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Root Cause Analysis for Failure of Door Lock Case Assembly during Caulking Process


Affiliations
1 Dept. of Mech. Engg., SRM Institute of Sci. and Tech., Kattankulathur, Tamil Nadu, India
2 Dept. of Mechatronics Engg., SRM Institute of Sci. and Tech., Kattankulathur, Tamil Nadu, India
3 Dept. of Mechatronics Engg., ISHIK University, ERBIL, KRG, Iraq
 

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This paper details the failure analysis of deformed passenger car door lock case and presents a solution to avoid the part deformation during caulking process. This failure was observed during the assembly of case and its cover by caulking process. Mechanical properties and chemical composition of case (Zn Al4 material) has been checked by universal testing machine and spectra material analyser. The material composition having less aluminium content leads to the casting strength and cast ability losses. In order to get the exact load requirement for caulking process, analysis has been carried out by using finite element method. In finite element method, the case and case cover model has created by AUTODESK INVENTOR and stress analysis was carried using same software. The induced stress and deflection are obtained for various load conditions. The experimental measurement was taken from the machine by using load cells. By comparing the experimental data with FEM data we found that the problem happened due to the overload. From this result data the machine design was optimized by changing booster and cylinder which is used to generate the load. The hydro pneumatic circuit of the caulking machine has been optimized and redesigned to avoid future problems.

Keywords

Caulking Process, Failure Analysis, Finite Element Method, Redesign, Stress Analysis.
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  • Root Cause Analysis for Failure of Door Lock Case Assembly during Caulking Process

Abstract Views: 581  |  PDF Views: 173

Authors

S. P. Sundar Singh Sivam
Dept. of Mech. Engg., SRM Institute of Sci. and Tech., Kattankulathur, Tamil Nadu, India
K. Saravanan
Dept. of Mechatronics Engg., SRM Institute of Sci. and Tech., Kattankulathur, Tamil Nadu, India
Ganesh Babu Loganathan
Dept. of Mechatronics Engg., ISHIK University, ERBIL, KRG, Iraq
D. Kumaran
Dept. of Mech. Engg., SRM Institute of Sci. and Tech., Kattankulathur, Tamil Nadu, India
S. Rajendra kumar
Dept. of Mech. Engg., SRM Institute of Sci. and Tech., Kattankulathur, Tamil Nadu, India

Abstract


This paper details the failure analysis of deformed passenger car door lock case and presents a solution to avoid the part deformation during caulking process. This failure was observed during the assembly of case and its cover by caulking process. Mechanical properties and chemical composition of case (Zn Al4 material) has been checked by universal testing machine and spectra material analyser. The material composition having less aluminium content leads to the casting strength and cast ability losses. In order to get the exact load requirement for caulking process, analysis has been carried out by using finite element method. In finite element method, the case and case cover model has created by AUTODESK INVENTOR and stress analysis was carried using same software. The induced stress and deflection are obtained for various load conditions. The experimental measurement was taken from the machine by using load cells. By comparing the experimental data with FEM data we found that the problem happened due to the overload. From this result data the machine design was optimized by changing booster and cylinder which is used to generate the load. The hydro pneumatic circuit of the caulking machine has been optimized and redesigned to avoid future problems.

Keywords


Caulking Process, Failure Analysis, Finite Element Method, Redesign, Stress Analysis.

References





DOI: https://doi.org/10.4273/ijvss.11.1.03