,QWHUQDWLRQDO-RXUQDORI,QQRYDWLRQVLQ(QJLQHHULQJDQG7HFKQRORJ\,-,(7

'HVLJQRI%XVK0RXQWLQJ)L[WXUHZLWK&ULWLFDO
3DUW$QDO\VLV
,VKZDU'*DYDOL
Department of Mechanical Engineering
SKN SinhgadInstitute of Technology & Science Lonavala, Pune0DKDUDVKWUD,QGLD

3URI6+0RUH
Department of Mechanical Engineering
SKN SinhgadInstitute of Technology & Science Lonavala, Pune0DKDUDVKWUD,QGLD

$EVWUDFW  )L[WXUH GHVLJQHG LV GHSLFWHG E\ VR PDQ\ RWKHUV KRZHYHU IL[WXUH GHVLJQHG LWVHOI KDYLQJ LQQRYDWLYH DUHD IRU
YDULRXVFRPSRQHQWV6RZHQHHGDSSO\WKHRUHWLFDONQRZOHGJHWRLQGXVWULDODSSOLFDWLRQ7RPDNHWKHSUHVVILWWHGDVVHPEO\
RIOHYHUZLWKKDQGLVWLPHFRQVXPLQJOHVVDFFXUDF\DQGKXPDQHUURU7KLVSDSHUSUHVHQWV'HVLJQDQGDQDO\VLVRIIL[WXUH
IRU EXVK PRXQWLQJ RQ OHYHU $IWHU FDUHIXO VWXG\ RI ILQDO DVVHPEO\ D IHZ FRQFHSWV GHVLJQHG $PRQJ WKHVH FRQFHSW EHVW
FRQFHSWVHOHFWHGDQGGHYHORSHGIL[WXUHWRPHHWWKHDVVHPEO\UHTXLUHPHQW6RWKHUHLVQHHGWRGHYHORSIL[WXUHZKLFKFDQ
KHOSWRLQFUHDVHSURGXFWLYLW\LQEDWFKW\SHSURGXFWLRQ

7KH GHVLJQ RI WKH IL[WXUH LV PRGHOHG XVLQJ 'VRIWZDUH PDQXIDFWXULQJ GUDZLQJ LV FUHDWHG XVLQJ VDPH VRIWZDUH 7KH
FULWLFDO SDUWV DUH YDOLGDWLQJ XVLQJ DQDO\VLV VRIWZDUH )L[WXUHV UHGXFH KXPDQ HUURU RSHUDWLRQ WLPH DQG LQFUHDVHV
SURGXFWLYLW\DQGKLJKTXDOLW\RIRSHUDWLRQ


,QGH[7HUPV)L[WXUHGHVLJQGLHVSULQJFRLOVSULQJ

,,1752'8&7,21
2YHU WKH IHZ GHFDGHV PDQXIDFWXULQJ LV SURJUHVVLQJ ZLGHO\ 7KH PDFKLQH WHFKQRORJLHV KLJKSHUIRUPDQFH
DGYDQFH WHFKQRORJ\ DQG PRGHUQ PDQXIDFWXULQJ SURFHVVHV DUH PDNLQJ WRGD\¶V LQGXVWULHV WR PDNH SDUWV IDVWHU DQG
EHWWHUWKDQHYHUEHIRUH6RWKHIL[WXUHPHWKRGDOVRDGYDQFHGFRQVLGHUDEO\KRZHYHUWKHEDVLFSULQFLSOHVRIFODPSLQJ
WKHZRUNSLHFHDQGORFDWLQJLVVWLOOWKHVDPH
0DVVSURGXFWLRQPHWKRGVDUHGHPDQGLQJDIDVWDQGHDV\PHWKRGRISRVLWLRQLQJZRUNIRUDFFXUDWHRSHUDWLRQVRQLW
-LJV DQG IL[WXUHV ZLOO EH VSHFLDOO\ GHVLJQHG VR WKDW ODUJH QXPEHUV RI FRPSRQHQWV FDQ EH PDFKLQHG RU DVVHPEOHG
LGHQWLFDOO\DQGWRUHTXLUHLQWHUFKDQJHDELOLW\RIFRPSRQHQWVJOREDOO\7KHHFRQRPLFDOSURGXFWLRQRUFRQVLGHULQJFRVW
RIHQJLQHHULQJFRPSRQHQWVLVJUHDWO\KHOSHGE\WKHSURYLVLRQRIMLJVDQGIL[WXUHV

,,,'(17,),&$7,212)352%/(0
'HVLJQOHYHUKROGLQJIL[WXUHWRPRXQWRQ$/SUHVVWRILWRQHEXVKLQOHYHUDVVKRZQLQILJXUH7KHOHYHULV
PDQXIDFWXUHGZLWKFDVWLQJSURFHVVDQGIXUWKHUPDFKLQHGWRPHHWILQDOUHTXLUHPHQWRISURGXFW$OOPDFKLQHGIDFHVDUH
PDUNHGLQ\HOORZFRORU7KH%XVKLVSXUFKDVHGSDUWRUYHQGRUSDUW'PRGHOVKRZQLQILJXUHKDYLQJWKHRXWVLGH
¡PP


 
9ROXPH,VVXH-XQH  ,661±
 ,QWHUQDWLRQDO-RXUQDORI,QQRYDWLRQVLQ(QJLQHHULQJDQG7HFKQRORJ\,-,(7

  

)LJXUH/HYHU )LJXUH%XVK)LJXUH)LQDO3URGXFW$VVHPEO\


7KHILJXUHLVVKRZVWKHILQDOSURGXFWDVVHPEO\7KH)LQDOSURGXFWDVVHPEO\VKDOOEHPDLQWDLQHGGLPHQVLRQ
IRUPERWWRPRIOHYHUWRWKHERWWRPRIWKHEXVK

,,,'(6,*12)),;785($1'$1$/<6,62)&5,7,&$/3$57
$V VHHPV WKDW WKDW WKH PDFKLQLQJ KDV GRQH RQ KROHV ZH FRXOG PRXQW WKLV ORFDWLQJ SLQ +RZHYHU ZH QHHG RQH
F\OLQGULFDOSLQDQGGLDPRQGORFDWLQJSLQWRDGMXVWWKHWROHUDQFHEHWZHHQWZRKROHV

Diamond Pin calculation:

:KHQZHKDYHWRXVHWZRKROHVLQZRUNSLHFHIRUORFDWLRQZHPXVWWDNHLQWRDFFRXQWWKHYDULDWLRQLQWKHFHQWUH
GLVWDQFHRIWKHWZRKROHVGXHWRWKHZHDURIWKHJXLGHEXVKHVIRUFXWWLQJWRRO
7KHYDULDWLRQFDQEHWDNHQFDUHRIE\PDNLQJRQHRIWKHWZRORFDWLRQSLQVGLDPRQGVKDSHG


  

)LJXUH3ULQFLSOHRI'LDPRQG3LQ)LJXUH'LPHQVLRQDO'HWDLOV)LJXUH'LDPRQRQGSLQGHWDLO


:KHUHILJXUHVKRZVWKHDOOSULQFLSOHRI'LDPRQGSLQDQGFDOFXODWHGLDPHWHUE\EHORZIRUPXOD
&&HQWUHGLVWDQFHEHWZHHQORFDWLQJSLQ
':RUNSLHFHERUHPLQ0D[PDWHULDOFRQGLWLRQRIKROH 
99DULDWLRQLQFHQWUHGLVWDQFH
G'LDPRQGSLQGLD0D[0LQPDWHULDO&RQGLWLRQRIVKDIW
: (QJDJHPHQWZLGWK'»


:KHUH
'LDPRQGSLQORFDWLQJKROHVXUIDFHGLD +

9ROXPH,VVXH-XQH  ,661±

 ,QWHUQDWLRQDO-RXUQDORI,QQRYDWLRQVLQ(QJLQHHULQJDQG7HFKQRORJ\,-,(7

    
' :RUNSLHFHERUHPLQ0D[PDWHULDOFRQGLWLRQRIKROH 
9DULDWLRQ9 
: (QJDJHPHQWZLGWK '  
3LHFHERUHPLQ0D[PDWHULDOFRQGLWLRQRIKROH 



G PP

5DGLDO &OHDUDQFH 'G LV PP %XW FOHDUDQFH DW ORFDWLRQ DW ORFDWLRQ 4 LV PP LH  WLPHV WKH UDGLDO
GLVWDQFH7KHSLQVVKRXOGEHPDGHIXUWKHUXQGHUVL]HWRSURYLGHSUHFLVLRQUXQQLQJILW+IZLWKZRUNSLHFH
'LDPRQGSLQ G I
 
)LJXUHVKRZVWKHQHZGLPHQVLRQGHWDLOVRI'LDPRQGSLQZKLFKLVFDOFXODWHG


,9&21&(37*(1(5$7,21

Concept I (Dog Pin Screw Arrangement):

)LJXUHVKRZV'LDPRQGSLQLVDFWXDWHGZLWK&RPSUHVVLRQVSULQJ:KHQ5$0LVPRYLQJGRZQZDUGWKHVSULQJ
ZLOOEHFRPSUHVVHGWLOOFRPSUHVVXQWLOGLDPRQGSLQLVWRXFKHGWKHVSULQJEORFN:HFDQDFKLHYHPPGLPHQVLRQ
ZKHQGLDPRQGSLQDQGVSULQJEORFNLVJHWPDWH

7KHUHWXUQLQJIRUFHRIFRPSUHVVLRQVSULQJLVFRQWUROOHGE\GRJSRLQWVFUHZ

Concept II (Lock Plate Arrangement):

 ,Q )LJXUH  VKRZV WKH FDVH WKDW DOVR ZH FRXOG DFKLHYH WKH  PP XVLQJ GLDPRQG SLQ DQG VSULQJ EORFN
+RZHYHULQWKLVFDVHZHFRXOGXVHVSULQJORFNSODWHLQVWHDGRIGRJSRLQWVFUHZ



  
)LJXUH&RQFHSW,  )LJXUH&RQFHSW,,)LJXUH&RQFHSW,,,



Concept III (Actuator Arrangement):

,Q)LJXUH6KRZVWKHFDVHWKHDFWXDWLRQRIGLDPRQGSLQFDQEHFRQWUROOHGZLWK'RXEOHDFWLQJSQHXPDWLFF\OLQGHU
,QWKLVFDVHZHFDQDFKLHYHWKHPPGLPHQVLRQZLWKGRXEOHDFWLQJSQHXPDWLFF\OLQGHUDQGSUR[LPLW\VHQVRU


9ROXPH,VVXH-XQH  ,661±

 ,QWHUQDWLRQDO-RXUQDORI,QQRYDWLRQVLQ(QJLQHHULQJDQG7HFKQRORJ\,-,(7

96(/(&7,21&21&(37'(6,*16:,7+02',),&$7,21

:H KDYH VHOHFWHG FRQFHSW , DV LW LV VLPSOH LQ FRQVWUXFWLRQ $V LWV VHHP WKDW WKH PRUH SDUWV WR EH PDFKLQHG DQG
PDQXIDFWXUHGLQ&RQFHSW,,DQGDOVRLQFRQFHSW,,,ZHQHHGWRSXUFKDVHDFWXDWRUF\OLQGHUDQGUHODWHGSRZHUSDFN
VHQVRU
&RQFHSW,QHHGWREHFRQFHQWUDWHGIRUFXVKLRQLQJHIIHFWRIGLHVSULQJDQGPDNHWKHHDV\WRPDQXIDFWXULQJSDUW
)LJXUHVKRZVWKHORFDWLRQRIGLHVSULQJLQIL[WXUH)LJXUHVKRZVWKHPD[LPXPDYDLODEOHGLVWDQFHLQIL[WXUH


 
)LJXUH'LH6SULQJ)L[WXUH  )LJXUH$YDLODEOH)L[WXUH+HLJKW



9,)25&(&$/&8/$7,2121',(635,1*
5$0H[HUWLQJIRUFH [1
:HKDYHVHOHFWHG7ZRVSULQJDWWKLVORFDWLRQ6RIRUFHDSSOLHGRQHDFKVSULQJ [1
&RQVLGHULQJ)266R7KHUHIRUHWKHIRUFHDFWLQJVLQJOHVSULQJLV[1 
9,,6(/(&7,212)',(635,1*)52067$1'$5'&$7$/2*

$VZHUHTXLUHGVSULQJGHIHFWLRQLVPPVRQHHGWRVHOHFWVSULQJFRQVLGHULQJVSULQJFRQVWDQW1PP

/RDGDFWLQJRQHDFKVSULQJZLWKRXW)26 [1

0D[VSULQJFRQVWDQW $FWXDOORDGUHTXLUHGGHIOHFWLRQ
  [
   1PP

7KHVSULQJFRQVWDQWRIVHOHFWLQJVSULQJVKRXOGEHOHVVWKDQ1PP
$YDLODEOHVSULQJOHQJWKLQIL[WXUHLVLQEHWZHHQWRPP
)LJXUH6KRZVWKH-,6VSULQJFDWDORJYDULRXVVSULQJGHWDLOV
 

9ROXPH,VVXH-XQH  ,661±

 ,QWHUQDWLRQDO-RXUQDORI,QQRYDWLRQVLQ(QJLQHHULQJDQG7HFKQRORJ\,-,(7


)LJXUH6SULQJ&DWDORJ

'HWDLOVRIVSULQJZKLFKLVVHOHFWHGIRUPFDWDORJ
2XWVLGH'LDPHWHU PP
,QQHU'LDPHWHU PP
)UHHOHQJWK PP
6SULQJ&RQVWDQW 1PP

+RZHYHUZHQHHGWRFKHFNOLIHRI'LHVSULQJ
$VSHU&DWDORJWKHOLIHRIVSULQJLQFUHDVHVZLWKOHVVGHIRUPDWLRQ

)LJXUHVKRZVWKDWVSULQJOLIHIRUYDULRXVGHIRUPDWLRQV
)UHHOHQJWK[GHIRUPDWLRQ F\FOH
)UHHOHQJWK[GHIRUPDWLRQ F\FOH

3HUFHQWDJHRIGHIRUPDWLRQUHTXLUHGIRUFXUUHQWDSSOLFDWLRQ
'HIRUPDWLRQUHTXLUHGIUHHOHQJWK[
[

1HHGWRFDOFXODWHOLIHRIVSULQJIRUGHIRUPDWLRQ
7KHOLIHLVFDOFXODWHGLQDQDO\VLV

9,,,$1$/<6,62)',(635,1*
0DWHULDO6WHHO6SULQJ
<RXQJ¶V0RGXOXV;1PP
'HQVLW\[NJPP
3RLVVRQ¶V5DWLR
<LHOG6WUHVV1PP

Boundary Condition: Life of spring: Fatigue life Testing:

  

9ROXPH,VVXH-XQH  ,661±

 ,QWHUQDWLRQDO-RXUQDORI,QQRYDWLRQVLQ(QJLQHHULQJDQG7HFKQRORJ\,-,(7


5HVXOW :LWK$QDO\VLV :LWK([SHULPHQW

/LIHRIWKH6SULQJ &\FOH &\FOH

,;6(/(&7,212)&2035(66,21635,1*,1',$021'3,1
'LDPRQGSLQPDWHULDO(1
:LJKWRI'LDPRQG3LQ 1


  

$YDLODEOHOHQJWK,Q'LDPRQGSLQDIWHULQLWLDOSUHFRPSUHVVHGFRQGLWLRQ PP
,QLWLDOFRPSUHVVLRQRIWKHVSULQJ PPDSSUR[

5HTXLUHGIUHHOHQJWKRIKHOLFDOFRPSUHVVLRQVSULQJ  7RPP

6RZHQHHGWRGHVLJQWKHWKUXVWIRUFHRUUHWXUQIRUFHRIDVSULQJLVPRUHWKDQ1
:HKDYHVHOHFWHGVSULQJIRUPVWDQGDUGVSULQJFDWDORJ
)UHHOHQJWK PP
2XWVLGH'LDPHWHU P
:LUH'LDPHWHU PP
6SULQJUDWH 1PP

7KHUHIRUH
6SULQJH[HUWLQJIRUFH LQLWLDOFRPSRIWKHVSULQJVSULQJFRPSGXHDSSOLHGORDGRISUHVV;VSULQJFRQVW
   ;
6SULQJH[HUWLQJIRUFH 1

;6(/(&7,21$1'9$/,'$7,212)'2*32,176&5(:
6RDVSHUHDVLO\DYDLODELOLW\RI'RJSRLQWVFUHZIURPSXUFKDVHGHSDUWPHQWLQ,QGXVWU\
:HKDYHVHOHFWHGIURP6WDLQOHVV6WHHO0['RJ3RLQWVFUHZ

7HQVLOH6WUHQJWK<LHOG03$
6KHDUVWUHQJWK  03$RI6WDLQOHVVVWHHO 
'HVLJQ6WUHVV0D[DOORZDEOHVWUHVV 1PP
 
'RJSLQGLDPHWHU PP
)RUFH LQLWLDOFRPSUHVVLRQPD[GHIOHFWLRQ;6SULQJFRQVW
 ;
 
)RUFH 1««&RQVLGHULQJ)26

6KHDUVWUHVVLQGXFHGLQH[WHQGHGSLQ IRUFH$UHD

9ROXPH,VVXH-XQH  ,661±

 ,QWHUQDWLRQDO-RXUQDORI,QQRYDWLRQVLQ(QJLQHHULQJDQG7HFKQRORJ\,-,(7

6KHDU6WUHVVLQGXFHGLQH[WHQGHGVSULQJ 1PP


 

5HVXOW $OORZDEOH6WUHVV $QDO\WLFDO :LWK$QDO\VLV 5HVXOW 

 
6KHDU VWUHVV ,QGXFHG LQ 1PP 1PP 1PP 6DIH 
'RJ3RLQW6FUHZ 



;,0$18)$&785,1*'5$:,1*)(:/,67('+(5(


  

;,,&21&/86,21
$QHIIRUWLVWDNHQWRGHVLJQWRKROGWKHFRPSRQHQWVLQIL[WXUHDQGFDOFXODWHGDOOGLPHQVLRQWRKROGVHFXUHO\7KLV
IL[WXUHSUHYHQWVWKHGDPDJHVEXVKZKLOHSUHVVLQJLQOHYHU7KHHIIRUWRIWKHRSHUDWRULVDOVRUHGXFHG
1HZ GHYHORSHG IL[WXUH LV WHFKQLFDOO\ MXVWLILHG DQG SURYHQ LWV HIIHFWLYHQHVV DFFXUDFLHV RYHU FRQYHQWLRQDOO\ WKH
FODPSLQJ IRUFH DYDLODEOH IURP 5$0 KDV YDOLGDWHG XVLQJ DQDO\VLV VRIWZDUH IRU FULWLFDO SDUW 9DULRXV QHZ
PDQXIDFWXUHGGUDZLQJZKLFKLVFUHDWHGIURPQHZGHVLJQHGKDVVXEPLWWHGWRIL[WXUH'HVLJQ&RPSDQ\

5()(5(1&(6

>@ 130DQLDU'39DNKDULD&%HUJHU'HVLJQ 'HYHORSPHQWRI5RWDU\)L[WXUHIRU&1&,QWHUQDWLRQDO-RXUQDORI(QJLQHHULQJ6FLHQFH
,QYHQWLRQSS±
>@ &5DGKD0DGKDYL %5DPX .6ULQLYDVXOX 'HVLJQ RI 0DFKLQLQJ )L[WXUH IRU 7XUELQH 5RWRU %ODGH ,QWHUQDWLRQDO -RXUQDO RI 5HVHDUFK LQ
(QJLQHHULQJDQG7HFKQRORJ\SS±
>@ 1%9 /DNVKPL .XPDUL *3UVDVQQD .XPDU 'HVLJQ DQG $QDO\VLV RI ,QGH[LQJ 7\SH RI 'ULOO -LJ ,265 -RXUQDO RI 0HFKDQLFDO DQG &LYLO
(QJLQHHULQJ,265-0&(SS±
>@ 3NDLUDQ396ULKDUL'HVLJQ$QG'HYHORSPHQW2I$Q$VVHPEO\)L[WXUH)RU0RXQWLQJ$&LUFOLS7R7KH3LVWRQ,QWHUQDWLRQDO-RXUQDORI
(QJLQHHULQJ5HVHDUFKDQG$SSOLFDWLRQVSS±
>@ &KDUOHV &KLNZHQGX 2NSDOD (]HDQ\LP 2NHFKXNZX & 7KH 'HVLJQ DQG1HHG IRU -LJV DQG)L[WXUHV LQ 0DQXIDFWXULQJ 6FLHQFH 5HVHDUFK
3S±
>@ 1%9 /DNVKPL .XPDUL1%9 /DNVKPL .XPDUL 'HVLJQ DQG $QDO\VLV RI ,QGH[LQJ 7\SH RI 'ULOO -LJ ,265 -RXUQDO RI 0HFKDQLFDO
(QJLQHHULQJSS±
>@ % 3\WWHO , %UXQQHU % .DLVHU & %HUJHU 0 0DKHQGUDQ )DWLJXH EHKDYLRXU RI KHOLFDO FRPSUHVVLRQ VSULQJV DW D YHU\ KLJK QXPEHU RI
F\FOHV±,QYHVWLJDWLRQRIYDULRXVLQIOXHQFHV,QWHUQDWLRQDO-RXUQDORI)DWLJXH
>@ '(0RXOWRQ7/HVVLQQHV$*RULHO\0RUSKRHODVWLFURGV3DUW,$VLQJOHJURZLQJHODVWLFURG-RXUQDORIWKH0HFKDQLFVDQG3K\VLFVRI
6ROLGVSS±
>@ ,3|OOlQHQ+0DUWLNND2SWLPDOUHGHVLJQRIKHOLFDOVSULQJVXVLQJIX]]\GHVLJQDQG)(0-RXUQDORI$GYDQFHVLQ(QJLQHHULQJ6RIWZDUH
SS±
>@ -L(XQ&KRL*\RXQJ'HN.R.L-X.DQJ7DJXFKLPHWKRGEDVHGVHQVLWLYLW\VWXG\RIGHVLJQSDUDPHWHUVUHSUHVHQWLQJVSHFLILFVWUHQJWKRI
ZLUHZRYHQEXON.DJRPHXQGHUFRPSUHVVLRQ-RXUQDORI&RPSRVLWH6WUXFWXUHVSS±

9ROXPH,VVXH-XQH  ,661±

 ,QWHUQDWLRQDO-RXUQDORI,QQRYDWLRQVLQ(QJLQHHULQJDQG7HFKQRORJ\,-,(7

>@ . 0LFKDOF]\N $QDO\VLV RI WKH LQIOXHQFH RI HODVWRPHULF OD\HU RQ KHOLFDO VSULQJ VWUHVVHV LQ ORQJLWXGLQDO UHVRQDQFH YLEUDWLRQ FRQGLWLRQV
6FL9HUVH6FLHQFH'LUHFWSS
>@ -LJDQG)L[WXUHGHVLJQE\3+-RVKL

9ROXPH,VVXH-XQH  ,661±