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MISRIMAL NAVAJEE MUNOTH JAIN ENGINEERING COLLEGE
Department of Mechanical Engineering
BATCH (2008-2012)
Final Year Project
SEMI AUTOMATIC CAMBER SETTING IN FIXTURE
Team members
J.BHARATH - 31008114301
G.SANMUGANATHAN - 31008114303
A.VIGNESH - 31008114304
V.VIJAYABASHKAR - 31008114306
Project Site: ICF
INTERNAL GUIDE EXTERNAL GUIDEMr.Siddhiq Ahmeed Gayas Mr.T.S.Ravichandran.
ABSTRACT
•In the Under Frame manufacturing there is a process called Camper setting which is done for withstanding the entire load, vibration, stress etc. the process is done manually by using the Screw jacks and tie rods
•Due to manual process, time consumption is more and accuracy is less. To overcome this problem, the hydraulic piston is introduced to camper the under frame in the train compartment.
MAINCOMPONETS OF COACH
Under frame Side walls End wall assembly Roof assembly Bogies
PRICIPAL OF FIXTURE
Locating Clamping Fool proofing
IMPORTANCE OF FIXTURE
To reduce the production time To reduce the cost of production To increase the accuracy To minimize the machining time To reduce the operator fatiuge
CAMBER
CAMBER Camber is a profile .It’s depend to raise a
height as per measure respectively .so it’s called negative deflection .
Why this needed? Camber setting is to avoid a creep stress on a
dynamic load.
CAMBER SETTING DIAGRAM
CAMBER SETTING PROCESS
Zero point setting Side wall clamping
VIEW OF ZERO PIONT
SIDE WALL CLAMPING
CAMBER SETTING USING HYDRAULIC SYSTEM
Hydraulic cylinder Pressure relief DCV Flow control valve Pilot operating check valve Pressure gauge Hydraulic motor and pump
MERITS OF USING THIS SYSTEM
Time consumption less High accuracy Simply to operated Semi skilled labour
DESIGN CALCULATION
Hydraulic cylinder for deflection 15 mm Hydraulic cylinder for deflection 6mm
15 mm DEFLECTION
Weight lifted by 1 cylinder = 144587/2 = 72294 N
Taking diameter of the cylinder as 80 mm Area = p/4* 802 = 5026.24 mm2
Pressure = Load/ Area = 72294/5026.54 Cylinder Thickness = 5 mm Therefore,outer diameter of cylinder = 90 mm Cylinder volume = stroke* area
= 417*p*802/4 = 2.096E6 mm3
= 2.096E-3 m3
6 mm DEFLECTION Weight lifted by one cylinder = 54255.825 N Taking diameter of cylinder as 80 mm Area of cylinder = p/4* 802 = 5026.24 mm2
Pressure = Load/ Area = 54255.825/ 5026.54 = 10.79 N/mm2
By measuring the distance between the bottom of under frame and ground, stroke length is taken as 417 mm
Cylinder Material is Mild steel Cylinder volume = stroke* area
= 417*p*802/4 = 2.096E6 mm3
PNEUMATIC BASE END CYLINDER
PNEUMATIC SIDE END CYLINDER
HYDRAULIC CAMBER CYLINDER
PNEUMATIC SIDEWALL CLAMPING ASSEMBLY
HYDRAULIC CAMBER SETTING FRONT VIEW
HYDRAULIC CAMBER SETTING ASSEMBLY
CIRCUIT DIAGRAMS
CONCLUSION
Thus, our project Design of Hydraulic system for Camber and Pneumatic systems for Side wall assembly completely aims on the time scaling and also with the view to reduce man power
Thus, we hope that this project work will surely satisfy the workers who are involved in the camber setting method and also in the side wall assemblies.
NEXT PROJECT
DESIGN AND FABRICATION OF DIE FOR BLOW FORMING
Guided by Mr. VIJAY ANANTH Asst prof.
Submitted by
A.RAMASUNDARESAN :31008114043
A.VIGNESH :31008114304
V.VIJAYABASHKAR :31008114306
E.S.VINOTHKUMAR :31008114307
ABSTRACT:
A stiff competition in the automobile and aerospace industries in recent times
has forced to innovate newer and better technologies for the fast paced world.
Aluminum automotive components made using a hot blow forming process are
reducing vehicle weight and increasing the fuel efficiency of today’s cars
Al 6063 disks of a super plastic forming grade gas-pressure formed to
hemispheres at constant forming pressures with back pressure. The forming operation
was performed using an in-house designed forming apparatus. The temporal change
of dome heights of the hemispheres were measured for the different forming and back
pressure applied. Forming test with dies were performed at 5800C.
INTRODUCTION:
Recent interest in lightweight and inexpensive alloys for transportation
systems has attracted attentions to aluminum – magnesium alloys. Al 6063 alloy
, because of its good weld ability , reasonably high corrosion resistance and
high strength with reasonable ductility , has been one of such alloys. Large
ductility required in forming engineering parts with contoured geometry has to
development of superplastic grade of the alloy. Deformation behavior and
microstructural evolution of the superplastic Al 6063 has been extensively
investigated for tensile deformation . the purpose of the present study is to
investigate the deformation behavior of Al6063 alloy using hemispherical dies.
Superplasticity
Superplasticity in materials is characterized by large neck free elongation under low flow stress when they are formed at temperature exceeding about one half of the melting point.
Superplastic forming is carried out essentially under isothermal conditions with very low strain rates.
SUPERPLASTIC BLOW FORMING PROCESS:
It is metal working process for forming sheet metal. It works
upon the theory of superplasticity which means that a
material can elongate beyond 100% of its original size.
It is manufacturing method used for making aluminum
automotive components . Parison is a tube like pipe which is
used to pass the argon gas . The parison is then clamped
into the Die and gas pumped into the mould. Aluminum is
heated one third of its melting point and argon pressure gas
is passed and aluminum forms the mould shape.
Superplastic Blow Forming Process
FORMULA
σ = k έ m where, ‘σ’ is effective flow stress, ‘έ’ is strain rate, ‘k’ is constant depends upon temperature
and grain size ‘m’ is strain rate sensitivity index .
LAYOUT OF THE DIE
DESIGN CALCULATION
DESIGN CALCULATION
For the analysis of the superplastic forming behaviour, the disk specimens
were assumed to bulge to spherical membranes of uniform thickness.
An applied pressure, P, In a hemispherical die of results Ro would deform a
disk specimen of the initial thickness T0 Into a spherical membrance of radius p.
By measuring the dome height HD of the membrane, and assuming the volume
constancy of the material, one can calculate the radius p, thickness t, strain e, and
shell stress , of the membrane.
MATERIALS DIMENSIONS QUANTITY
MALE DIE MILD STEEL
DIAMTER=100 mm THICKNESS=25 mm
1
FEMALE DIE MILD STEEL
DIAMETER=100mm THICKNESS=100 mm
1
PARISON TUBE DIAMETER =20 mm 1
ALIGN BOLT 4
BILL OF MATERIALS:
BENEFITS:
Weight saving of 40% on a typical mid size
automobile which reduces green house gas emission and
increase fuel economy.
No color and fit issues on the auto assembly where
two piece construction as become one piece.
simply of auto assembly process.
completive advantage for US industry in
manufacturing light weight automotive components.
Low-cost tooling
Low environmental impacts –non-lead die tubes,
low noise
Reduced weight for high fuel efficiency
Improved structural performance
PHOTOGRAPHS:
COMPONENT PRODUCED:
Cost of the project
MATERIALS COST
MALE DIE 400
FEMALE DIE 800
MACHINING 900
BOLT 100
PARISON TUBE WITH 300REDUSER
TOTAL COST 2500
CONCULSION
Thus we have successfully design and fabricated a
die for conducting blow forming tests. Blow forming tests has
been conducted for different pressure and temperatures.