distortion of shaft when it when it is machined especially
when slot or key ways are cut. Shaft of large diameter can be forged and turned to its size by
lathe machine.
3.6.4 Manufacturing Process for Turn table
 The turn table is made from steel Fe300 by forging or casting process in circular
shape in the required dimension including machining allowance.
 Facing and turning are used to make the required surface finish and specific
dimension.
 Drilling also applicable for making hole for insertion of the bolt.
3.6.5 Manufacturing Process of Bolt and Nut:-
 The bolt and nut are made by either casting or forging process in the required dimensions
including machining allowance
 Facing and turning are used to make the surface finish and specific required dimension.
 Drilling the nut to make hole, and then threading the nut to make internal thread.
 Threading the bolt externally.
 Chamfering the bolt.
 Filet may be required to decrease sharpness edge of the nut.
3.7 COST ESTIMATION
Cost estimation is an art or finding the cost, which is likely to be incurred on the manufacture of
an article, before it actually manufactured. Thus, it is the calculation of a probable cost of an
article before the manufacturing starts. It also includes predetermination of the quantity and
quality of materials, labour required, etc. estimating requires highly technical knowledge about
manufacturing methods and operation times etc.

NUMBER
Part of
machine
Bill of
materials
Quantity Cost of element
Material
cost
Labour
cost
Total
cost
1 Handle Plain carbon
steel
1 140 220 160
2 Connecting
bar
Plain carbon
steel
1 140 100 240
3 Column
bar
Ductile cast
iron
1 80 60 140
4 Nut Bronze 4 100 30 130
5 Bolt Carbon steel 8 200 30 230
6 Shaft Carbon steel 1 200 50 250
7 Base Ductile cast
iron
1 300 100 400
8 Pin Forged steel 3 60 30 90
9 Turn table IronFe300 1 150 40 190
10 Mounting
arm
Ductile cast
iron
1 200 50 250
11 Bead
breaker
Stainless
steel
1 170 40 210
12 Swing arm Ductile cast
iron
1 130 30 160
Total cost 2750
Table 5 cost estimation
3.8 Method of assembly
1 First put the base at the bottom, and then connect the base with the frame. The base and
the frame are connected through pin.
2.Set the handle on the frame by the help of pin and on the handle there is connecting bar
which is connected with pin and on the connected bar there is bead breaker.
3. Put the turn table and rotating shaft on the base and connected by bolt.
4. Connect swing arm and connected arm together and also connect swing arm on the
column through welding.
5. Again connected mounting head on the connect on the mounting arm.
6. Finally we get the desired manually operated mechanical tire rim separator machine.
3.9 Lubrication system
Lubrication is important to prevent damage in moving parts. The lubricants specified are those
which most nearly meet the requirements of the parts involved. In some places excessive heat or cold is a
problem to overcome, in others it is extreme pressure, water etc. A lubricant is a substance introduced to
reduce friction between surfaces in mutual contact, which ultimately reduces the heat generated when the
surfaces move.
PERSONAL SAFETY

Whenever you perform a task in the workshop you must use personal protective clothing and
equipment that is appropriate for the task and which conforms to your local safety regulations
and policies. Among other items, this may include:
 Work clothing - such as coveralls and steel-capped footwear
 Eye protection - such as safety glasses and face masks
 Hand protection - such as rubber gloves and barrier cream
3.10WORKING PRINCIPLE OF MECHANICAL TIRE-RIM SEPARATOR
Before we put the tire on the base first we remove the air from the tire then put on the base and
push the tire by the help of the handle by human power. it push the tire at least four times in both
side .after we push the tire put the tire on the rotation plate by means of mounting arm can be
attached on the tire and the locking mechanisms can be control the spring force at the top.
By using the handle lever we can rotate the plate on the shaft and the tire –rim can be separated
in simple mechanism without affect the tire and rim with low cost and in short time.
3.10.1 STEEP OF MECHANICAL TIRE –RIM SEPARATOR
1 First we remove the air from the tire before starting
2 after remove the air put the tire on the base
3 by the help of handle and connected bar push the tire until the loosened the hole bead
from the rim
4 after we push the tire take again the tire on the rotation shaft
5 attach the tire and mounting and dismounting head by the help of spring force in
mechanism of locking system
6 put the chuck on the center of rotation shaft to keep the tire
7 With the mounting head in position, spread tire grease (or a similar lubricant) liberally
on the complete circumference of the broken tire bead
8 . Insert the lever between the tire bead and the front section of the mounting head
9 Move the tire bead over the mounting head
10 With the lever (or hands) held in position, rotate the turntable in a clockwise direction
11 Continue until the tire is completely separated from the wheel rim. And remove the inner
tube (if there is one)
12 . Insert the lever between the other side of the tire bead and the front section of the
mounting head. Move the tire bead over the mounting head
13 Repeat the above steps for the other side of the tire

3.11 DETAIL DRAWING
Figure 3.12-Swing arm
Fig 3.13 Bead breaker
Figure -3.14 Pin coneector with bar

Figure-3.15 handle holder
Figure-3.16 Handle with bead breaker

Figure-3.17 handle
Figure -4.25Mounting with swing arm
Figure-3.18 Column with swing arm

Figure -3.19 shaft
Figure-3.20 Turn table
Figure -3.21 pin connected

3.12 ASSEMBLE DRAWING
Fig 3.22 assembly drawing
Part No Part name Material
1 Handle Plain carbon
steel
2 Bead breaker Stencils steel
3 Column Cast iron
4 Swing arm pin Cast iron
5 Mounting arm Cast iron
6 Swing arm Cast iron
7 Turn table IronFe300
8 Handle position Plain carbon
steel
9 Base Cast iron
Table part list

CHAPTER FOUR
CONCLUSION AND RECOMMENDATION
4.1 CONCLUSION
We have discussed that almost that have been join out parts of mechanical tire-rim separator. In
each parts of our machine we tried the best to express each and every component of machine
briefly .we hope that this thesis gives detail information for manufactures about all parts
machine that it contain. Also we tried to clarify to any reader that introduces our design to
application activities to different aspects of mechanical engineering works .In our design of
mechanical tire –rim separator we use 400N maximum man power to push the tire by the help of
handle .Using this machine reduces wear, tear and damage of tire and rim. By using this machine
people can save their capacity, money which leads the employee to change their life status.

4.2 RECOMMENDATION
We recommend that designing and making analysis of machine or component is nothing if it is
not translated into a working machine. This project should be continued until it will be
manufactured and observing results checks in fields.
We also recommended that this mechanical tire-rim separator is designed for passenger car but if
also design for heavy duty car.
It is further recommended that the development program be continued. Program
Continuation would involve the detailed design, production and testing of prototype assemblies.

REFERENCE
1 Text book of machine Design; R.S. KHURMI and J.K.GUPTA, first edition, 1979.
2 Ferdinand p.Beer, “mechanics of materials" 2𝑛𝑑
edition, MC Graw Hill, London, 1992.
3 Lord Chilver-carl, strength of materials & structures, fourth edition, Arnold, London,
4 Second edition. Manufacturing Technology, Foundry, Forming and Welding
5 A Textbook of Material Science and Metallurgy I, Dhanpat Rai, 5th Editio
6 Shigley’s Mechanical Engineering Design 8th
Edition 2010
7 HiTech Division,www.nhbb.com radial ball bearings standard diameter 10-25mm
8. Ju mp up ^ Wheel Rim European Patent 6 June 2007, retrieved on 2008-06-13.

Design of Mechanical Tire-Rim Separator-1.pdf

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