Selection of Material

3. Material Selection

Factors affecting the selection of materials

Availability of
material
Component
Cost of processing
shape

Selection of Dimensional
Cost of the material material tolerance

Service Mechanical
requirements properties
Fabrication
requirements

TVSM / PED / MSE / MHSE Slide 26

 Factors affecting the Selection of Material

3. Material Selection
Factors affecting the selection of materials:
(i) Component shape: The shape and size of a component has great effect on the choice of the processing

unit which ultimately effects the choice of the material.

(ii) Dimensional tolerance: The required dimensional tolerance for finished components will, influence the

choice of materials.

(iii) Mechanical properties: To select a suitable material for specific conditions, all mechanical properties,

e.g., hardness, strength, etc.

(iv) Fabrication requirements: Method of processing of the material also affects the properties of a

component.

(v) Service requirements: Service requirements are dimensional stability, strength, toughness, heat

resistance, corrosion resistance, fatigue and creep resistance, electrical and thermal conductivity etc. where

as fabrication requirements are cast-ability.

TVSM / PED / MSE / MHSE Slide 27

 Factors affecting the Selection of Material

3. Material Selection

Factors affecting the selection of materials:

(vi) Cost of the material: the cost of raw material accounts about 50 per-cent of the finished cost. The cost

of the material is a major factor which influences the choice of the material or process.

(vii) Cost of processing: The type of material affects the detailed aspect of design and hence the choice of

material as well as the process is selected at the early design state, e.g., whether the material is to be joined

by spot welding, screws or rivets, must be decided at the design state.

(viii) Availability of material: The selection of material amongst the available large range of different types

of materials the wisest choice should be made keeping in view the above factors to achieve the efficient

utilization of materials.

TVSM / PED / MSE / MHSE Slide 28

 Selection of Material

3. Material selection:
One of the most challenging task of an engineer is the proper selection of the
material for a particular job. The properties and behavior of a material depends upon the
several factors. e.g., composition, crystal structure, conditions during service and the
interaction among them.

TVSM / PED / MSE / MHSE Slide 29

 Selection of Materials

3. Selection of Material

Development of trolley must be linked closely with the following guidelines:

The trolleys are meant for A class parts,

 Frame Assembly – Fabricated trolleys

 Engine assembly – Fabricated trolleys (part above 20kg), Semi-modular trolleys (below 20 kg).

 Wheel assembly- Fabricated trolleys

 Fuel tank assembly – Fabricated trolleys

 All vehicle sub-assembly parts – Modular trolleys, fabricated trolley

 All machined parts handling – Modular trolleys

 All castings - Modular trolleys

 Styling parts for LBH above 150*150*150 – Modular trolleys

 Fabricated styling parts – Flat deck, modular trolleys.

TVSM / PED / MSE / MHSE Slide 30

 Selection of Material

3. Selection of Material - Steels

Square tubes Rectangular tube Equal angle

Round tube Round rod Flats

TVSM / PED / MSE / MHSE Slide 31

 Selection of Material

3. Selection of Material - Steels

TVSM / PED / MSE / MHSE Slide 32

 Selection of Material

3. Selection of Material - Steels

TVSM / PED / MSE / MHSE Slide 33

 Selection of Material

3. Selection of Material - Steels

TVSM / PED / MSE / MHSE Slide 34

 Selection of Material

3. Selection of Material - Steels

TVSM / PED / MSE / MHSE Slide 35

 Concept design

4. Concept design
Base:
It is the basement of the trolley structure. It have in top side all structures, in
bottom side wheel mounting plates to fix the wheels and front & rear towing fixtures.

Material : In variety of materials, the base structure material is standardized to,

MS Square tube – 30 x 30 x 2.

Base size : Base size of the trolley is arrived based on the size of gangway, trolley capacity
and standardization between trolleys. In the parts of standardization, 3 variety of base size
are followed,
1200 L x 800 W
1400 L x 900 W
1500 L x 1000 W

TVSM / PED / MSE / MHSE Slide 36

 Concept design

4. Concept design

Trolley height :
Approx. 1200 mm to 1400 mm

Quantity per trolley:

Trolley Dimension = 1200 x 600 x 1200

Part Dimension = 565 x 315 x 260

1200 x 600 x 1200

Quantity =
650 x 400 x 350 (with clearance buffer)

Quantity = 9 (3 Layers with 3 part each layer)

TVSM / PED / MSE / MHSE Slide 37

 4. Concept design

Structure design:
Trolley structure design is the most critical and important step in the design. Structure will
play 3 major things are,
1. Support
2. Clamp
3. Locate

Location

Support

TVSM / PED / MSE / MHSE Slide 38

 4. Concept design

Structure design:

Operating
clearance (50 mm)

clearance (80 mm)

Operating

TVSM / PED / MSE / MHSE Slide 39

 4. Concept design

Structure design:

TVSM / PED / MSE / MHSE Slide 40

 4. Concept design
Structure design:

 Easy handle of parts (loading & unloading)

- Loading and unloading of parts should be easy to reduce

the handling time and reduce operator fatigue.

 Part should not touch each other

Part to part gap should be provided to avoid part damage.

 Capacity of the trolley

Trolley capacity should be unitized.

TVSM / PED / MSE / MHSE Slide 41

 DFMEA

5. DFMEA
DFMEA (Design Failure Mode Effective Analysis) is used to identify failure modes in
the design, causes for the failure and improvement ideas to improve the design.

TVSM / PED / MSE / MHSE Slide 42

 Final design

6. Improved trolley design

Positive stopper
arrangement

PVC Sleeve to
avoid paint scratch

TVSM / PED / MSE / MHSE Slide 43

 Design validation

6. Design Analysis of trolley for static and dynamic loads

TVSM / PED / MSE / MHSE Slide 44

 Static load testing

TVSM / PED / MSE / MHSE Slide 45

 Static load testing

TVSM / PED / MSE / MHSE Slide 46

 Improved design

6. Improved design
 Identified improvement points will be addressed into the design.
 Verify the design as per the check list before release the design.

Positive stopper
arrangement

TVSM / PED / MSE / MHSE Slide 47

 Release Manufacturing Drawing

7. Release Manufacturing drawing

Details drawing with dimensions and bill of material will be prepared for manufacturing.

Manufacturing drawing Bill of Materials

TVSM / PED / MSE / MHSE Slide 48

 Costing

8. Cost estimation

TVSM / PED / MSE / MHSE Slide 49

 Sample approval

9. Sample receipt and approval

Receipt one number of sample as per the drawing, conduct trails and get the feedback from the
users.

TVSM / PED / MSE / MHSE Slide 50