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.