International Journal of Vehicle Structures and Systems

S. P. Sundar Singh Sivam ¹, K. Saravanan ², Ganesh Babu Loganathan ³, D. Kumaran ¹, S. Rajendra kumar ¹

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

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.

Full Text

   

S. P. Sundar Singh Sivam ¹, Ganesh Babu Loganathan ², V. G. Umasekar ¹, K. Saravanan ³, P. S. Suresh Kumar ⁴, Saravanan Raja ⁵

Affiliations
1 Dept. of Mech. Engg., SRM Institute of Sci. and Tech., Kattankulathur, Tamil Nadu, IN
2 Dept. of Mechatronics Engg., ISHIK University, Kurdistan Regional Government, Erbil, IQ
3 Dept. of Mechatronics Engg., SRM Institute of Sci. and Tech., Kattankulathur, Tamil Nadu, IN
4 Research and Development, Materials Engg. Dept., Renault Nissan Tech. Business Center India Pvt Ltd, Chengalpattu, Tamil Nadu, IN
5 Quality Assurance and Control, NTN NEI Manufacturing India Pvt Ltd, Chennai, IN

Abstract

Heat treatment of metal alloys is one of the most widely used techniques for achieving the desired mechanical properties by modifying the microstructure namely the grain and or by altering the second phases present in heat treat able alloys. At times heat treated materials undergo further process like forming, machining, welding etc. Thus the present work describes the effect of heat treatment of AISI 1050 steel and its associated micro structural changes that correlate it with the mechanical behaviour. AISI 1050 steel is widely used in the production of bearings, landing gear, actuators and aerospace structural components. In this study, different samples of AISI 1050 steel were heat treated to temperature above the austenitic region and were subjected to annealing or normalising, or spheroiding. It is indicative that the properties of the AISI 1050 steel can be easily altered by heat treatment to suit a particular application and for secondary processing. The property comparison includes micro structural grain size, yield strength, tensile strength, hardness and percentage elongation. Thus the results provide a better insight on the process of increasing the versatility of the AISI 1050 steel for its demanding use in aerospace structural applications and related mechanical processing. It was found that the effect of heat treatment has resulted in increased grain size, decreased strength and hardness, and improved properties which were more suitable for machining and forming process.

Keywords

AIS11050 Steel, Heat Treatment, Micro Structure, Mechanical Properties.

Full Text

   

S. P. Sundar Singh Sivam ¹, Ganesh Babu Loganathan ², K. Saravanan ³, V. G. Umasekar ¹, T. P. Mohammed Rameez ¹

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

Abstract

Automotive side impacts are particularly dangerous as location of impact is very close to the passenger, who can be immediately reached by the impacting vehicle. FMVSS 214 static is a US safety regulation for occupant safety during side impacts, in which the vehicle is tested at static loading conditions to measure its load baring capacity and integrity of side closures. The CAE load case, virtually simulating the test, was handled as a quasi-static problem in this study. Impact beam is a component that helps in improving vehicle passive safety performance during side impacts by minimizing door intrusion to the occupant cabin. It plays an important role in achieving side impact regulatory norms. Through this study, a mass optimized front door impact beam design was developed for a passenger car with the help of CAE simulations; FMVSS 214S regulation norms are met. Component thickness, material and cross section shape were the design variables considered for the study. A methodology to perform the component level simulation of the impact beam loading such that it replicates component behaviour during full vehicle simulation was developed. This has helped in reducing the total problem calculation time in solver. This also has minimized the computational cost for the project. CAE simulations required for the study were done using LS-DYNA. ANSA and PRIMER were used as pre-processors and hyper-graph and meta-post were used for post processing.

Keywords

Impact Beam, Automotive Side Impact, FMVSS 214 Static, Optimization, Quasi-Static Analysis.

Full Text

   

S. P. Sundar Singh Sivam ¹, V. G. Umasekar ², Ganesh Babu Loganathan ³, D. Kumaran ², K. Saravanan ⁴

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

Abstract

This study presents the optimization of machining parameters on ZE41 Mg alloy fabricated by gravity die casting and Technique for Order Preference by Similarity to Ideal Solution (TOPSIS). Focus on the optimization of machining parameters using the technique to get minimum surface roughness, cutting force, thermal stress, residual stress, chip thickness and maximum MRR. A number of machining experiments were conducted based on the L27 orthogonal array on computer numerical control vertical machining center. The experiments were performed on ZE41 using cutting tool of an ISO 460. 1-1140-034A0-XM GC3 of 20, 25 and 30mm diameter with cutting point 140 degrees, for different cutting conditions. TOPSIS and ANOVA were used to work out the fore most important parameters cutting speed, feed rate, depth of cut and tool diameter which affect the response. The expected values and measured values are fairly close. Finally, the study for optimizing machining process is surveyed and results show improvement in real experiments.

Keywords

Mg Alloy, Different Cutting Conditions, TOPSIS, ANOVA, Machining, L27 Array.

Full Text

   

S. P. Sundar Singh Sivam ¹, Ganesh Babu Loganathan ², K. Saravanan ³, V. G. Umasekar ¹, S. Rajendrakumar ¹

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

Abstract

Industrial enterprises increasingly demand optimum quality of products keeping in consideration a strict adherence where forming parameters are concerned. As far as incorporating the vital forming process upon an assortment of materials is concerned, it has grown excruciatingly challenging for industrial enterprises for laying out the adequately precise and suitable parameters. The flaws that are engendered during the process of sheet metal forming are inevitable. Flaws of this nature can be, however, kept within minimal proportions by introducing variations into the process parameters by Trial and Error methodology. This evidently results in a subsequent financial loss, not to mention an irrevocable loss of time and material. Dynaform simulation of defects combined with optimization is carried out with the help of Minitab. This method, as can be conjectured with considerable ease, yields optimum results, for it replaces much to our convenience the need for specialist industrial expertise besides leading to considerable savings in cost, time and material. This study would optimize the SS304sheet metal forming parameters FLD, thickness and thinning with three input parameters, namely, the lower binder force, tool travel velocity and binder close velocity.

Keywords

Sheet Metal Forming, Binder Close Velocity, Taguchi Orthogonal Array, Defect Measurements.

Full Text