The camshaft and crankshaft are key components that convert reciprocating to rotational motion in automobile engines. The camshaft uses lobes to push the valves open and closed according to the rotation of the crankshaft. Crankshafts are typically made of forged steel or cast iron and experience high static and dynamic stresses that require high rigidity. Surface hardening through carburizing or nitriding increases the hardness of these components. New microalloyed steels and treatments like plasma ion nitriding further enhance strength.
Design of clutch theory Prof. Sagar a DhotareSagar Dhotare
This covers following points,
Introduction to clutch
Classification
Requirement of good friction clutch
Requirements of material used for friction clutch
Material used for friction clutch
Considerations in Designing a Friction Clutch
Design of Single Disc or Plate Clutch
Design of Multi Disc or Plate Clutch
Design of Cone Clutch
Comparison between Single and Multi Plate Clutch
Comparison between Plate and Cone Clutch
Crankshaft Manufacturing Process sequence Omar Amen
This presentation slides Discusses how to manufacture crankshaft
Slides contains:
- Introduction to crankshaft ( what is the crankshaft ).
- Main parts of crankshaft.
- Types of crankshaft.
- Design of crankshaft.
- Finite element analysis for crankshaft ( Structure Analysis & Thermal Analysis ).
- Material selection ( select the suitable materials for manufacture crankshaft and suitable percentage of alloying elements in crankshaft according to required mechanical properties ).
- Manufacturing process sequence ( Forging steps & Machining steps ).
- field research for crankshaft manufacturing (Nallicheri, 1991, contains conditions of manufacturing , Cost Analysis according to factors, and Cost Analysis according to process ).
The document discusses the design and validation process for a crankshaft. It begins with an overview of crankshafts and their function in converting linear piston motion to rotational motion in engines. It then outlines the 5 main steps in the design and validation process: 1) conceptual design, 2) process analysis and selection, 3) testing, 4) production, and 5) quality improvement. Key aspects of each step like dimensions, stresses, fatigue testing, and hardening processes are covered. The goal is to take an initial design concept and improve it using analysis, testing, manufacturing, and standards to validate the design.
This document discusses the design of connecting rods for internal combustion engines. It describes the functions of connecting rods as transmitting force between the piston and crankshaft. Key aspects covered include common connecting rod designs, considerations for determining connecting rod length, materials used, forces acting on connecting rods, and design parameters such as cross-sectional dimensions and crankpin/piston pin sizes. Formulas are provided for calculating cross-sectional moments of inertia to ensure equal resistance to buckling in both planes.
This document provides an overview of different types of gears including their key components and terminology. It discusses common gear types like spur gears, helical gears, bevel gears, and worm gears. For each type it provides examples of advantages and disadvantages as well as typical applications. The document also discusses gear materials and common modes of gear failure such as scoring, wear, pitting, plastic flow, and tooth fracture.
An epicyclic or planetary gear system consists of one or more planet gears that revolve around a central sun gear. The planet gears are mounted on a carrier that can also rotate relative to the sun gear. An outer ring gear meshes with the planet gears. Epicyclic gearing allows for large gear ratios in a small space through the planetary motion of gears revolving and rotating simultaneously. Applications include marine gearboxes, electric screwdrivers, lathe back gears, hoists, pulley blocks, wristwatches, bicycle transmissions, and automobile transmissions.
Gears are used to transfer motion and torque between rotating shafts. They work by engaging teeth along the edge of one gear with another gear. This allows for speed and torque conversions between driving and driven components. There are several types of gears including spur gears, helical gears, bevel gears, and worm gears which can transmit power at 90 degree angles. Gear ratios are calculated based on the number of teeth and are used to increase torque or reduce speed between connected rotating parts like motors and pumps.
Design of clutch theory Prof. Sagar a DhotareSagar Dhotare
This covers following points,
Introduction to clutch
Classification
Requirement of good friction clutch
Requirements of material used for friction clutch
Material used for friction clutch
Considerations in Designing a Friction Clutch
Design of Single Disc or Plate Clutch
Design of Multi Disc or Plate Clutch
Design of Cone Clutch
Comparison between Single and Multi Plate Clutch
Comparison between Plate and Cone Clutch
Crankshaft Manufacturing Process sequence Omar Amen
This presentation slides Discusses how to manufacture crankshaft
Slides contains:
- Introduction to crankshaft ( what is the crankshaft ).
- Main parts of crankshaft.
- Types of crankshaft.
- Design of crankshaft.
- Finite element analysis for crankshaft ( Structure Analysis & Thermal Analysis ).
- Material selection ( select the suitable materials for manufacture crankshaft and suitable percentage of alloying elements in crankshaft according to required mechanical properties ).
- Manufacturing process sequence ( Forging steps & Machining steps ).
- field research for crankshaft manufacturing (Nallicheri, 1991, contains conditions of manufacturing , Cost Analysis according to factors, and Cost Analysis according to process ).
The document discusses the design and validation process for a crankshaft. It begins with an overview of crankshafts and their function in converting linear piston motion to rotational motion in engines. It then outlines the 5 main steps in the design and validation process: 1) conceptual design, 2) process analysis and selection, 3) testing, 4) production, and 5) quality improvement. Key aspects of each step like dimensions, stresses, fatigue testing, and hardening processes are covered. The goal is to take an initial design concept and improve it using analysis, testing, manufacturing, and standards to validate the design.
This document discusses the design of connecting rods for internal combustion engines. It describes the functions of connecting rods as transmitting force between the piston and crankshaft. Key aspects covered include common connecting rod designs, considerations for determining connecting rod length, materials used, forces acting on connecting rods, and design parameters such as cross-sectional dimensions and crankpin/piston pin sizes. Formulas are provided for calculating cross-sectional moments of inertia to ensure equal resistance to buckling in both planes.
This document provides an overview of different types of gears including their key components and terminology. It discusses common gear types like spur gears, helical gears, bevel gears, and worm gears. For each type it provides examples of advantages and disadvantages as well as typical applications. The document also discusses gear materials and common modes of gear failure such as scoring, wear, pitting, plastic flow, and tooth fracture.
An epicyclic or planetary gear system consists of one or more planet gears that revolve around a central sun gear. The planet gears are mounted on a carrier that can also rotate relative to the sun gear. An outer ring gear meshes with the planet gears. Epicyclic gearing allows for large gear ratios in a small space through the planetary motion of gears revolving and rotating simultaneously. Applications include marine gearboxes, electric screwdrivers, lathe back gears, hoists, pulley blocks, wristwatches, bicycle transmissions, and automobile transmissions.
Gears are used to transfer motion and torque between rotating shafts. They work by engaging teeth along the edge of one gear with another gear. This allows for speed and torque conversions between driving and driven components. There are several types of gears including spur gears, helical gears, bevel gears, and worm gears which can transmit power at 90 degree angles. Gear ratios are calculated based on the number of teeth and are used to increase torque or reduce speed between connected rotating parts like motors and pumps.
The document discusses various components that connect the transmission to the drive wheels, including the propeller shaft, universal joints, constant velocity joints, and slip joints. It provides details on the construction and function of each component. The propeller shaft transmits power from the transmission to the rear differential. Universal joints and constant velocity joints allow the shaft to transmit power through varying angles, while slip joints allow adjustments to the shaft length during vehicle movement.
The crankshaft converts the reciprocating motion of pistons into rotational motion to drive the propeller. It is made of chrome-nickel-molybdenum steel and can be a single piece or multiple pieces joined together. The crankshaft rotates within the crankcase and is supported by main bearing journals, with crankpins or throws offset from the center to enable the pistons' reciprocating motion. It is subjected to bending and twisting forces that must be analyzed at positions of maximum stress.
This document provides an overview of braking systems, including drum brakes and disc brakes. It describes the basic components and functioning of brakes, how braking converts kinetic energy to heat, and the requirements of effective braking. Drum brakes use brake shoes that expand inward or outward to create friction with the brake drum. Disc brakes use calipers and pads that clamp onto a brake disc attached to the wheel. The document compares advantages and disadvantages of drum brakes versus disc brakes.
This document discusses the fundamentals and types of mechanisms. It covers topics such as statics, dynamics, kinematics, kinetics, links, kinematic pairs, constrained motions, inversions of mechanisms, and common mechanisms. Examples are provided to illustrate concepts like the four bar chain, slider crank chain, Geneva mechanism, Ackermann steering, and rear wheel sprocket of a bicycle. Mechanisms are analyzed based on their motion, forces, components, and ability to transform input energy into useful work.
The crankshaft converts the up and down motion of pistons into rotational motion to power the wheels. It has several key parts: webs connect crankpins to the shaft, counterweights balance the crankshaft, and crank journals connect to connecting rods. Crankshafts are manufactured through processes like forging, machining, grinding, balancing, and heat treatment to achieve the proper shape and mechanical properties. Materials like steel are commonly used due to their strength and fatigue resistance.
The document discusses automobile chassis frames. It defines a frame as the undercarriage or structure that supports the engine, cab, and body of a vehicle. There are three main types of frames: conventional frames with side members and cross members, integral frames where all components attach directly to the body, and semi-integral frames that have a partial front frame. The document outlines the functions of frames, provides examples of frame designs, and describes the materials, design considerations, and manufacturing processes involved in building frames, including cutting, bending, welding, and inspection stages. It concludes with details from a field visit to an automotive manufacturing plant.
Module 1 introduction to kinematics of machinerytaruian
This document provides information about the Kinematics of Machines course offered by the Department of Mechanical Engineering at JSS Academy of Technical Education in Bangalore, India. It lists the course code, textbooks, reference books, course outcomes, and chapter topics that will be covered. The topics include basic definitions related to kinematic elements, pairs, chains, and mechanisms. It describes types of kinematic pairs and chains, including four-bar chains, single slider-crank chains, and double slider-crank chains. It also covers degrees of freedom, Grubler's criterion, and inversions of mechanisms.
An axle is a central shaft that supports rotating wheels. On vehicles, the axle can be fixed to the wheels and rotate with them, or fixed to the vehicle with the wheels rotating around it. Bearings are provided where the axle is mounted. The document discusses different types of rear axles like full floating, semi floating, and three quarter floating axles. It also discusses front axles, describing them as either dead or live axles. Finally, it lists four types of stub axles used to connect front wheels to front axles: Elliot, reversed Elliot, Lamoine, and reversed Lamoine.
The document discusses the design and components of a gear box. It explains that a gear box provides variable speed and torque from a rotating power source to another device using gears and gear trains. The main components of a gear box include gears, shafts, clutches and forks. Different types of gear boxes are described such as sliding mesh, constant mesh and synchromesh gear boxes. The functions, working and advantages of using preferred numbers in gear box design are also summarized.
Universal joints and constant velocity joints allow a drive shaft to transmit power through a variable angle to accommodate different angles between the driving and driven shafts. A Rzeppa joint specifically consists of an inner and outer spherical shell with grooves that guide balls to allow angular movement between the input and output shafts up to 30 degrees.
The document provides information about braking systems. It discusses the main functions of braking systems which are to stop the vehicle safely and control the vehicle when descending hills. It describes the two main types of braking system layouts - front/rear hydraulic split and diagonal split. It explains the components of braking systems including the brake pedal, master cylinder, brake lines, and discusses different types of braking systems such as mechanical, hydraulic, pneumatic, and discusses components like brake linings. It provides diagrams to illustrate hydraulic and mechanical braking systems.
A clutch connects and disconnects a driving shaft, such as an engine crankshaft, to a driven shaft that provides output power. A clutch uses friction between two surfaces to transmit torque from the driving shaft to the driven shaft. When the clutch pedal is pressed, springs in the pressure plate disengage the clutch plates from the flywheel, disconnecting the driven shaft. Releasing the pedal engages the clutch plates between the flywheel and pressure plate using the springs, connecting the driven shaft. A single plate clutch has one clutch plate that connects the flywheel to the driven shaft through friction to transfer power.
The document provides details about the design of a screw jack. It includes an introduction that discusses the background and history of screw jacks. It then outlines the objectives, scope, limitations and methodology of the screw jack design project. The document is divided into multiple chapters that cover literature reviews, detailed design and analysis of the screw jack parts, results and discussion, conclusions, and part/assembly drawings. The design aims to develop a screw jack that can lift a maximum load of 1.65 tons and optimize the existing design by replacing the hand lifter with a pedal lever to reduce energy usage.
An automobile differential couples the drive shaft to the rear driving wheels. It allows the outer wheel to rotate faster than the inner wheel during a turn by splitting torque equally between the wheels. A differential consists of one input and two outputs for the two driving wheels. It allows the wheels to rotate at different speeds to accommodate turns while keeping the average rotational input equal to the drive shaft. Differentials are commonly used in automobiles but also have non-automotive applications like performing analog arithmetic or controlling gun aim. There are different types of differentials like epicyclic, spur gear, and bevel gear differentials.
This technical seminar presentation summarizes the key components and functions of an automobile differential system. It discusses:
1) The main parts of a differential system including the pinion gear, ring gear, spider gears, differential case assembly, and rear drive axles.
2) How differentials work by allowing the outer wheels to travel farther than the inner wheels when turning, while maintaining equal torque to both wheels.
3) The drawback of a standard open differential which can send all torque to a single slipping wheel, and how limited-slip differentials address this issue.
Fixture is a work holding and support device used in the manufacturing industry.
In this slide all the details of Fixture is given and one problem statement is also given to manufacture a Fixture.
The document describes a project report for the design and fabrication of a two speed variable transmission gearbox. It was submitted by two students, G. Aravind and S. Arun Muzhithevan, in partial fulfillment of their Bachelor of Engineering degree in Mechanical Engineering at St. Joseph's College of Engineering. The report provides an acknowledgment of those who assisted and supervised the project, a table of contents, descriptions of gearboxes and gear types such as spur gears, and explanations of concepts such as pitch circles and lines of action.
The document discusses different types of machine elements used for joining parts, including fasteners, screws, bolts, nuts, keys, and cotter joints. It describes various thread types like V-threads, square threads, and ACME threads. It also explains different forms of bolts, nuts, keys, and cotter joints; when each type would be used; and how they function to join parts together both permanently and temporarily.
MECNICOM provides wear-resistant plates, welding electrodes, and repair services for heavy mining and quarrying equipment. Their products and services help extend the lifespan of equipment components that are subjected to heavy abrasion and impact. This includes manufacturing and installing wear plates for shovel buckets, excavator arms, feeders, screens, and crusher components. MECNICOM also performs on-site repairs using specialized welding electrodes to rejoin or rebuild worn parts and structures. Their superconditioning and repair services can increase the lifespan of equipment by up to 6 times compared to conventional materials.
Free Vibration and Transient analysis of a Camshaft Assembly using ANSYSIRJET Journal
This document discusses a finite element analysis of a camshaft assembly using ANSYS. It begins with an introduction to camshaft assemblies and their importance in controlling valve timing in internal combustion engines. The document then describes modeling a camshaft assembly in ANSYS and performing a free vibration analysis to determine the assembly's natural frequencies and mode shapes. Materials properties for chilled cast iron and billet steel that could be used for the camshaft are provided. The goals of the project are to design, model, and analyze the camshaft assembly under finite element analysis to make the design robust under all possible load cases.
The document discusses various components that connect the transmission to the drive wheels, including the propeller shaft, universal joints, constant velocity joints, and slip joints. It provides details on the construction and function of each component. The propeller shaft transmits power from the transmission to the rear differential. Universal joints and constant velocity joints allow the shaft to transmit power through varying angles, while slip joints allow adjustments to the shaft length during vehicle movement.
The crankshaft converts the reciprocating motion of pistons into rotational motion to drive the propeller. It is made of chrome-nickel-molybdenum steel and can be a single piece or multiple pieces joined together. The crankshaft rotates within the crankcase and is supported by main bearing journals, with crankpins or throws offset from the center to enable the pistons' reciprocating motion. It is subjected to bending and twisting forces that must be analyzed at positions of maximum stress.
This document provides an overview of braking systems, including drum brakes and disc brakes. It describes the basic components and functioning of brakes, how braking converts kinetic energy to heat, and the requirements of effective braking. Drum brakes use brake shoes that expand inward or outward to create friction with the brake drum. Disc brakes use calipers and pads that clamp onto a brake disc attached to the wheel. The document compares advantages and disadvantages of drum brakes versus disc brakes.
This document discusses the fundamentals and types of mechanisms. It covers topics such as statics, dynamics, kinematics, kinetics, links, kinematic pairs, constrained motions, inversions of mechanisms, and common mechanisms. Examples are provided to illustrate concepts like the four bar chain, slider crank chain, Geneva mechanism, Ackermann steering, and rear wheel sprocket of a bicycle. Mechanisms are analyzed based on their motion, forces, components, and ability to transform input energy into useful work.
The crankshaft converts the up and down motion of pistons into rotational motion to power the wheels. It has several key parts: webs connect crankpins to the shaft, counterweights balance the crankshaft, and crank journals connect to connecting rods. Crankshafts are manufactured through processes like forging, machining, grinding, balancing, and heat treatment to achieve the proper shape and mechanical properties. Materials like steel are commonly used due to their strength and fatigue resistance.
The document discusses automobile chassis frames. It defines a frame as the undercarriage or structure that supports the engine, cab, and body of a vehicle. There are three main types of frames: conventional frames with side members and cross members, integral frames where all components attach directly to the body, and semi-integral frames that have a partial front frame. The document outlines the functions of frames, provides examples of frame designs, and describes the materials, design considerations, and manufacturing processes involved in building frames, including cutting, bending, welding, and inspection stages. It concludes with details from a field visit to an automotive manufacturing plant.
Module 1 introduction to kinematics of machinerytaruian
This document provides information about the Kinematics of Machines course offered by the Department of Mechanical Engineering at JSS Academy of Technical Education in Bangalore, India. It lists the course code, textbooks, reference books, course outcomes, and chapter topics that will be covered. The topics include basic definitions related to kinematic elements, pairs, chains, and mechanisms. It describes types of kinematic pairs and chains, including four-bar chains, single slider-crank chains, and double slider-crank chains. It also covers degrees of freedom, Grubler's criterion, and inversions of mechanisms.
An axle is a central shaft that supports rotating wheels. On vehicles, the axle can be fixed to the wheels and rotate with them, or fixed to the vehicle with the wheels rotating around it. Bearings are provided where the axle is mounted. The document discusses different types of rear axles like full floating, semi floating, and three quarter floating axles. It also discusses front axles, describing them as either dead or live axles. Finally, it lists four types of stub axles used to connect front wheels to front axles: Elliot, reversed Elliot, Lamoine, and reversed Lamoine.
The document discusses the design and components of a gear box. It explains that a gear box provides variable speed and torque from a rotating power source to another device using gears and gear trains. The main components of a gear box include gears, shafts, clutches and forks. Different types of gear boxes are described such as sliding mesh, constant mesh and synchromesh gear boxes. The functions, working and advantages of using preferred numbers in gear box design are also summarized.
Universal joints and constant velocity joints allow a drive shaft to transmit power through a variable angle to accommodate different angles between the driving and driven shafts. A Rzeppa joint specifically consists of an inner and outer spherical shell with grooves that guide balls to allow angular movement between the input and output shafts up to 30 degrees.
The document provides information about braking systems. It discusses the main functions of braking systems which are to stop the vehicle safely and control the vehicle when descending hills. It describes the two main types of braking system layouts - front/rear hydraulic split and diagonal split. It explains the components of braking systems including the brake pedal, master cylinder, brake lines, and discusses different types of braking systems such as mechanical, hydraulic, pneumatic, and discusses components like brake linings. It provides diagrams to illustrate hydraulic and mechanical braking systems.
A clutch connects and disconnects a driving shaft, such as an engine crankshaft, to a driven shaft that provides output power. A clutch uses friction between two surfaces to transmit torque from the driving shaft to the driven shaft. When the clutch pedal is pressed, springs in the pressure plate disengage the clutch plates from the flywheel, disconnecting the driven shaft. Releasing the pedal engages the clutch plates between the flywheel and pressure plate using the springs, connecting the driven shaft. A single plate clutch has one clutch plate that connects the flywheel to the driven shaft through friction to transfer power.
The document provides details about the design of a screw jack. It includes an introduction that discusses the background and history of screw jacks. It then outlines the objectives, scope, limitations and methodology of the screw jack design project. The document is divided into multiple chapters that cover literature reviews, detailed design and analysis of the screw jack parts, results and discussion, conclusions, and part/assembly drawings. The design aims to develop a screw jack that can lift a maximum load of 1.65 tons and optimize the existing design by replacing the hand lifter with a pedal lever to reduce energy usage.
An automobile differential couples the drive shaft to the rear driving wheels. It allows the outer wheel to rotate faster than the inner wheel during a turn by splitting torque equally between the wheels. A differential consists of one input and two outputs for the two driving wheels. It allows the wheels to rotate at different speeds to accommodate turns while keeping the average rotational input equal to the drive shaft. Differentials are commonly used in automobiles but also have non-automotive applications like performing analog arithmetic or controlling gun aim. There are different types of differentials like epicyclic, spur gear, and bevel gear differentials.
This technical seminar presentation summarizes the key components and functions of an automobile differential system. It discusses:
1) The main parts of a differential system including the pinion gear, ring gear, spider gears, differential case assembly, and rear drive axles.
2) How differentials work by allowing the outer wheels to travel farther than the inner wheels when turning, while maintaining equal torque to both wheels.
3) The drawback of a standard open differential which can send all torque to a single slipping wheel, and how limited-slip differentials address this issue.
Fixture is a work holding and support device used in the manufacturing industry.
In this slide all the details of Fixture is given and one problem statement is also given to manufacture a Fixture.
The document describes a project report for the design and fabrication of a two speed variable transmission gearbox. It was submitted by two students, G. Aravind and S. Arun Muzhithevan, in partial fulfillment of their Bachelor of Engineering degree in Mechanical Engineering at St. Joseph's College of Engineering. The report provides an acknowledgment of those who assisted and supervised the project, a table of contents, descriptions of gearboxes and gear types such as spur gears, and explanations of concepts such as pitch circles and lines of action.
The document discusses different types of machine elements used for joining parts, including fasteners, screws, bolts, nuts, keys, and cotter joints. It describes various thread types like V-threads, square threads, and ACME threads. It also explains different forms of bolts, nuts, keys, and cotter joints; when each type would be used; and how they function to join parts together both permanently and temporarily.
MECNICOM provides wear-resistant plates, welding electrodes, and repair services for heavy mining and quarrying equipment. Their products and services help extend the lifespan of equipment components that are subjected to heavy abrasion and impact. This includes manufacturing and installing wear plates for shovel buckets, excavator arms, feeders, screens, and crusher components. MECNICOM also performs on-site repairs using specialized welding electrodes to rejoin or rebuild worn parts and structures. Their superconditioning and repair services can increase the lifespan of equipment by up to 6 times compared to conventional materials.
Free Vibration and Transient analysis of a Camshaft Assembly using ANSYSIRJET Journal
This document discusses a finite element analysis of a camshaft assembly using ANSYS. It begins with an introduction to camshaft assemblies and their importance in controlling valve timing in internal combustion engines. The document then describes modeling a camshaft assembly in ANSYS and performing a free vibration analysis to determine the assembly's natural frequencies and mode shapes. Materials properties for chilled cast iron and billet steel that could be used for the camshaft are provided. The goals of the project are to design, model, and analyze the camshaft assembly under finite element analysis to make the design robust under all possible load cases.
Welcome to International Journal of Engineering Research and Development (IJERD)IJERD Editor
This document discusses the use of fracture split connecting rods for automotive engines made from C70S6 material. C70S6 is a suitable material for fracture splitting due to its brittle fracture properties and lower ductility. Testing was conducted on C70S6 material and fracture split connecting rod components to validate their mechanical properties and ability to withstand the loads from a maximum 210 bar firing pressure engine. Finite element analysis also showed safety factors above 1.4 for the connecting rod design. The chemical composition and microstructure of C70S6 provides benefits over conventional steels for fracture splitting applications in connecting rods.
design and analysis of scissor jack presentation 4.pptxyohannestube
A screw jack uses a screw thread to lift heavy loads by applying minimal force. It converts rotational motion into linear motion to lift objects. Screw jacks are commonly used to change tires on cars. They can be operated manually or electrically. This document discusses the components, design requirements, and material selection for a screw jack. It aims to design a screw jack that can easily be moved in a working environment and lift loads up to 6.5kN between heights of 310mm to 417mm. Cast iron is selected for the frame due to its strength and ductility. Steel is suitable for the screw and nut due to its strength. The design process involves analyzing forces, dimensions, and stresses.
Detailed design report on design of upright and hubZubair Ahmed
The document describes the design process for an upright component in an automobile suspension system. It discusses 14 design parameters that were considered. Several design concepts and models were explored before settling on a final design (Design 4). The key points of the final design are that it is CNC milled from aluminum alloy 6351 T-6, weighs 760 grams, and addresses the weaknesses identified in previous designs. Loading scenarios analyzed include steering effort, braking forces, remote bump forces, and cornering forces. Finite element analysis was used to evaluate stresses and predict fatigue life under the different loading conditions.
The document discusses Mechadyne's concentric camshaft technology which enables independent phasing of cam lobes on a single camshaft using an inner and outer shaft connected by pins and slots. This allows for variable lift and duration control as well as dual independent VVT. Applications include enabling twin-phaser VVT on cam-in-block and SOHC engines. Benefits over baseline engines include 5% fuel economy improvement, 10% increased mean torque, mass reduction of 3.5-4kg, and reduced complexity. Contact information is provided for more information.
Project aim is contribute in torsional vibration th eory and their practical experiences used in damper s which are widely used in automobile application & civil applications. Projec t is sponsored by �Hodek vibration Technologies pvt ltd�,pune. This is largest dampers manufacturer of torsional vibration dampers for diesel engines. This report paper high lights a number of important considerations for the torsional viscous damper system as well as design philosophies to ass ess and mitigate the risk of torsional failures. Damping properties are of si gnificant importance in determining the dynamic res ponse of structures,and accurate prediction of them at the design stage,es pecially in the case of light-weight,wind-sensitiv e buildings,is very desirable. Unfortunately,damping parameters cannot be deduced deterministically from other structural properties and recourse is generally made to data from experiments conducted o n completed structures of similar characteristics. Such data is scarce but valuable,both for direct use in design and for fur thering research into the phenomenon of damping.
1. The Moventas XL Life Extension Program aims to extend the life of GE 1.5MW wind turbine gearboxes through technology upgrades validated by Sentient Science's computational testing.
2. Sentient Science used its DigitalClone technology to simulate and compare the upgraded Moventas PLH-1100-XL gearbox against the legacy design. The simulations showed lower contact stresses with the upgraded design.
3. Key upgrades included a case-carburized ring gear, integrated 2-row planet gear bearings, improved surface roughness, material specifications, and a new white etch-resistant bearing material for high-speed stages.
This document discusses the design and manufacturing of a testing machine to analyze the tribological behavior of sliding contact materials. It provides background information on tribology and its importance. The testing machine was designed and manufactured to measure the dynamic coefficient of friction of various materials in order to evaluate their potential for applications requiring low friction and wear resistance. Common problems with mechanical seals are also summarized, including failure due to restricted motion, thermal degradation, material attacks, and incorrect installation.
The document is a micro project report on the manufacturing of a camshaft. It discusses the various materials used to make camshafts such as cast iron, steel, and aluminum. It also outlines the processes involved which include designing, casting, forging, heat treatment, and machining operations like turning, drilling, and grinding. The aim is to collect information about the different materials and manufacturing methods for camshafts.
This presentation runs through case studies illustrating why machine failures are an invaluable source of knowledge. Yes, it comes at an expense, downtime, repairs and can have a significant impact on safety. However, it is the key lessons from a failure investigation that drive continuous improvement and, with it, commercial success and an environment where safety is paramount.
The studies draw on the concept of the price of non-conformance and why solely focusing on commercial short term gain can ultimately lead to long term pain. This is particularly true for critical assets that can affect production and safety if something goes wrong.
IRJET- Design and Analysis of Crane Hook by using Composite MaterialIRJET Journal
This document describes a study that analyzed the design and stresses in a crane hook made of compacted graphite iron composite material compared to a forged steel crane hook. The crane hook model was designed in CATIA V5 and then both materials were analyzed in ANSYS for stresses and deformations under load. The results showed that the compacted graphite iron crane hook had lower stresses and weight than the forged steel design. Therefore, the study concluded that compacted graphite iron could be an improved alternative material for crane hooks compared to traditional forged steel.
The crankshaft converts the reciprocating motion of the piston into rotational motion. It consists of journals, crank webs, and crankpins. Crankshafts can be single-piece, shrunk-fit, or welded constructions. Stresses in the crankshaft include bending, twisting, and residual stresses from shrink fitting. Materials are typically carbon steels. Large two-stroke engines use semi-built crankshafts constructed by shrink fitting forged webs and journals. Medium-speed four-stroke engines use forged one-piece crankshafts. Connecting rods transmit force between the piston and crankshaft and help lubricate the bottom end.
The document discusses current-insulated bearings and how they can prevent damage caused by electrical current. It provides 3 key points:
1) Electrical current passing through bearings can cause damage like craters and welding beads on the raceways. This can lead to bearing failure.
2) Current-insulated bearings like ceramic-coated bearings act as resistors and capacitors to disrupt the flow of current. This prevents damage from occurring.
3) A variety of ceramic-coated bearing models from different manufacturers are available in sizes ranging from 60-180mm to insulate against voltages up to 1,000VDC.
Design and Analysis Of Hybrid Car Using Tubular Frame Chasis and Helium GasIRJET Journal
This document describes the design and analysis of a hybrid car using a tubular frame chassis and helium gas. It discusses the components of the car including the electric DC motor, frame, battery, and drive. Chromoly steel 4130 is selected for the tubular frame chassis due to its high strength and stiffness properties. Helium gas is selected to fill the chassis due to its low density, lifting properties, and compliance with regulations. Structural analysis using ANSYS software shows the maximum deformation of the chassis design is within permissible limits. The car is powered by a battery and electric DC motor, with the goal of reducing weight through the use of helium gas in the frame.
This document summarizes a study on the finite element analysis and design of experiments of a parabolic leaf spring for a mini loader truck. The leaf spring was modeled in CATIA V5 and analyzed for maximum von Mises stress and displacement. Design of experiments was conducted by varying the camber and eye distance. The results showed that increasing camber decreases displacement while increasing stress, and increasing eye distance increases both displacement and stress. The optimum leaf spring dimensions can be determined from the design of experiments analysis.
The Ecotec 2.2L I-4 engine used in drag racing versions of the Cavalier and Sunfire can generate up to 1,000 horsepower while using mostly production-based components. These front-wheel drive race cars showcase the potential of the Ecotec engine. The production version of the Ecotec puts out 144 horsepower and 155 pound-feet of torque using lightweight aluminum construction and dual overhead camshafts with 4 valves per cylinder. The modular design of the Ecotec makes it suitable for a variety of applications.
This document presents information on a magnetic repulsion permanent engine (MRPE). It consists of 3 sentences:
The MRPE works by using repulsion and attraction forces between permanent magnets and a ferromagnetic plate to push and pull magnetic pistons inside cylinders, replacing the combustion process of a traditional engine. It describes the basic components, including the magnetic pistons, cylinder, flywheel rod, repulsion-attraction plate, and control electronics to synchronize piston movement. The document outlines the working principle, operation cycle, speed control, and advantages over fossil fuel engines, such as being fuel-less, low maintenance, and environmentally friendly.
This document summarizes a milling workshop that discussed:
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Engine materials for camshaft and crankshaft
1. Material and technology
for Automotive engine:
brief overview
o The camshaft
o The crankshaft
Materials and technology for automotive engine
Catania, 06/07/2012, A.Manicone
3. The camshaft - 1
The valve operating mechanism
transforms rotation of the
crankshaft into reciprocating
motion in the valves.
The valves protrude into
the combustion chamber and
are pushed back by the reactive
force of the valve spring.
Ωcamshaft= Ωcrankshaft/2
- Ωcamshaft high: contact pressure is reduced by the inertia of the valve lifter (oil is
providing hydrodynamic lubrication);
- Ωcamshaft low: contact pressure is highest and lubrication most challenging.
Materials and technology for automotive engine
Catania, 06/07/2012, A.Manicone
4. The camshaft - 2
Machining, dimension
accuracy, clearance, rou
Wear of sliding portion
ghness Friction condition 1. Rugged surface due to wear
1. Lubrication
2. Contact 2. Adhesive wear
Lubricating oil 3. Foreign object 3. Fatigue wear
condition 4. Corrosive wear
Flaking (scagliatura)
Pitting (corrosione per vaiolatura)
• It is very important to choose an appropriate combination of materials.
• The torque from the crankshaft drives the camshaft: it must have high torsional rigidity.
Materials and technology for automotive engine
Catania, 06/07/2012, A.Manicone
5. The camshaft - 3
Chill hardening cannot be used where the gap between the cam lobes is narrow because
of the difficulty in using the chiller, so forged camshafts are used.
Tough martensite is more resistant to pitting than the chill microstructure.
Materials and technology for automotive engine
Catania, 06/07/2012, A.Manicone
6. The camshaft - 4
• Finishing – boring and grinding
• ASSEMBLING
• E.g.: Hydroforming
Materials and technology for automotive engine
Catania, 06/07/2012, A.Manicone
8. The crankshaft - 1
The crankshaft converts reciprocative motion to rotational motion.
Two types:
• the monolithic type
• the assembled type
Materials and technology for automotive engine
Catania, 06/07/2012, A.Manicone
9. The crankshaft - 2
Note:
Included lead or MnS
Carbon steel particles significantly
function as a chip
breaker and a solid
Alloyed steel lubricant and increase
machinability.
Micro Alloyed steel
Typical materials • less expensive
• nodular cast iron: for high-
volume, low-load production. • lower rigidity: abnormal vibrations (resonance)
• increases in rigidity of more than 10%
• reduces noise levels and harshness
• forged steel: for fuel-efficient • makes possible a careful design
engines requiring a high power-to-
displacement ratio. • more expensive
Materials and technology for automotive engine
Catania, 06/07/2012, A.Manicone
10. The crankshaft - 3
• Static: combustion pressure, inertial
forces of the piston and con-
rod, bearing load and drive torque.
STRESS on
Crankshaft • Dynamic: The vibration causes
dynamic stress. If it occurs at the
resonating frequency, the deformation Fatigue fracture of a carbon steel
will be very high and will instantly S50C crankshaft
rupture the crankshaft.
HIGH STATIC AND DYNAMIC RIGIDITY:
- increasing the crankpin diameter (increasing weight)
- using forged steel
- Surface-hardening methods
Materials and technology for automotive engine
Catania, 06/07/2012, A.Manicone
11. Fatigue behaviour: principles and survey
Principi (macro)
σa Wöhler [1860]
Ampiezza
tensione
applicata
Vita finita * Legge di Basquin:
σa = σf’ (2Nf)b
*
Tipici
Curva tipica
acciai
per acciai
σL
Leghe di
alluminio
Vita infinita
104 105 106 107
Cicli alla rottura, Nf
Dipende da:
•Tipo di materiale • Concentrazione di • Contenuto di inclusioni e
tensioni impurezze
• Trattamento termico • Tensione media e
superficiale tipo di sollecitazione
Materials and technology for automotive engine
Catania, 06/07/2012, A.Manicone
12. The crankshaft - 4
HOT FORGING PROCESS (for a four-stroke crankshaft)
• The coarse structure is broke down and is
replaced, as recrystallisation proceeds, by one
which is of relatively fine grain
• Impuritires are redistribuited in a fibrous form
• Introduction of compressive residual stresses
Materials and technology for automotive engine
Catania, 06/07/2012, A.Manicone
13. The crankshaft - 5
SURFACE HARDENING
(carburizing, nitring, carbonitring and nitrocarburizing):
• CARBURIZING
O: origins
S: a few beachmarks
B: arrest lines
R: ratchet marks
Pitting observed at a crankpin surface
Materials and technology for automotive engine
Catania, 06/07/2012, A.Manicone
14. The crankshaft - 6
SURFACE HARDENING
(carburizing, nitring, carbonitring and nitrocarburizing):
• CARBURIZING
Compressive residual stress
generated by carburizing
Materials and technology for automotive engine
Catania, 06/07/2012, A.Manicone
15. The crankshaft - 7
Modern carburizing technology: Acetylene Vacuum Carburizing- AvaC
Steel
Fe
Acetilene Siti di adsorbimento
Cr
C H2
Mn
Materials and technology for automotive engine
A. Manicone Catania, 06/07/2012, A.Manicone
16. The crankshaft - 7
Avac - Adsorbimento (T>Taustenitizzazione)
Steel
Fe
Acetilene Siti di adsorbimento
Cr
C H2
Mn
Materials and technology for automotive engine
A. Manicone Catania, 06/07/2012, A.Manicone
17. The crankshaft - 7
Avac - Decomposizione in radicali
Steel
Fe
Acetilene Siti di adsorbimento
Cr
C H2
Mn
Materials and technology for automotive engine
A. Manicone Catania, 06/07/2012, A.Manicone
18. The crankshaft - 7
Avac - Inizio cementazione (T>Taustenitizzazione)
Steel
Fe
Acetilene Siti di adsorbimento
Cr
C H2
Mn
Materials and technology for automotive engine
A. Manicone Catania, 06/07/2012, A.Manicone
19. The crankshaft - 7
Avac - Inizio cementazione (T>Taustenitizzazione)
Steel
Fe
Acetilene Siti di adsorbimento
Cr
C H2
Mn
Materials and technology for automotive engine
A. Manicone Catania, 06/07/2012, A.Manicone
20. The crankshaft - 7
Avac - Inizio cementazione (T>Taustenitizzazione)
Steel
Fe
Acetilene Siti di adsorbimento
Cr
C H2
Mn
Materials and technology for automotive engine
A. Manicone Catania, 06/07/2012, A.Manicone
21. The crankshaft - 7
Diffusione nell‘acciaio (T>Taustenitizzazione)
Steel
Fe
Acetilene Siti di adsorbimento
Cr
C H2
Mn
Materials and technology for automotive engine
A. Manicone Catania, 06/07/2012, A.Manicone
22. The crankshaft - 7
Saturazione
Steel
Fe
Acetilene Siti di adsorbimento
Cr
C H2
Mn
Materials and technology for automotive engine
A. Manicone Catania, 06/07/2012, A.Manicone
23. The crankshaft - 7
SURFACE HARDENING
(carburizing, nitring, carbonitring and nitrocarburizing):
• NITRING: NH3
decomposes at the steel surface to catalytically generate elemental nitrogen, which
diffuses into the material. The nitrogen expands the iron lattice and also forms hard
compounds (the nitrides Fe4N and Fe3N) with iron atoms.
Nitridable steel reaches the necessary hardness by forming stable nitrides (Al, Cr, V…)
• NITROCARBURIZING, CARBONITRURING
• higher hardness surface,
• but lower toughness
• INDUCTION HARDENING
Materials and technology for automotive engine
Catania, 06/07/2012, A.Manicone
24. The crankshaft - 8
RECENT TRENDS: Micro alloyed steel, via plasma ion nitring
Precipitation hardening is the main method for increasing strength at the
cooling stage after hot forging.
Micro-alloyed steel contains a small amount of V, which dissolves in the
matrix during hot forging above 1,200 °C. During air cooling, the dissolved V
combines with carbon and nitrogen to precipitate as vanadium carbide and
nitride at around 900 °C.
the vanadium
carbide and nitride will
be more finely
dispersed.
Materials and technology for automotive engine
Catania, 06/07/2012, A.Manicone
25. The crankshaft - 9
Manufacturing process
• Trade-off:
machinability-fatigue
resistance
• Surface roughness
For low and medium loaded bearings: Ra = 15
microinch max. Rz = 60 microinch max.
For highly loaded bearings: Ra = 10 microinch
max. Rz = 30 microinch max.
Materials and technology for automotive engine
Catania, 06/07/2012, A.Manicone
26. The crankshaft - 10
Conclusions: Methods to strengthen crankshafts
Materials and technology for automotive engine
Catania, 06/07/2012, A.Manicone
27. Material and technology
for Automotive engine:
brief overview
Thanks for
attention
Materials and technology for automotive engine
Catania, 06/07/2012, A.Manicone