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

= 2.096E-3 m3

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.