Design And Fabrication Of Automobile Engineering Essay

October 4, 2017 Engineering

CE1.2 ) This undertaking was based on planing and manufacturing a machine which can be used for the intent of cutting duplicate keys of any sort of cars. Normally for two or four Wheelers, two keys are supplied by the car maker through traders, of which one will be preserved in the bank, as most of the vehicles are financed by the fiscal establishment. Merely one key is left with the clients. So there are more opportunities of losing the key supplied by the maker. The lone redress is continuing original key and do usage of the extra key or vise-versa. So the aim of the undertaking was to plan and manufacture a machine which can double the original cardinal really exactly and accurately within short span of clip, to avoid the user of the car from the incapacitated status in the event of the loss of the keys. My duty was to execute the design process of assorted parts, do necessary computations based on that, pull technology drawings of some parts and co-operate with the undertaking mates to make fiction and assembly of the machine.

Organizational Chart

CE1.3 ) In the full continuance of the undertaking, I on a regular basis met undertaking supervisor Prof. Anantharama, one time a hebdomad. I besides discussed different facets with the Head of the Mechanical Engineering Department Prof. B.P. Yadav. In the class of the work, I must seek their sentiment clip so that I knew I was on the right way to the success of the undertaking.

Undertaking Supervisor

Prof. Anantharama B.

Head of Mechanical Engineering Department: Prof. B.P. Yadav

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Under alumnus pupil

Maine

Lab Assistant ( Mechanical Engg. Deptt. ) : Mr. Dualat Ram

Personal Workplace activity

CE1.4 ) I planned to make the undertaking in two phases. The first phase trades with designing of the machine and the 2nd phase trades with its fiction and concluding assembly. In the first phase I performed design considerations of assorted parts of the machine. I discussed with my undertaking usher Prof. Anantharama about assorted computations required to organize design process to find power evaluation of the electric motor, design of shafts, design of belts and blocks, design of bearings and design of fixture.

CE1.5 ) Before get downing the designing of machine, I should acquire clear apprehension of the working rule involved and description of assorted parts and procedures involved in the machine. From the class of Manufacturing Process, I knew in order to acquire high surface quality and truth of form and dimension ; usage of crunching procedure is the best option. After treatment with undertaking supervisor and undertaking couples I followed four factors in the choice of the grinding wheel. There were four changeless factors such as stuff to be land, sum of stock to be removed, country of contact and type of crunching machine. There were four variable factors such as wheel velocity, work velocity, status of machine and personal factor.

CE1.6 ) The mean length of bit formation during surface grinding was calculated as follows:

L = ( D/2 ) * @

D=grinding wheel diameter.

@ is really little angle.

Cos @ = [ ( D/2 ) -d ] /D/2=1-2d/D

D=depth of cut

Besides, Cos @ =1- @ 2/2

Comparing the equations

@ =2/D

L=

F=feed

W=width of cut in millimeter.

Entire volume of stuff removed per unit volume=F*d*W

I had used following parametric quantities in design process of crunching operation:

Depth of cut, length up to 80 millimeters, thickness up to 3 millimeters and the traverse gesture of the fixture for the machining procedure.

CE1.7 ) Then I put my concentration on the design process for finding of the power evaluation of the electric motor, finding of size of goaded block, belt tenseness, design of belt, pitch length of the belt, finding of the film editing forces etc. By utilizing mechanical design schemes I had calculated power evaluation of electric motor in the undermentioned manner:

Power required for machining is given by:

Pm = Ps * Zw

Where Ps = specific cutting energy.

Zw = metal remotion rate = degree Fahrenheit * ap * Vtrav

f=cross provender = 5 mm/pass

ap= back battle

Vtrav=traverse velocity =250 mm/min

Therefore, Zw = 5 * 2 * 250 =2500 mm3/min=41.66 mm3/sec

Ps=4 GJ/m3 for brass or Cu metals

Therefore, Pm=4*109*41.66*10-9

Pm=166.64 Watts

— m=80 % ( overall efficiency )

Power evaluation = Pe=Pm/ — m=166.64/0.80

Pe=208.3 Watts

Or, Pe=0.277 HP

Nearest evaluation available in market was 1/3 HP=247.5 Watts.

CE1.8 ) I used following specification for the grinding wheel used in my undertaking A-60-P-BN

where, A-abrasive ( Al2O3 )

60-grain size ( medium )

P-grade ( difficult )

BN-resinoid bond

Resinoid bond is specified

After treatment with Mechanical design lector ( H.O.D ) , I used diameter of driver block as D=165 millimeter and diameter of goaded block as d=63 millimeter.

Speed of motor ( n ) = 1420 revolutions per minute.

V1=V2

i.e. D*n=d*N

where, N=rpm of crunching wheel=speed of goaded block

hence, N=D*n/d= ( 165*1420 ) /63

N=3719.04 revolutions per minute

Wheel velocity ( V ) = ( 3.14*Dw*N*60 ) /1000

V= ( 3.14*170*3719*60 ) /1000

V=33.10m/s

Using standard mechanical design preparations I had calculated belt tensenesss on tight side and on loose side. Harmonizing to computations they were observed as follows:

T1=belt tenseness on tight side=11.97 N

T2=belt tenseness on slack side=4.2 N

Cuting forces and radial forces were calculated as follows:

Fz=Pm/V

Pm=166.64 Watts ( power required for machining )

V=33.10m/s ( wheel velocity )

Fz=166.64/33.10=5.03 N

Radial force Fy=2*Fz

Or, Fy=10.06 N

CE1.9 ) Horizontal and perpendicular forces on the cutter shaft were calculated by the bending minute diagram and found that design was safe. Design of bearing and fixture shaft used was besides safe based on the bending minute diagram. My observations at the terminal of design procedure were as follows:

Specifications of motor

Power rating=247.5 Watts ( 1/3 HP )

Speed= 1420 revolutions per minute

Voltage=230 Volt

Current=3 A.

Frequency=single stage, 50 Hz.

Ambient temperature=40 0C

Start capacitor=50 micro F.

Specifications of Cutter

Diameter of cutter=170 millimeter.

Type: A-60-P-BN

Thickness of cutter=2mm.

CE1.10 ) In the 2nd phase of the undertaking I had done the fiction portion utilizing squad attempt of my undertaking couples. After treatment with undertaking usher I used the undermentioned stuff for the assorted constituents:

Name of the component Material used

Frame C-45 steel

Shafts C-45 steel

Supports mild steel

Fixture dramatis personae Fe

Tracer support mild steel

Straps cast Fe

I developed technology drawings of the cutter shaft and fixed back uping shaft. By the co-operation of the research lab adjunct fiction of the parts was completed on clip.

CE1.11 ) At the terminal of the concluding phase of the assembly, base home base was foremost welded to the angle plates. The fixture back uping was fixed in between the supports. Fixture was allowed to skid the shaft without clash with lubrication of shaft and fixture. The two straps were assembled to fixture utilizing bolts. These two straps act as clamping device and serve the intent of keeping work piece and maestro piece. Then tracer support was bolted to establish home base in forepart of one of the clinch. Now cutting wheel was mounted on the cutter shaft at one terminal utilizing rims and nut. I faced some jobs while mounting crunching wheel because of un-due stringency and inordinate clamping, strain was developed. But it was sort out on clip.

Drumhead

CE1.12 ) The machine was based on the rule of follow up system. The intent of this system is to supply contour on a space with matching to contour on the maestro piece. Such a system permits rapid reproduction of same parts with a just sum of flexibleness. The undertaking was really of import for me. First it was a large undertaking I attempted for the first clip in which I applied theoretical and practical cognition of mechanical design every bit good as of fabricating procedure to acquire an existent state of affairs by planing a machine which can do extra key utilizing a maestro key in really little clip. Second, I got the chance to do creative activity in scientific discipline field independently. Third, this undertaking enhanced my rigorous consideration to the scientific discipline research since I made tonss of computation for planing and manufacturing a machine to acquire better consequences.

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