Informatics Publishing Limited

Abstract

Forging is a process in which to transform the shape of metal using heat and localized compressive forces.die is the shaping part of the forging process. The project work emphasizes on the design and development of forging die. Before going to the die design principle, a detailed study is conducted on forging processes, forging equipments, forging dies and materials. After studying the various aspects involved in the die design, die design for connecting rod is made. Here in the design of forging die, the product is made most accurately so as to get the forged product free from all defects and as per the requirements given in the product drawing. In industrial view the forging die for connecting rod helps for the mass production of product without any defects of the material after forging. For the analysis of die defects all the required data are collected and based on this study the suitable actions should be suggested for reducing the die failures and for increasing the die life for connecting rod. The product thus obtained by forging is at good strength and free from any defects.

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Abstract

Gears are the most important component in a power transmission system. Their effectiveness should not decrease with a constant prolonged application and should have well anti wear properties. The assembled gear transmits mechanical energy from a prime mover to an output device. A gearbox can also change the speed, direction, or torque of mechanical energy. Gear box is indicated when the application involves high speeds, large power transmission where noise abatement is important. Thus gear needs to be redesigned, providing energy saving by weight reduction, providing internal damping, reducing lubrication requirements, without increasing cost. This work is to explore the development of composite automotive gear box with optimum design and composite material selection at conceptual design stage for weight reduction to get better fuel efficiency with fulfilling needs of anti-fade characteristics, less power loses due to weight, corrosion resistant design and more consolidated design. The demands of material performances are so great and diverse that no one material is able to satisfy them. Composite material system results in a performance unattainable by the individual constituents. Composite materials offer the advantage of a flexible design that can be tailored to the design requirements. The specific composite materials Glass filled polyamide in particulate form is used for herringbone gears owing to better strength, recyclability, low density and less friction. Glass/epoxy is used for gear housing and shafts for strength requirements, orthotropic properties. Finite element analysis allows entire designs to be constructed, refined, and optimized before the design is manufactured with dynamic effects in low cost.

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Much emphasis has been placed upon vibrations in cutting tools during recent years because many people have recognized that accuracy, surface finish and, last but not least, production costs are considered. Today we use modern instruments and easy available for the investigation of cutting tool vibration. However, in the final analysis, the completed surface itself will return the dynamic behaviour of the cutting tool.

The scope of this project is to replace the conventional material by using composite material. However, a few or no studies were found to compare the material properties when the parts possess constant stiffness. Composite materials based on constant stiffness structures will provide a better comparison of size, weight damping properties etc., for the cutting tool structure manufactured using alternative composite material suggested for it. For this project oil palm reinforced fibre, steel and cast iron structure exhibiting constant stiffness were modelled analytically and calculated mathematically. A beam with rectangular shape has been select for analysis to simulate the machine tool components such as bed, beam and ram. The analytical (FEM) method was used to arrive at the dimensions of the structures which provide same stiffness. The dimensions calculated analytically were confirmed by testing them numerically.

The recent research on high speed precision cutting tools aims at developing an alternative material for the structures which exhibit good damping and stiffness characteristics.

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