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Gandhi, Chaitanya
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Design and Analysis of Automotive Steering Sheet Metal Yoke for High Strength and Rigidity Requirement

Rane NSK Steering Systems Pvt. Ltd.-Chaitanya Gandhi, Pranav Shinde, Mohanraj Ramamoorthi, Bharathkumar Krishnadoss
VIT University-Aditya Yadav
Published 2019-10-11 by SAE International in United States
The increasing demand for light weighting products due to introduction of various standards and norms for controlling CO2 emissions and to meet the customer requirement of low cost with higher strength and rigidity of product in automotive industry, sheet metal manufacturing technique is adopted for automotive steering yoke for light commercial vehicle. Currently forged yokes are used for higher strength requirement, while sheet metal yokes are being used for small tonnage vehicle. The attempt has been made to improve overall strength and rigidity of the yoke produced by sheet metal operation using SAPH 440 steel with 6.5mm thickness for light commercial vehicle segments. The major challenge identified for this development was developing such a high strength and thickness material with consistency of dimension during forming process and meeting the torsional strength requirement of 500 Nm. In this development with the help of plastic data, the forming analysis of yoke model has been carried out to analyze the feasibility of the design at desired thickness of yoke considering the dynamic bending force, spring back effect and…
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Die Design Parameter Optimization for Steering Intermediate Tube Using Taguchi Method

Rane NSK Steering Systems Pvt Ltd.-Mohanraj Ramamoorthi, Chaitanya Gandhi, Bharathkumar Krishnadoss, Arunkumar Nagarajan
Published 2019-10-11 by SAE International in United States
The increasing demand for lower cost and higher reliability of product of Indian OEM’s, one of the approach is using cheaper raw material considering design for X. In current steering intermediate tube, the development of replacing the imported material of STKM11A by local material of same grade has been done. The microstructure comparison shows there is variation in grain size and Mechanical properties of local and imported material and thus affects the formability of material. Increasing in mechanical properties such as hardness and tensile strength of material leads to challenge in actual forming as it affects the die life and its performance. In this paper, Non-linear explicit Axial cold forming process of Intermediate tube has been simulated through Finite Element Analysis Tool for both the local and imported material with optimization of die parameters. Dimensional requirement was one of the important parameter to correlate between the Design and Forming simulation. The parameter identified by past experience were Rough die opening angle, Mandrel forming angle, co-efficient of friction, Lobe width and Angle. Through Taguchi method, effect…
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