Final Rear Forward Axle Housing Snorkel

7/26/2019 Final Rear Forward Axle Housing Snorkel

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Rear Forward Axle Housing Snorkel Boring Position Capability Improvement

CHAPTR ! "

I#TR$%&CTI$#1.1 AXLE

Axle is the important part of the differential. The axle is a straight shaft that is

fixed in a location; it is combined with bearing or brushing use to mount rotating wheel or

gears. The wheel or gear can be attached to it with a built in gearing or bushing. A bearing

or brushing fits inside the center of the wheel and allow it to rotate without affecting the

axle itself. The purpose of axle is to secure the wheels or gears to specific locations

relative to other wheels or gear. The wheels would not remain in fixed position and the

force and vehicle would make the wheel bend flat. n automobile two t!pes of differential

are used which are front axle and rear axle. The power developed b! the engine is

transferred to the wheels through clutch" gear box" universal #oints" propeller shaft" final

drive" differential and rear axles.

Fig "'"( Axle

$epartment of %echanical Engineering" %T" %!sore. 1


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1.& AXLE '()*+,

An axle assembl! on a car or truck is the set of components that allow the wheels

to rotate freel!. Two wheels are usuall! connected b! a shaft known as an axle. t sits

inside axle housing" and is held in place b! bearings or bushings that allow it to rotate

within the axle housing. $amage to the axle itself can cause the entire assembl! to fail" so

the housing acts as a protective la!er for the spinning axle. Lubrication of the axle is also

made possible because of the housing.

The axle housing ma! also contain other components that allow for steering" driving" or

load bearing. f axle housing is intended primaril! for bearing a load it ma! be called a

dead axle because it is not used to propel the vehicle forward. %an! front wheel drive

vehicles feature a rear dead axle that is meant onl! for load bearing and for keeping the

left and right rear wheels on track. f the axle is part of the drive s!stem" it ma! be known

as a drive axle.

*ometimes an axle is not a solid piece" but instead two pieces that connect within the axle

housing. This allows the wheels to rotate at different speeds the gears that drive these

wheels will be contained within the axle housing" as will the two separate axle pieces. A

driveshaft ma! also enter the housing at its front" usuall! in the center" to connect with

an! drive gears for the wheels. The housing allows these components to be protected from

impacts" and it also allows lubrication to be contained within the space" preventing

premature breakdown of the axle components.

Larger trucks ma! feature more than one axle to help support the weight of the vehicle

without causing excess strain on the axle itself. (ne axle is devoted entirel! to supporting

the truck-s weight" while the other axle is not weightbearing at all and allows the axle

shaftto spin with far less stress. This is sometimes known as a full float axle s!stem" and

it is common on dump trucks" tractor trailers" and other large" loadbearing vehicles.

*emifloating axles will still end up supporting some of the weight of the vehicle" and

nonfloating axles are usuall! responsible for supporting the entire load of the vehicle.

1./ 0EA0 AXLE

0ear axle transmits power from differential to the wheels so that vehicle ma! turn.

0ear axle isnt a single part but it consist two parts which are connected to the

$epartment of %echanical Engineering" %T" %!sore. &
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differential. (uter end of the rear axle carries the wheel while inner end is connected b!

sun gear of the differential.

The propeller shaft is provided with two universal #oints and also a sliding #oint. The

spring is fixed rigidit! in the middle" to the rear axle. The front end of the spring is fixed

rigidl! on the frame" while the rear end is supported in a shackle. The driving thrust is

transmitted to the frame b! the front half the springs. $ue to the tor2ue traction" the

spring deflects. The up down movement of the rear axle induces. 3ariation in the length

of propeller shafts which gets compensated b! the slip #oint. 4onse2uence of the rear axle

movement and deflection of the spring is" to alter the position of the final drive shafts

also. This shafts position ma! result in bending of the propeller shafts which is avoided

b! using a universal #oint at the rear end of the propeller shaft.

1.5 *+(06EL 7(0E

Fig "')( Snorkel Bore

The above figure shows snorkel bore in axle housing. This t!pe of axles is used in heav!

dut! vehicles. A front engine rear axle drives heav! capacit! vehicles re2uires snorkel

bore to connect a forward rear axle to backward rear axle. (ne end of the shaft isconnected to snorkel bore and other end is connected to rear end axle.

1.8 90(4E** 4A9A7LT:

9rocess 4apabilit! refers to the uniformit! of the process.

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t is #udged b! 4omparing process performance with process re2uirements. *ince meeting

*pecification limits is one of the basic re2uirements" capabilit! anal!sis. )suall! involve

the specification limits in their calculation.

Pro*ess *apabilityanal!sis is a vital part of an overall 2ualit!improvement 9rogram.

Among the ma#or uses of data from a process capabilit! anal!sis are the following

1. 9redicting how well the process will hold the tolerances.

&. Assisting product developers. 0educing the variabilit! in a manufacturing process.

"'+'" CAPABI,IT- I#%ICS(

There are several statistics that can be used to measure the capabilit! of a process

4p" 4pk" 9pand 9pk.

1. The statistics assume that the population of data values is normall! distributed.

&. 3ariabilit! can be stated as either shortterm or longterm.

/. 4p and 4pkare based on short term variabilit!.

5. 9p and 9pkare based on total variabilit!.

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*hort term variabilit! is defined as the average within subgroup variabilit!.

Total variabilit! is estimated b! treating the data as one big sample using onl! the overall

mean and looking at how the data points var! around this one overall mean

Cp( t simpl! relates the 9rocess 4apabilit! to the *pecification 0ange and it does not

relate the location of the process with respect to the specifications. 3alues of 4p exceeding1.// indicate that the process is ade2uate to meet the specifications. 3alues of 4pbetween

1.// and 1.?? indicate that the process is ade2uate to meet specifications but re2uire close

control. 3alues of 4p below 1.?? indicate the process is not capable of meeting

specifications.

Cpk t considers process average and evaluates the process spread with respect to where

the process is actuall! located. ,enerall!" a 496greater than 1.// indicates that a process

is capable in the short term. 3alues less than 1.// tells that the variation is either too wide

compared to the specification or that the location of the variation is offset from the center

of the specification. 4pk@ 4p onl! when the process is perfectl! centered. 4prepresents the

highest possible value for 4pk.

1.= XT)0E

A fixture is a production tool that locates" holds" and supports the work securel! so

the re2uired machining operations can be performed. *et blocks and feeler or thickness

gauges are used with fixtures to reference the cutter to the work piece.

A fixture should be securel! fastened to the table of the machine upon which the work is

done. Though largel! used on milling machines" fixtures are also designed to hold work

for various operations on most of the standard machine tools. ixtures var! in design

from relativel! simple tools to expensive" complicated devices. ixtures also help to

simplif! metal working operations performed on special e2uipment.

"'.'" T-PS $F FI/T&R

The names used to describe the various t!pes of fixtures are determined mainl! b!

how the tool is built. Bigs and fixtures are made basicall! the same wa! as far as locators

and petitioners are concerned. The main construction difference is mass. 7ecause of the

increased tool forces fixtures are built stronger and heavier than a #ig would be for the

same part.

These are commonl! used product processing stage. t depends on the t!pe of operation

i.e. being performed on the work piece and classified as"

Simple 0ixture(t is emplo!ed for simple operations.

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1illing 0ixture(t is speciall! emplo!ed for milling operations.

,at2e 0ixture(t is emplo!ed for holding the work piece during lathe operation.

Boring 0ixture( t is emplo!ed in boring operation to hold the work piece for

enlarging the hole.

Pro0iling 0ixture(These are used to guide tools for machining contours that the

machine cannot normall! follow. These contours can be either internal or external.

*ince the fixture continuousl! contacts the tool" an incorrectl! cut shape is almost

impossible.

"'.') C,A1PI#4

The various forces acting upon the w


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&. 0estrict all six degrees of freedom so that the part cannot move.

A widel! used method of accomplishing these two ob#ectives uses the /&1 principle" so

called because it entails three steps that emplo! three" then two" then one fixed points of

known location. *ince that adds up to six fixed points" its also known as the six point

method.n the three steps of the /&1 method" three mutuall! perpendicular planes" called datum

planes" are introduced" one at each step. These three planes define the work piece

position" and together with opposing clamping forces full! constrain the part.

or a fixture designer" the ma#or portion of design time is spent deciding how to locate the

work piece in the fixture. :ou know that an! free bod! has a total of twelve degrees of

freedom as below = translational degrees of freedom( DX" X" D:" :" D" and =

rotational degrees of freedom

4lockwise around X axis F4C XG

Anticlockwise around X axis F44C XG

4lockwise around : axis F4C :G

Anticlockwise around : axis F44C :G

4lockwise around axis F4C G

Anticlockwise around axis F44CG

Ce must fix all the 1& degrees of freedom except the three transitional degrees of

freedom (-X, -Y and -Z)in order to locate the work piece in the fixture. *o" H degrees of

freedom of the work piece need to be fixed.

7! using the 56)6" met2odas shown below

1 0est the work piece on t2reenon6*ollinear pointsof the bottom sur0a*e 7/-8" and

able to fix the 9:" CR$T6/" ACR$T6/" CR$T6- and ACR$T6- degrees of

freedom'

& +ow" rest the work piece at twopoints of side sur0a*e 7/:8" and able to fix the 9-

andACR$T6: degrees of freedom.

/ +ow" rest the work piece at onepoint of the ad;a*ent sur0a*e 7-:8" and able to fix

the 9/ and CR$T6:degrees of freedom. *o" successfull! H re2uired degrees of

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freedom can be fixed b! using the /&1 principle of fixture design and the /&1

method is the fundamental principle for all t!pes of fixture design.

CHAPTR ! )

,ITRAT&R S&R=-

The literature review has been carried out to identif! the effort made in the field of

designing of #igs and fixture to the focal area of present work.

"' /iumeikung et allhave studied about fixture planning. ixture planning determines

precise locating the rigid clamping of a work piece according to work pieces design and

process re2uirements. Locating surfaces are classified as plane" pin holes and external

profiles. 4ommonl! used fixtures locating methods on the primar! locating method

include 1G/&1 point locating for prismatic; it uses / locations on the primar! locating

surface" & locators on the secondar! locating surface and 1 locator on the tertiar! locating

plane.

&G 1 plane ad & planes locating for general parts with & holes. it uses a primar! locating

rate locating of plane" a primar! pin and secondar! pin to restrict the freedom of a work

piece.

/G vblock locating for external c!lindrical parts. 1 wide vblock or & short vpads ma! be

used to hold the work piece. The clamping planning determines clamping surfaces and

points on the work piece and clamping components" the magnitude of each clamping

force and the clamping se2uence when the stabilit! of the work piece becomes a concern.

To bold a specific part" several design constraints ma! be applied. Among them" 5 main

constraints in the fixture planning are as follow.

F1G,eometrical constraints accurate locating of a work piece should be ensured to meet

machining accurac! re2uirements of a work piece.

F&GAccessibilit! constraints There should be no interference among fixture components"

work piece and machining tools during assembl! and machining. n addition" it should be

eas! to load and unload the work piece.

F/Gorce constraints The fixtures should be strong enough to resist the forces and

moments produced b! clamps and machining tools. A minimum clamp force should be

specified for the work piece stabilit!.

F5G$eformation constraints The stiffness of a fixture s!stem should be sufficient to keepthe work piece deformation with in the design interference.

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)' Parves2 ?umar et all'3conducted the process capabilit! anal!sis for boring operation

b! understanding the concepts methodologies and making critical assumptions. As

9rocesscapabilit! anal!sis has become an important integrated part in the applications of

statistical techni2ues for 2ualit! assurance. Iualit! assurance in mass production isachieved using statistical processcontrol techni2ues. The processcapabilit! anal!sis"

which is a *94 Techni2ue" helps to determine the abilit! for manufacturing between

tolerance limits and engineering specifications. The capabilit! anal!sis gives information

about the changes and tendencies of the s!stems during production. n this stud!" 4ontrol

charts for variables are implemented to achieve a good control over the process. *94

techni2ue was used to evaluate machines capabilit! FcpG and process centering F cpkG of

manufacturing process to find whether the process is capable or not. The number of

nonconforming part was determined in observed values" in short and long periods of time.

After monitoring the process a significant improvement has been experienced in terms of

increase in process capabilit! indices and reduction in defective parts per million FppmG.

The shikawa $iagram for critical defeats is drawn" the root causes for each are identified

and the suitable remedial measures are suggested. aults regarding manufacturing outof

tolerance limits were eliminated" the variabilit! in the process and the cost due to low

2ualit! production were reduced in the particular compan!. n toda!s competitive

market" *94 is not the most fre2uentl! used techni2ue in small and mediumsiJed

companies. The most important problems in 7usiness are that there are no trained

emplo!ees to appl! it and there is insufficient investment. 4onse2uentl!" *94 must be

applied widel! and continuousl! to achieve 2ualit! improvement.

5' SHAI,SH S PACHBHAI3have investigated about fixture design and assembl!. n

machining fixtures" from clamping work piece deformation can be minimiJe and it is

essential to maintain the machining accurac!. n recent times h!draulic techni2ues are

usuall! adopting to save time and increase accurac!. Loading and unloading of work

piece in manual clamping is the time consuming process so is to reduce the set up time

and process time is the main aim of the process. 'ence now da!s in all industr! h!draulic

clamps are adopting to reduce the time consumed and increase the productivit! from that

best 2ualit! of product can be obtained. The main aim for adopting the h!draulic c!linder

is to reduce the processing time and reduction in position variation while machining of a

part taking place. All the values of deformation and von misses stress calculated with

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A+*:* software is comparativel! lower than standard values and hence" we can

conclude that design is safe. As per calculation" the proposed fixtures have a direct impact

on product 2ualit!" productivit! and cost.

' iang ,i3 1'A has investigated about fixture design and assembl!" a t!pical fixturedesign for prismatic parts consists of / essential elements locators" clamps and

supporters. Locators are emplo!ed to position the work piece in the static e2uilibrium so

as to remove all degrees of freedom. 4lamps are used to hold the work piece firml!

against the locators during the machining process. The primar! design factors of fixture

clamps comprising external cuttings force and tool direction etc.." have to be taken into

account during a fixture design process. As machining fixtures sub#ected to external

emitting forces" the & fixture elements have to guarantee that the work piece is rigidl!

located and assure it respectivel!. 0epresentativel! refers to the work piece and the

subse2uent work piece can be precisel! located in the same position b! the fixture.

%epartment o0 1e*2ani*al ngineering3 1IT3 1ysore'"


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CHAPTR ! 5

PR$B,1 %FI#ITATI$#

/.1 *TAT*T4AL I)ALT: 4(+T0(L

*tatistical 2ualit! control involves the use of various methods to measure and anal!Je

a process. The overall ob#ectives of *I4 are

To improve the 2ualit! of process output

To reduce process variabilit! and achieve process stabilit!

*olving processing problem

5'"'" TH SC T$$,S

Iualit! tools can be used in all phases of production process" from the start of

product development up to product marketing and customer support. The > I4 Tools are

simple statistical tools used for problem solving. These tools were developed b! the

Iualit! preceptors such as $eming and Buran. shikawa has stated that these > tools can

be used to solve H8 percent of all problems. The following are the > I4 Tools

1G 'istogram

&G 4heck *heet

/G 9areto $iagram

5G $efect 4oncentration $iagram

8G 4ause K Effect $iagram

=G 4ontrol 4harts

>G *catter $iagram

rom the above > I4 tools we make use of cause and effect diagram as it is a tool that is

useful for identif!ing and organiJing the known or possible causes of 2ualit!" or the lack

of it. The structure provided b! the diagram helps to think in a ver! s!stematic wa!. *ome

of the benefits of constructing a 4auseandEffect $iagram are that it

'elps determine the root causesof a problem or 2ualit! characteristics using a

structured approach.

Encourages group participation and utiliJes group knowledge of the process.

)ses an orderl!" eas!toread format to diagram causeandeffect relationships.

ndicates possible causes of variation in a process.

%epartment o0 1e*2ani*al ngineering3 1IT3 1ysore'""


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ncreases knowledge of the process b! helping ever!one to learn more about the

factors at work and how the! relate.

dentifies areas where data should be collected for further stud!.

5'"') CA&S D FFCT %IA4RA1

A graphic tool that helps identif!" sort" and displa! possible causes of a problem or 2ualit!

characteristic. t consists of a central stem leading to the effect FproblemG with multiple

branches coming off the stem listing various groups of possible cause of the problem.n a

t!pical manufacturing problem" the groups ma! consist of five %s %en" %achines"

%aterials" %ethod and %easurement. The six % %one! ma! be added if it is relevant. n

some cases Environment is one of the main groups. mportant subgroups in each of these

main groups are represented on the middle bones and these branch off further into

subsidiar! causes represented as small bones. The arrows indicate the direction of the

path from the cause to the effect. (wing to its characteristic appearance it is known as

isherbone $iagram.

Fig 5'"( Cause and 00e*t %iagram

%epartment o0 1e*2ani*al ngineering3 1IT3 1ysore'")


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/.& 90(7LE% $E+T(+

Fig 5')( Rear Axle Housing

As shown in the figure there are two axes in the component

Axis of snorkel bore

Axis of axle shaft

The x and ! distance between these two axis is 1??.=?mm and 1?=.==mm respectivel!

with the tolerance limit of 1H? microns.

At the present scenario" there is a variation in the distance between the two axes due to

which the desired position of snorkel bore is not achieved with the dimensions mentioned

above.

This variation is due to the clearance in the existing ublock F?.1 mmG and bore locator

F?.8mmG. (ur work is reduce this clearance in order to achieve position of the snorkel

bore from the reference plane

The below figure shows the clearance that exists in various components of the machine

%epartment o0 1e*2ani*al ngineering3 1IT3 1ysore'"5


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"' &6 Blo*k

Fig 5'5( &6Blo*k

)' B$R ,$CAT$R

Fig 5'( Bore ,o*ator

/./ %ET'($(L(,:



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*tud! of the complete process of operations that are carried out in the ba!.

*tud! of the component which is actuall! having a problem of var!ing position.

*tud! of the existing fixture which is causing the problem in the component.

To overcome that above problem design of a new fixture is recommended b!

including e#ector pins to restrict the movement of the component.

7! doing the above process we would conclude that the process under consideration

of 4+4 machine can be improved.

5'5'" ST&%- $F C$1P$##T

The casting is supplied to AAL from outside b! vendors. (nce the AAL receives

the component AAL personals inspect the component. f there are an! problems the

component is re#ected" otherwise it is accepted and it is taken through the different

process such as welding two housing halves" machining process which includes boring"

face milling" drilling etc".

Axle housing is made up of carbon steel casting of 58?%pa tensile strength

%ain chemical composition of carbon steel casting

Table 5'"(

C2emi*al *omposition

Residual elements(

ELE%E+T* CE,'TFmax

G

+46EL ?.5?

4'0(%)% ?./8

4(99E0 ?.5?

%epartment o0 1e*2ani*al ngineering3 1IT3 1ysore'"+

ELE%E+T* CE,'TFmaxG

4A07(+ ?.&8

%A+,A+E*E 1.&?

9'(*9'(0()* ?.?5?

*)L9')0 ?.?/8

*L4(+ ?.=?


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%(L:7$E+)% ?.18

Table 5')( Residual elements

5'5') ST&%- $F /ISTI#4 FI/T&R

Fig 5'+( Bore ,o*ator

Fig 5'.( &6Blo*k

The above figure shows the fixture which is currentl! used for machining

operation of axle housing. As mentioned in the problem definition the desired distance

between the axis of the shaft and the axis of snorkel bore to be achieved cannot be done

using this fixture due to clearance between the component and the fixture bod!. Therefore

it is necessar! to design a new fixture which provides all the re2uirements in order to

overcome these problems and to achieve desired position of snorkel bore.

%epartment o0 1e*2ani*al ngineering3 1IT3 1ysore'".


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/.5 (7BE4T3E

The current bore locator and )block in use leads to above mentioned problems'

*othe main ob#ective of our pro#ect is to eliminate this problem and

To improve the process capabilit!.

To optimiJe the clearance between the component and )block.

To optimiJe clearance between component and bore locator.

To achieve accurac! in dimensional position of the snorkel bore.

To obtain repeatabilit! in tolerance.

CHAPTR6

%SI4# $F FI/T&R

5.& $E*,+ A+$ %($ELL+, ( 7(0E L(4AT(0 A+$ 37L(46

The current pro#ect work is aimed at designing fixture to carr!out boring and surface

milling operations



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The important ob#ective of this fixture is to reduce the clearance between the component

and the fixture bod!" hence it is necessar! e#ector pins to the bore locator and M3 shaped

block instead of M) shaped block.

The successful design of fixture is the result of designers abilit! to anal!Je all the

operations performed on the component to incorporate design feature in the fixture thateliminates the difficulties or problems associated with such operations

FACT$RS T$ B C$#SI%R% BF$R %SI4#I#4

The successful design of a fixture depends upon the anal!sis of several factors which

have to be carefull! studied before the actual work is taken ahead.

*tud! of component

*tud! the t!pe and capacit! of machine

*tud! the locating element *tud! the clamping elements

*tud! the e#ecting devices

*tud! the power devices for operating clamping elements

*tud! clearance re2uired between fixtures

*tud! safet! devices

*tud! of rigidit! and vibration problems

*tud! the method of manufacturing of fixture base" bod! or frame.

4.1.2 FACTORS CONSIDERED FOR DESIGN

There are 8 factors considered in design of fixture"

1. Location

Ensure that work is given with desired constraint.

ntroduce fool proofing devices such as fouling pins" pro#ections etc" to prevent

incorrect positioning of work piece

%ake location progressive.

&. 4lamping

9osition of clamper to be best resistance to cutting forces without causing deformation

to work piece. f possible make the clamps integral with fixture bod!.

/. *tabilit! and 0igidit!

%ake fixture as rigid as re2uired for operation.

9rovide means of positioning and bolting the e2uipment to machine tool.

5. 4learance

Allow ample clearance to allow for variation of work piece siJe.

Allow ample clearance for operators to handle.

8. 'andling

%ake e2uipment eas! to handle and ensure that no sharp corners are present and

providing lifting points.

%epartment o0 1e*2ani*al ngineering3 1IT3 1ysore'">


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Figure '5 7L(46 7($:

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%epartment o0 1e*2ani*al ngineering3 1IT3 1ysore')


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5.&.1 3 7L(46 A**E%7L:

Figure '+ 37lock assembl!

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')') BI,, $F 1ATRIA,S F$R =6B,$C?

A bill of material F7(%G is a list of the raw materials" subassemblies" subcomponents"

components" parts and 2uantities of each needed to manufacture an end product. +o

ph!sical dimension is described in a 7(%.

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1 7ase 9late %ild *teel 1

& ,uide 0od E+ /1 &

/ 37lock 7od! %ild *teel 1

5 Cear 9ad E+ /1 &

8 +ut %ild *teel 5

Table '"( Bill o0 materials 0or =6blo*k

5./ XT)0E

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Figure '


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Figure '" *L$E *'AT 7)*'



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'5'" FI/T&R ASS1B,- EITH C$1P$##T

Figure '"+ XT)0E A**E%7L: CT' 4(%9(+E+T

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'5') BI,, $F 1ATRIA,S F$R FI/T&R

9A0T +( $E*409T(+ %ATE0AL I)A+TT:

1 9iston 4am Attachment E+ /8/ 1

& *lide *haft ,uide E+ /8/ =

/ Locking 9late %ild 9late 1

5 9late %ild *teel 1

8 *lide *haft 4hange 9art E+ /8/ O

= Top 9late %ild *teel 1

> 7ase 9late %ild *teel 1

O *lide *haft E+ /8/ =

H *lide *haft ,uide 7ush E+ /8/ 5

Table ')( 7ill of materials for fixture

%epartment o0 1e*2ani*al ngineering3 1IT3 1ysore')@


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' FI#A, ASS1B,- $F C$1P$##T EITH FI/T&R A#% =6B,$C?

Figure '". A**E%7L: ( 4(%9(%E%T CT' XT)0E A+$ 37L(46

%epartment o0 1e*2ani*al ngineering3 1IT3 1ysore'5


31/38


CHAPTR +

C$ST A#% STI1I#ATI$#

8.1 CE,'T 4AL4)LAT(+ ( A XT)0E

IT1

#&1B

R

C$1P$##T &A#TIT- VOLUME(mm3)

DENSITY*10

6

(Kgmm3)

EI4HT

1 7ase 9late 1 151/>?? 7.85 11.09

2

3ertical bod!

outside 1 1060287 7.85 83.23

3 3ertical bod! 1 570200.2 7.85 17.7

4 Top plate 1 706858.3 7.85 5.54

5

9iston cam

Attachment 1 712540.6 7.85 5.59

6*lide shaft

guide

6 162601.4 7.85 7.62

7 *lide shaft 6 30766.21 7.85 1.449

8*lide *haft

,uide bush4 171051.59 7.85 5.37

9*lide shaft

4hange part6 22790.6 7.85 1.43

10 0ough locator 1 1590431.6 7.85 12.48

11 3 block 1 239601.6 7.85 1.88

12 ,uide 0od 2 273220.48 7.85 4.285

133 block 7ase

plate1 714924.35 7.85 5.61

14 Cear 9ad 2 3000.44 7.85 0.471

15 +ut 4 12000.56 7.85 0.3768

Table +'"( Ceight calculation of fixture

%epartment o0 1e*2ani*al ngineering3 1IT3 1ysore'5"


32/38


+') C$ST CA,C&,ATI$# $F FI/T&R

IT1

#&1B

R

C$1P$##TT &A#TIT-

=$,&1

7mm58

DENSITY*10

6

(Kgmm3)

C$ST

1 7ase 9late 1 151/>?? >.O8 885.8

2

3ertical bod!

outside 1 1?=?&O> >.O851=1.8

3 3ertical bod! 1 8>?&??.& >.O8 OO8.=

4 Top plate 1 >?=O8O./ >.O8 &>>

5

9iston cam

Attachment 1 >1&85?.= >.O8 5&5=.O

6*lide shaft

guide6 1=&=?1.5 >.O8 /55>>.H

7 *lide shaft 6 /?>==.&1 >.O8 O>15.=5

8*lide *haft

,uide bush4 1>1?81.8H >.O8 1=1HO.8&

9*lide shaft

4hange part6 &&>H?.= >.O8 O=&>.88

10 0ough locator 1 18H?5/1.= >.O8 H515.=15

11 3 block 1 &/H=?1.= >.O8 58=.55

12 ,uide 0od 2 &>/&&?.5O >.O8 &?8H.&&

133 block 7ase

plate1 >15H&5./8 >.O8 1/5=.?O

14 Cear 9ad 2 /???.55 >.O8 11/.?5

15 +ut 4 1&???.8= >.O8 1O?.=5

Table +')( 4ost calculation of fixture

SPCI1# CA,C&,ATI$#(

XT)0E 4(*T E*T%AT(+

Total 4ost of ixture @ %aterial 4ost D Labour 4ostD 4!linder 4ost

%epartment o0 1e*2ani*al ngineering3 1IT3 1ysore'5)


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@O88/1./&D1&???DO8??@1?=?/1./&

37L(46 4(*T E*T%AT(+

Total 4ost of 3block @ %aterial 4ost D Labour 4ost

@5188.5&D18??@8=88.5&

8./ 90(4E** *'EET

$PRATI$#S PR$CSS $F $PRATI$#S



34/38


*hot 7lasting t is the process used to polish the metal surface

Tack Celdingt is the temporar! weld used to create initial #oint 7etween

two housing halves

*eam Celding t is the process in which the & halves are completel! welded

*traddle acing

t is a process in which material of both sides are removed b!

multiple tools mounted on the saddle

0ing and 4overn this process the ring is welded to one side of the housing

and cover is welded to the other end of the housing.

4old *wagen this process outer edge of the housing is pressed to

re2uired lange diameter

lange acingn this process removal of material is carried out at both the

faces of the housing

riction Celdingn this process the spindle is welded to the housing. $ue to

the friction between spindle and housing end.

lange Celding This is a process in which the flange is welded to the housing

*trengtheningt is a process of testing strength of a welded #oint b! appl!ing

heav! load on the welded part.

4entre less ,rindingt is the machining process which removes the material from

the Cork piece using abrasive cutting

$eburringt is the process of removing burrs remains on the surface of

the 'ousing

Table +'5( 9rocess *heet



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C$#C,&SI$#

A rear axle with a snorkel bore part number 4/1&1+4=1& is used in heav! dut!

vehicles. *norkel bore is present in forward rear axle through which the power is

transmitted to the backward rear axle.

At the present scenario" there is a variation in the distance between the two axes due to

which the desired position of snorkel bore is not achieved" as there was some clearance

between the component and the fixture due to which it is unable to machine the

component as per re2uired dimensions and tolerance limit" thus a new fixture is to be

designed to eliminate the clearance and to obtain the desired position of the snorkel bore.

7! introducing the new ixture and 37lock following advantages can be achieved.

%achining dimensional deviations eliminated and component is as per drawing

0e2uired tolerance and accurac! achieved

(peration time is reduced and productivit! is increased.

%epartment o0 1e*2ani*al ngineering3 1IT3 1ysore'5+


36/38


RFR#CS

1.Xiumei6ang and Iing#in 9eng MMixture easibilit! %ethods and Techni2ues for

ixture 9lanning" 3olume 8" ssue 15" Banuar! &??O" pages 5&55//

&. 9arvesh 6umar 0a#vanshi " $r. 0.%.7elokar" MMmproving the 9rocess 4apabilit! of a

7oring (peration b! the Application of *tatistical Techni2ues" nternational Bournal of

*cientific K Engineering 0esearch 3olume /" ssue 8" %a!&?1& 1 **+ &&&H881O

3. *hailesh * 9achbhai" Laukik 9 0aut" P$esign and $evelopment of '!draulic ixture

for %achining '!draulic Lift 'ousingQ" ntl #ournal of %echanical Engineering and

0obotics" 3ol. /" +o. /" Bul!" &?15. **+ &&>O N ?15H.

5. Iiang Li" %.A MM3irtual 0ealit! for ixture $esign and Assembl!" )niversit! of

+ottingham (ctober &??O.

%epartment o0 1e*2ani*al ngineering3 1IT3 1ysore'5.


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C!"#$"#%+T0($)4T(+...............................................................................................................1

1.1 AXLE.........................................................................................................................1

1.& AXLE '()*+,......................................................................................................&

1./ 0EA0 AXLE..............................................................................................................&

1.5 *+(06EL 7(0E....................................................................................................../

1.8 90(4E** 4A9A7LT:..........................................................................................5

1.8.1 4A9A7LT: +$4E*.........................................................................................5

1.= XT)0E...................................................................................................................8

1.=.1 T:9E* ( XT)0E.........................................................................................=

1.=.& 4LA%9+,........................................................................................................=

1.=./ L(4AT(+.........................................................................................................>

LTE0AT)0E *)03E:.....................................................................................................O

90(7LE% $E+TAT(+.............................................................................................11

/.1 *TAT*T4AL I)ALT: 4(+T0(L...................................................................11

/.1.1 T'E *I4 T((L*.............................................................................................11

/.1.& 4A)*E K EE4T $A,0A%......................................................................1&

/.& 90(7LE% $E+T(+.......................................................................................1/

/./ %ET'($(L(,:...................................................................................................18

/./.1 *T)$: ( 4(%9(+E+T..............................................................................18

/./.& *T)$: ( EX*T+, XT)0E..................................................................1=

/.5 (7BE4T3E............................................................................................................1>

$E*,+ ( XT)0E.....................................................................................................1O

5.& $E*,+ A+$ %($ELL+, ( 7(0E L(4AT(0 A+$ 37L(46...........1O

A4T(0* T( 7E 4(+*$E0E$ 7E(0E $E*,++,....................................1O

5.1.& A4T(0* 4(+*$E0E$ (0 $E*,+......................................................1O

5.& 3 N 7L(46.............................................................................................................&?

5.&.& 7LL ( %ATE0AL* (0 37L(46.........................................................&/

5./ XT)0E.................................................................................................................&55./.1 XT)0E A**E%7L: CT' 4(%9(+E+T...............................................&H

5./.& 7LL ( %ATE0AL* (0 XT)0E........................................................../?

5.5 +AL A**E%7L: ( 4(%9(+E+T CT' XT)0E A+$ 37L(46..../1

4(*T A+$ E*T%+AT(+.........................................................................................../&

8.1 CE,'T 4AL4)LAT(+ ( A XT)0E........................................................../&

8.& 4(*T 4AL4)LAT(+ ( XT)0E.................................................................../&

8./ 90(4E** *'EET................................................................................................../8

4(+4L)*(+................................................................................................................../=0EE0E+4E*.................................................................................................................../>



38/38


Documents

Final Rear Forward Axle Housing Snorkel