Abstract: The rear axle has a housing, tubes for the axle shafts, a final drive (including the differential with reduction gears), and the axle shafts. The rear axle is joined to the frame or body of the motor vehicle (to the supporting body if the motor vehicle has no frame) by a suspension. The rear axle test rig machine is used for testing the braking system of rear axle. The existing machine does not have any mechanism for applying brake. The brake is applied manually and higher force is required for pulling the brake cable. The force applied is in backward direction with the help of hand and applying tensile force on it. More cycle time is required for performing work in existing system. Manual operation increases the operator fatigue. The modified rear axle test rig machine consists of handbrake assembly, clamping fixture (dowel pin), cable fixture, stud, L shaped plates etc. The brake is applied by handbrake by pulling it in upward direction causing tension in wire. The modified rear axle machine reduces cycle time and increases safety for workers. The proper tension in wire helps for proper braking and the tension in wire can be adjusted with help of dowel pin.
Design And Analysis of Test Rig for Rudder PedalIRJET Journal
This document describes the design and analysis of a test rig for rudder pedals. Finite element analysis was used to analyze the test rig design and verify that it can withstand loads from testing the rudder pedals. The test rig model was analyzed under static and dynamic loads up to 1400kg, and was found to have a maximum stress of 67.7N/mm^2 and displacement of 0.49mm, meeting design requirements. The analysis validated the test rig design for safely testing rudder pedals without damage.
FEA OF A CRANKSHAFT IN CRANK-PIN WEB FILLET REGION FOR IMPROVING FATIGUE LIFEijiert bestjournal
A crankshaft is often designed with a fillet radius to improving fatigue life of crankshaft. The fatigue life of crankshaft is depend on the proper fillet radius. This fillet radius is changes than fatigue life is also changes of crankshaft. In most of the time fatigue failure is occur in crank-pin web fillet region. The crankshaft fillet rolling process is one of the commonly adopted methods in engineering to improve fatigue life of the crankshaft. A finite element analysis is implemented to approximate the stress distribution induced in the crankpin fillet region. The modelling of crankshaft is created by Creo-parametric. Finite element analysis is performed to obtain the variation of stress at critical locations and fatigue life of the crank shaft using the ANSYS software and applying th e boundary conditions. Radius of fillet is changes in model of crankshaft to improvement in fatigue life. Th is work in doing for optimization of a crankshaft in crank-pin web fillet region with fatigue life as well as to study a relation between fillet radius/diameter of crankpin to fatigue life. .
Performance Analysis of 5-D Coupling for Parallel Angular TransmissionIJSTA
This document analyzes the performance of a 5-dimensional coupling used for parallel angular power transmission. Experimental tests were conducted on a test rig using a dynamometer to measure torque, power, and efficiency at varying loads and speeds with 30mm parallel offset and 40 angular offset. The results showed that maximum power and efficiency were achieved at around 1200 rpm for 30mm parallel offset and 900 rpm for 40 angular offset. Therefore, these speeds are recommended for maximum power transmission efficiency under these offset conditions.
ME010 801 Design of Transmission Elements
(Common with AU010 801)
Teaching scheme Credits: 4
2 hours lecture, 2 hour tutorial and 1 hour drawing per week
Objectives
To provide basic design skill with regard to various transmission elements like clutches, brakes, bearings and
gears.
Module I (20 Hrs)
Clutches - friction clutches- design considerations-multiple disc clutches-cone clutch- centrifugal clutch -
Brakes- Block brake- band brake- band and block brake-internal expanding shoe brake.
Module II (17 Hrs)
Design of bearings - Types - Selection of a bearing type - bearing life - Rolling contact bearings - static
and dynamic load capacity - axial and radial loads - selection of bearings - dynamic equivalent load -
lubrication and lubricants - viscosity - Journal bearings - hydrodynamic theory - design considerations -
heat balance - bearing characteristic number - hydrostatic bearings.
Module III (19 Hrs)
Gears- classification- Gear nomenclature - Tooth profiles - Materials of gears - design of spur, helical,
bevel gears and worm & worm wheel - Law of gearing - virtual or formative number of teeth- gear tooth
failures- Beam strength - Lewis equation- Buckingham’s equation for dynamic load- wear loadendurance strength of tooth- surface durability- heat dissipation - lubrication of gears - Merits and
demerits of each type of gears.
Module IV (16 Hrs)
Design of Internal Combustion Engine parts- Piston, Cylinder, Connecting rod, Flywheel
Design recommendations for Forgings- castings and welded products- rolled sections- turned parts,
screw machined products- Parts produced on milling machines. Design for manufacturing - preparation
of working drawings - working drawings for manufacture of parts with complete specifications including
manufacturing details.
Note: Any one of the following data book is permitted for reference in the final University examination:
1. Machine Design Data hand book by K. Lingaiah, Suma Publishers, Bangalore/ Tata Mc Graw Hill
2. PSG Design Data, DPV Printers, Coimbatore.
Text Books
1. C.S,Sarma, Kamlesh Purohit, Design of Machine Elements Prentice Hall of India Ltd NewDelhi
2. V.B.Bhandari, Design of Machine Elements McGraw Hill Book Company
3. M. F. Spotts, T. E. Shoup, Design of Machine Elements, Pearson Education.
Reference Books
1. J. E. Shigley, Mechanical Engineering Design, McGraw Hill Book Company.
2. Juvinall R.C & Marshek K.M., Fundamentals of Machine Component Design, John Wiley
3. Doughtie V.L., & Vallance A.V., Design of Machine Elements, McGraw Hill Book Company.
4. Siegel, Maleev & Hartman, Mechanical Design of Machines, International Book Company
COMPARATIVE ANALYSIS OF CRANKSHAFT IN SINGLE CYLINDER PETROL ENGINE CRANKSHAF...ijiert bestjournal
The crankshaft is also referred as crank. It is responsible for conversion between reciprocating
motion and rotational motion. In a reciprocating engine, it translates reciprocating linear piston
motion into rotational motion. In a reciprocating compressor, it converts the rotational motion
into reciprocating motion. Here the failure of crankshafts for two wheelers mostly occurs in the
crankpin. Thus the crankpin is an important component that mostly decides the life of the
crankshaft. The crankshaft considered here is of Pulsar 180 DTSi. It is a petrol engine crankshaft
made from Alloy steel 41Cr4.Abnormal sound was heard in crankshaft while it is in operation. It
was identified as failure of crankshaft. Severe wear has been observed at crankpin bearing
location where the oil hole is provided. Here the analysis of the two wheeler crankshaft is done.
Its results are then compared and verified numerically, then by the use of ANSYS software. The
results compared here are Von Mises Stresses and the strain occurring on the crankshaft.
Design Optimization Of Chain Sprocket Using Finite Element AnalysisIJERA Editor
This document summarizes a study that performed design optimization of a chain sprocket using finite element analysis. The sprocket was first designed and analyzed using ANSYS software for static and fatigue analysis. Based on the results, the sprocket design was optimized for weight reduction while ensuring it remained safe and reliable. The modified design was re-analyzed using static, fatigue, and modal analyses in ANSYS. The analyses confirmed the optimized design had reduced weight and stress while maintaining a sufficient safety factor and fatigue life for use.
IRJET- Design and Finite Element Analysis(FEA) of Formula Student ChassisIRJET Journal
This document discusses the design and finite element analysis of a Formula Student race car chassis. The chassis was modeled in Solidworks and analyzed in Altair Hypermesh. Several types of analyses were performed, including front impact, side impact, rear impact, bump, front/rear axial, front/rear torsional, lateral bending, and roll over analyses. The analyses calculated stress levels and displacements under simulated load conditions. Factors of safety ranged from 1.19 to 12.6, indicating the design would withstand the expected forces without yielding. Validation testing found the torsional rigidity to be 20-61.8% lower than FEA predictions, due to limitations of the physical test setup. The analyses and testing
STRESS ANALYSIS OF SPUR GEAR BY USING ANSYS WORKBENCHSumit Nagar
The document discusses analyzing the stress on a spur gear using ANSYS Workbench. It begins by providing background on different types of gears and power transmission systems. It then describes spur gears in particular, including their structure, functions, advantages, disadvantages, and applications. The document outlines the objectives of performing finite element analysis on a spur gear model to minimize stresses at critical locations, validate results with experimental data, and compare to theoretical analyses. The goal is to optimize the gear shape to reduce stresses.
Design And Analysis of Test Rig for Rudder PedalIRJET Journal
This document describes the design and analysis of a test rig for rudder pedals. Finite element analysis was used to analyze the test rig design and verify that it can withstand loads from testing the rudder pedals. The test rig model was analyzed under static and dynamic loads up to 1400kg, and was found to have a maximum stress of 67.7N/mm^2 and displacement of 0.49mm, meeting design requirements. The analysis validated the test rig design for safely testing rudder pedals without damage.
FEA OF A CRANKSHAFT IN CRANK-PIN WEB FILLET REGION FOR IMPROVING FATIGUE LIFEijiert bestjournal
A crankshaft is often designed with a fillet radius to improving fatigue life of crankshaft. The fatigue life of crankshaft is depend on the proper fillet radius. This fillet radius is changes than fatigue life is also changes of crankshaft. In most of the time fatigue failure is occur in crank-pin web fillet region. The crankshaft fillet rolling process is one of the commonly adopted methods in engineering to improve fatigue life of the crankshaft. A finite element analysis is implemented to approximate the stress distribution induced in the crankpin fillet region. The modelling of crankshaft is created by Creo-parametric. Finite element analysis is performed to obtain the variation of stress at critical locations and fatigue life of the crank shaft using the ANSYS software and applying th e boundary conditions. Radius of fillet is changes in model of crankshaft to improvement in fatigue life. Th is work in doing for optimization of a crankshaft in crank-pin web fillet region with fatigue life as well as to study a relation between fillet radius/diameter of crankpin to fatigue life. .
Performance Analysis of 5-D Coupling for Parallel Angular TransmissionIJSTA
This document analyzes the performance of a 5-dimensional coupling used for parallel angular power transmission. Experimental tests were conducted on a test rig using a dynamometer to measure torque, power, and efficiency at varying loads and speeds with 30mm parallel offset and 40 angular offset. The results showed that maximum power and efficiency were achieved at around 1200 rpm for 30mm parallel offset and 900 rpm for 40 angular offset. Therefore, these speeds are recommended for maximum power transmission efficiency under these offset conditions.
ME010 801 Design of Transmission Elements
(Common with AU010 801)
Teaching scheme Credits: 4
2 hours lecture, 2 hour tutorial and 1 hour drawing per week
Objectives
To provide basic design skill with regard to various transmission elements like clutches, brakes, bearings and
gears.
Module I (20 Hrs)
Clutches - friction clutches- design considerations-multiple disc clutches-cone clutch- centrifugal clutch -
Brakes- Block brake- band brake- band and block brake-internal expanding shoe brake.
Module II (17 Hrs)
Design of bearings - Types - Selection of a bearing type - bearing life - Rolling contact bearings - static
and dynamic load capacity - axial and radial loads - selection of bearings - dynamic equivalent load -
lubrication and lubricants - viscosity - Journal bearings - hydrodynamic theory - design considerations -
heat balance - bearing characteristic number - hydrostatic bearings.
Module III (19 Hrs)
Gears- classification- Gear nomenclature - Tooth profiles - Materials of gears - design of spur, helical,
bevel gears and worm & worm wheel - Law of gearing - virtual or formative number of teeth- gear tooth
failures- Beam strength - Lewis equation- Buckingham’s equation for dynamic load- wear loadendurance strength of tooth- surface durability- heat dissipation - lubrication of gears - Merits and
demerits of each type of gears.
Module IV (16 Hrs)
Design of Internal Combustion Engine parts- Piston, Cylinder, Connecting rod, Flywheel
Design recommendations for Forgings- castings and welded products- rolled sections- turned parts,
screw machined products- Parts produced on milling machines. Design for manufacturing - preparation
of working drawings - working drawings for manufacture of parts with complete specifications including
manufacturing details.
Note: Any one of the following data book is permitted for reference in the final University examination:
1. Machine Design Data hand book by K. Lingaiah, Suma Publishers, Bangalore/ Tata Mc Graw Hill
2. PSG Design Data, DPV Printers, Coimbatore.
Text Books
1. C.S,Sarma, Kamlesh Purohit, Design of Machine Elements Prentice Hall of India Ltd NewDelhi
2. V.B.Bhandari, Design of Machine Elements McGraw Hill Book Company
3. M. F. Spotts, T. E. Shoup, Design of Machine Elements, Pearson Education.
Reference Books
1. J. E. Shigley, Mechanical Engineering Design, McGraw Hill Book Company.
2. Juvinall R.C & Marshek K.M., Fundamentals of Machine Component Design, John Wiley
3. Doughtie V.L., & Vallance A.V., Design of Machine Elements, McGraw Hill Book Company.
4. Siegel, Maleev & Hartman, Mechanical Design of Machines, International Book Company
COMPARATIVE ANALYSIS OF CRANKSHAFT IN SINGLE CYLINDER PETROL ENGINE CRANKSHAF...ijiert bestjournal
The crankshaft is also referred as crank. It is responsible for conversion between reciprocating
motion and rotational motion. In a reciprocating engine, it translates reciprocating linear piston
motion into rotational motion. In a reciprocating compressor, it converts the rotational motion
into reciprocating motion. Here the failure of crankshafts for two wheelers mostly occurs in the
crankpin. Thus the crankpin is an important component that mostly decides the life of the
crankshaft. The crankshaft considered here is of Pulsar 180 DTSi. It is a petrol engine crankshaft
made from Alloy steel 41Cr4.Abnormal sound was heard in crankshaft while it is in operation. It
was identified as failure of crankshaft. Severe wear has been observed at crankpin bearing
location where the oil hole is provided. Here the analysis of the two wheeler crankshaft is done.
Its results are then compared and verified numerically, then by the use of ANSYS software. The
results compared here are Von Mises Stresses and the strain occurring on the crankshaft.
Design Optimization Of Chain Sprocket Using Finite Element AnalysisIJERA Editor
This document summarizes a study that performed design optimization of a chain sprocket using finite element analysis. The sprocket was first designed and analyzed using ANSYS software for static and fatigue analysis. Based on the results, the sprocket design was optimized for weight reduction while ensuring it remained safe and reliable. The modified design was re-analyzed using static, fatigue, and modal analyses in ANSYS. The analyses confirmed the optimized design had reduced weight and stress while maintaining a sufficient safety factor and fatigue life for use.
IRJET- Design and Finite Element Analysis(FEA) of Formula Student ChassisIRJET Journal
This document discusses the design and finite element analysis of a Formula Student race car chassis. The chassis was modeled in Solidworks and analyzed in Altair Hypermesh. Several types of analyses were performed, including front impact, side impact, rear impact, bump, front/rear axial, front/rear torsional, lateral bending, and roll over analyses. The analyses calculated stress levels and displacements under simulated load conditions. Factors of safety ranged from 1.19 to 12.6, indicating the design would withstand the expected forces without yielding. Validation testing found the torsional rigidity to be 20-61.8% lower than FEA predictions, due to limitations of the physical test setup. The analyses and testing
STRESS ANALYSIS OF SPUR GEAR BY USING ANSYS WORKBENCHSumit Nagar
The document discusses analyzing the stress on a spur gear using ANSYS Workbench. It begins by providing background on different types of gears and power transmission systems. It then describes spur gears in particular, including their structure, functions, advantages, disadvantages, and applications. The document outlines the objectives of performing finite element analysis on a spur gear model to minimize stresses at critical locations, validate results with experimental data, and compare to theoretical analyses. The goal is to optimize the gear shape to reduce stresses.
1) The document simulates testing of an ATV roll cage in ANSYS to evaluate its performance against crashes.
2) A model of the roll cage and vehicle is created using pipe, mass, and spring elements. The roll cage is tested under front impact, rear impact, side impact, torsional stiffness, front wheel bump, and rollover conditions.
3) The results show that under all test conditions, the stress and deflection of the roll cage are within safe limits, though further optimization may be possible to reduce weight.
In structural design, torsional moment may, on occasion, be a significant force for which
provision must be made. The most efficient shape for carrying a torque is a hollow circular shaft;
extensive treatment of torsion and torsion combined with bending and axial force is to be found
in most texts on mechanics of materials.
When a simple circular solid shaft is twisted, the shearing stress at any point on a transverse
cross-section varies directly as the distance from the center of the shaft. Thus, during twisting,
the cross-section which is initially planar remains a plane and rotates only about the axis of the
shaft.
Torsion members are frequently encountered in structures and machines. A structural member
may need to resist torques induced by a load, such as wind or gravity. Machinery examples
include motor vehicle drive shafts, torsion bar suspensions, ship propeller shafts, and centrifugal
pump shafts. In the analysis of torsionally loaded members, we are primarily concerned with the
torsion stress and the angle of twist on the shaft. In our laboratory experiment, the primary
emphasis is on the recognition of torsion on the usual structural members, how the torsion
stresses may be approximated and how such members may be selected to resist torsion effects.
Design & Fabrication of Low Cost Small-Scale Fatigue Testing MachineAvinash Barve
Many engineering machines and mechanical components are subjected to fluctuating stresses, taking place at relatively high frequencies and under these conditions, failure is found to occur. This is “fatigue failure”.
Fatigue is a failure of material or machine due to the action of repeated or fluctuating stress on a machine member for some number of times/cycles. This failure begins with a small crack. The initial crack is so minute that it cannot be detected by the naked eye and is even quite difficult to locate . And this led to the invention of a fatigue the testing machine.
In view of effective design that will not fail accidentally, this research is conceived. This testing machine will determine the strength of materials under the action of fatigue load. Specimens are subjected to repeated varying forces or fluctuating loading of specific magnitude while the cycles or stress reversals are counted to destruction. The first test will include the fatigue test of the material . The second test which we are going to combine testing of bending or torsion. Thus the results of these processes will be plotted through software integration.
The document proposes the design and development of a universal testing machine with a load capacity of 0.3kN. The applicants, Aashish Kholiya and Ravi Teja, are undergraduate students at IIT Ropar who are undertaking this project under the guidance of Dr. Dhiraj Mahajan. They plan to design components like the ball screw, base plate, select appropriate sensors and a stepper motor. Their objectives are to develop a low-cost machine with high accuracy. They have conducted preliminary work on component design and sensor selection. A work plan with timeline is also provided to complete the project in 6 months. If approved, the project will be executed at IIT Ropar.
IRJET-Analysis of Load Factors and Modes of Failure on Spur GearIRJET Journal
The document analyzes the load factors and modes of failure in spur gears. A finite element analysis is conducted to determine the load distribution factor in AGMA formulas for spur gears with different shaft misalignments. The 3D gear model is imported into ANSYS to calculate maximum bending and contact stresses using FEA. The results are then compared to analytical calculations to estimate the load distribution factor. Key factors influencing bending stress on gear teeth are also considered, including load distribution, stress concentration, and external factors.
Springs are elastic machine elements that deflect under load and return to their original shape when the load is removed. This document discusses the design of helical compression springs. It defines spring terminology such as mean diameter, spring index, solid length, and pitch. It presents the load-stress and load-deflection equations for spring design. It also discusses stresses in springs, series and parallel spring connections, surge, and the design procedure for helical springs. As an example, it solves a problem involving the design of concentric springs for an aircraft engine valve.
The document discusses the design of aircraft fuselages. It notes that fuselages must house passengers and luggage with proper strength and light weight. Fuselages experience both distributed and concentrated loads from various sources. A circular cross-section is commonly used as it efficiently handles these loads. Fuselage structures typically consist of a thin-walled tube with transverse frames, stringers, and cutouts. The document provides an example problem calculating the ultimate bending strength of a circular fuselage cross-section made of aluminum with stringers of different sizes. It considers linear and nonlinear stress distributions to determine the maximum moment the fuselage can withstand before failure.
DESIGN & DEVELOPMENT OF EXPERIMENTAL SETUP OF INTEGRATED FATIGUE TESTING MACHINEAvinash Barve
This document summarizes a student project to design and develop an experimental setup for an integrated fatigue testing machine. A group of 8 students worked on the project under the guidance of a professor. The machine was designed to perform both fatigue tests and torsional tests to study the effects of fluctuating stresses on materials. It includes an electric motor, adjustable chucks to hold different sized samples, and sensors to collect computerized data on sample failures. The design was analyzed using ANSYS and the components were fabricated according to the design. The future scope discusses expanding the design to handle larger samples and additional tests like compression.
The document describes the design of a lifting mechanism for agricultural equipment attachments. The mechanism uses wedges and a power screw actuated by hand to lift attachments like plows. It aims to provide lifting capability with reduced cost, size, and weight compared to hydraulic mechanisms. Key components include a holder, bell crank, two wedges, base, and power screw. Calculations are shown for component sizing. A prototype is tested lifting a 10kg L-shaped attachment. Analysis shows the bell crank can withstand over 300kg of load with minimal deflection and stress. The mechanism performs as intended and has potential for industrial and other lifting applications.
Torsional oscillation of a single rotor with viscous dampingSaif al-din ali
SAIF ALDIN ALI MADIN
سيف الدين علي ماضي
S96aif@gmail.com
Torsional oscillation of a single rotor with viscous damping
• Effect of including a damper in a system undergo ng torsional oscillation
• The amount of damping in the system depends on the extent to which the conical portion of a rotor is exposed to the viscous effects of given oil
This document is a thesis submitted by Pravardhan S. Shenoy to the University of Toledo in partial fulfillment of a Master of Science degree in Mechanical Engineering. The thesis, advised by Dr. Ali Fatemi, involves dynamic load analysis and optimization of a connecting rod. The study performs load analysis on the connecting rod to determine dynamic loads over time. Finite element analysis is conducted under quasi-dynamic and static loads. The connecting rod is then optimized for weight and cost subject to constraints like fatigue life.
Modeling and Analysis of Two Wheeler Connecting Rod by Using AnsysIOSR Journals
Connecting rod is a major link inside of a internal combustion engine. It is the intermediate member
between the piston and the crankshaft. Its primary function is to transmit the push and pull from the piston pin
to the crank pin thus converting the reciprocating motion of piston in to rotary motion of the crank. In this paper
a static analysis is conducted on a connecting rod of a single cylinder 4-stroke petrol engine. The model is
developed using Solid modeling software i.e. PRO/E (creo-parametric). Further finite element analysis is done
to determine the von-misses stresses shear stress and strains for the given loading conditions.
1. The document discusses different types of clutches including positive clutches and friction clutches. It describes the key components and operation of a single plate clutch commonly used in automotive applications.
2. Formulas are presented for calculating the torque capacity of clutches under uniform pressure and uniform wear conditions based on geometric parameters, pressure, and coefficient of friction.
3. The document provides an example problem demonstrating the use of the formulas to design a multi-plate clutch meeting specific torque and speed requirements.
DESIGN AND FABRICATION OF FATIGUE TESTING MACHINERakesh J M
The document discusses the design and development of a low-cost fatigue testing machine for sheet metals. It aims to address the limitations of existing universal fatigue testing machines which are expensive and require skilled labor. The proposed prototype will be cheaper and easier to operate, making it more suitable for small industries. It will use components like a stepped pulley system and a hammer mechanism driven by a motor to apply cyclic loads on sheet metal specimens. The design considerations, methodology, calculations and test results validating the prototype are presented. The machine is able to successfully determine the fatigue strength of aluminum, brass and copper sheet metals at a lower cost.
Static & Dynamic Analysis of Spur Gear using Different MaterialsIRJET Journal
The document describes a study analyzing the static and dynamic behavior of a spur gear made from different materials using finite element analysis. A spur gear model is created in Solidworks and imported into ANSYS for static structural and modal analysis. The static analysis determines deformation and stresses under torque loading, while modal analysis determines natural frequencies and mode shapes. Analysis is performed for structural steel, gray cast iron, aluminum alloy, and epoxy glass composite materials. Results show the composite material has the lowest deformation and weight but higher stresses compared to the metal materials. The natural frequencies are also reported for different materials.
Torsion refers to the twisting of a shaft when a torque or twisting moment acts on it. The angle of twist is defined as the angle through which the shaft's cross section rotates due to the torque. Torque causes rotation, while torsion is the effect produced by torque. Torsion occurs in a shaft when it is subjected to two equal and opposite twisting moments, known as pure torsion. The torsion equation relates the angle of twist in a shaft to the applied torque based on certain assumptions about the shaft's material properties and dimensions. Power can be transmitted through a rotating shaft by applying torque that causes torsion.
ME6503 design of machine elements - question bank.Mohan2405
This document contains questions and problems related to the design of machine elements, specifically regarding shafts and couplings. It includes 20 questions in Part A testing basic recall and understanding, 13 multi-part problems in Part B applying concepts to design scenarios, and 4 complex design problems in Part C. The topics covered include stresses in shafts, hollow vs solid shafts, keys and keyways, rigid and flexible couplings, and the design of shafts and keys based on strength and rigidity considerations.
This document summarizes a study on evaluating and improving the strength of an upper control arm for a vehicle suspension system. Finite element analysis was used to analyze the stiffness, slippage between the arm and bushings, and fatigue life. The initial design was made of gray cast iron. Static analysis found the first modified design had lower displacement and stress than the original. Slippage analysis indicated no slipping of the front, rear or ball joints. Fatigue analysis found the original design would fail while modified designs of aluminum or steel would be safe, with a second modified steel design having the highest life and fewest repeats to failure.
Design of Machine Elements 2 mark Question and Answersbaskaransece
This document provides information on the design of machine elements including shafts, keys, and couplings. It begins with definitions of key terms like factor of safety and design processes. It then discusses loads, stresses, materials selection factors. Specific topics covered include types of shafts and stresses on shafts, standard shaft sizes, hollow vs solid shafts, keys and keyways, couplings, and manufacturing methods for shafts.
Unit 2 Design Of Shafts Keys and CouplingsMahesh Shinde
This document provides information about the design of shafts, keys, and couplings. It discusses transmission shafts, stresses induced in shafts, and shaft design based on strength and rigidity. It presents formulas for shaft design using maximum shear stress theory, distortion energy theory, and the ASME code. Several examples are provided to demonstrate how to calculate the diameter of a shaft given the power transmitted, loads on the shaft, material properties, and other parameters using these theories and codes. Assignments involving similar calculations of shaft diameters are presented.
Design and Performance Analysis of Mechanical Hydro Pneumatic Suspension SystemIRJET Journal
The document describes the design and analysis of a mechanical hydro pneumatic suspension system. It aims to improve ride comfort in light commercial vehicles. The proposed system uses a helical coil spring with varying pitch, hydraulic and pneumatic cylinders filled with oil and nitrogen gas respectively. SolidWorks simulations show von Mises stresses below yield strength and displacements under 0.01 mm, indicating the design can withstand loads of 3000N with a safety factor of 2. Calculations confirm the damping ratio meets standards for an under-damped suspension providing a smooth ride. In summary, the suspension system design utilizes mechanical, hydraulic and pneumatic components to enhance ride quality in small commercial vehicles.
Review of shaft failure in Coil Car AssemblyIRJET Journal
This document summarizes a study on failures of shafts in coil car assemblies. The researchers investigated a failed coil car shaft and found that reversed bending fatigue caused it to fracture, occasionally due to misalignment. They calculated loads on the existing shaft theoretically and analytically and found the stresses exceeded permissible levels, indicating it was prone to failure. To improve shaft design, they examined increasing diameter and using fillets/chamfers to disperse stresses. A literature review showed other shaft failures were due to low radius of curvature, incorrect chamfer size increasing stress concentration, and vibrations from imbalance.
1) The document simulates testing of an ATV roll cage in ANSYS to evaluate its performance against crashes.
2) A model of the roll cage and vehicle is created using pipe, mass, and spring elements. The roll cage is tested under front impact, rear impact, side impact, torsional stiffness, front wheel bump, and rollover conditions.
3) The results show that under all test conditions, the stress and deflection of the roll cage are within safe limits, though further optimization may be possible to reduce weight.
In structural design, torsional moment may, on occasion, be a significant force for which
provision must be made. The most efficient shape for carrying a torque is a hollow circular shaft;
extensive treatment of torsion and torsion combined with bending and axial force is to be found
in most texts on mechanics of materials.
When a simple circular solid shaft is twisted, the shearing stress at any point on a transverse
cross-section varies directly as the distance from the center of the shaft. Thus, during twisting,
the cross-section which is initially planar remains a plane and rotates only about the axis of the
shaft.
Torsion members are frequently encountered in structures and machines. A structural member
may need to resist torques induced by a load, such as wind or gravity. Machinery examples
include motor vehicle drive shafts, torsion bar suspensions, ship propeller shafts, and centrifugal
pump shafts. In the analysis of torsionally loaded members, we are primarily concerned with the
torsion stress and the angle of twist on the shaft. In our laboratory experiment, the primary
emphasis is on the recognition of torsion on the usual structural members, how the torsion
stresses may be approximated and how such members may be selected to resist torsion effects.
Design & Fabrication of Low Cost Small-Scale Fatigue Testing MachineAvinash Barve
Many engineering machines and mechanical components are subjected to fluctuating stresses, taking place at relatively high frequencies and under these conditions, failure is found to occur. This is “fatigue failure”.
Fatigue is a failure of material or machine due to the action of repeated or fluctuating stress on a machine member for some number of times/cycles. This failure begins with a small crack. The initial crack is so minute that it cannot be detected by the naked eye and is even quite difficult to locate . And this led to the invention of a fatigue the testing machine.
In view of effective design that will not fail accidentally, this research is conceived. This testing machine will determine the strength of materials under the action of fatigue load. Specimens are subjected to repeated varying forces or fluctuating loading of specific magnitude while the cycles or stress reversals are counted to destruction. The first test will include the fatigue test of the material . The second test which we are going to combine testing of bending or torsion. Thus the results of these processes will be plotted through software integration.
The document proposes the design and development of a universal testing machine with a load capacity of 0.3kN. The applicants, Aashish Kholiya and Ravi Teja, are undergraduate students at IIT Ropar who are undertaking this project under the guidance of Dr. Dhiraj Mahajan. They plan to design components like the ball screw, base plate, select appropriate sensors and a stepper motor. Their objectives are to develop a low-cost machine with high accuracy. They have conducted preliminary work on component design and sensor selection. A work plan with timeline is also provided to complete the project in 6 months. If approved, the project will be executed at IIT Ropar.
IRJET-Analysis of Load Factors and Modes of Failure on Spur GearIRJET Journal
The document analyzes the load factors and modes of failure in spur gears. A finite element analysis is conducted to determine the load distribution factor in AGMA formulas for spur gears with different shaft misalignments. The 3D gear model is imported into ANSYS to calculate maximum bending and contact stresses using FEA. The results are then compared to analytical calculations to estimate the load distribution factor. Key factors influencing bending stress on gear teeth are also considered, including load distribution, stress concentration, and external factors.
Springs are elastic machine elements that deflect under load and return to their original shape when the load is removed. This document discusses the design of helical compression springs. It defines spring terminology such as mean diameter, spring index, solid length, and pitch. It presents the load-stress and load-deflection equations for spring design. It also discusses stresses in springs, series and parallel spring connections, surge, and the design procedure for helical springs. As an example, it solves a problem involving the design of concentric springs for an aircraft engine valve.
The document discusses the design of aircraft fuselages. It notes that fuselages must house passengers and luggage with proper strength and light weight. Fuselages experience both distributed and concentrated loads from various sources. A circular cross-section is commonly used as it efficiently handles these loads. Fuselage structures typically consist of a thin-walled tube with transverse frames, stringers, and cutouts. The document provides an example problem calculating the ultimate bending strength of a circular fuselage cross-section made of aluminum with stringers of different sizes. It considers linear and nonlinear stress distributions to determine the maximum moment the fuselage can withstand before failure.
DESIGN & DEVELOPMENT OF EXPERIMENTAL SETUP OF INTEGRATED FATIGUE TESTING MACHINEAvinash Barve
This document summarizes a student project to design and develop an experimental setup for an integrated fatigue testing machine. A group of 8 students worked on the project under the guidance of a professor. The machine was designed to perform both fatigue tests and torsional tests to study the effects of fluctuating stresses on materials. It includes an electric motor, adjustable chucks to hold different sized samples, and sensors to collect computerized data on sample failures. The design was analyzed using ANSYS and the components were fabricated according to the design. The future scope discusses expanding the design to handle larger samples and additional tests like compression.
The document describes the design of a lifting mechanism for agricultural equipment attachments. The mechanism uses wedges and a power screw actuated by hand to lift attachments like plows. It aims to provide lifting capability with reduced cost, size, and weight compared to hydraulic mechanisms. Key components include a holder, bell crank, two wedges, base, and power screw. Calculations are shown for component sizing. A prototype is tested lifting a 10kg L-shaped attachment. Analysis shows the bell crank can withstand over 300kg of load with minimal deflection and stress. The mechanism performs as intended and has potential for industrial and other lifting applications.
Torsional oscillation of a single rotor with viscous dampingSaif al-din ali
SAIF ALDIN ALI MADIN
سيف الدين علي ماضي
S96aif@gmail.com
Torsional oscillation of a single rotor with viscous damping
• Effect of including a damper in a system undergo ng torsional oscillation
• The amount of damping in the system depends on the extent to which the conical portion of a rotor is exposed to the viscous effects of given oil
This document is a thesis submitted by Pravardhan S. Shenoy to the University of Toledo in partial fulfillment of a Master of Science degree in Mechanical Engineering. The thesis, advised by Dr. Ali Fatemi, involves dynamic load analysis and optimization of a connecting rod. The study performs load analysis on the connecting rod to determine dynamic loads over time. Finite element analysis is conducted under quasi-dynamic and static loads. The connecting rod is then optimized for weight and cost subject to constraints like fatigue life.
Modeling and Analysis of Two Wheeler Connecting Rod by Using AnsysIOSR Journals
Connecting rod is a major link inside of a internal combustion engine. It is the intermediate member
between the piston and the crankshaft. Its primary function is to transmit the push and pull from the piston pin
to the crank pin thus converting the reciprocating motion of piston in to rotary motion of the crank. In this paper
a static analysis is conducted on a connecting rod of a single cylinder 4-stroke petrol engine. The model is
developed using Solid modeling software i.e. PRO/E (creo-parametric). Further finite element analysis is done
to determine the von-misses stresses shear stress and strains for the given loading conditions.
1. The document discusses different types of clutches including positive clutches and friction clutches. It describes the key components and operation of a single plate clutch commonly used in automotive applications.
2. Formulas are presented for calculating the torque capacity of clutches under uniform pressure and uniform wear conditions based on geometric parameters, pressure, and coefficient of friction.
3. The document provides an example problem demonstrating the use of the formulas to design a multi-plate clutch meeting specific torque and speed requirements.
DESIGN AND FABRICATION OF FATIGUE TESTING MACHINERakesh J M
The document discusses the design and development of a low-cost fatigue testing machine for sheet metals. It aims to address the limitations of existing universal fatigue testing machines which are expensive and require skilled labor. The proposed prototype will be cheaper and easier to operate, making it more suitable for small industries. It will use components like a stepped pulley system and a hammer mechanism driven by a motor to apply cyclic loads on sheet metal specimens. The design considerations, methodology, calculations and test results validating the prototype are presented. The machine is able to successfully determine the fatigue strength of aluminum, brass and copper sheet metals at a lower cost.
Static & Dynamic Analysis of Spur Gear using Different MaterialsIRJET Journal
The document describes a study analyzing the static and dynamic behavior of a spur gear made from different materials using finite element analysis. A spur gear model is created in Solidworks and imported into ANSYS for static structural and modal analysis. The static analysis determines deformation and stresses under torque loading, while modal analysis determines natural frequencies and mode shapes. Analysis is performed for structural steel, gray cast iron, aluminum alloy, and epoxy glass composite materials. Results show the composite material has the lowest deformation and weight but higher stresses compared to the metal materials. The natural frequencies are also reported for different materials.
Torsion refers to the twisting of a shaft when a torque or twisting moment acts on it. The angle of twist is defined as the angle through which the shaft's cross section rotates due to the torque. Torque causes rotation, while torsion is the effect produced by torque. Torsion occurs in a shaft when it is subjected to two equal and opposite twisting moments, known as pure torsion. The torsion equation relates the angle of twist in a shaft to the applied torque based on certain assumptions about the shaft's material properties and dimensions. Power can be transmitted through a rotating shaft by applying torque that causes torsion.
ME6503 design of machine elements - question bank.Mohan2405
This document contains questions and problems related to the design of machine elements, specifically regarding shafts and couplings. It includes 20 questions in Part A testing basic recall and understanding, 13 multi-part problems in Part B applying concepts to design scenarios, and 4 complex design problems in Part C. The topics covered include stresses in shafts, hollow vs solid shafts, keys and keyways, rigid and flexible couplings, and the design of shafts and keys based on strength and rigidity considerations.
This document summarizes a study on evaluating and improving the strength of an upper control arm for a vehicle suspension system. Finite element analysis was used to analyze the stiffness, slippage between the arm and bushings, and fatigue life. The initial design was made of gray cast iron. Static analysis found the first modified design had lower displacement and stress than the original. Slippage analysis indicated no slipping of the front, rear or ball joints. Fatigue analysis found the original design would fail while modified designs of aluminum or steel would be safe, with a second modified steel design having the highest life and fewest repeats to failure.
Design of Machine Elements 2 mark Question and Answersbaskaransece
This document provides information on the design of machine elements including shafts, keys, and couplings. It begins with definitions of key terms like factor of safety and design processes. It then discusses loads, stresses, materials selection factors. Specific topics covered include types of shafts and stresses on shafts, standard shaft sizes, hollow vs solid shafts, keys and keyways, couplings, and manufacturing methods for shafts.
Unit 2 Design Of Shafts Keys and CouplingsMahesh Shinde
This document provides information about the design of shafts, keys, and couplings. It discusses transmission shafts, stresses induced in shafts, and shaft design based on strength and rigidity. It presents formulas for shaft design using maximum shear stress theory, distortion energy theory, and the ASME code. Several examples are provided to demonstrate how to calculate the diameter of a shaft given the power transmitted, loads on the shaft, material properties, and other parameters using these theories and codes. Assignments involving similar calculations of shaft diameters are presented.
Design and Performance Analysis of Mechanical Hydro Pneumatic Suspension SystemIRJET Journal
The document describes the design and analysis of a mechanical hydro pneumatic suspension system. It aims to improve ride comfort in light commercial vehicles. The proposed system uses a helical coil spring with varying pitch, hydraulic and pneumatic cylinders filled with oil and nitrogen gas respectively. SolidWorks simulations show von Mises stresses below yield strength and displacements under 0.01 mm, indicating the design can withstand loads of 3000N with a safety factor of 2. Calculations confirm the damping ratio meets standards for an under-damped suspension providing a smooth ride. In summary, the suspension system design utilizes mechanical, hydraulic and pneumatic components to enhance ride quality in small commercial vehicles.
Review of shaft failure in Coil Car AssemblyIRJET Journal
This document summarizes a study on failures of shafts in coil car assemblies. The researchers investigated a failed coil car shaft and found that reversed bending fatigue caused it to fracture, occasionally due to misalignment. They calculated loads on the existing shaft theoretically and analytically and found the stresses exceeded permissible levels, indicating it was prone to failure. To improve shaft design, they examined increasing diameter and using fillets/chamfers to disperse stresses. A literature review showed other shaft failures were due to low radius of curvature, incorrect chamfer size increasing stress concentration, and vibrations from imbalance.
IRJET- Shock Absorber Testing using FFT Analyzer with DewesoftIRJET Journal
1) The document describes testing of shock absorbers using an FFT analyzer to analyze dynamic characteristics under varying conditions like road texture and spring stiffness.
2) A test rig was designed that could subject one end of the suspension to vibrations simulating road bumps while the other end experienced loading simulating vehicle and passenger weight.
3) Shock absorbers from two motorcycles (Hero Splendor and Honda Shine) were tested on the rig under different spring stiffnesses, oil types, loads, and speeds to determine optimum motion transmissibility.
IRJET- Theoretical Analysis of Rocker ArmIRJET Journal
This document analyzes the stresses in a rocker arm made of different materials through theoretical calculations. It describes the geometry and loads acting on the rocker arm. Stresses like bending stress, shear stress, and von-Mises stress are calculated for materials including EN8 steel, S-glass fiber, HDPE, and composite. The results show that EN8 steel and the composite material experience the highest stresses, while HDPE has the lowest stresses but highest deformation. Graphs compare the calculated shear and von-Mises stresses between the different materials.
IRJET- Investigation of Stresses in Rear Half Axle of an AutomobileIRJET Journal
The document investigates stresses in the rear half axle of an automobile using finite element analysis. It considers various cases like increasing angular velocity, inclination of the axle, and additional loads. Von-Mises and maximum principal stresses increase with higher angular velocity and additional loads. At a constant speed, stresses increase up to a certain inclination angle and then remain similar. Comparing FEA results to analytical calculations shows good agreement at higher angular velocities. The maximum stresses occur at the junction of the axle and gear.
Design and Analysis Nose Landing Gear SupportIJSRD
Nose landing gear support bracket is one of the main parts in the nose landing gear assembly, whose function is to maintain the stability of the landing gear during the movements. This work is focused on the FEA analysis of support bracket by varying the stress concentration area, The objective of this work is to determine the static and modal analysis of support bracket with different stress concentration areas, then analysis is done using ANSYS WORKBENCH, These results could provide some useful suggestions for design and improvement for the better component
Failure analysis and redesign of shaft of overhead craneLaukik Raut
The document describes the failure analysis and redesign of the shaft in the gearbox of an overhead crane with a 25-tonne capacity. The original shaft failed due to high shear stresses. An analysis found the shear stress exceeded allowable values. The shaft was then redesigned with a larger diameter and different materials. Finite element analysis showed SAE 6150 steel would experience the lowest shear stresses, below allowable limits, making it the best material to prevent future failures.
Design and Development of All-Terrain Vehicle : Volume 2IRJET Journal
1. The document describes the design and analysis of double wishbone and trailing arm suspension systems for all-terrain vehicles.
2. CAD models of the suspension systems were created in CatiaV5 and analyzed in ANSYS to determine stresses and deformations.
3. For both systems, calculations were shown to determine dynamic spring forces based on vehicle parameters. Maximum stresses of 157 MPa and 366 MPa were found for the double wishbone and trailing arm respectively under dynamic loading.
Design, Analysis & Balancing of 5 Cylinder Engine CrankshaftIJMER
This document summarizes the design, analysis, and balancing of a 5 cylinder engine crankshaft. It discusses modeling the crankshaft in Solidworks and analyzing it in ANSYS using finite element analysis. Calculations are shown for designing the crankshaft and crankpin based on engine specifications. Loading and boundary conditions are applied for static structural analysis to determine stresses and deflection. Von Mises and shear stresses from the analysis match theoretical calculations. The conclusions are that finite element analysis is effective for determining permissible stresses and that the 5 cylinder design provides weight optimization and lower cost compared to a 6 cylinder configuration.
Vibrational Analysis of Pinion Shaft for the Diagnose of Cracks in Heavy Load...IRJET Journal
This document analyzes vibrational stresses in the pinion shaft of heavy loaded vehicles to diagnose cracks. It discusses how vibrations can cause cracks in the pinion shaft due to torsional vibration and instability. The authors used 3D modeling and finite element analysis in ANSYS to analyze bending stresses, shear stresses, and natural frequencies in the stepped pinion shaft under different loading conditions. The results showed that higher natural frequencies and mass participation in mating parts can induce high stresses and increase the likelihood of crack initiation. Proper vibrational analysis of the shaft is important to maximize power transfer and maintain proper gear meshing and interference.
Vibration analysis applied to conveyor belt.IRJET Journal
1) Researchers analyzed vibration frequencies of a conveyor belt carrying different weights to compare results.
2) Vibration measurements were taken of the conveyor belt carrying 1kg, its normal weight, and 4kg, which causes more effort.
3) Mathematical calculations and graphs of the belt, motor, and bearing frequencies were produced to analyze the effects of different weights and extend equipment life.
Increasing life of spur gears with the help of finite element analysisijmech
The Focus of this research is on mathematical analysis of life of gears and reducing noise frequency of gears due to change of material from C-45 to 19mncr5. Calculations for gears life was done with the help of Lewis equation and Buckingham formula. Basically life of a gear is depending upon the stress, more the stress on gear lesser life of gear will be. In this paper some major condition to perform a gear without failure is achieved i.e. tangential force should be less than tangential load to sustain static load, dynamic
load should be less than endurance load to sustain dynamic load and wear load should be less than static
load to sustain wear load. After calculation of 19mncr5 material we evaluate that endurance load acting on the gear which is greater than the dynamic load so our gear come out be safe. Also this study shows declination of noise level in 19mncr5 material compare to C-45 material.
Static Analysis and Mass Optimization of Automotive Valve SpringIRJET Journal
This document summarizes research conducted to optimize the mass of an automotive valve spring through static analysis and finite element modeling. The researchers first modeled and analyzed an existing valve spring design. They validated the finite element model by comparing stress results to conventional calculations. Next, they performed a response surface study to optimize the spring design by varying the spring index and identifying combinations of design parameters that reduce mass while maintaining stress and deformation limits. Their optimized design achieved a 5.74% reduction in mass. In conclusion, static modeling and finite element analysis enabled validation of the initial design and optimization to develop a lighter valve spring that meets performance requirements.
DESIGN, OPTIMIZATION AND FINITE ELEMENT ANALYSIS OF CRANKSHAFTijiert bestjournal
Crankshaft is a crucial component in an engine asse mbly. Crankshaft is consisting of two web sections and one crankpin,which converts the reciprocating displacement of the pist on to a rotary motion with a four link mechanism. G enerally crankshafts are manufactured using cast iron and forged steel mater ial. In this work to design and finite element anal ysis of crankshaft of 4 cylinder petrol engine of Maruti swift Vxi. of 1200 cubic capacity. The finite element analysis in ABA QUS software by using six materials based on their composition viz. Cast iron,EN30B,SAE4340,Structural steel,C70 Alloy steel and Aluminium based composite material reinforced with silicon carbide & fly ash. The parameter like von misses stress,deformation;maximum and minimum principal stress & strain were obtained from analysis software. The results of Finite element show that t he Aluminium based composite material is best mater ial among all. Compare the result like weight and Stiffness parameter. It is resulted of 65.539 % of weight,with reduction i n deformation.
IRJET- Material Optimization of Upper Control ARM for Double Wishbone Suspens...IRJET Journal
This document discusses material optimization of the upper control arm for a double wishbone suspension system. It begins by describing the components and purpose of a double wishbone suspension system. It then outlines the objectives of optimizing the material of the upper control arm to reduce weight and cost while increasing strength. Various materials are considered and analyzed using FEA software to determine the best material. Based on the results, AISI 4130 steel is identified as having the best performance with a deformation of less than 1mm and a safety factor of 1.5, making it a suitable and sustainable material for the upper control arm.
Design Optimization Of Chain Sprocket Using Finite Element AnalysisIJERA Editor
Chain sprocket is one of the important component of chain drive for transmitting power from one shaft to another. To ensure efficient power transmission chain sprocket should be properly designed and manufactured. There is a possibility of weight reduction in chain drive sprocket. In this study, chain sprocket is designed and analysed using Finite Element Analysis for safety and reliability. ANSYS software is used for static and fatigue analysis of sprocket design. Using these results optimization of sprocket for weight reduction has been done. As sprocket undergo vibration, modal analysis is performed
Experimental analysis of circular disc with diametral slotsIAEME Publication
Discs are important structural elements in engineering application such as pressure vessel,missiles and liquid container. The turbine, brake disc and diaphragm clutch spring are the wellknown examples for the industrial application of the annular plate with radial slots. The natural frequencies of component are of great interest in the analysis for response of structures to various excitations. Annular discs are fundamental structural elements studied in ocean engineering
applications from offshore platforms to under water acoustic transducers.
Optimum design of braking system for a formula 3 race cars with numeric compu...IRJET Journal
The document describes the design and analysis of the braking system for a Formula 3 race car. Key points:
- A bike's disc rotor and calipers were selected to reduce weight. Calculations showed the clamping force was sufficient and thermal analysis validated the safety of using the bike's rotor.
- Calculations determined braking forces, torques, bias, and performance. A tandem master cylinder provided independent circuits.
- Steady state and dynamic thermal-structural analyses in ANSYS and ABAQUS showed temperature distributions, stresses, and deformations met requirements.
- The implemented system achieved a weight reduction of around 11kg compared to a standard system, improving performance.
Design, fabrication and performance evaluation of melon shelling machineeSAT Journals
The document describes the design, fabrication, and testing of a melon shelling machine. It discusses the methodology used, including design calculations for components like the shelling cylinder, shaft, belt drive, and bearings. Testing showed the machine achieved 62.5-70.95% shelling efficiency depending on whether a flat bar or flexible rubber was used for shelling. While the flexible rubber achieved higher shelling, it also resulted in more partially shelled seeds. Overall, the machine was successful in improving melon shelling performance compared to traditional methods.
IRJET - Design and Analysis of Connecting Rod using Different MaterialsIRJET Journal
This document describes the design and analysis of a connecting rod using different materials through finite element analysis. The connecting rod was modeled in NX 10 software and analyzed in ANSYS Workbench. Materials analyzed included titanium alloy, beryllium alloy, magnesium alloy, and aluminum 360. ANSYS was used to analyze von mises stress, strain, deformation, factor of safety, and weight reduction for each material. Aluminum alloy was found to have a higher factor of safety, lower weight, lower stress, and was stiffer than forged steel. Fatigue analysis can also determine the lifetime of the connecting rod. The connecting rod was designed, modeled, and analyzed to compare the performance of different materials.
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Chapter wise All Notes of First year Basic Civil Engineering.pptxDenish Jangid
Chapter wise All Notes of First year Basic Civil Engineering
Syllabus
Chapter-1
Introduction to objective, scope and outcome the subject
Chapter 2
Introduction: Scope and Specialization of Civil Engineering, Role of civil Engineer in Society, Impact of infrastructural development on economy of country.
Chapter 3
Surveying: Object Principles & Types of Surveying; Site Plans, Plans & Maps; Scales & Unit of different Measurements.
Linear Measurements: Instruments used. Linear Measurement by Tape, Ranging out Survey Lines and overcoming Obstructions; Measurements on sloping ground; Tape corrections, conventional symbols. Angular Measurements: Instruments used; Introduction to Compass Surveying, Bearings and Longitude & Latitude of a Line, Introduction to total station.
Levelling: Instrument used Object of levelling, Methods of levelling in brief, and Contour maps.
Chapter 4
Buildings: Selection of site for Buildings, Layout of Building Plan, Types of buildings, Plinth area, carpet area, floor space index, Introduction to building byelaws, concept of sun light & ventilation. Components of Buildings & their functions, Basic concept of R.C.C., Introduction to types of foundation
Chapter 5
Transportation: Introduction to Transportation Engineering; Traffic and Road Safety: Types and Characteristics of Various Modes of Transportation; Various Road Traffic Signs, Causes of Accidents and Road Safety Measures.
Chapter 6
Environmental Engineering: Environmental Pollution, Environmental Acts and Regulations, Functional Concepts of Ecology, Basics of Species, Biodiversity, Ecosystem, Hydrological Cycle; Chemical Cycles: Carbon, Nitrogen & Phosphorus; Energy Flow in Ecosystems.
Water Pollution: Water Quality standards, Introduction to Treatment & Disposal of Waste Water. Reuse and Saving of Water, Rain Water Harvesting. Solid Waste Management: Classification of Solid Waste, Collection, Transportation and Disposal of Solid. Recycling of Solid Waste: Energy Recovery, Sanitary Landfill, On-Site Sanitation. Air & Noise Pollution: Primary and Secondary air pollutants, Harmful effects of Air Pollution, Control of Air Pollution. . Noise Pollution Harmful Effects of noise pollution, control of noise pollution, Global warming & Climate Change, Ozone depletion, Greenhouse effect
Text Books:
1. Palancharmy, Basic Civil Engineering, McGraw Hill publishers.
2. Satheesh Gopi, Basic Civil Engineering, Pearson Publishers.
3. Ketki Rangwala Dalal, Essentials of Civil Engineering, Charotar Publishing House.
4. BCP, Surveying volume 1
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তাই একজন নাগরিক হিসাবে এই তথ্য গুলো আপনার জানা প্রয়োজন ...।
বিসিএস ও ব্যাংক এর লিখিত পরীক্ষা ...+এছাড়া মাধ্যমিক ও উচ্চমাধ্যমিকের স্টুডেন্টদের জন্য অনেক কাজে আসবে ...
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LAND USE LAND COVER AND NDVI OF MIRZAPUR DISTRICT, UPRAHUL
This Dissertation explores the particular circumstances of Mirzapur, a region located in the
core of India. Mirzapur, with its varied terrains and abundant biodiversity, offers an optimal
environment for investigating the changes in vegetation cover dynamics. Our study utilizes
advanced technologies such as GIS (Geographic Information Systems) and Remote sensing to
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Accurate understanding of land use and cover is imperative for the development planning
of any area. Consequently, a wide range of professionals, including earth system scientists, land
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cover support policymakers and scientists in making well-informed decisions, as alterations in
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हिंदी वर्णमाला पीपीटी, hindi alphabet PPT presentation, hindi varnamala PPT, Hindi Varnamala pdf, हिंदी स्वर, हिंदी व्यंजन, sikhiye hindi varnmala, dr. mulla adam ali, hindi language and literature, hindi alphabet with drawing, hindi alphabet pdf, hindi varnamala for childrens, hindi language, hindi varnamala practice for kids, https://www.drmullaadamali.com
A review of the growth of the Israel Genealogy Research Association Database Collection for the last 12 months. Our collection is now passed the 3 million mark and still growing. See which archives have contributed the most. See the different types of records we have, and which years have had records added. You can also see what we have for the future.
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Modification in Rear-Axle Test Rig Machine for Testing Rear Wheel Braking System
1. ISSN 2393-8471
International Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME)
Vol. 2, Issue 1, pp: (117-125), Month: April 2015 – September 2015, Available at: www.paperpublications.org
Page | 117
Paper Publications
Modification in Rear-Axle Test Rig Machine
for Testing Rear Wheel Braking System
Chetan Bidkar1,
Salman Shaikh2
, Shreyas Dixit3
, Shubham Walke4
,
Prof. S.M. Karlekar5
1,2,3,4
Research Scholars, 5
Assistant Professor
1,2,3,4,5
Mechanical Engg Department, Rajarshi Shahu School of Engineering & Research,
Narhe, Pune University, Pune, India
Abstract: The rear axle has a housing, tubes for the axle shafts, a final drive (including the differential with
reduction gears), and the axle shafts. The rear axle is joined to the frame or body of the motor vehicle (to the
supporting body if the motor vehicle has no frame) by a suspension. The rear axle test rig machine is used for
testing the braking system of rear axle. The existing machine does not have any mechanism for applying brake.
The brake is applied manually and higher force is required for pulling the brake cable. The force applied is in
backward direction with the help of hand and applying tensile force on it. More cycle time is required for
performing work in existing system. Manual operation increases the operator fatigue. The modified rear axle test
rig machine consists of handbrake assembly, clamping fixture (dowel pin), cable fixture, stud, L shaped plates etc.
The brake is applied by handbrake by pulling it in upward direction causing tension in wire. The modified rear
axle machine reduces cycle time and increases safety for workers. The proper tension in wire helps for proper
braking and the tension in wire can be adjusted with help of dowel pin.
Keywords: Rear axle, Hand brake, Cable Holder, Clamping Fixture, L shaped plates.
1. INTRODUCTION
The rear axle test rig machine is used for checking of differential action, oil leakage, air leakage testing and noise during
forward and reverse rotation. The rear axle test rig machine is used for testing the braking system of rear axle. The rear
axle assembly is used on rear-wheel drive vehicles. This assembly is the final leg of the drive train. It is often called the
final drive or rear end. The rear axle assembly is often mistakenly called the differential. The differential is only part of
the rear axle assembly. The rear axle assembly includes the differential assembly, the rear drive axles, and there rear axle
housing. An axle test stand with a 10 HP, 2880 RPM variable speed input drive motor to drive the axle unit and torque
transmitted is 25 N-m. Two work holding fixtures are situated on a rear axle bed to enable a component to be
loaded/unloaded while axle is being tested.
2. PROBLEM STATEMENT
The existing work system is not safe to workers.
More cycle time is required for performing work in existing system. Braking is done manually.
Manual operation increases the operator fatigue.
Higher application of force is required for braking
3. OBJECTIVE OF THE PROPOSED WORK
The modification of rear axle test rig machine is done by application of handbrake which is operated through clamping
holder and wire fixture. This proposed modification reduces cycle time and increases human safety. The modified rear
2. ISSN 2393-8471
International Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME)
Vol. 2, Issue 1, pp: (117-125), Month: April 2015 – September 2015, Available at: www.paperpublications.org
Page | 118
Paper Publications
axle test rig machine consists of handbrake assembly, clamping fixture (dowel pin), cable fixture, stud, L shaped plates
etc. The brake is applied by handbrake by pulling it in upward direction causing tension in wire. The modified rear axle
machine reduces cycle time and increases safety for workers.
4. DESIGN
A. Selection of material:
Selection of material has a high effect on the structure strength. The most significant factor to evaluate the material
strength is by referring to the yield strength, σy and the modulus of elasticity, E of the material. Mott (2004) stated that,
yield strength can be defined as the portion of the stress-strain diagram where there is a large increase in strain with little
or no increase in stress. He also stated that modulus of elasticity can be define as stress proportionality to strain when the
part of the stress-strain diagram is straight. Modulus of elasticity indicates the stiffness of the material or its resistance to
deformation. Metal materials: plain carbon steel. All investigators concluded that using these materials it can with stand
load and stresses acting on the various parts.
B. Design of Handbrake:
Motor specifications:
Power developed by motor = 10 HP
Voltage V = 440 volts
Current I = 12.5 Amps
Power developed by motor (P) =746 10 = 7460 W
Speed= 2880 rpm
We know that,
Power developed by motor, P=
7460=
T= 24.735 N-m
Hence, the torque developed by motor , T= 24.735 N-m
Hand brake
Fig. 4.1.1 FBD for hand lever
F1 is output force
F2 is applied force on hand lever.
d1 is distance between pivot point and lower side of lever
d2 is distance between pivot point and upper side of lever
d1=0.08 m
d2=0.24 m
3. ISSN 2393-8471
International Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME)
Vol. 2, Issue 1, pp: (117-125), Month: April 2015 – September 2015, Available at: www.paperpublications.org
Page | 119
Paper Publications
24.735=F1 (0.08)
F1=309.18N (31.51 kg)
F2 =103.06 N (10.51 kg)
Force multiplied by Hand Brake =
=
= 3
Fig. 4.1.2 FBD of resolution of forces of hand lever
Taking moment about y axis,
∑My =0
Taking reaction about y axis,
∑Fy =0
F1 = R + F2
R =F1 - F2
= 309.18 – 103.06
R=93.51 N ( )
Hence, the resultant force acting on hand lever is R=93.51 N ( ).
Fig. 4.1.3 Force Analysis
4. ISSN 2393-8471
International Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME)
Vol. 2, Issue 1, pp: (117-125), Month: April 2015 – September 2015, Available at: www.paperpublications.org
Page | 120
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Rb= ( ) R
= ( ) 93.51
Rb = 64.11 N.
Rb1 = Rb2 = = 32.055
(In handbrake mounting bolt b1 & b2 are fixed at same distance from hand lever. Hence, the reaction at bolt b1 & b2 is
same.)
Ra= ( ) R
Ra = 29.45 N.
Ra1 = Ra2 = = 14.72 N
(In handbrake mounting bolt a1 & a2 are fixed at same distance from hand lever. Hence, the reaction at bolt a1 & a2 is
same.)
Fig.4.2 L Plate
C. Design Of l – plates
Material: MS 10C4– deep drawn, hot rolled
Properties of 10C4:
a) Tensile strength (min) = 340 to 420
b) Elongation (min) = 17 % to 26%
c) Load impact value = 55 N-m
Welding: CO2 welding
Filler material: copper wire
Failure of fillet weld occurs due to shear along minimum cross section at throat.
The shear strength of parallel fillet weld can be estimated as,
P = 0.707 h l1
Permissible weld stresses for weld metal,
Type of load is shear
Type of weld is fillet
5. ISSN 2393-8471
International Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME)
Vol. 2, Issue 1, pp: (117-125), Month: April 2015 – September 2015, Available at: www.paperpublications.org
Page | 121
Paper Publications
The reverse load acting on the plate and weld, so permissible shear stress for fillet weld is taken as 35 as per code
of AWS (American welding society).
We have,
= 35
t = 0.707 h
l = 165 mm
Therefore,
h =
But 15mm should be added to the length of each weld to allow for starting and stopping of weld run.
l1 = l + 15
= 165 + 15
= 180 mm
P = 0.707 5.657 180 35 = 25.1968 KN
So, tensile force on plate is 25.1968 KN on each plate.
Now, we have the strength of plate,
=
=
=
= 38.176
i.e. < allowable (38.17 < 340 ),
So, design is safe.
D. Design of Cable Holder:
Fig.4.3 Cable holder
The cable holder is used for fixing the cable and allowing the wire to be screwed internally to the dowel pin.
Material: MS 35C8
= 550 to 650 … [Reference no.10]
For Wire Cable,
Mb = f1 d
6. ISSN 2393-8471
International Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME)
Vol. 2, Issue 1, pp: (117-125), Month: April 2015 – September 2015, Available at: www.paperpublications.org
Page | 122
Paper Publications
= 309.18 (40-19) 0.3
Mb = 1947.83N-mm
Now,
b =
Y = = = 10.5mm
I = = = 166666.67
b =
= 0.1227
So, b < allowable
Hence, design is safe.
E. Design Of Clamping Holder:
Fig.4.4 Clamping holder
Material: MS 45C8 W=309.18
d=8 mm
t allowable= 630
s allowable= 50
Tensile stress in dowel pin:
t = =
t = 6.1509
t < allowable
Hence, design is safe in tensile stress
Shear stress induced in threads of dowel pin:
s =
=
s = 0.492
s all > s
Hence, the design is safe in shearing.
7. ISSN 2393-8471
International Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME)
Vol. 2, Issue 1, pp: (117-125), Month: April 2015 – September 2015, Available at: www.paperpublications.org
Page | 123
Paper Publications
5. EXPERIMENTATION
Experimental Set Up:
The rear axle test rig machine is used for testing the braking system of rear axle. It consists of following components:
1. Oil tank
2. Oil Pump.
3. Induction motor
4. Transmission shaft.
5. Universal Joint
6. Oil drainage
7. Clamping fixture
8. Control Panel
9. Machine Bed
10. Coupling
11. Differential oil
Fig 5.1 Experimental setup
Testing:
The rear axle to be tested is lifted from the trolley with the help of pneumatic cranes and the placed on the fixture of the
rear axle test rig machine.
The rear axle is tightly fixed in the fixture and the differential is connected to propeller shaft through universal joint to the
motor. Oil is filled through the motor to the differential valve and then the valve is tightened. The axle wheels and the
propeller shaft are provided with safety covers for workers safety. The motor is switched ON and the axle wheels starts
rotating.
The steps involved in testing of rear axle are as follows:
a) The step consists of rotation of axle wheels in forward direction and reverse direction. The differential under goes for
oil leakage test and the testing of brake is done by using handbrake which is mounted on the machine bed of the rear
axle test rig machine.
8. ISSN 2393-8471
International Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME)
Vol. 2, Issue 1, pp: (117-125), Month: April 2015 – September 2015, Available at: www.paperpublications.org
Page | 124
Paper Publications
b) The brake cable is clamped in the fixture and the wire is joined to the dowel pin through the stud which is bolted to
the bracket of the handbrake.
c) When handbrake is operated, the brakes are applied and the wheel stops rotating while the other wheel rotates due to
differential action.
d) The differential is tested for noise during forward and reverse testing. In the same way the wheel are checked for
braking on the side of the rear axle test rig machine.
e) The T1, T2 and TX rear axle are tested for differential action on the rear axle test rig machine.
f) After testing of the rear axle the motor is turned off and the oil is drained from the differential through the pipe to the
oil tub.
g) The valve is tightened and the cable is removed from the cable fixture and the wire is wound to the axle.
h) The universal coupling is detached from the differential of the rear axle and the tested rear axle is lifted with help of
the pneumatic cranes and placed in the accepted trolley.
The total operational time taken to test the rear axle is approximately 14 minutes. The maximum allowable time for
testing of rear axle is 17minutes. By modifying the rear axle test rig machine there is increase in safety for workers and
reduction in cycle time.
6. RESULT AND DISCUSSION
Table 6.1Cycle Time per Axle
Sr. No. Operation Maximum Allowable
Time (minutes)
Time Required After Modification
(minutes)
1 Loading of rear axle 4 4
2 Differential oil filling and removal 4 4
3 Right hand side testing 2.5 1
4 Left hand side testing 2.5 1
5 Unloading 4 4
Total time : 17 14
Table 6.2 Cycle Time per Day
No. of Axle tested per
Day
Time Required Before
Modification (minutes)
Time Required After
Modification (minutes)
Save In Time per Day
(minutes)
56 952 784 168
Table 6.3 Estimation of Force
Sr. No. Operation Force Before Modification (N) Force After Modification(N)
3 Right hand side testing 309.18 103.06
4 Left hand side testing 309.18 103.06
The modified rear axle test rig machine consists of handbrake assembly, clamping fixture (dowel pin), cable fixture, stud,
L shaped plates etc.The brake is applied by handbrake by pulling it in upward direction causing tension in wire. The
modified rear axle machine reduces cycle time and increases safety for workers. The proper tension in wire helps for
proper braking and the tension in wire can be adjusted with help of dowel pin.
7. CONCLUSIONS
9. ISSN 2393-8471
International Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME)
Vol. 2, Issue 1, pp: (117-125), Month: April 2015 – September 2015, Available at: www.paperpublications.org
Page | 125
Paper Publications
The rear axle test rig machine is operated by application of hand force for braking of rear axle. The force applied is in
backward direction with the help of hand and applied force is tensile force. This reduces human safety causing severe
accidents. The modification of rear axle test rig machine is done by application of handbrake which is operated through
clamping holder and wire fixture. This proposed modification reduces cycle time and increases human safety. In this way,
we have successfully implemented the modifications
ACKNOWLEDGEMENT
We would like to thanks to Mr. S. M. Karlekar for giving us an opportunity to present our work.
REFERENCES
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Addis Ababa, 2007.
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worldwide automotive conference, MSC, 2000.
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worldwide automotive conference, MSC, 1999.
[9] “On-Line Diagnostics of Rear Axle Transmission Errors”, V. Milenkovic, S. Shmuter and N. Field.
[10] Design Data Book, V.B. Bhandari
[11] Design of machine elements, V.B. Bhandari
[12] Mechanical engineering design. Shigley JE (1977). McGraw-Hill
[13] Mechanical engineering design. Shigley JE, Mischke C (1989). McGraw-Hill New York.
[14] http://www.forcemotors.com/page/index/company_profile
[15] http://www.testrigs.com/axle-differential-testing.html
[16] http://www.hbm.com/en/menu/applications/torque measurement/application reports/ Siemens