“DESIGN & MANUFACTURING OF MULTINUT ASSEMBLING

AND REMOVING TOOL FOR A FOUR WHEEL VEHICLE”

A Dissertation submitted in partial fulfillment of the requirement for the award of
degree of
MASTER OF TECHNOLOGY
in
MECHANICAL ENGINEERING
With specialization
CAD/CAM
By
MANDALA PHANINDRA

Regd.No: 18JQ1D0412

Under the Guidance of

Mr.V.SATYANARAYANA M.Tech,
Assistant Professor
Department of Mechanical Engineering

Department of Mechanical Engineering

KAKINADA INSTITUTE OF TECHNOLOGY AND SCIENCE
(Approved by AICTE affiliated to JNTU Kakinada)

DIVILI, PEDDAPURAM– 533433

 KAKINADA INSTITUTE OF TECHNOLOGY AND SCIENCE
(Approved by AICTE affiliated to JNTU Kakinada)

DIVILI, PEDDAPURAM– 533433

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that the entitled “DESIGN &

dissertation
MANUFACTURING OF MULTI NUT ASSEMBLING AND
REMOVING TOOL FOR A FOUR WHEEL
VEHICLE” is the Bonafide record of the project work done by MANDALA PHANINDRA
with Regd.No 18JQ1D0412, submitted in partial fulfillment of the requirements for the
award of M.Tech (CAD/CAM) in Mechanical Engineering during the academic year 2018-
20.

EXTERNAL EXAMINER

PROJECT SUPERVISOR HEAD OF THE DEPARTMENT

Mr.V.SATYANARAYANA M.Tech Mr Y.DHANA SEKHAR M.Tech (Ph.d)
Assistant Professor, Associate Professor & HOD,
Department of Mechanical, Department of Mechanical
KITS Engineering College, Divili. KITS Engineering College, Divili.
 ACKNOWLEDGEMENTS

I take this opportunity to express my gratitude and appreciation to all those who supported me to
complete this endeavor effort. I am very much grateful to my guide Mr.V.SATYANARAYANA,
Assistant Professor and Mr.Y.DHANA SEKHAR, Associate Professor HOD, DEPARTMENT
OF MECHANICAL ENGINEERING, KAKINADA INSTITUTE OF TECHNOLOGY &
SCIENCE,
DIVILI for suggesting this thesis and giving valuable guidance through the preparation of this
project and for providing generous assistance encouragement and spending many of their
valuable hours with me throughout the project work.
I am very much thankful to our beloved Principal Dr.E.SARVA RAMESWARUDU, &
Mr.B.SRINIVASA RAO, Chairman, KAKINADA INSTITUTE OF TECHNOLOGY &
SCIENCE for providing facilities to complete this project.
I am very much thankful to our faculty and supporting staff of the Mechanical
Engineering department for guidance, support and facilities to complete this project.
I am very much thankful to the management of our college for providing various resources
to complete this project.

MANDALA PHANINDRA,

Regd.No: 18JQ1D0412.
 KAKINADA INSTITUTE OF TECHNOLOGY AND SCIENCE
(Approved by AICTE affiliated to JNTU Kakinada)

DIVILI, PEDDAPURAM– 533433

DEPARTMENT OF MECHANICAL ENGINEERING

DECLARATION

This project work, entitled “DESIGN & MANUFACTURING OF MULTI

NUT ASSEMBLING AND REMOVING TOOL FOR A FOUR
WHEEL VEHICLE'' has been carried out in partial fulfillment of the
requirements for the award of the Degree of Master of Technology in CAD/CAM
of Jawaharlal Nehru Technology University, Kakinada. We hereby declare that this
project work/project report has not been submitted to any other University/Institute
for the award of any Degree.

MANDALA PHANINDRA,

Regd.No: 18JQ1D0412.
 ABSTRACT

Vehicle is an important machine in human daily life. Nowadays, each family has at

least one car to make the transportation easier and faster. For a car, the tool set-up for each

vehicle is a T-nut wrench and carjacker which is hard to use for a woman or teen to open their

car’s nut. One of the problems of a vehicle is tire problems. If the vehicle tires have some

problem then the user must remove the tires and fix the problem. And for a car user, it’s

difficult to remove the tire's nut especially for women users.

In the present work a product that is four wheeler multiple-opening spanners for tightening and

removing the four nuts in a single stroke of a hand operated lever is designed. We have

developed a gear planetary mechanism to reduce the time and effort of the person. In our

project we have tried to focus on the minimization of human effort and time consumed for

fixing all four nuts of the ø112mm PCD tire with a single stroke of lever. It can be successfully

used as a standard tool provided with a new vehicle. Also, it can be used in assembly line of

automobiles, workshops and service stations

 INDEX
CONTENTS Page. No.

CHAPTER-1
1. INTRODUCTION
Present Study… 1

Machine description 2

Field of use and benefits 2

CHAPTER -2

2. SURVEY ON PRESENT SCENARIO

Traditional nut removing machines. 3

Need of multi nut removing machines… 5

CHAPTER -3

3. COMPONENTS AND DESCRIPTION

List of components… 6

List of materials 7

Dimensions of the components… 7

Introduction of gears 9

Types of gears 9

Bearings… 14

History of bearings 14

Types of bearings 15

Shaft 19
 History of shafts 19
Types of shafts 19

Solid shafts… 20
Cast iron 21

Introduction of cast iron 21

Properties of cast iron 21

Metal plates… 22

Nut bits… 23

Wheels… 23

Types of Wheels… 23

Rim Sizes & Designations 24

Tyre Types… 25

Tyre Information 25

In another example 28

Nut & Bolts… 29

Bolts 29

Nuts 33

Fabrication 34

Assembly 36

CHAPTER – 4
DESIGN AND CALCULATION
Design 37

Introduction 37

Brief history of CAD/CAM development 37

 Design procedure 38

Design for metal plate 38

Design for gears 39

Design For bearings 41

Design for shaft 41

Assembling process 42

Abbreviations Used 45

Wheel pitch circle diameter 45

Design calculations 46

Design for planet gear 48

Design for pinion shaft 49

Design for compound shaft 51

Design for output shaft 52

Design of bearing 53

CHAPTER -5

ADVANTAGES AND DISADVANTAGES APPLICATIONS 55

Project Cost
...........................................................................................................................56

FUTURESCOPE……….................................................................. ...............58

CONCLUSION 59

REFERENCES 60

LIST OF FIGURES
DESCRIPTION
Fig.1.1 Facing problem in highway 2

Fig.2.1 Pneumatic torque wrench 4

Fig.2.2 Electrical impact machine 4

Fig. 2.3 T – shape spanner 4

Fig.2.4 Four way wheel Spanner 4

Fig.2.5 Angular Spanner… 4

Fig.3.1 Spur Gear 10

Fig.3.2 Helical Gear… 10

Fig.3.3 Herringbone Gear 11

Fig.3.4 Bevel Gear… 11

Fig.3.5 Worm Gear 12

Fig.3.6 Rack and Pinion Gear 12

Fig.3.7 Internal Gear 13

Fig.3.8 Face Gear 13

Fig.3.9 Sprockets… 13

Fig. 3.10 Ball Bearings 16

Fig. 3.11 Roller Bearings 16

Fig. 3.12 Ball Thrust Bearings… 17

Fig. 3.13 Taper Roller Bearings… 17

Fig. 3.14 Spherical Roller Bearings… 18

Fig. 3.15 Thrust Bearings… 18

Fig. 3.16 Solid Shaft 21

Fig. 3.17 Metal Plate 22

Fig. 3.18 Nut Removers 23

Fig. 3.19 Car Wheel 24

Fig. 3.20 Tyre Rim 24

Fig. 3.21 Representation with letter 27

Fig. 3.22 Assembly 36

Fig. 3.23 Tyre taken 36

Fig. 3.24 Hand operated lever 36

Fig.4.1 Plate with holes… 39

Fig.4.2 Planetary gear 40

Fig.4.3 Pinion gear 40

Fig.4.4 Ball bearing 41

Fig.4.5 Assembling of shafts 42

Fig.4.6 Assembling of gears… 43

Fig.4.7 Completed assembling 43

Fig.4.8 Front view 44

Fig.4.9 Top view 44

Fig. 4.10 Side view 45

LIST OF TABLES
Table3.2 List of Materials 7

Table4.3 Abbreviations Used 45

Table5 Project cost 56

 CHAPTER-1

INTRODUCTION
Vehicle is an important machine in human daily life. Nowadays, each family has at least
one car to make the transportation easier and faster. For a car, the tool set-up for each vehicle is a
T-nut wrench and carjacker which is hard to use for a women or teen to open their car’s nut. One
of the problems of a vehicle is tire problems. If the vehicle tires have some problem then the user
must remove the tires and fix the problem. And for a car user, it’s difficult to remove the tire's nut
especially for women users.

The disadvantages are waste of time and force needed. In India and other countries'
automotive market there is no tool that is easy to use to remove the nuts. The time to open a car’s
tire nut is too long and the car user’s time is wasted with utilization of high force and especially
this is a big hurdle for women users. To overcome the waste of time and high force needed, a tool
has been designed to remove four nuts of a tire in single time with decremented applied force.

CAR is not a symbol of luxury anymore. It is a need for every family. People need car due
to several reasons. Some of them are, to go to a destination, to travel conveniently, to do daily job
and to move things to a greater distance. The problem that occurs the most during car operation is
the problem with tire puncture. The punctured tire needed to be replaced with a spare tire.
Therefore, drivers need to know basic knowledge of tire replacement procedures if such a
problem occurs. In order to change the tire, one requires minimal skills. Virtually every car has
tire replacement tools such as the L-shaped nut remover and jack supplied by the manufacturer.

Present study:

We have many methods to remove the nuts. It is by mechanically, electrically and also by
the use of pneumatic machines. We remove nuts one by one by using the above methods.

Need for improvement in the present method is the lack of sufficient manpower. And
equipment is more expensive. These equipment take more space and not use this equipment in
travelling time. In any highway road if the car suddenly punctures then we

1
require a mechanic to arrange a car wheel. So all these problems face in present generation.

Fig 1.1 Facing problem in highway

Machine description

If we consider a four wheeler, removing and replacing the car wheel is a very frequent job
performed by the worker. Normally, each of the four nuts are removed or tightened individually
by simultaneously applying the spanner. But with the help of the mechanism developed we can
loosen or tighten all four nuts at a time and at the single stroke of the man power.

Field of use and benefit

This can be made to use during assembling and dismantling of wheels in automobiles. It
can be successfully used as a standard tool of the vehicle. Also, it can be used in assembly lines of

automobiles, garages and workshops, service stations.

2
 CHAPTER-2

SURVEY ON PRESENT SCENARIO

TRADITIONAL NUT REMOVING MACHINES:
Known torque-responsive power screw drivers which are driven by electric motors or
pneumatically have a relatively high speed of rotation in order to obtain a short screwing in time.
Since the maximum moment of tension for the screw to be screwed requires a determined torque,
the driving power of the screw driver must likewise be made high in accordance with the
relatively high speed of rotation, although a high torque is required for only a short time during
the tightening of the screw, unless some shock action is utilized for the purpose of producing this
peak degree. The limitation of the degree of tightening of the screw is usually affected by means
of ratchet couplings or striking mechanism.

When screwing in expansion screws, this degree of tightening must be kept constant
within very narrow, since these screws are stressed almost to their yield point during screwing in.
Torque-responsive screwing drivers having shock effects are useless for this purpose. The degree
of tightening achieved is greatly dependent on the number of blows applied, which however
cannot be kept constant because of the rapid succession of blows, while in addition the power of
the individual blow is variable within wide limits because of the indeterminable reaction of work
piece, screw and screwing tool on the striking operation. In addition, the shock effect causes rapid
wear on the striking surface, which results in a considerable variation of the face of the blows and
a relatively short life of the screwdriver.

Torque-responsive screwdrivers having striking mechanisms are impractical where

accurate tensioning of a screw is necessary. It has moreover been found that, at the high speeds
used, ratchet couplings also apply a powerful shock action and are therefore likewise unsuitable
for tightening expansion screws.

3
Fig2.1Pneumatic torque wrench Fig 2.2

Electrical impact machine

Fig 2.3 T – shape spanner Fig 2.4 Four way wheel Spanner

Fig 2.5Angular Spanner

4
 NEED OF MULTI NUT REMOVAL MACHINE:

The above nut removal machines are costly and they cannot be taken in journey time.
These are operated by only a skilled person. Also, these machines occupy more space and power
is more required for these types of machines.

Normal nut removal wrenches are cheap and it occupies less space as compared with
above machines. But in this main drawback is it removes only a single nut and force to be applied
is more. It takes more time and energy as compared with above machines. Both machines contain
similar characteristics that at a single time only one nut is removed. These types of problems are
faced in journey time. Suddenly our car is punctured in the highway or village outside then no one
helps to remove the wheel and no mechanic sheds will be available in that time so in this time we
require a tool kit to remove the car wheel.

So, these types of problems we have a solution that is a special tool to remove all nuts
of the car wheel at single stroke. In this used mechanism is gear mechanism. It is smoothly rotated
in clockwise and anticlockwise by applying man force. This tool occupies less space and it does
not require any special energy like electric or pneumatic type. This tool is operated by any
unskilled persons and also ladies are operated easily. This tool cost is cheap and it saves time and
energy of the worker.

Fig 2.7 Tyre removing in race

5
 CHAPTER-3
COMPONENTS AND DESCRIPTION
The block diagram of the fabrication of rotating carrying cart is shown in fig. The main components of
this project are

LIST OF COMPONENTS:
1. Gears

2. Bearings

3. Shafts

4. Cast Iron

5. Wheels

6. Bolts & Nuts

7. Metal plates

8. Stand

9. Hand operated lever

10. Nut bits

6
 LIST OF MATERIALS:
Sl. no Name of the parts Type of Material Quantity

1 Gears Mild steel 5

2 Shafts Mild steel 5
3 Bearings Mild steel 10
4 Nut bits steel 4
5 stand Cast iron 1
6 wheel Rubber & aluminium 1
7 Metal plates Iron 2
8 Bolts Cast iron 4
9 Hand operated lever Iron 1

Dimensions of the

components: Gears:
Diameter of the pinion (Dp) = 54mm

Number of teeth on pinion (Tp) =22

Diameter of the gear (DG) =64 mm

Number of teeth on gear (TG) =24

Bearings:
Type of Bearing = Ball bearing

Bore diameter = 16mm

Diameter of the bearing =40mm

Shaft:

Shaft type = solid shaft

Diameter of the shaft = 16mm

Length of the shaft = 150mm

7
Metal plates:
Shape of the plate = Square Size of

the plate =300*300mm

Thickness of the plate=10mm

Wheel:
Pitch circle of the wheel = 112mm

Nut to nut distance = 80mm

Nut size =19mm

Stand:
Height of the stand = 170 mm

Length of the stand = 300mm

Width of the stand =150 mm

8
 INTRODUCTION OF GEARS
A gear or cogwheel is a rotating machine art having cut teeth, or cogs, which is mesh
with another toothed part in order to transmit torque, in most cases with teeth on the one gear
being of identical shape, and often also with that shape on the other gear. Two or more gears
working in tandem are called a transmission and can produce a mechanical advantage through
a gear ratio and thus may be considered a simple machine. Geared devices can change the
speed, torque, and direction of a power source. The most common situation is for a gear to
mesh with another gear, however a gearcan also mesh with a non-rotating part, called rack,
thereby producing translation instead of rotation. Numbers of gears are there in the present
society out of them some of the different types of gears are explained in detail below.

TYPES OF GEARS:
(a) spur gear

(b) Helical gear

(c) Worm gear

(d) Bevel gear

(e) Rack and pinion gear

(f) Herringbone gear

(g) Internal & external gears

(h) Face gears

(i) Sprockets

a. Spur gear
Spur gear Parallel and coplanar shafts connected by gears are called spur gears. This
arrangement is called spur gearing. Spur gears have straight teeth and are parallel to the axis of
the wheel. Spur gears are the most common type of gears. The advantages of spur gear are their
simple design, economy of manufacture and maintenance and absence of end thrust. They impose
only radial loads on the bearings. Spur gears are known as slow speed gears. If noise is not a
serious design problem spur gears can be used at almost any speed. Parallel and co- planer shafts
connected by gears are called spur gears. This arrangement is called spur gearing. Spur gears have
straight teeth and are parallel to the axis of the wheel. Spur gears are the most common type of
gear.

9
 Fig3.1Spur gear

b. Helical gears

Helical gears have their teeth inclined to the axis of the shafts in the form of a
helix, hence the name helical gears.

These gears are usually thought of as high speed gears. Helical gears can take
higher loads than similarly sized spur gears. The motion of helical gear is smoother and
quieter than the motion of spur gears. Single helical gears impose both radial loads and
thrust loads on their bearings and so require the use of thrust bearings. The angle of the
helix on both the gear and the must be the same in magnitude but opposite in direction.

Fig 3.2 Helical Gear

c. Herringbone gears
Herringbone gears resemble two helical gears that have been placed side by side. They are
often referred to as "double helical". In the double helical arrangement the thrusts are
counter-balanced. In such double helical gears there is no thrust loading on the bearings.

10
 Fig 3.3 Herringbone Gear

d. Bevel gears
Bevel gear intersecting but coplanar shafts connected by gears are called bevel gears. This
arrangement is known as bevel gearing. Straight bevel gears can be used on shafts at any angle,
but right angles are the most common. Bevel gears have conical blanks. The teeth of straight
bevel gears are tapered in both thickness and tooth height.

Fig 3.4 Bevel Gear

e. Worm gears
Worm gears are used to transmit power at 90 and where high reductions are required. The
shafts of worm gears lie in parallel planes and may be skewed at any angle between zero and a
right angle, In worm gears one gear has screw threads. Due to this worm gears are quiet,
vibration free and give a smooth output.

11
 Fig 3.5 Worm Gear

f. Rack and pinion

Rack and pinion is a toothed bar or rod that can be thought of as a sector gear with an
infinitely large radius of curvature. Torque can be converted to linear force by meshing a rack
with a pinion: the pinion turns: the rack moves in a straight line. Such a mechanism is used in
automobiles to convert the rotation of the steering wheel into left-to- right motion of the tie rod(s).
The rack and pinion gear type is employed in the tooth shape of an interchangeable set of gears
may be specified for the rack (infinite radius) and the tooth shapes for gears of particular actual
radii then derived from that. The rack and pinion gear type is employed in a rack railway.

Fig 3.6 Rack and Pinion Gear

g. Internal & External gear

An external gear is one with the teeth formed on the outer surface of the cylinder or cone.
Conversely an internal gear is one with the teeth formed on the inner surface of a cylinder or
cone. For bevel gears an internal gear is one with the pitch angle exceeding 90 degrees. Internal
gears do not cause direction reversal.

12
 Fig 3.7 Internal Gear

h. Face gears

Face gears transmit power at (usually) right angles in a circular motion. Face gears are not
very common in industrial applications.

Fig 3.8 Face Gear

i. Sprockets

Sprockets are used to run chains or belts. They are typically conveyor systems.

13
Fig 3.9 Sprockets

14
 BEARINGS
Bearings are the machine elements, which supports another moving machine element
permitting the relative motion between the Contact surfaces with minimal friction. A great variety
of rolling bearing types and designs are known, the manifolds of the bearings are justified by their
various purposes. The first use of a bearing was in an axle assembly by carriage maker and
inventor Phillip Vaughan in 1791. Phillip Vaughan used ball bearings to eliminate the direct
contact between the drive shaft and axle in his carriages which put an end to carriage axles
wearing out as a result of friction. The success of ball bearings in drive shafts was soon made
public and on the back of this success, factory engineers found a range of other applications for
bearings in the manufacturing industry which opened up a whole new world of motor-driven
machines which have dramatically changed the industrial world. There are now a huge variety of
industries and everyday objects around us which require bearings to operate such as washing
machines, tumble driers and even food processors. Below are some more common uses of
bearings.

A bearing is a machine element that constrains relative motion to only the desired motion,
and reduces friction between moving parts. The design of the bearing may, for example, provide
for free linear movement of the moving part or for free rotation around a fixed axis; or, it may
prevent a motion by controlling the vectors of normal forces that bear on the moving parts. Many
bearings also facilitate the desired motion as much as possible, such as by minimizing friction.
Bearings are classified broadly according to the type of operation, the motions allowed, or to the
directions of the loads (forces) applied to the parts.

The term "bearing" is derived from the verb "to bear"; a bearing being a machine element
that allows one part to bear (i.e., to support) another. The simplest bearings are bearing surfaces,
cut or formed into a part, with varying degrees of control over the form, size, roughness and
location of the surface. Other bearings are separate devices installed into a machine or machine
part. The most sophisticated bearings for the most demanding applications are very precise
devices; their manufacture requires some of the highest standards of current technology.

History of bearings

The idea of using a rolling element to move heavy items dates back to ancient Egypt. The
Egyptians used logs to roll their large stone pieces closer to the construction areas when building
the pyramids. At first bearings were manufactured of Lignum Vitae, a very heavy, hard, naturally
oily wood native to Central America and the West Indies. The natural oils in this wood assisted in
the manufacturing process by acting as a cutting fluid. These bearings are best known for
"wet"applications such as propeller driven vessels,water wheels, and pumps. Wooden bearings
were known to be long wearing (approx. 7- year average life span), strong, readily available and
easy to replace.

15
 They were lubricated with tallow or other animal fats. In many turbine type applications,
you will still find wooden bearings, however Lignum Vitae is not as readily available as it once
was. Many companies are using Rock Maple impregnated with Petroleum Wax as a suitable
substitute. Leonardo da vinci, famous for his painting and drawings, also had many ideas for
mechanical engineering projects. Many of his drawings were of pumps, hoists, cranes, and various
weapons of war. During his employ as a hydraulic engineer 4 serving the Duke of Milan, he spent
much of his time analyzing bearings, linkages, gears and various other mechanical transmission
modes. Many of Davinci's ideas are still celebrated in the engineering world today.

Types of bearings:
a. Ball bearings

b. Roller bearings

c. Ball thrust bearings

d. Tapered roller bearings

e. Spherical roller bearings

f. Thrust bearings

a. Ball bearings
Ball bearings are the most common and most used type of bearing found in a number of
objects. Also known as anti-friction bearings, ball bearings where the load is relatively small.
Loads in a ball bearing are transmitted are small metallic or ceramic spheres used to reduce
friction between axles and shafts in numeric applications.

These bearings are able to handle both thrust and radial loads, and are used for
applications where the load is relatively small. Load in a ball bearing is transmitted from the outer
surface to the ball and from the ball to the inner surface. Since the ball is spherical in shape, it
contacts the inner and outer race at a very small point, which helps it spin evenly and smoothly.

16
 Fig 3.10 Ball bearings

b. Roller bearings
Roller bearings use cylinders instead of spheres that mean the contact between the inner
and outer race is a line not a point. Thus, the load is spread over a larger area enabling the bearing
to handle greater loads than ball bearings.

Fig 3.11Roller bearings

c. Ball thrust bearings

These kinds of bearings are designed to handle almost exclusively thrust loads in low-
speed low-weight applications. Bar stools, for example, make use of ball thrust bearings to
support the seat. Ball thrust bearings are composed of all bearings supported in a ring. They are
used in low thrust applications where the radial load is very small. Thrust roller bearings are made
of small tapered rollers arranged so that their axes converge at a point on the axis of the bearing.

17
 Fig 3.12 Ball thrust bearing

d. Tapered roller bearings

Tapered roller bearings use conical rollers that run on conical races. Both the inner and
outer raceways are segments of cones and the rollers are also made with a taper. Unlike other
roller bearings, they support both radial and axial loads, and are able to carry higher loads. The
conical geometry of tapered roller bearings provides a larger contact patch, which allows greater
loads to be carried as compared to spherical(ball) bearings.

Fig 3.13 Taper roller bearing

e. Spherical roller bearings

Rollers used in spherical roller bearings are thicker in the middle and narrow at the ends,
and its race is shaped to match. They can adjust to support misaligned loads.

The constructions of spherical rollers are complex and difficult to produce so they are
expensive. Apart from that these bearings have higher friction compared to ball bearings because
different parts of the spherical rollers run at different speeds on the rounded race.

18
 Fig 3.14 Spherical roller bearing

f. Thrust bearings:
Thrust bearings are particular types of rotary bearing that allow rotation between parts
used but they are designed to support axial loads like vertical shafts for which spherical, conical
or cylindrical rollers are used. They are used in gear sets like in car transmissions between gears
and between the housing and the rotating shafts.

Fig 3.15 Thrust bearing

19
 SHAFTS:
A shaft is a rotation member usually with cylindrical shape which is used to transmit
torque, power and motion between various elements such as electric or combustion motors and
gear sets, wheels, flywheels, pulleys, or turbines and electric generators. Shafts can be solid or
hollow. During power transmission, shafts twist and stresses and deformations are taking place.

Torsion is twisting of an object due to an applied torque. When a shaft twists, one end
rotates relative to the other the through bore can be utilized for various purposes lighter in weight
compared to solid shafts of the same diameter. Notably, the through bore does not have high
concentricity with the shaft, and cannot be used as an accurate guiding bore.

History of shafts:
Shafts are always made to have circular cross-section and could be either solid or hollow.
The shafts are classified as straight, cranked, flexible or articulated. Straight shafts are commonest
to be used for power transmission. Such shafts are commonly designed as stepped cylindrical
bars, that is, they have various diameters along their length, although constant diameter shafts
would be easy to produce. The stepped shafts correspond to the magnitude of stress which varies
along the length. Moreover, the uniform diameter shafts are not compatible with assembly,
disassembly and maintenance.

Such shafts would complicate the fastening of the parts fitted to them, particularly the
bearings, which have to be restricted against sliding in axial direction. While determining the form
of a stepped shaft it is borne in mind that the diameter of each cross- section should be such that
each part fitted on to the shaft has convenient access to its seat.

The parts carried by axle or shaft are fastened to them by means of keys or splines and for
this purpose the shaft and axle are provided with key ways or splines. The bearings that support
the shafts or axle may be of sliding contact or rolling contact type. In the former case the journal
of the shaft rotates freely on thin lubricant layer between itself and bearing, while in the latter case
the inner race of the bearing is force fitted on the journal of the shaft and rotates with the shaft
while outer race is supported in the housing and remains stationary.

Types of shafts:
The types of shaft are mentioned in the introduction. A stepped shaft with three seats for
supported parts which can be pulleys, gears or coupling. Two seats for bearings are also indicated.
These bearings will be rolling contact type. A single crank shaft. The crank may be connected to
another element like the connecting rod which may have a combined rotary and reciprocating
motion. The connection is through a bearing often called crank

20
pin. The straight part of the shaft may support a pulley or a gear. The connection will be through a
key. Multiple crank shafts are shown in Figure. Each crank pin would carry a connecting rod and
each crank pin will be between the supporting bearings. The other shaft types are explanatory.

1) stepped shaft

2) A single crank shaft

3) Multiple crank shafts

4) Flexible shaft

5) Articulated shaft

6) Solid shaft

7) Hollow shaft

Solid shaft:
Solid and hollow shafts are high precision shafts made from quenched and tempered steel
to rolling bearing quality and are supplied in metric sizes. Hollow shafts are particularly suitable
for reduced-mass designs. For location, solid shafts can be provided with radial and axial threaded
holes or can, by accordance with a customer drawing.

The material quality guarantees high dimensional and geometrical accuracy (roundness,
parallelism). Due to their high surface hardness and surface quality, the shafts are highly suitable
as precision raceways for linear ball bearings. Hugh precision shafts are also suitable as guide
rods for plain bushes, as stretch and levelling rollers and in the construction of equipment and
automatic machinery.

They can be combined with linear bearings, yoke and stud type track rollers, ball bearing
track rollers and profiled track rollers to give linear guidance systems that are rigid, precise,
economical and ready to fit, with high load carrying capacity and a long operating life.

Shafts made from cf53 are induction hardened and ground: the surface hardness is
670Hv+170 HV (59HRC+6HRC). Hollow shafts are only available made from quenched and
tempered steel.

21
 Fig 3.16 Solid shaft

CAST IRON

Introduction of cast iron

Cast iron is the most important and most widely used casting alloy and its inoculation
phenomenon was discovered in 1920 and patented by Meeh in 1924. There are many studies on
this phenomenon, which are summarised and analysed in Elements such as Ba, Ca and Sr, which
are usually introduced to a bath in ferrosilicon, are the most important inoculants of cast iron.
Ferrosilicon that contains these elements is treated as a complex inoculant. The purposes of this
study were to analyse the inoculation effects and explain the inoculation mechanism of cast iron.

Properties of Cast Iron

The properties of cast iron depend to a great ex-tend on the morphology, amount and
anisotropy of the graphite phase. Graphite flakes with random orientation present in grey cast iron
limit its application for many years. It is due to its low tensile strength and low ductility.
Therefore, some methods to control graphite morphology as modification, spheroiding treatment
and alloying have been developed.

The plastic deformation as the reason for the strength improvement in cast irons have been
related mainly to high temperature processing and reported occasionally. It is understandable
when brittleness and difficulty in obtaining products without cracks, especially of grey cast iron,
is taken into account. On the other hand, hot deformation involves the main disadvantage, the
thermal softening effects which restrict the strength level possible to obtain. Therefore, any
solution involving the cold deformation processing of cast irons would be

22
preferable when the high strength iron is the main goal which is considered. Only one paper
describing deformation in cold conditions such as the upset forging of globular cast iron has been
found throughout the last year's literature survey. True strain of ~0.38 in sound compressed
products after special melt treatment and graphitizing were obtained. Higher degrees of
deformation have required steel holders with 7.5 mm wall thickness. Application of grey cast
iron, due to its low strength and trace quantities of ductility caused by randomly distributed
graphite flakes, is very limited. In a very exceptional paper on plastic deformation of grey cast
iron, hot compression at 900C in a steel cylinder has enabled it to achieve true strain ~1.6.
Graphite flakes flakes were aligned normally to compression direction with some flakes adhered
to each other. Special ferritizing treatment applied after deformation doubled tensile strength up to
~250 Mpa in comparison to state before compression. First attempts to apply back pressure to
extrusion of cast irons were done at the beginning of the sixties of last century by Pugh and low
and Bulychev and beresnev.
The benefits of back pressure application have been demonstrated by extrusion of one of
the grey cast iron grades (EN-GJL-200), however, achieved result was not very spectacular and
description of the experimental conditions very brief. Since then, no studies of application of
hydrostatic extrusion to deformation of cast irons have been reported. In present paper
improvement of mechanical properties in grey and ductile cast irons processed by severe plastic
deformation (SPD) in cold conditions is undertaken. Unique process of hydrostatic extrusion with
Back pressure is 1958-1963 for conventional extrusion of bismuth, magnesium and brass and
presented by Pugh, Green and Gunn [11, 12]. It was shown, that for selected brittle materials back
pressure imposed on existing products restrain their fracture by lowering tensile stresses in
processed materials below the critical stresses necessary to crack initiation and propagation.

Metal plates:
Metal plates are so many types they are present in iron, aluminium etc .We use iron metal
plates with 10 mm width and 300mm square plates. These are used to insert bearings and shafts
and to give support to all parts.

Fig 3.17 Metal plate

23
 Nut bits:
These are the nut bits used to remove the nuts and tightening also. There are so many
types. It changes with sizes. In this we are using 19mm size nut bits. The nut bit material is steel
or mixed alloy steel.

Fig 3.18 Nut Remover

WHEELS:

Wheels must be strong enough to support the vehicle and withstand the forces caused by
normal operation. At the same time, they must be as light as possible; to help keep un- sprung
weight to a minimum. Wheels can be made from cast aluminium alloy or magnesium alloy. Alloy
wheels are popular because of their appearance and because they are lighter than similar steel
wheels. Aluminium is a better conductor of heat, so alloy wheels can dissipate heat from brakes
and tyres more effectively than steel ones. Most wheels have ventilation holes in the flange, so air
can circulate to the brakes. Most passenger car wheels are of, or drop- centre design. This design
allows for tyre removal and fitting. The removal and fitting of tyres should be carried out
according to manufacturer's instructions.

Types of Wheels:
Passenger cars normally use rims which are of well based, or drop centre design. The
drop enter is used for mounting and demounting the tyre onto the rim. Wheels must be strong
enough to carry the mass of the vehicle and withstand the forces that are generated during use.
The wheel centre must accurately locate the wheel rim centrally on the axle. It must also provide
the required distance from the centreline of the wheel, to the face of the mounting flange.

This is called offset. Offset is important because it brings the tyre centre line into close
alignment with the larger inner hub bearing and reduces load on the stub axle. This allows the
inside of the wheel centre to be shaped to provide space for the brake assembly, usually located
inside the wheel. Ventilation slots allow air to circulate around the brakes.

24
The rim must be accurately shaped and dimensioned and strong enough to support the tyre under
the load of the vehicle and the forces generated by the motion of the vehicle.

Fig 3.19 Car wheel

When inflated, the tyre is locked to the rim by tapering the bead seat towards the flange,
or by safety ridges or humps, close to the flange. In the event of sudden deflation, or blow-out,
safety ridges prevent the tyre moving down into the well. This helps maintain control of the
vehicle while the brakes are applied. Well-based rims can also be used on heavy commercial
vehicles for tubeless tyres.

Rim Sizes & Designations

To ensure correct fit between a tyre and rim, all manufacturers of wheels and tyres comply
with standard dimensions, as recommended by automotive manufacturers. The width of the rim is
the distance across the rim flanges, at the bead seat. Its diameter is the distance across the centre
of the rim from bead seat to bead seat.

Fig 3.20 Tyre rim

The shape of well-based rims is provided by a letter code, such as J, K, JJ and KK. The
width of the rim and the diameter is traditionally stated in inches. A rim designated 7 JJ by 14
would refer to a rim measuring 7 inches across the rim flanges and 14 inches in

25
diameter from bead seat to bead seat, with the profile conforming to a JJ code. The rim width and
diameter can also be stated in millimetres. Metric rims are not interchangeable with Imperial rims.
The tyre must be an exact fit on the rim, to fulfil a number of functions.

• It ensures that the narrow contact area between the beads of the tyre and the rim will
seal the air in a tubeless tyre.

• It transfers all the forces between the tyre and the wheel, without slipping or chafing.

• It ensures the friction between the tyre and the rim prevents the tyre turning on the rim.

Tyre Types:
The tyre provides a cushion between the vehicle and the road to reduce the transmission
of road shocks. It also provides friction to allow the vehicle perform its normal operations.
Modern tyres are manufactured from a range of materials. The rubber is mainly synthetic. Two
types of tyre construction are common – cross-ply and radial. Most passenger cars now use radial
tyres, as do most 4-wheel-drives and heavy vehicles. Tube tyres require an inner tube to seal the
air inside the tyre.

Tubeless tyres eliminate the inner tube by making the complete wheel and tyre assembly
air-tight. A special, air-tight valve assembly is needed. This can be a tight fit into the rim, or it can
be held with a nut and sealing washers.

Tyres can be identified by markings on the sidewalls. This typically includes the maker’s
name, the rim size, and the type of tyre construction, aspect ratio, maximum load and speed and,
in some cases, intended use. Regulations cover the allowable dimensions for wheels and tyres on a
particular vehicle. These dimensions are usually set out on the tyre spec attached to the vehicle.
Incorrectly selected wheels and tyres can overload wheel bearings and change steering
characteristics. The tyre chart lists the wheel and tyre sizes approved by the manufacturer for the
vehicle. Using other wheels and tyres may be illegal. The repairing of punctures on tyres must be
carried out in accordance with current legalization.

Tyre Information:
Information on tyre aspect ratio is now included in the sidewall marking, together with
the type of construction, speed rating and maximum permitted pressure. The speed rating of the
tyre is given by the letter code, which indicates maximum recommended speed for that tyre.
Common symbols for passenger car tyres include;

26
• S, for up to 180 kilometres per hour.

• H, up to 210 kilometres per hour.

• V, up to 240 kilometres per hour.

• And Z for over 240 kilometres per hour.

Radial ply tyres have always been marked with the section width in Millimetres, but

with the rim diameter in inches. For example:

• 185 is section width in millimetres.

• 70 indicates a 70% aspect ratio.

• H is the speed rating, for up to 210 kilometres per hour.

• R indicates radial ply construction. • 13 indicates the tyre is

Suitable for fitting to a 13-inch diameter rim.

Totally metric types are also manufactured. For example:

• 190 is the section width in millimetres.

• The aspect ratio is 65%.

• The speed rating is H, for up to 210 kilometres per hour.

• R indicates radial ply construction.

• 390 indicates the tyre is suitable for fitting to a 390 mm diameter rim.

Metric-diameter rims cannot be fitted with inch-diameter tyres, or vice-versa. Although

tyre markings may remain traditional, e.g. 255 45 Z-R 17, there is a worldwide move towards an
I-S-O metric standard which

27
 Fig 3.21 Representation with letter

Uses letters:

• P for passenger,

• LT for light truck,

• C for commercial,

• And T means temporary use as a spare wheel.

The tyre may have a load index number, indicating the maximum load a tyre can carry at
the speed indicated by its speed symbol, which follows the number.e.g. a P-series metric size code
may read in full – P205/65 R15 92H.

• P for passenger car tyre,

• 205 is the section width in millimetres,

• With 65% aspect ratio,

• R – Radial ply construction,

• 15 inch diameter rim,

• 92 load index, for a maximum load of 630 kilograms,

• And H for a speed rating up to 210 kilometres per hour.

Further development of high-speed tyres has expanded the speed

Categories to include W and Y.

28
 In another example:
• Z indicates a speed over 240 kilometres per hour, but the load and speed rating is
taken as the maximum load and speed, That is,

• 89 for a maximum load of 580 kilograms,

• And W for 270 kilometres per hour.

29
NUTS AND BOLTS: BOLTS:
A screw or bolt is a type of fastener, typically made of metal, and characterized by a
helical ridge, known as a male thread (external thread) or just thread. A screw is an inclined
plane wrapped around a nail. Some screw threads are designed to mate with a complementary
thread, known as a female thread (internal thread), often in the form of a nut or an object that has
the internal thread formed into it. Other screw threads are designed to cut a helical groove in a
softer material as the screw is inserted. The most common uses of screws are to hold objects
together and to position objects.

A screw will usually have a head on one end that contains a specially formed shape that
allows it to be turned, or driven, with a tool. Common tools for driving screws include
screwdrivers and wrenches. The head is usually larger than the body of the screw, which keeps the
screw from being driven deeper than the length of the screw and to provide a bearing surface.
There are exceptions; for instance, carriage bolts have a domed head that is not designed to be
driven; set screws often have a head smaller than the outer diameter of the screw; J-bolts have a
J-shaped head which is not designed to be driven, but rather is usually sunk into concrete allowing
it to be used as an anchor bolt. The cylindrical portion of the screw from the underside of the head
to the tip is known as the shank; it may be fully threaded or partially threaded. The distance
between each thread is called the "pitch".

The majority of screws are tightened by clockwise rotation, which is termed a right-hand
thread; a common mnemonic device for remembering this when working with screws or bolts is
"right-tightly, left-loosely." Another rule is this: curl the fingers of your right hand around the
screw with your thumb pointing in the direction you want the screw to go. If the screw is
right-handed (most screws are) and you turn the screw in the direction of your fingers the screw
will move in the direction of your thumb. Screws with left-hand threads are used in exceptional
cases. For example, when the screw will be subject to counter clockwise torque a
left-hand-threaded screw would be an appropriate choice. The left side pedal of a bicycle has a
left-hand thread.

30
Fastener Categories

31
Fastener Categories

Head
Styles

32
Drive Types

Washer Types

33
 NUTS:
A nut is a type of fastener with a threaded hole. Nuts are almost always used opposite a
mating bolt to fasten a stack of parts together. The two partners are kept together by a combination
of their threads' friction, a slight stretch of the bolt, and compression of the parts. In applications
where vibration or rotation may work a nut loose, various locking mechanisms may be employed:
Adhesives, safety pins or lock wire, nylon inserts, or slightly oval-shaped threads. The most
common shape is hexagonal, for similar reasons as the bolt head - 6 sides give a good granularity
of angles for a tool to approach from (good in tight spots), but more (and smaller) corners would
be vulnerable to being rounded off. It takes only 1/6th of a rotation to obtain the next side of the
hexagon and grip is optimal. However polygons with more than 6 sides do not give the requisite
grip and polygons with less than 6 sides take more time to be given a complete rotation .Other
specialized shapes exist for certain needs, such as wing nuts for finger adjustment and captive nuts
for inaccessible areas.
Nuts are graded with strength ratings compatible with their respective bolts; for example,
an ISO property class 10 nut will be able to support the bolt proof strength load of an ISO
property class 10.9 bolts without stripping. Likewise, an SAE class 5 nut can support the proof
load of an SAE class 5 bolt, and so on.
A wide variety of nuts exists, from household hardware versions to specialized
industry-specific designs that are engineered to meet various technical standards.

34
 Nut Types

Fabrication:
In the fabrication process the following operations are used: -
i. Turning

ii. Facing
iii. Grinding

iv. Grooving
v. Drilling

vi. Assembly

35
Turning
It may be defined as the machining operation for generating external surfaces of the
revolution by the action of the cutting tool on a rotating workpiece. When the same action is
applied to internal surfaces of the revolution, the process is termed as boring.

Facing
Facing operation machines, the ends of the workpiece. It provides a surface which is
square with the axis of the workpiece from which to start the job. Facing is done by feeding the
cross slide or compound in or out. The cutting tool moves from the centre of the job towards its
periphery and vice – versa. Facing is primarily used to smooth off a saw- cut end of a piece of bar
stock or to smooth the face of roughcasting.
Grinding
It is carried out while the work is rotating on the lathe. Filling is often restored to when
i. Only a very small amount of stock is to be removed from a diameter.

ii. For removing sharp corners on the workpiece. Filling is a hand operation. A clean, sharp,
single cut mill file of 200 or 250 mm length is held in the hand and the file flat is placed
on the work near the left end of the part to be filled. The file is held at a slight angle and
not at right angles to the workpiece. For carrying out the filling operation, the file is
pressed lightly on to the work piece and moved forward so that the workpiece rotates by 2
or 3 revolutions during the forward or cutting stroke of the file. Pressure on the file is
relieved during its return strokes but its movement overlaps the cut made by the file during
the cutting stroke. Generally long strokes are taken and the file is cleaned frequently with
the file card.
Grooving
Work pieces on which threads are to be cut close to a shoulder are usually undercut or
grooved to make threads cutting somewhat easier. Diameters which are to be ground up to a
shoulder are usually undercut so that the grinding wheel will not leave a small radius in the corner.
Grooving operation reduces the diameter of the workpiece at a narrow surface near the shoulder
etc. The grooving tool is fed into the revolving work piece at right angle to it using a cross-slide
handwheel.
Drilling
Drilling is the process of making holes in a work piece. Either the workpiece rotates or the
drill is stationary or vice-versa. When drilling on the lathe is being done, generally the workpiece
rotates in the chuck and the drill held in the tail stock is fed into the workpiece by means of the
hand wheel on the outer end of the tail-stock assembly. It is possible to do drill by holding and
rotating the drill in the lathe spindle while keeping the work stationary, supported by a special

36
special pad mounted in tail-stock quill. Since drill feed is by hand, care must be taken, particularly
in drilling small holes. Coolant should be withdrawn occasionally to clear chips from the hole and
to aid in getting coolant to cutting edges of the drill..

ASSEMBLY
Bearing seats are assembled on base plates with the help of a hammer. Bearings are fitted
in their respective seats. Studs are tightened at their positions on the lower base plate. Now the
output shaft is fitted in the bearing on the lower base plate. Compound shaft is fitted in such a
way so that the pinion of the compound shaft correctly meshes with the output shaft’s gear.
Adjustments are made with the help of shim and packing. Now the input shaft is fitted on the
upper base plate. The gears are welded on their shafts. Now these shafts are assembled on the
lower and upper base plate. Clearance is adjusted by the help of shim. Upper base plate
containing the input shaft is fitted on the lower base plate. Centre distance between the two base
plates is adjusted with the help of lock nuts at all the corners. The shafts are correctly fitted in the
bearings. Applying lubricants in between gears and bearings for free rotation.

Fig 3.22 AssemblyFig 3.23 Tyre taken

Fig 3.24 Hand operated lever

37
 CHAPTER – 4
DESIGN AND CALCULATION

DESIGN:
Introduction
All engineering activities necessarily begin with some ideas with high or low innovative
content, translated into definite plans for their realization in the form of products. This is the
essence of design engineering. The ultimate success depends on a thorough consideration of how
the product will be made and used as well as on the attention to detail paid by the design
engineering. This is applicable equally for a minor redesign of an existing product or for a most
innovative one.

The project model is designed in UNIGRAPHICS. That is also called NX software.

It is CAD/ CAM based software.

BRIEF HISTORY OF CAD/CAM DEVELOPMENT

The roots of current CAD/CAM technologies go back to the beginning of civilization
when engineers in ancient Egypt recognized graphics communication. Orthographic projection
practiced today was invented around the 1800’s. The real development of CAD/CAM systems
started in the 1950s. CAD/CAM went through four major phases of development in the last
century. The 1950’s was known as the era of interactive computer graphics. MIT’s
ServoMechanisms Laboratory demonstrated the concept of numerical control (NC) on a three-axis
milling machine. Development in this era was slowed down by the shortcomings of computers at
the time. During the late 1950’s the development of Automatically Programmed Tools (APT)
began and General Motors explored the potential of interactive graphics.

The 1960s was the most critical research period for interactive computer graphics. Ivan
Sutherland developed a sketchpad system, which demonstrated the possibility of creating
drawings and altercations of objects interactively on a cathode ray tube (CRT). The term CAD
started to appear with the word ‘design’ extending beyond basic drafting concepts. General
Motors announced their DAC-1 system and Bell Technologies introduced the GRAPHIC 1 remote
display system.

38
 During the 1970’s, the research efforts of the previous decade in computer graphics had
begun to be fruitful, and potential of interactive computer graphics in improving productivity was
realized by industry, government and academia. The 1970’s is characterized as the golden era for
computer drafting and the beginning of ad hoc instrumental design applications. National
Computer Graphics Association (NCGA) was formed and Initial Graphics Exchange Specification
(IGES) was initiated. In the 1980’s, new theories and algorithms evolved and integration of
various elements of design and manufacturing was developed. The major research and
development focus was to expand CAD/CAM systems beyond three-dimensional geometric
designs and provide more engineering applications.

The present day CAD/CAM development focuses on efficient and fast integration and
automation of various elements of design and manufacturing along with the development of new
algorithms. There are many commercial CAD/CAM packages available for direct usages that are
user-friendly and very proficient.

Some of the design software’s are

1. AutoCAD and Mechanical Desktop are some low-end CAD software systems, which are
mainly used for 2D modelling and drawing.

2. NX, Pro-E, CATIA and I-DEAS are high-end modelling and designing software systems
that are costlier but more powerful. These software systems also have computer aided
manufacturing and engineering analysis capabilities.

3. ANSYS, ABAQUS, NASTRAN, Fluent and CFX are packages mainly used for analysis
of structures and fluids. Different software is used for different purposes. For example,
Fluent is used for fluids and ANSYS is used for structures.

4. Geomagic and Collab CAD are some of the latest CAD systems that focus on
collaborative design, enabling multiple users of the software to collaborate on
computer-aided design over the Internet.

The NX 9.1 software contains more features than other ones so we choose this software for design
purposes.

Design procedure:

Design for metal plate

i. First, we go to the menu button then choose NX 9.0 software. Then we go to select the
model option then the drawing window is open.

ii. Go to insert select sketch in task then take datum axis direction. Take a rectangle tool in
the toolbar. Draw the 30*30mm square.

iii. After completing the sketch then click finish sketch. And go to option extrude then select

39
 drawing and give extrude distance 10mm then click ok. the plate with 10mm size width is
obtained.

iv. Take the centre point on square and then give feed above and below 56mm distance and
also apply to left and right. Then draw a circle with φ40 in all 4 sides and centre.

v. Then go to extrude, select circles and take the subtract option and remove the solid surface
in the circle portion. The plate with the whole portion is completed and saved in the
computer. Below given figure.

Fig 4.1 Plate with holes

Design for gears

i. Go to insert select sketch in task then take datum axis direction. Draw a circle with outer
diameter 54 mm and inner diameter 44 mm.

ii. Draw centre line passed through two circles. From the inner centre line draw a line
2.5 mm distance in left and right directions .The same procedure is followed as
the outer circle also but with lines are 1mm.

iii. Join above outer circle left line with inner circle left line and same as outer circle right
line with inner circle right line.

40
iv. Take the trim option and the excess portion of the outer circle is removed. take extrude
command select part and 10mm thickness is given and click apply. The portion is
extruded.

v. Go to the pattern command select patron portion give the vector direction and choose specific
point and give the number of patrons that is 22 and give how much angle we need That is 360
degrees.
vi. Then same procedure is applied in planet gear design and give number patrons are
24. The remaining procedure is the same.

Fig 4.2 Spur gear

Fig 4.3 Pinion gear

41
 Design for bearings

i. Go to insert option click sketch in task tool and select datum line. Go to insert a
spherical ball with Φ5mm.

ii. Draw a circle inner radius is Φ16mm and take another circle surrounded by the above
circle is Φ 25mm.then insert spherical ball on circle and take circle with Φ30 mm.

iii. And take another circle with Φ40mm.then go to extrude select portion and give extrude
distance is 10mm and click ok. The bearing part iscompleted.

Fig 4.4 Ball bearing

Design for shaft:

i. Go to insert option click sketch in task tool and select datum line. Draw a circle with
diameter 16mm.

ii. Select extrude command and give length is 200mm.the shaft design is completed.

42
 Assembling process
i. In NX 9.0 version take assembling process and then take plate drawing and bearing
design. Take an alien tool mate to both central axes and then the bearings are inserted into
the plate.
ii. Next take shaft design and then insert into the bearings. Then take pinion gear design and
insert into the central shaft. Take planet gear and insert the remaining four shafts.

iii. The middle shaft is fixed at one end and free at the other end plate. Remaining four shafts
opposite to the above one. The assembling process iscompleted.

Fig 4.5 Assembling of shafts

43
 Fig 4.6 Assembling of gears

Fig 4.7 Completed assembling

44
Views:

Fig 4.8 Front view

Fig 4.9 Top view

45
 Fig 4.10 Side view

Abbreviations Used:

M module
M Bending moment
Dp Pitch circle diameter of pinion
DG Pitch circle diameter of gear
Dg Diameter of gear shaft

WT Tangential load

WR Resultant load

Yp Lewis form factor

σ Allowable stress

T Twisting moment
Te Equivalent twisting moment

46
Tp Number of teeth on pinion

Tg Number of teeth on gear

Wheel pitch circle diameter:

We know the wheel pitch circle diameter that is Φ112mm then nut to nut distance is
calculated by the formula is

Diameter (D) = √ (2) *s then

Nut to nut distance (S) = 112 /1.414 =80 mm

Design calculations

Design for pinion gear

Let Torque required for one nut = 70N-m

Total torque required = 4×70N-m

= 280N-m

We know that from the pinion gear

Number of teeth (T) =22

Take pitch circle diameter (Dp) =49mm

Then (pc) = circular pitch

(pc) = π Dp / T

= π * 49/22= 7 mm
Diametral pitch ( pd) = T/ Dp = π/pc

47
 =π /7 =0.448

Module (m) = Dp/T =49 /22

=2.25

Maximum tangential force on tooth (wT) = σw*b*π*m*yp

Take σw = 325 mpa

b = width of gear face

= 10 mm

m = 2.25

yp = Lewis form factor

= 0.175- (0.841/ Dp)

= 0.175- (0.841/ 49)

= 0.1367

WT =325*10*π*2.2*0.1367

= 3070 N

Other dimensions of the pinion gear

Addendum = 0.943*m = 0.943*2.25 = 2.121

Dedendum = 1.257*m = 1.257*2.25 = 2.82

Minimum total depth = 2.200*m = 2.200*2.25 = 4.95

Minimum clearance = 0.314*m = 0.314*2.25 = 0.7065

Backlash = 0.175*m = 0.175*2.25 = 0.353

Thickness of the tooth = 1.493*m = 1.493*2.25 = 3.359 Outside

diameter of the pinion = (Tp+2) *m

= 24*2.25 =54mm

48
 Design for planet gear

We know that from the planet gear

Number of teeth (T) =24

Take pitch circle diameter of gear (Dg)=59mm

Then (pc) = circular pitch

(pc) = π Dp / T

= π * 59/24

= 7.72 mm

Diametral pitch ( pd) = T/ Dp = π/pc

= 24/59 =0.448

Module (m) = Dp/T =59 /24

=2.45

Maximum tangential force on tooth (wT) = σw*b*π*m*yp

Take σw = 325 mpa

b = width of gear face

= 10 mm

m = 2.45

yp = Lewis form factor

= 0.175- (0.841/ Dg)

= 0.175- (0.841/ 59)

= 0.1401

WT =325*10*π*2.2*0.1367

= 3504N

49
Other dimensions of the pinion gear

Addendum = 0.943*m = 0.943*2.45 = 2.310

Dedendum = 1.257*m = 1.257*2.45 = 3.079

Minimum total depth = 2.200*m = 2.200*2.45 = 4.95

Minimum clearance = 0.314*m = 0.314*2.45 = 0.7693

Backlash = 0.175*m = 0.175*2.45 = 0.3846

Thickness of the tooth =1.493* m = 1.493*2.45 =3.657

Outside diameter of the pinion = (Tp+2) *m

= 26*2.45 =64mm

Design for pinion shaft

Normal load acting on pinions tooth (Wn) = WT /cosΦ

= 3070 / cos 20 =7522

Weight of pinion (Wp) = 0.00118* Tp*b*m2

= 0.00118*22*10*2.252

=1.134N

2
Therefore resultant load on pinion (WR) = (W + W 2+2* W p* W *n cosΦ)0.5

= (75222+1.3142+2*7522*1.314*cos20)0.5

=7522 N

Assuming pinion is overhung on shaft at 60 mm

Bending moment on shaft due to WR is M

50
 Then we take M = WR* 60 = 7522*60

=451351 N-mm

And twisting moment on shaft due to WT is T

T = WT * Dp / 2 = 3070*49 /2 = 75215 N

Equivalent twisting moment is Te = (M2+ T2)0.5

= (4513512 +752152)0.5

= 457575 N-mm

dp be the diameter of pinion shaft

Then Te= π*τ* dp3/16

book) d 3 =457575*16/ (π*569) (τ is taken from data hand

dp= 16 mm (say)

51
Design for compound shaft

Normal load acting on pinions tooth (Wn) = WT /cosΦ

= 3070 / cos 20 =7522

Weight of gear (Wg) = 0.00118* Tg*b*m2

= 0.00118*24*10*2.452

=1.7 N

2
Therefore resultant load on gear (WR) = (W + W 2+2* W g*W n*cosΦ)0.5

= (75222+1.72+2*7522*1.7*cos20)0.5

=7523 N

Assuming pinion is overhung on shaft at 30 mm

Bending moment on shaft due to WR is M

Then we take M = WR* 30 = 7523*30

=225707 N-mm

And twisting moment on shaft due to WT is T

T = WT * Dg / 2 = 3070*59 /2 = 90565 N

Equivalent twisting moment is Te = (M2+ T2)0.5

= (2257072 +905652)0.5

= 243198 N-mm

Dg be the diameter of gear shaft

3
Then Te= π*τ* d /16 (τ is taken from data hand book) d 3

=243198*16/(π*250)
dp= 18mm (say)

52
 Design for output shaft

Maximum tangential force on output gear

WT’= ( WT*Dg/Dp)

=3070*59/49

=3696N

Normal load acting on tooth (Wn) = WT’/ cosΦ

= 3696 / cos 20 =3933

Weight of gear (Wg) = 0.00118* Tg*b*m2

= 0.00118*24*10*2.452

=1.7 N

2
Therefore, resultant load on gear (WR) = (W + W 2+2* W g*W n*cosΦ)0.5

= (39332+1.72+2*3933*1.7*cos20)0.5

=3935 N

Assuming gear is overhung on shaft at 5mm Bending

moment on shaft due to WR is M

Then we take M = WR* 5 = 3935*5

= 19675 N-mm

And twisting moment on shaft due to WT is T

T = WT ‘* Dg / 2 = 3693*59 /2 = 109032 N

Equivalent twisting moment is Te = (M2+ T2)0.5

= (196752 +1090322)0.5
= 11079211 N-mm

53
 dg be the diameter of gear shaft

Then Te= π*τ* d 3/16

d3 =110792*16/(π*180) (τ is taken from data hand

book)
dp= 14mm (say)
Design of bearing

Take axial load from gear calculation =WA =3070 N Take

radial load from gears = WR=7522 N Let

speed (N) = 1000 r p m

Assume required life of bearing = 3 years, 10 hr per day Life of

bearing in hours (LH) = 3*365*10 =10905hrs

Life of bearing in revolutions (L) =60*N* LH =60*1000*10950=657*106revolutions For

the single row deep groove ball bearing

WA/ WR = 3070/7522 = 0.408 = e

From the data hand book at (e) =0.44

X=radial load factor =0.56

Y = thrust (or) axial load factor = 1

Equivalent basic dynamic load W

W = X WR+Y WA

= (0.56*7522)+(1*3070) W

= 7283 N

From the data hand book, we find that for the uniform and steady load ,the service factor ks
for ball bearing is one
ks = 1

54
The bearing should be selected for W =7283 N We

know that basic dynamic load rating C

C = W*(L / 106) (1/k)

For ball bearing K= 3

C = 7283 (657*106/106)1/3

C = 63313.85 N = 63.31 KN= 64 KN (say)

From the data hand book the bearing number 410 having C = 64 KN may be selected. Calculation

is completed.

55
 CHAPTER -5

ADVANTAGES AND DISADVANTAGES APPLICATIONS

Advantages:

i. The tool is manufactured by simple mechanisms and easily available materials are
used in the manufacturing process.

ii. This tool occupies less floor space and transportation is simple.

iii. This tool is less cost as compared to other nut removing tools.

iv. This tool is operated by normal people, not required special skilled persons.

v. Not required any special energies like electrical, pneumatic by the operation
process.

vi. Any nut size is removed by using this multi nut remover.

vii. Time less to remove the nuts as compared to single nut removing tools.

viii. At a time 4 nuts are removed and at the same fixed together.

Disadvantages:

i. This tool is not adjustable. It is a fixed design for car models.

ii. This design is depending upon the wheel pitch circle diameter

iii. If the car nuts are rusted then nut removing is difficult.

iv. For easily moving gear wheels any time we applying lubricant

v. If the nuts are struck then removing the nuts is difficult.

vi. Weight of the tool is heavy as compared with other nut removing tools.

56
Applications

Application domain of MULTI NUT remover or tightener is in automobile industries.

According to our pre planned project we describe the following places where it can be used
successfully:

i. It can be used as standard equipment provided with a new vehicle for the purpose of
opening and refitting a punctured wheel in the midway.

ii. It can be used in workshops to open a wheel in place of using pneumatic guns which are
restricted to the availability of light and compressed air. It can be easily operated with
hands.

iii. It can be used in assembly lines of automobiles where more time is consumed in tightening all
the four nuts one by one. As it takes less time to fit a new tyre, it will lead to increased
productivity.

Project cost:

Material cost:

s:no Part name No. Pieces cost

1 Gears 6 1200
2 Bearings 10 400
3 Iron plates 2 800
4 Shafts 5 450
5 Stand 1 100
6 Hand Lever 1 100
7 Tool bits 4 200
8 bolts 4 40
Total cost = 3290

Fabrication cost

Fabrication cost of the project = 2000

57
Total project cost = material cost + fabrication cost

= 3290 + 2000 = 5290

58
 FUTURE SCOPE

i. The multi nut remover is fixed to a certain model of the car so in further work we will
change the tool into an adjustable type which can be suited for any model of the car.

ii. We will try to reduce the cost of the model in further work.

iii. The weight of the model is heavy so in future we will try to reduce the weight by
fabricating the model with different lightweight materials.

iv. Now the operating energy of the model is mechanical energy so in further steps
we will try to arrange a motor to rotate the tool.

59
 CONCLUSION

We introduce one product that is four wheeler multiple-opening spanners for tightening and
removing the four nuts in a single stroke of a hand operated lever. We have developed a gear planetary

mechanism to reduce the time and effort of the person. In our project we have tried to focus on the
minimization of human effort and time consumed for fixing all four nuts of the ø112mm PCD tire with
a single stroke of lever. It can be successfully used as a standard tool provided with a new vehicle.

Also it can be used in assembly lines of automobiles, workshops and service stations.

60
 REFERENCES:

http://science.howstuffworks.com/gear-ratio.htm

http://Gears.Machines-Direct_com.htm\

www.mechanical stuffs .com

www.sciencedirect.com/gearmaterials/1925.jsp

www.engineeredge.com/search/gearterminology/1215.html

Machine design - R.S.KHURMI, J.K.GUPTA THEORY

OF MACHINES –J.K.GUPTA

61