Materials Today: Proceedings 67 (2022) 1170–1174

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Materials Today: Proceedings

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Design and analysis of multi nut remover / tightener for car wheel
Tapaswinee Das ⇑, Subham Samantaray, Bhavik Thacker, M.D. Danish, Rajeev Ranjan Kumar, Pintu Kumar
Department of Mechanical Engineering, Siksha ’O’ Anusandhan Deemed to be University, Bhubaneswar-751030, Odisha, India

a r t i c l e i n f o a b s t r a c t

Article history: The car is no longer a symbol of luxury; it has become a necessity for all families. People need cars for
Available online 20 August 2022 various reasons, some of which will arrive at their destinations, travel comfortably, do daily chores,
and deliver things to their destinations at a greater distance. The most common problem when driving
Keywords: a car is a flat tire. The flat tire must be replaced with a spare tire. Therefore, the driver should have a basic
Gears understanding of how to replace tires when such problems occur. Almost all vehicles have tire changing
Nut tools, such as nut pullers and jacks provided by manufacturers. The process of loosening or tightening
Wheel
nuts of a car wheel with the standard tools like L-shaped spanner, wrench and socket is already a tedious
Automotive
one. This work is aimed at designing a compact tool that will remove the four nuts of a car wheel simul-
taneously by consuming less time, less money and less energy. The design and analysis have been done
using SOLIDWORKS software. The tool is easy to handle and can become a standard equipment for tyre
removal.
Copyright Ó 2022 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the Advances in Energy and
Environment for Sustainable Development.

1. Introduction
The automotive industry in India is 6th largest in the world.
India has 22 cars per 1000 individuals. Four wheelers in India,
especially cars have become a necessary means for every family.
In the recent times there has been a tremendous increase of vehi-
cles on roads. Driving a car is not the whole part of the process but
to deal with any issues that happen with one’s vehicle randomly on
roads is also a point of concern. Sometimes the tyres have to be
detached from the car in order to deal with any issue that might
have occurred. One such problem which every car user deal with
is a flat tyre or a tyre puncture which might require the wheels
to be taken out and replaced with a new one. Many times the com-
muter may not be lucky enough to be near a repair garage when
such an issue is encountered. There might be times when such
an issue needs to be fixed and there are no power sources nearby.
These days every car manufacturer provides a standard jack and L-
shaped nut remover. To pull out all the 4 nuts with the help of a L-
shaped nut remover requires some labour. This mostly happen to
the female and the aged drivers. The setbacks of this instrument
are time waste and force needed. A power operated nut remover
mostly used in garages and factories is also dependent on a power
⇑ Corresponding author.
E-mail address: tapaswineedas@soa.ac.in (T. Das).
source. One should also think of a scenario when there are no
power sources available nearby. The problem to tighten the nuts
does occur most times even if the nuts are successfully removed.
And the driver’s safety is also at risk if the required torque is not
applied in tightening the nuts. All these concerns bring us to an
idea. The idea behind this tool is to save time, money and energy
consumption while being reasonably convenient in its usage.
Several similar devices have been developed before having fea-
tures such as sun gear, planetary gear, shaft having box spanner
attached to it etc. Some of these devices are electrically, manually
controlled. Sivabalan et al. [1] designed an adjustable unified
wheel remover. To actuate the four socket spanners at a time bevel
gear arrangement was used with twelve driven and one pinion
gears. To make the project adjustable cam and follower mechanism
was used. Azman et al. [2] designed an all-wheel nut remover. In
their design attention was paid to ergonomics because the user
has to support it with hand while using which could be stressful
and time consuming.
Bhanage et al. [3] designed a tool which is compatible with car
wheels of PCD (Pitch Circle Diameter) 114.3 mm having five lug
nuts and which will be operated with the help of a power source.
Prasanth et al. [4] designed a tool using CATIA and ANSYS which
is compatible with car wheels of PCD 100 mm having four lug nuts
and which is operated with the help of a power source. Kumar et al.
[5]’s design is compatible with car wheels of PCD 114.3 mm having

https://doi.org/10.1016/j.matpr.2022.07.428
2214-7853/Copyright Ó 2022 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the Advances in Energy and Environment for Sustainable Development.
T. Das, S. Samantaray, B. Thacker et al. Materials Today: Proceedings 67 (2022) 1170–1174

five lug nuts and which operates without a power source. Ojo and Number of teeth: 24.
Olugbade [6] designed a tool which is compatible with car wheels Material: Medium carbon steel (EN8).
of PCD 114.3 mm having four lug nuts and which does not require
a power source to be operated. The entire assembly is mounted on 3.2. Bearings
a stand. Gomesh et al. [7] designed a four wheeler opening spanner
which operates on 100 mm PCD wheels and it does require a power Type of bearing: Ball bearing.
generating motor which makes it less convenient to be portable. Bore diameter for input shaft: 15 mm.
Bhanage et al. [8] designed an all nut remover which works on five Bore diameter for output shaft: 20 mm.
lug nuts at once with less requirement of torque and more effi- Thickness: 11 mm.
ciency. It is applicable for wheels with PCD of 114.3 mm. It uses
epi-cycling gearing which helps in giving the device a more com- 3.3. Shafts
pact form. With a ratio of 2:1 on the rotation of driven and driver
gears, theoretically it reduces the requirement of torque by three Shaft type: Solid shaft.
times. Avinash et al. [9] designed a tool which operates on four Diameter of input shaft: 15 mm.
lug nuts. It makes use of a specially designed removing tool similar Length of input shaft: 180 mm.
to a box spanner to have improved friction between nut and itself Diameter of output shaft: 20 mm.
to prevent it from becoming loose while operation. It makes use of Length of output shaft: 98.5 mm.
a DC motor for its operation. It was chosen over an AC motor
because of numerous reasons such as better speed control for
3.4. Wheel
acceleration, precise voltage control, convenience in portability etc.
The existing designs are faced with some drawbacks arising due
Pitch circle of the wheel: 100 mm.
to heavy weight, large storage space requirement, need of electric-
Nut size: M12
1.5.
ity. In this work a multi nut remover has been designed using a
Socket Spanner Specification: 19 mm.
planetary gear system which will be compatible with car wheels
of PCD 100 mm having four lug nuts and will not require a power
3.5. Cover plate
source to be used and won’t occupy much space in the boot space
of a car.
Thickness: 11 mm.
Area: 165
165 mm2.
2. Method
4. Design and analysis
All engineering activities must start with ideas with high or low
innovation content, which are based on specific plans imple- In this work SOLIDWORKS software has been used to imple-
mented in the form of products. The ultimate success depends on ment design ideas for the model and for the analysis of the gear
careful consideration of the purpose of the product, build, appear- arrangement in multi nut remover.
ance and attention to details in the design. This applies not only to In SOLIDWORKS stress analysis, the maximum stress developed
minor changes to existing products, but also to more innovative with the application of 133.33 N/m2 of torque to the driver gear
products. Proper methods should be followed which will help in and keeping fixtures on the output shaft is 8.86x107N/m2 and max-
making a decision on what further steps have to be carried out imum allowable stress for the arrangement is 1.83
108 N/m2 con-
which must meet buyer/user expectations. They can be summa- sidering EN8/080 M40 grade steel as the choice of material for
rized under the conditions of satisfying all required functions, gears. So, the gear arrangement is safe to be used. The factor of
technically attractive products, and economically easy to buy and safety (FOS) plot for gear assembly using SOLIDWORKS is shown
safe to use. in Fig. 9. In this plot, a value of 3 is obtained for the gear assembly
Brainstorming approach can be defined as a problem solving which is more than the required value i.e. 1.5. The Fig. 10 shows
technique of measuring products, services and practices by taking the stress profile of the gear assembly using SOLIDWORKS.
into consideration the advantages and disadvantages of a product
against the usual practices that are being followed by competitors
4.1. Theoretical calculation
or those recognized as market leaders. It can help forecast the
trends in the industry and it can identify key innovations and
For Driver Gear, PCD (Dp) = 40 mm.
key technologies.
For Driven Gear, PCD (Dg) = 60 mm.
Fig. 1 shows the mind mapping process. The possibilities of cre-
Pressure Angle = 20°.
ating different forms of Multiple Nut Remover are shown in the
Gear Ratio = PCD of Driven Gear / PCD of Driver Gear = 1.5.
blue coloured circles. Similarly the different characteristics of each
By using Gear Ratio.
type are shown as well. The Figs 2–7 shows the different compo-
Number of teeth for Driver Gear (Zp) = 16.
nents of the compact tool. The multi nut remover assembly design
Number of teeth for Driven Gears (Zg) = 16
Gear Ratio = 16
is shown in Fig. 8.

1.5 = 24.
Zp = 16 and Zg = 24 are chosen because both the values are pre-
3. Dimensions of components sent in Lewis Form Factor Table.
Diametral Pitch (Pd) = Zp/Dp = 16/40 = 0.4 mm1.
3.1. Gears Module (m) = Dp/Zp = 40/16 = 2.5 mm.
Face Width (b) = 10
m = 10
2.5 = 25 mm.
Module of both gears: 2.5 mm. Mechanical Properties of EN8/080 M40:
Face Width of both gears: 25 mm. Ultimate tensile strength (Sut) = 550 N/mm2.
Diameter of the pinion: 40 mm. Yield strength (Syt) = 280 N/mm2.
Number of teeth: 16. Young’s Modulus (E) = 200000 N/mm2.
Diameter of the gear: 60 mm. Poisson’s Ratio = 0.3.
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T. Das, S. Samantaray, B. Thacker et al. Materials Today: Proceedings 67 (2022) 1170–1174

Fig. 1. Brainstorming / Mind Mapping Approach for Multi Nut Remover.

Fig. 2. Spur Gear. Fig. 5. Spanner Attachment.

Fig. 3. Ball Bearing.

Fig. 6. Cover Plates.

Fig. 4. Grab Handle. Fig. 7. 19 mm Socket Spanner.

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T. Das, S. Samantaray, B. Thacker et al. Materials Today: Proceedings 67 (2022) 1170–1174

Permissible Bending Stress for driver gear (rbp) = (1/3)Sut = 55

0/3 = 183.33 N/mm2 (For driver gear).
Permissible Bending Stress for driven gear (rbg) = (1/3)Sut = 5
50/3 = 183.33 N/mm2 (For driven gear).
rbp
Y p < rbg
Y g
Therefore, driver gear is more prone to bending than the driven
gears.
Beam Strength:
Beam Strength ðF b Þ ¼ m
b
rbp
Y p
¼ 2:5
25
183:33
0:295
Fig. 8. Multi Nut Remover Assembly Design.
¼ 3380:14N
When driven gear and driver gear are constructed using same
material then at that time driving gear is found to be weaker than
driven gear in bending, so we have to find out effective force (Feff)
for calculating factor of safety (FOS).
Effective load for precise estimation:
F eff ¼ ðK a
K m
F t Þ=K v
Ka = 1.25 for moderate shock & precise gearing.
Km = 1.2 for face width upto 50 mm.
V = 22 m/s for fine hobbing process.
where,
K = Application Factor (Combined Shock & Fatigue Factor).
Km = Load Distribution Factor.
Ft = Tangential Component of Force.
Kv = Dynamic Factor.
V = Pitch Line Velocity.
Torque required for four nuts (T) = 480Nm [3,5].
Fig. 9. Factor of Safety (FOS) plot of gear assembly using SOLIDWORKS. Assuming humans can turn the driving gear at the rate of
30 rpm [5], therefore,
P = (2
p
N
T)/60 = (2
3.14
30
480)/60 = 1507.96 W
(Power transmitted by Driving Gear).
Ft = 500
cos(20°) = 469.85 N (Tangential Force) [6].
p p
Kv = 5.6/(5.6 + V) = 5.6/(5.6 + 22) = 0.5441 (Dynamic Factor).
Feff = (Ka
Km
Ft)/Kv = (1.25
1.2
469.85)/0.5441 = 1295.
30 N.
F b ¼ FOS
F eff
FOS = Fb/Feff = 3380.14/1295.30 = 2.6 which is higher than 1.5.
As the available FOS is greater than the required factor of safety,
so the design of gears is safe.

5. Discussion

In this work SOLIDWORKS software has been used to perform

stress analysis and factor of safety plot was also obtained for the
gear arrangement and the values obtained are very close to the val-
ues obtained with theoretical calculation.
Fig. 10. Stress profile of gear assembly using SOLIDWORKS. Factor of safety (Theoretical result): 2.6.
Factor of safety (Numerical result): 3.0.
In both the results the value of FOS is more than 1.5 which is the
Table 1 minimum requirement and thus the arrangement of gear is safe to
Lewis Form Factor (Y).
be used considering the material choice for the gear is a medium
Number of teeth 20° Full Depth carbon grade steel specifically EN8 steel.
16 0.295
24 0.307 6. Advantages and limitations

The Table 1 shows the Lewis Form Factor (Y) of driver and dri-
ven gear for different number of teeth.
Permissible Bending Stress (Same material is used for driver
gear and driven gear):
There are certain advantages which come with the usage of this
tool.
 Less consumption of energy for removing four nuts simultane-
ously when compared to a standard L-shaped wrench.

1173
T. Das, S. Samantaray, B. Thacker et al.
 A higher torque is obtained at the spanners with input of a
lower torque.
 The output torque obtained does not get distributed among the
output gears, each gear receives the same torque from the tor-
que provided as input.
 This tool will not require a source of power to operate.
 Less maintenance compared to a motor operated nut remover.
 This tool will cost less compared to a motor operated nut
remover.
 This tool weighs less close to 2 kg compared to designs before
and not depending on a power source makes it portable.
 This tool will occupy less storage space compared to several
earlier designs.
Every tool has certain limitations as well. Some of the limita-
tions are as follows:
 This tool has been designed to work on 100 mm PCD wheels
with four lug nuts only. It is not adjustable.
 This tool requires manual operation and thus compared to sev-
eral earlier designs functioning with motor this will require a
bit more effort.
7. Conclusion
This tool is specifically designed for wheels which adopt
100 mm PCD for the lug nuts which is the case with most of the
cars. There is no need of any power source to operate the tool. It
can be manually operated with much less force compared to what
would have been required when using a L-shaped spanner. It is
compact and does not require much maintenance. The numerical
analysis result is very close to the theoretical value, and the gear-
box design is safe. Since the design is safe, product assembly and
testing can be carried out.
CRediT authorship contribution statement
Tapaswinee Das: Conceptualization, Methodology, Software,
Supervision. Subham Samantaray: Writing – original draft. Bha-
vik Thacker: Visualization, Investigation. M.D. Danish: Software,
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Materials Today: Proceedings 67 (2022) 1170–1174
Validation. Rajeev Ranjan Kumar: Validation, Software. Pintu
Kumar: Writing – review & editing.
Data availability
The data that has been used is confidential.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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