Chapter 1: ABSTRACT

An Inspection Tool is basically a Gauge which is the main aspect of this project.
The component to be tested on it is a Yoke Shaft, a product being manufactured in
Mahindra Sona Limited, Nasik. Various applications are being related to yoke shaft,
out of which transmission plays an important role, also in automobiles, etc.
Focussing these factors it is the prime requirement to design a gauge which will
take into account the parameters like compatibility, super finishing of the tool, proper
material selection, tribological considerations, overcoming failures, and reducing cycle
time for inspection, high accuracy and easy handling located near to the machines.
Currently the inspection process consumes lot of iterations and time.
Efforts have been done to throw light on the design of a highly precise gauge
which will check if the offset distance between the axis of splines and bores is within the
prescribed tolerance zone, as well as the centrality of bores simultaneously. This accuracy
needs to be kept throughout the hobbing process. Further, this check will ensure the
proper lubrication and alignment during the assembly of the component with other parts.
Manufacturing of the proposed design is the next step after computing number of
iterations. These gauges will ultimately emphasis on the dimensional accuracy and
efficiency of the product.

1
Chapter 2: COMPANY PROFILE

MAHINDRA SONA LTD.

Address: - Mahindra Sona Limited,

Plot No. 89/1, MIDC,
Satpur, Nashik -422 101
.
The manufacturing unit is situated at Nashik about 180 km North-east of Mumbai
and employs about 370 people. Its constructed area is around 10000 Sq. meters. The
Nashik plant commenced production in 1979 following a technical and financial joint
venture between Mahindra & Mahindra Limited and Dana Corporation USA, named
Mahindra Spicer Limited.

In 1984, Mahindra Spicer Limited merged with its parent company Mahindra &
Mahindra Limited and became MSL Division of the parent company. In March 1995,
Mahindra & Mahindra Limited and Sona Koyo Steering Systems Ltd. formed a new
company MAHINDRA SONA LIMITED to take over the automotive component
business of MSL Division of Mahindra & Mahindra Ltd.

The company is engaged in designing and manufacturing a wide range of auto

ancillary products such as propeller shafts, clutches, universal joint kits, steering joints,
steering column parts and axle shafts. The company is original equipment supplier to
almost all vehicle manufacturers in India and caters to the spare parts market through a
wide distribution network.

The company has been certified for ISO-9001 in 1995 and QS-9000 in1999. The
company firmly believes that the high standards of quality can only be achieved through
strong systems and the support of its people.

2
 Mahindra Sona Limited manufactures Yoke shafts, Propeller Shafts and
components for Automotive Applications like Passenger Cars, Multi Utility Vehicles,
Sport Utility Vehicles, Light Commercial Vehicles, Medium Commercial Vehicles and
Heavy Commercial Vehicles. MSL Drive Shafts also cater to wide Industrial
Applications like Earth Moving Equipment, Engine Dynamometer Testing, and Radiator
Fan Drive for Railways, Steel Rolling Mills, and Printing Machineries etc, MSL’s other
products include Steering Universal Joints for. Automotive Applications like Passenger
Cars, Multi Utility Vehicles and Heavy Commercial Vehicles.

The other product line of Mahindra Sona Limited is for the Automotive Clutches.
This includes the worlds latest Diaphragm Type and the convential lever type for
Passengers Cars, Multi Utility Vehicles, Sport Utility Vehicles, Light Commercial
Vehicles, Medium Commercial Vehicles, Heavy Commercial Vehicles and Farm
Tractors.

3
Chapter 3: THEORY OF GAUGE

The gauges used in the industries have been used to perform various functions for
controlling the quality of the components like shafts, keys, joints. The gauges are actually
dimension measuring instruments. The dial gauges are specifically designed for this
purpose.

1st Principle Method

The existing system for checking the angularity of a splined yoke shaft is a tedious
job. In the 1st principle method, the Yoke shaft is mounted between the two centres. Thus,
now it has only rotational degree of freedom. With the help of a height gauge the bore
axis is made horizontal. With reference to this position the angularity of the splines is
measured by using a dial gauge.
The procedure for the 1st principle method is:

1. The Yoke shaft is placed between the two centres.

2. The height gauge is used at both the bores of the yoke shaft to make it perfectly
horizontal w.r.t. the platform.
3. Then using a dial gauge the angularity is measured at a roughly horizontal spline.
4. Then the angularity is measured at a diametrically opposite spline..
5. The difference between the two readings is the angularity for the Yoke shaft.

Use of 1st principle method

Although the 1st principle method sounds simple, it is not so. It requires a very
skilled person for the measurement. It is tedious for the operator.
The company required a method or a gauge which was simpler in operation. The
gauge should be such that anyone should be able to use it, also it should be within the
reach of the operator.

4
Concept for the gauge3

Inspite of advancement in machine tool technology, it is impossible to achieve

dimensional perfection due to various reasons such as human error, vibrations, tool wear,
deflection,..etc.
It has been realised that perfect components are difficult to produce and any
attempt towards perfection will result in extra cost of the component. If the dimensions
are to be maintained within a very close degree of accuracy, lot of time will be consumed.
The functional aspects of the component can be achieved even without going for its exact
dimensions. As no two things are identical in nature a kind of permitted variations has a
significant importance.
A comparator gauge is used to find out by how much the dimensions of a given
component differ from that of a known datum. A dial indicator forms an integral part of
the comparator gauge. If the dimension is greater or less than the standard, then the
difference will be shown on the dial.

Yoke Shaft

A die cast of Yoke shaft is procured from the vendors. The company performs
operations like Boring, Drilling, Grooving, Coating and Grinding on the die cast. Thus a
finished product is obtained.
The Yoke shaft is used along with the propeller shaft of the vehicles. We designed
a gauge for the Yoke Shaft No. 3382901. This Yoke shaft is supplied to JCB,Ashok
Leyland, Nissan and other such heavy vehicle Companies.

Chapter 4: PROBLEM STATEMENT

5
 Design and Manufacture the gauge to check the angularity of Yoke shaft which
should fulfil the following requirements:
1. The system should be simple in working.
2. The time required for measurement should be minimum.
3. The system should be within reach.
4. The gauge should be easy to operate for anyone.
5. A few changes made, the gauge can be used to check other yoke shafts.

[Fig. 1] Courtesy MSL

Chapter 5: DESIGN OF VARIOUS COMPONENTS

6
 5.1 BED

 Material SAE8620 / 20MnCr5

 Basic size 500mm x 200mm x 20mm
 Quantity: 1

No. Specification Function

1 Case Hardening
2 Length 500mm
3 Width 200mm
4 Thickness 20mm
5 4 x M8 Tap, holes
6 4 x Ø7 Dowell holes
7 Super finishing on the upper To reduce wear and tear due to the sliding
surface.
Creates a hard, wear resistant skin but preserving
a tough and ductile interior.
Long Enough to slide the job
.
Ease of loading the job, as the width is 50%
more than the maximum width of the job.
Guide plates are bolted to the Base plate using
M6 x 20 screws.
For fixing the Guide Plates to the Base plate
using Allen screws.
For accurate positioning of the Guide Plates on
the Base plate.
motion of the Locator.

7
8
 5.2 GUIDE PLATES

 Material SAE8620 / 20MnCr5

 Basic size 261mm x 24mm x 20mm
 Quantity: 2

No. Specification Function

1 Case Hardening
2 Length 261mm
3 Guide plate is provided with For proper mating with the Locator and sliding
a step.
4 2 C’Holes, M14x1
5 2 x Ø7 Dowell holes
6 Super finishing
mating surfaces.
Creates a hard, wear resistant skin but preserving
a tough and ductile interior.
Length of the Guide Plates is 1.25 times that of
the Locator for easy in sliding and rotating.
in a determined path.
For fixing the Guide Plates to the Base plate
using Allen screws.
For accurate positioning of the Guide Plates on
the Base plate.
on the To reduce wear and tear due to the sliding
motion of the Locator.

9
10
 5.3 MALE PART

 Material SAE8620 / 20MnCr5

 Basic size 100mm x 30mm x 100mm
 Quantity: 1

No. Specification Function

1 Height 100mm It comes in contact with the Alignment Mandrel
at its diameter.
2 1 x Ø10 hole with C’ Bore. For attaching the Mandrel to the Male Part.

3 Housing, Ø20 For mounting of spring.

4 Super finishing on the To reduce wear and tear due to the sliding
mating surfaces. motion of the Locator.

11
12
 5.4 FEMALE PART

 Material SAE8620 / 20MnCr5

 Basic size: 140mm x 20mm x 180mm (rect. Plate)
40mm x 30mm x 180mm (guide plates, 2 nos.)

No. Specification Function

1 A rectangular plate For sliding of male part.

2 Thickness 30mm It matches exactly with the step of the male part
provided for sliding.
3 2 C’ Bore, M7 x 1 Provided for fixing the female part to bed.

4 2 C’ Bore, M14 x 1 For attaching the guide plates to the rect. Plate.

5 2 x Ø7 Dowell holes For accurate positioning of the Guide Plates on

the rectangular plate.
5 Super finishing on all the To reduce wear and tear due to the sliding
mating surfaces. motion over the Base plate.

13
14
15
 5.5 RING

 Material SAE8620 / 20MnCr5

 Basic size ID Ø40, 5mm thick
 Quantity: 1

No. Specification Function

1 ID Ø 40 To accommodate the spline locator.

2 Thickness 5mm For attaching the cantilever strips.

3 Cantilever strips. These are welded at the circumference of the

50mmx15mmx10mm: 3nos. ring to transfer the response.
4 Super finishing on the inner To reduce wear and tear and to help in easy press
surface. fit of the Ring in the Locator.

16
17
18
 5.6 SPLINE HOLDER

 Material SAE8620 / 20MnCr5

 Basic size 60mm x 30mm x 144mm (rect. Block)
167mm x 100mm x 12mm (rect. Plate)
 Quantity: 1

No. Specification Function

1 Bore, Ø40 To accommodate the spline locator.

2 Height 144mm
3 2 C’ Bore, M7 x 1
4 Chamfer, 2 x 450
So that the dial gauge comes in plane with the
top surface of the cantilever strips.
Provided for fixing the rectangular block to the
rectangular plate.
To avoid sharp edges for safety precautions.

19
20
21
 5.7 SPLINE LOCATOR

 Material SAE8620 / 20MnCr5

 Specification: 16x Ømm x 25mm
 Quantity: 1

No. Specification Function

1 Case Hardening Creates a hard, wear resistant skin but preserving
a tough and ductile interior.
2 Minor Diameter Ø12 So that the spline locator will accommodate the
splines of yoke shaft.

3 Outer Diameter Ø12 To accommodate the hole in spline holder

4 Super finishing on the outer As it comes in contact with the Alignment

surface. Mandrel

22
23
 5.8 ALIGNMENT MANDREL

 Material SAE8620 / 20MnCr5

 Basic size Ø34.7mm x 155mm
 Quantity: 1

No. Specification Function

1 Case Hardening
2 Diameter Ø34.7
4 Chamfer, 2 x 450
Creates a hard, wear resistant skin but preserving
a tough and ductile interior.
So that the Yoke Shaft is inserted in to the
alignment mandrel.
To avoid sharp edges for safety Precautions

5 Super finishing on the outer As it comes in contact with the Yoke Shaft.
surface.

OTHER STANDARD COMPONENTS

 Spring: Ø20 Mean Dia., 1.5mm Wire Dia.
 Bolts: M6, M7, M10, M14
 Dial Indicator: Make- Baker Co.
Least Count: 1 µm

24
25
Chapter 6: MANUFACTURING OF VARIOUS COMPONENTS

6.1 BED:

Material: SAE8620 / 20MnCr5

Qty: 1
Raw Material Size: 500mm x 200mm x 20mm
Weight: 15 kg
Raw Material Cost: Rs. 1000
Process time: 8 hrs
Manufacturing Cost: Rs. 440
Component cost: Rs. 1440

No. Operation Description Machine Used Machine Tool Rate Cost

(Rs./hr) (Rs)
1 Blank Sizing Milling Shell End Mill 100 100
Machine
2 Case Hardening & 250
Tempering
3 C’ Bore
M8 through Drilling Ø7 drill 30 15
Drill Machine M8 Tap 30 15
Ø7 through
4 Blank thickness Grinding Surface Grinder Abrasive 60 60
Wheel

26
 6.2 GUIDE PLATE:

Material: SAE8620 / 20MnCr5

Qty: 2
Raw Material Size: 261mm x 24mm x 20mm
Weight: 1.0 kg
Raw Material Cost: Rs. 85
Process time: 8 hrs
Manufacturing Cost: Rs. 315
Component cost: Rs. 400

No. Operation Description Machine Used Machine Rate Cost

Tool (Rs./hr) (Rs)
1 Sizing Milling Step Milling 100 200
Machine
2 Case Hardening & Tempering 25
3 Boring
Ø7 through Drilling Ø7 Drill 30 15
C’ Bore Ø14 through Machine Ø14 Drill 30 15

4 Surface Grinding all over Surface Abrasive 60 60

Grinder Wheel

27
 6.3 MALE PART:

Material: SAE8620 / 20MnCr5

Qty: 1
Raw Material Size: 100mm x 30mm x 100mm
Weight: 2.34 kg
Raw Material Cost: Rs. 95
Process time: 6 hrs
Manufacturing Cost: Rs.275
Component cost: Rs. 370

No. Operation Description Machine Used Machine Tool Rate Cost

(Rs./hr) (Rs)
1 Sizing Milling Step Milling 100 200
Machine
2 Boring
C’ Bore Ø20 Drilling Ø 20 30 15
through Machine

4 Surface Grinding all over Surface Abrasive 60 60

Grinder Wheel

28
 6.4 FEMALE PART:

Material: SAE 8620 / 20MnCr5

Qty: 1
Raw Material Size: 140mm x 20mm x 180mm (rect. plate)
40mm x 30mm x 180mm (guide plates, 2 nos.)
Weight: 5.6 kg
Raw Material Cost: Rs. 405
Process time: 7 hrs
Manufacturing Cost: Rs.385
Component cost: Rs790

No. Operation Description Machine Used Machine Rate Cost

Tool (Rs./hr) (Rs)
1 Blank Sizing Milling Shell End 100 100
Machine Mill
2 Step Milling Milling Step Milling 100 100
Machine
3 Case Hardening and Tempering 75
4 Boring
C’ Bore Ø7 through Drilling Ø7 drill 30 15
C’ Bore Ø14 through Machine Ø14 drill 30 15

5 Chamfer Surface Abrasive 40 20

Grinder Wheel
6 Surface Grinding all over Surface Abrasive 60 60
Grinder Wheel

6.5 RING:

29
 Material: SAE 8620 / 20MnCr5
Qty: 1
Raw Material Size: Ø40, 5mm thick
Weight: 0.2 kg
Raw Material Cost: Rs. 15
Process time: 6 hrs
Manufacturing Cost: Rs.165
Component cost: Rs. 180

No. Operation Description Machine Used Machine Tool Rate Cost

(Rs./hr) (Rs)
1 Case Hardening and 50
Tempering
2 Boring
Ø7 through Drilling Ø 7 drill 30 15
(Cantilever strips) Machine
3 V- Butt Weld Arc Welding Copper 150 40
Machine Electrodes
4 Surface Grinding all over Surface Grinder Abrasive 60 60
Wheel

6.6 SPLINE HOLDER:

Material: SAE 8620 / 20MnCr5

30
 Qty: 1
Raw Material Size: 60mm x 30mm x 144mm (rect. block)
167mm x 100mm x 12mm (rect. plate)
Weight: 3.6 kg
Raw Material Cost: Rs 145
Process time: 10hrs
Manufacturing Cost: Rs. 310
Component cost: Rs. 455

No. Operation Description Machine Machine Tool Rate Cost

Used (Rs./hr) (Rs)
1 Blank Sizing Milling Shell End 100 100
Machine Milling
2 Step Milling Milling Step Milling 100 100
Machine
3 Boring
Ø40 through Drilling Ø40 drill 30 15
C’ Bore Ø7 through Machine Ø7 drill 30 15

5 Chamfer Surface Abrasive 40 20

Grinder Wheel
6 Surface Grinding both faces Surface Abrasive 60 60
Grinder Wheel

6.7 SPLINE LOCATOR:

31
 Material: SAE 8620 / 20MnCr5
Qty: 1
Raw Material Size: Ø 25 x 25
Weight: 97 gm
Raw Material Cost: Rs. 10
Process time: 5 hrs
Manufacturing Cost: Rs.215
Component cost: Rs 225

No. Operation Description Machine Machine Rate(Rs./hr) Cost(Rs)

Used Tool
1 Turning Lathe Turning 100 100
2 Case Hardening and 25
Tempering
3 Chamfer Surface Abrasive 60 30
Grinder Wheel
4 Surface Grinding both Surface Abrasive 60 60
faces Grinder Wheel

6.8 ALIGNMENT MANDREL:

32
 Material: SAE 8620 / 20MnCr5
Qty: 1
Raw Material Size: Ø34.7mm x 155mm
Weight: 1.15 kg
Raw Material Cost: Rs. 50
Process time: 6 hrs
Manufacturing Cost: Rs.330
Component cost: Rs. 380

No. Operation Description Machine Used Machine Tool Rate Cost

(Rs./hr) (Rs)
1 Turning Lathe Turning 100 100
2 Case Hardening and 50
Tempering
3 Centre Drilling Lathe Drill 100 100
4 Chamfer Surface Abrasive 40 20
Grinder Wheel
5 Surface Grinding both faces Surface Abrasive 60 60
Grinder Wheel

Chapter 7: CASE HARDENING OF VARIOUS COMPONENTS

33
 The various components in the inspection tool which has been manufactured are
prone to lot of wear over the period of time. So components such as mandrel, guide plates
etc. needed case hardening.

Hardness is normally required only on the surface of the specimen, alloying of the
whole specimen is not necessary. According to our requirement we employed the
carburising process for case hardening.

Carburising2:

Here the specimen is heated beyond the upper critical temperature in a sealed
container having the atmosphere of carbon. The heating is continued for 4-10 hours
depending on the depth of the penetration required. As a result, carbon penetrates into the
surface layer making the specimen harder.

Process:

The case hardening is carried out in the pit type furnace also called as the ‘Old
vertical retort furnace’ .
The charge is loaded into the furnace, the time being 2-2.5 hours. During this
period the temperature achieved is about 920ºC.
For the carburising of the charge, LPG is used as the medium of carbon. At high
temperature the LPG dissociates into carbon and hydrogen. This carbon
penetrates into the the charge thus causing carburising.
The discharge of the LPG is 1.2 litre/hr.( for a required case depth of 1.2-1.5 mm,
hardness :- 59-60 RC.)
This process goes on for 9.5 hours.
After the penetration of carbon in the charge, the charge is cooled in the pit
furnace for about 2.5 hrs. Here the temperature drops from 920-820ºC.
The charge is removed from the pit furnace and dipped into the quenching oil.
(Oil name: 22XFQ)
The charge is then removed from the quenching oil tank and then washed.

Chapter 8: DESIGN OF SPRING

34
Constraints in Spring Design1:

The spring should be such that after mounting the yoke shaft on the mandrel, the
male part should not slide down until a small amount of load is applied by the operator.
Free length of the spring should be about 29mm. On application of load, deflection
should be about 1mm.

Considering the weight of the components and force applied by the operator the
total load on spring comes out to be about 70N.

Material available- Plain Carbon Steel

Shear strength- 400MPa

Modulus of rigidity- 80GPa.

From the above given data

F = 70N; δ = 1mm Lf = 29mm τ = 400N/mm2 G = 80x103N/mm2

Assumption:

Spring index C = D/d = 6

Clearance between adjacent coils = c = 3mm

Ls + δ + (n + 1) x c = Lf

Where,

Ls = solid length n = no. of turns

Ls = (n + 2) x d

. . . (n + 2)d + 1 + (n+103 = 29

. . . nd + 2d + 3n = 25……………………………………………..eqn 1

Now

δ = (8 x F x C3 x n)/(G x d)

. . . 1 = (8 x 70 x 63 x n)/(80 x 103 x d)

. . . n/d = 2.2314

. . . n = 2.2314d nd = 2.2314d2……………………………eqn 2

Substituting eqn 2 in eqn 1

35
2.2314d2 + 2d + 3 x 2.2314d = 25

Solving above eqn

d = 2.46mm

d ≈ 2.5mm

D = Cd

D = 15mm

n = d x 2.2314

n = 5.57

n = 6 turns

. . . Wire diameter of spring is 2.5mm

. . . Mean coil diameter = 15mm

. . . No. of turns = 6

Considering shear failure of spring

τmax = Kw(8FC/πd2)

Kw = (4C-1)/ (4C-4) + 0.615/C

. . . Kw = 1.2525

. . . τmax = 1.2525[(8 x 70 x 6)/(π x 2.52)]

. . . τmax = 214.33N/mm2 < 400N/mm2

. . . Design is safe

Chapter 9: STRESS ANALYSIS OF SPRING

1. Material

36
 Part
No. Material Mass Volume
Name

1 Spring [SW]AISI 1020 0.0138668 kg 1.75529e-006 m^3

Elastic modulus 2e+011 N/m^2

Poisson's ratio 0.29 NA

Mass density 7900 kg/m^3

Yield strength 3.5157e+008 N/m^2

2. Load & Restraint Information

Restraint

Restraint1 <spring> On 1 Face(s) immovable (no translation).

Description: Fixed Bottom most Surface

Load

Load1 <spring> On 1 Face(s) apply normal force 70 N using

uniform distribution

Description: Load on Top most Surface

3. Study Property

37
 Mesh Information

Mesh Type: Solid mesh

Mesher Used: Standard

Automatic Transition: Off

Smooth Surface: On

Jacobian Check: 4 Points

Element Size: 1.2068 mm

Tolerance: 0.060341 mm

Quality: High

Number of elements: 8881

Number of nodes: 17036

Solver Information

Quality: High

Solver Type: FFE

4. Stress Results

38
 Name Type Min Location Max Location

(-
(-
6.83688
0.504114
mm,
mm,
6598.63 1.37103e+008
VON: von N/m^2 N/m^2 0.190768
Plot1 0.407115
Mises stress mm,
mm,
-
6.2798
0.427651
mm)
mm)

5. Displacement Results

Name Type Min Location Max Location

(-1.79372
(0 mm,
mm,
0 1.11206
URES: Resultant mm 0 mm, mm
Plot2 30.25 mm,
displacement
6.25
9.83781
mm)
mm)

6. Static Nodal Stress Plot

39
7. Static Displacement Plot

Chapter 10: COST ESTIMATION OF INSPECTION TOOL

40
No. Description Quantity Rate Cost (Rs)

1 BED 1 Rs. 1440 Rs. 1440

2 GUIDE PLATE 2 Rs. 400 Rs. 800

3 MALE PART 1 Rs. 370 Rs. 370

4 FEMALE PART 1 Rs. 790 Rs. 790

5 RING 1 Rs. 180 Rs. 180

6 SPLINE HOLDER 1 Rs. 455 Rs. 455

7 SPLINE LOCATOR 1 Rs. 225 Rs.450

8 ALIGNMENT MANDREL 1 Rs. 380 Rs. 380

9 DIAL GAUGE (1 µm) Rs. 4000 Rs. 4000

10 OTH. STANDARD PARTS Rs. 150

TOTAL Rs. 8695

Chapter 11: ASSEMBLY OF INSPECTION TOOL

41
 1. The Bed forms the rigid base for the assembly of the gauge.
2. The two Guide Plates are mounted on the Bed with the help of four Allen screws.
3. There are four Dowell holes provided on the Bed as well as on the Guide Plates
for the accurate positioning of the Guide Plates.
4. Female Part is attached to the end of the Bed with the help of another set of Allen
screws.
5. The Alignment Mandrel is attached to the Male Part. This assembly is inserted in
the slot provided in the female part.
6. The spring is placed between the male part and the bed.
7. The Spline holder is free to slide length wise along the Bed.
8. The Guide Plates restrict the motion of the spline holder in the cross direction and
vertically upwards, limiting it to only 1 degree of freedom.
9. The Spline Locator is inserted in the bore of the spline holder.
10. The Ring is mounted on the spline locator such that the spline locator has only
rotational degree of freedom.
11. A M6 screw is provided for gripping of the ring to the spline locator.
12. The Dial Gauge is mounted on the spline holder by fixing the arm of the gauge on
the cantilever strip.

Chapter 12: WORKING OF INSPECTION TOOL

42
 The inspection tool is to be located of a horizontal surface.
Ensure that the dial gauge reading is set at some fixed reading at a pressure.
Insert the Yoke Shaft in the Alignment Mandrel.
Now move the spline holder in the splined portion of the yoke shaft by
adjusting the rotation of the spline locator.
Once the position of the Yoke Shaft is fixed with respect to the gauge, observe
the reading on the dial indicator.
If the reading shown is within the permissible limits(i.e. 1.3 TIR), then the
product is accepted otherwise rejected.

Chapter 13: ADVANTAGES OF THE DEVICE

43
 1. Its simple in construction and ease in operation make it suitable to be operated
even by unskilled labour.
2. It saves a lot of time for inspection than the previous system.
3. The gauge system can be used for the different size of the Yoke Shafts because of
the standardization.
4. All the degrees of freedom are restricted ensuring accurate reading.
5. Due to compact size, it can easily be kept near the lathe machine.
6. It relieves the physical stress on labour which was occurring during manual
inspection.
7. The efficiency of the system has been increased to great extent.
8. The precision of the system is high i.e. repeatability of the system is high.
9. The wastage of material has been dropped considerably.
10. The gauge has simple manual operation.
11. The gauge gives the direct reading on dial.
12. The system does not need any external power source.
13. The system facilitates for individual product testing.
14. The system has low capital cost as it is mechanically operated.
15. It has low maintenance cost.

All these advantages make it suitable to be used for the purpose according to
which it is designed.

Chapter 14: LIMITATIONS OF THE DEVICE

44
 1. The system is not automated.
2. As analog gauge is used there is no digital display.
3. Operational errors can occur which leads to errors in readings.
4. Because of the sliding movement wearing takes place at various places.
5. Weight is high.

Chapter 15: DEVICE RESULT

45
 Time for one job is measured using a stop watch. It is less than 45 seconds. Due
to this reduction in time, the sample size of the batch can be increased, thus ensuring
greater accuracy. The gauge has simple operation as it uses the base of 1 st principle
method. The operation is simple thus no skilled operators are required to carry out the
measurement.
Simple operation makes the process less tedious for the operator. The time
required for measurement is less it reduces the stress of the operator due to quick
measurement.
This gauge also facilitates individual product testing.

Chapter 16: FUTURE SCOPE

46
 Taking an overview of this project, it is purely a mechanical one. There is a
possibility of inducing automation in the response measuring instrument i.e. the dial
indicator can be replaced by a digital display in combination with sensor circuit.

Also the device can be directly connected to the manufacturing unit such that the
error occurring can be manipulated by the device and the same signal can be sent to the
manufacturing unit to compensate the error.

47
Chapter 17: CONCLUSION

The gauge designed by us is an effective solution given to Mahindra Sona

Limited for the problem faced by them for checking the angularity of yoke shaft which is
being used in the propeller shaft for the power transmission purpose. This checking, in an
effective manner saves a lot of time at the assembly line too.

While working under the project we got a chance to learn how the actual
management is being carried out in the plant and the span of control results in the passing
information from one level to another.

We also learnt the various aspects of Manufacturing such as cost analysis and the
working cycle of the worker. The actual concepts of production were understood by us
practically. The problems which come in the way were dealt with and working in a team
actually prepared us for the future to come, when we would actually step in the industry.

In short the overall experience of the project was very informative and an eye
opening which actually showed the difference in practical concepts and theoretical
concepts. The events occurred gave us an immense knowledge about the actual industrial
environment.

48
Chapter 18: REFERENCES

BOOKS
1. Mechanical Springs (Chapter 10, pg 296) from Design of Machine Elements by
V. B. Bhandari. Retrieved, March, 21st 2010
2. Heat Treatment of Steels (Chapter 4, article 4.40, pg 4-33) from Metallurgy by
A. S. Gholap & M. S. Kulkarni Retrieved, March, 25 th 2010
3. Metrology and Quality Control (Chapter 4, article 4.10, pg 4-22) by
R. K. Jain. Retrieved, April, 12th 2010

SOFWARES
1. CATIA V5R16
2. AUTOCAD-2008
3. SOLID WORKS-2005

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